14 minute read
1000 Hours Service
1.Driver's seat
1.1.General safety check
•Check for play in seat gliders. Max. allowed in length or sideways: 1 mm. Grease the gliders. •Check shock absorbers for oil leakages. •Check seat mounting to the dump truck. •Check safety belt and lock mechanism for wear and damage. •Check that no pins are loose / worn in the seat base. • Replace worn/damaged parts.
2.Engine
2.1 Replace fuel filter 4*
The filter consist of one filter unit.
1.Wash the filter externally and unscrew it, wrench in toolkit. Discard the filter according to environmental requirements. 2.Fit the new genuine filter and tighten it by hand. •Never use tools to tighten the filter! The filter may be damaged and the fuel flow hampered. 3.Bleed the fuel system, procedure on next page, item 2.2. 4.Start engine and check for leaks.
CAUTION
Observe extreme cleanliness when working with the fuel system. Otherwise may operational interruption easily occur and the injection equipment may be damaged.
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2.2 Bleed fuel system:
1.Turn the starter switch to pos. I so that the fuel shut-off valve opens. 2.Undo the connection on the fuel filter outlet (1) (upwards). 3.Pump with the hand pump (3) until bubble-free fuel flows out of the opened connection. 4.Tighten the connection on the filter. 5.Remove overflow valve (2) from the fuel shut-off valve's outlet.
6.Pump with the hand pump until bubble-free fuel flows out of the opened overflow valve. 7.Tighten the overflow valve and pump with the hand pump additional 10 strokes.
If the engine is difficult to start after bleeding: 1.Open the overflow valve again and pump with the hand pump until bubble-free fuel flows out. 2.Close the overflow valve firmly and start the engine.
WARNING
The engine may be hot! Use gloves when pumping with the hand pump to avoid burning your hands.
2.3.Check batteries 11*
•Checking battery charge shall also be carried out after the first 8 hours of operation. Use a hydrometer to check the density of the electrolyte. The density of a fully charged battery should be: 1.240 at higher than +20 oC 1.280 at +20 oC, 1.294 at 0 oC, 1.308 at -20 oC.
Recharge the battery if the density is lower than 1.20. A discharged battery freezes at -5 oC.
WARNING
The electrolyte level must be correct when charging! During recharge a explosive gas is emitted. Open cell plugs and ventilate properly to avoid explosion!
The first belt circuit
The second belt circuit Maintenance to be performed every 1000 hours of operation.
2.4.Check poly-V belt condition
•Checking of poly-V belt condition shall also be carried out after the first 8 and 100 hours of operation. 1. The first belt circuit:
•Stop the engine to inspect the poly-V belt (1). •Change the belt (1) if damaged or worn. •Check that the automatic belt tensioner (2) is in proper working order and keeps the V-belt correctly tensioned. 2.The second belt circuit.
•The second belt circuit has to be adjusted manually. •It shall be tensioned to 15 - 20 Nm as shown on illustration.
2.5.Air filter 10*
Up to serial number 410251.
NOTE
For cleaning/replacement of air filter from serial no. 410252 (SERIES II), see page 159.
Up to serial no. 410251, the air filter is located in the fender on right hand side of the dump truck. Unscrew the steps on right hand side fender.
continue overleaf
Prefilter
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4
Outer element
Inner element 2
Outer element (- 410251) :
Clean element every 1000th hour of operation or if the air filter warning light illuminates at full load on the engine. Replace it after 6 times of cleaning, or at least once a year. 1.Loosen all clamps and remove the prefilter (1). 2.Remove outer element (2). Do not remove inner element when cleaning outer element! 3.Clean prefilter and inside of filter housing with compressed air.
4.Direct dry compressed air (less than 7 bar) to the element from inside along its folds, then direct it from the outside along its folds, and then from inside again. 5.Check that the element is clean and undamaged, and reinstall it.
6.Reinstall the prefilter, and fasten all the clamps.
Turn the prefilter so that the dust cap (4) is pointed downwards (max angle: 20°). 7.Reinstall the steps.
Inner element (- 410251):
Replace element every 3rd replacement of the outer element, or at least every 3rd year. 1.Loosen all clamps and remove the prefilter (1). 2.Remove outer element (2). Then remove inner element (3). 3.Cover the air inlet port. 4.Clean prefilter and inside of filter housing with compressed air. 5.Remove cover on the inlet air port. 6.Install a new inner element into the housing. 7.Install a new or cleaned outer element.
8.Reinstall the prefilter, and fasten all the clamps.
Turn the prefilter so that the dust cap (4) is pointed downwards (max angle: 20°). 9.Reinstall the steps
CAUTION
• Do not attempt to reinstall a cleaned inner element. • Do not clean or replace the element when the engine is running. • Replace the element if small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning. • If the element is usable, wrap it and store it a dry place. • Do not use an element in which folds, gasket or seal are damaged. • When cleaning the element, do not hit or hammer it. • Do not dismantle the inner element unnecessarily. • Punch a mark in the edge of the inner element each time the outer element is replaced.
2.5.Air filter 10*
From serial number 410252 (SERIES II).
From serial number 410252, the air filter is located on the top of the engine, under the bonnet. •Always stop the engine before servicing the air filter. •Open the bonnet and apply the bonnet catcher.
Fig. 1
Fig. 2
Fig. 3
Dust cap
Outer element (410252 -):
Clean element every 1000 hours of operation or if the air filter warning light illuminates at full load on the engine. •Replace the outer element after 5 times of cleaning, or at the latest after 2 years. 1.Loosen all clamps and remove the cover (fig. 1). 2.Remove outer element with a light turning movement (fig. 2). Do not remove inner element when cleaning outer element!
3.To blow out the filter element, use tube with a bent end which is attached to a compressed air gun; the end of the tube must be bent by approx. 90°. It must be of sufficient length to reach down to the bottom of the filter element.
Blow out the filter element using dry compressed air (max. 5 bar) by moving the tube up and down inside the filter element until there is no more dust coming out (fig. 3). •Never wash out or brush out the outer element. When blowing out make sure that no dust is allowed to enter the inside area of the outer element.
4.Punch a mark in the edge of the inner element each time the outer element is cleaned.
5.Check the cleaned element for damage of the paper element and of the rubber seals.
•Cracks and holes in the paper element can be discovered by shining through light from an electric bulb (fig. 4). 6.Never carry on using a damaged outer element. In case of doubt, always fit a new outer element. 7.Reinstall the outer element, the cover, and fasten all the clamps. Turn the cover so that the dust cap is pointed downwards (max angle: 15°).
Fig. 5
Fig. 6
Servicing the dust cap (410252- )
The dust cap require very little maintenance. Possible dust packs to be removed by squeezing the cap (fig. 5).
Inner element (410252- ):
•Replace element every 5th cleaning of the outer element, or at the latest after 2 year. •Do not clean the inner element and do not reuse it after it has been taken out. Only open the seal in order to
replace the inner element.
1.Loosen all clamps and remove the cover. 2.Remove outer element.
3.Remove the inner element; Use a suitable tool (e.g. screw driver) to push through the seal of the inner element from the inside to the outside and pull both the straps upwards (fig. 6). 4.Use both straps to take hold of the inner element and then pull out with a light turning movement (fig. 7). 5.Install a new inner element into the housing. 6.Install a new or cleaned outer element.
7.Reinstall the cover, and fasten all the clamps.
Turn the cover so that the dust cap is pointed downwards (max angle: 15°).
CAUTION
• Do not attempt to reinstall a cleaned inner element. • Do not clean or replace the elements when the engine is running. • Replace the outer element if small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning. • Do not use an element in which folds, gasket or seal are damaged. • When cleaning the element, do not hit or hammer it. • Do not dismantle the inner element unnecessarily. • Punch a mark in the edge of the inner element each time the outer element is cleaned.
3.Fuel tank
3.1.Drain condensation, at least once a year 13*
It is an advantage to do this procedure after the dump truck has been stationary for a while (e.g. weekend) if possible. 1.The drain cock is to be found on the left hand side of the the fuel tank, behind the cab.
2.Place a suitable container to catch spillage. 3.Remove blanking plug and install draining hose (tool kit). 4.Open the drain cock. 5.Drain until water/sediment-free fuel comes out.
6.Close the drain cock.
7.Remove the draining hose and reinstall the blanking plug.
NOTE
If a large amount of dirt and contamination has collected into the tank: • Drain all fuel. • Remove the flange for the hoses and clean inside of the tank.
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4.Transmission
4.1.Change oil 20*
Clean strainer 22* at least once a year
•Changing transmission oil and cleaning of the strainer shall also be carried out after the first 100 hours of operation.
Drain oil:
1.The dump truck must be standing on level ground. 2.The oil must be at operating temperature. 3.Unscrew the dip stick (1). 4.Remove the rear belly plate. 5.Unscrew drain plug (2), at the bottom of the transmission and drain the oil into a suitable container.
6.Clean the drain plug with magnetic insert, replace seal if necessary and reinstall the plug. •Tightening torque: 80 Nm.
continued overleaf
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4
Clean stranier:
7.The strainer is located on the right hand side of the drain plug. 8.Remove the bolts and washers (3). 9.Remove the cover (4) and the spring (5). 10.Remove the strainer (6) and clean it with diesel oil or flushing oil. 11.The strainer must be replaced if it is damaged. 12.Procedure for reinstall the strainer :
To check and confirm that the strainer is being installed into the strainer mounting section properly, apply a gauge (a scale etc.) on the end face of the block (mating surface to the cover) to make sure the tip end of the strainer bolt is not projecting beyond the end face of the block, see figure 1.
NOTE
It is very important that the strainer is installed properly, if the cover (4) is installed while the strainer (6) is not installed to the strainer mounting section properly and completely, the tip end of the strainer may be damaged and the strainer structure may break.
Depress the cover by hand to let it come to close contact with the end face of the block 13.Put the O-ring on the block. 14.Reinstall the spring. 15.Depress the cover by hand to let it come to close contact with the end face of the block, see figure 2. 16.Securely holding the cover in close contact with the end face of the block, install the bolts and washers, see figure 3.
Tightening torque: 98 - 123 Nm 17.Reinstall the rear belly plate.
Check and make sure that the end face of the block and the cover are in close contact
Fill new oil:
18.Fill new oil according to the transmission oil list and oil specification sheet (chapter 6) through the dip stick tube.
19.Insert the dip stick again and turn handle clockwise to tighten the sealing.
Transmission oil pump
Engine 7
Fill hose with oil:
20.Open the bonnet. 21.Disconnect the hose (7) at the transmission filter. 22.Raise the end of the hose, and fill the hose with oil (8). 23.Connect the hose.
continued overleaf
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Transmission filter Transmission oil pump
Transmission filter
NOTE
• From serial no. 410234 it is not necessary to carry out items 20-23 in regards to the introdcution of a new hydraulic pump. • If the hydraulic pump on the transmission is modified according to Moxy Service/Parts Information no. 20/2000 on older dump trucks than serial no. 410234, then it is not necessary to carry out items 20- 23.
Contact your Moxy Dealer if you have questions about hydraulic pump modifications.
Check:
24.Start engine and let it idle for 2-3 minutes. 25.When the engine is started, check oil level (9) (see daily maintenance, for procedure) at low idle. Both too low and too high level can cause serious internal damage! 26.Warm up the oil and check for leaks. Recheck level and adjust if necessary.
NOTE
• Do not overfill! Both too high and too low level can cause serious internal damage! • For rough operation conditions the oil must be changed more often (every 500 hours) and the strainer must be cleaned as well.
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5.Front differential
5.1 Change oil, at least once a year 30*
•Change front diff. oil shall also be carried out after the first 500 hours of operation. 1.Remove the rear belly plate. 2.Open level / filling plug (1), special spanner in tool kit. 3.Unscrew drain plug (2). 4.Drain the oil into a suitable container.
5.Clean the drain plug, replace seal if necessary and reinstall. •Tightening torque: 80 Nm. 6.Fill new oil, according to the oil specification sheet (chapter 6), through the level / filling plug, level shall be at lower edge of hole when dump truck is horizontal. 7.Clean the plug, replace seal if necessary and reinstall. •Tightening torque: 80 Nm. 8.Reinstall the rear belly plate.
CAUTION
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6.Rear differential
6.1.Change oil, at least once a year 31*
•Change rear diff. oil shall also be carried out after the first 500 hours of operation. 1.Open level/filling plug (1). 2.Unscrew drain plug (2) underneath the housing. 3.Drain the oil into a suitable container.
4.Clean the drain plug, replace seal if necessary and reinstall. •Tightening torque: 80 Nm. 5.Fill new oil, according to the oil specification sheet (chapter 6), through the level/filling plug, level shall be at lower edge of hole when dump truck is horizontal. 6.Clean the plug, replace seal if necessary and reinstall. •Tightening torque: 80 Nm.
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CAUTION
7.Front reduction gears
7.1.Change oil, at least once a year 33*
•Change front reduct. gear oil shall also be carried out after the first 500 hours of operation. 1.The dump truck must be horizontal. 2.Turn the hub, so that the plug is pointed downwards. 3.Unscrew the plug (1). 4.Drain the oil into a suitable container.
5.Turn the hub 90o, so that the level indicator is horizontal (2). 6.Fill new oil, according to the oil specification sheet (chapter 6), through level/filling plug, level shall be at lower edge of hole when dump truck is horizontal. 7.Clean plug, replace seal if necessary and reinstall. •Tightening torque: 80 Nm. 8.Recheck oil level after test driving.
CAUTION
8.Electrical system
8.1.Check wiring
The wiring harness must not be damaged. Check that the cables on the articulation hinge and on the rear frame/body are not squeezed, have sharp bends or loose/bad connections
