Daewoo Doosan ADT MT40B MT40B SERIES II Operation & Maintenance Manual - PDF DOWNLOAD

MX159464-1 August 2014

ADT

Operation & Maintenance Manual MT40B / MT40B SERIES II MT40B / MT40B - Serial Number 513002 and Up

Operation & Maintenance Manual MT40B / MT40B SERIES II ADT MT40B / MT40B - Serial Number 513002 and Up

DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United States and various other countries around the world.

Copyright 2014 OperationDOOSAN and Maintenance Manual

MX159464-1 August 2014 Copyright Doosan 2011

1. Foreword

MT40B/MT40B SERIES II E

OPERATING & MAINTENANCE MANUAL

Serial no.

513002 and up

This manual also applies for MT40B Coal Hauler

NOTE Operating & Maintenance Manuals are available in certain other languages. If other languages are required, please contact your local Moxy Dealer for details of availability.

Manufacturer:

Dealer:

Moxy Engineering AS N - 6440 Elnesvågen - NORWAY Printed in Norway

Operating & Maintenance Manual

Part no.: 159464 Edition: March 1 2003

1. Foreword

2

Operating & Maintenance Manual

Table of contents

1. Foreword

1. Foreword ................................................................. 5 - 8 Foreword ....................................................................... 5 Safety information ......................................................... 6 Introduction ................................................................... 7 2. Safety instructions .............................................. 9 - 36 3. Operating controls ............................................. 37 - 78 Overview of the instruments and controls .................

Instruments .................................................................

Warning / Indicator lights ............................................

Switches .....................................................................

Controls ......................................................................

Cab ventilation ............................................................

Other cabin equipment ...............................................

Performance chart ....................................................

Engine and retarder brake capacity chart ...............

Torque limit tables ....................................................

Reference information (fill in tables) .......................

Product signs ............................................................

Periodic service (fill in tables) ..................................

183 184 185 185 186 187

9. Alphabetical Index ......................................... 189 - 194

39 40 46 53 61 69 72

4. Running-in period ............................................... 79 - 84 Running-in operation ................................................. 81 Running-in services ................................................... 82 5. Operating instructions ....................................... 85-112 Some simple rules to be observed prior to operation 87 Starting the engine ..................................................... 88 Operating the dump truck ........................................... 90 Parking the dump truck .............................................. 99 Stopping the engine ................................................. 100 Checks after stopping the engine ............................ 100 Loading and tipping ................................................. 101 Tyre handling ............................................................ 102 Cold weather ............................................................ 104 Long term storage .................................................... 105 Battery power assistance ......................................... 106 Towing the dump truck ............................................. 107 External air filling ...................................................... 107 Manual release of parking brake ............................. 108 Tyre filling point ........................................................ 108 Troubleshooting ....................................................... 109 6. Lubricants ....................................................... 113 - 120 Lubrication schedule ................................................ 115 Oil specification sheet .............................................. 117 Filling capacities ....................................................... 118 Transmission oil list .................................................. 119 7. Maintenance ................................................... 121 - 174 Maintenance precautions ........................................ 123 Maintenance table .................................................... 124 8 Hours / Daily service ............................................. 125 40 Hours / Weekly service ........................................ 135 500 Hours Service .................................................... 139 1000 Hours Service ................................................. 151 2000 Hours Service ................................................. 159 4000 Hours Service ................................................. 169 Yearly recommended maintenance ........................ 173 8. Technical data ................................................ 175 - 188 Measurements .......................................................... 177 Engine ....................................................................... 178 Transmission ............................................................ 178 Hydraulic system ...................................................... 179 Air system ................................................................. 179 Tyre pressures .......................................................... 179 Electrical system ....................................................... 180 Metering conversion table ........................................ 182 Tool kit content .......................................................... 182

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1. Foreword

4

Operating & Maintenance Manual

1. Foreword

Foreword This manual provides rules and guidelines which will help you use this dump truck safely and effectively.

This manual describes procedures for operating, handling, lubricating, maintenance, checking and adjustment. It will help the operator to achieve peak performance through effective, economical and safe dump truck operation and maintenance.

• Keep this manual in the dump truck at all times and ensure that all personnel read it carefully before operating the dump truck.

• Continue studying the manual until proper operating methods are completely adopted as personal habit.

• This manual describes the basic techniques. The operator's skill will increase with correct knowledge of dump truck operation.

• Operation, inspection and maintenance should be carefully carried out, and safety must be given first priority.

If this manual has been lost or has become dirty and cannot be read, request a replacement manual from your local Moxy Dealer.

If you sell the dump truck, be sure to give this manual to the new owners.

Moxy Engineering AS cannot be held responsible for damage or injury caused through use of improper spare parts not specified by Moxy Engineering AS, improper handling, operation and utilisation of the dump truck in other ways than those described in this manual. Nor can Moxy Engineering AS be held responsible for unauthorised modifications or the non-adherence to local, national government or international regulations.

This Operating & Maintenance Manual may contain standard extra equipment and optional accessories that are not available in your area. Please consult your local Moxy Dealer for those items you may require.

Moxy Engineering AS aim to continuously improve the dump trucks and therefore retain the right to make design changes and improvements whenever we feel it will improve the efficiency of the dump truck.

Moxy Engineering AS also reserve the right to change data and equipment without prior notice, as well as amending instructions for maintenance and other service measures.

WARNING • This dump truck complies with EC directives 89/392/EEC with amendments and 89/336/EEC with amendments.

Dump trucks complying with the directives display the CE mark.

The dump truck must not be modified in such a way that it no longer complies with the EC directive.

• Improper operation and maintenance of this dump truck can be hazardous and could result in serious injury or death.

• Operators and maintenance personnel should read this manual throughly before operation or maintenance.

• Some actions involved in operation and maintenance of the dump truck can cause serious accidents, if they are not carried out in a manner described in this manual.

• The procedures and precautions given in this manual apply only to intended uses of the dump truck. If you use your dump truck for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in the prohibited uses or actions which are described in this manual.

• Moxy Engineering AS delivers dump trucks that comply with all applicable regulations and standards of the country to which it has been shipped. If this dump truck has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regualtions of your country, consult your local Moxy Dealer before operating the dump truck.

• Safety descriptions are given in SAFETY INFORMATION on page 6 and in SAFETY INSTRUCTION, chapter 2.

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1. Foreword

Safety information Most accidents are caused by the failure to follow safety rules for the operation and maintenance of the dump truck. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the dump truck before operation and performing maintenance.

To identify safety messages in this manual, the following signal words are used:

NOTE

-

This word is used for precautions that must be taken to avoid actions which could shorten the life of the dump truck.

CAUTION

-

This word denotes safety messages for hazards which could result in minor or moderate injury if the hazard is not avoided. This word might also be used for hazards where the only result could be damage to the dump truck.

WARNING

-

This word denotes safety messages where there is a potentially dangerous situation which could result in serious injury or death if the hazard is not avoided. These safety messages usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the dump truck.

DANGER

-

This word denotes safety messages where there is a high probability of serious injury or death if the hazard is not avoided. These safety messages usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the dump truck.

To identify labels on the dump truck, the following colours are used.

YELLOW & BLACK -

These colours are used on safety labels where there is high/potential/ moderate probability of death/injury if the hazard is not avoided.

GREEN & WHITE

These colours are used on information labels.

-

Know the capacity and limits of your dump truck!

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Operating & Maintenance Manual

1. Foreword

Introduction Intended use This Moxy articluated dump truck is designed to be used mainly for earthmoving at sites, both on and off road conditions.

General description Moxy MT40B is an articulated, 6-wheel drive dump truck. The free-swinging rear tandem housing, and the special Moxy articulation system, provide excellent performance in soft and difficult terrain. The special body design ensures that a low centre of gravity is maintained and an even load distribution to front and rear wheels, for stability on uneven ground and for fast easy tipping. The Moxy dump truck is designed and manufactured to work under difficult conditions.

In addition, the wide range of optional equipment allows the dump truck to be used for several different applications

Operators cab

Head and side light

Exhaust pipe

Engine bonnet

Dump body

Fuel tank

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1. Foreword

8

Operating & Maintenance Manual

2. Safety Instructions

Safety Instructions

WARNING Read and follow all safety precautions. Failure to do so may result in serious injury or death.

This safety section also contains precautions for standard extra equipment and optional accessories.

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2. Safety Instructions

Contents

2. Safety instructions .................................................. 9 - 36 1. Dump truck knowledge ........................................ 11 2. General precautions ............................................ 11 3. Precautions before starting the engine .............. 15 4. When staring the engine ..................................... 17 5. Do not go close to high-voltage cables .............. 17 6. Battery hazard prevention ................................... 18 7. Rules to follow when filling fuel or oil ................. 19 8. Air conditioner system hazard prevention .......... 19 9. Expansion tank coolant level .............................. 20 10. Machine turning ................................................... 20 11. Emergency steering ............................................ 20 12. Travelling on slopes ............................................ 21 13. Operation of brakes ............................................. 21 14. Engine overspeed ............................................... 21 15. Wading ................................................................. 22 16. Dangerous loads (exhaust heated body) ........... 22 17. Welding on the dump truck .................................. 23 18. Top tailgate .......................................................... 24 19. Engine bonnet ..................................................... 25 20. Body support ........................................................ 26 21. Service position ................................................... 27 22. Wheel chocks ....................................................... 27 23. Articulation lock ................................................... 28 24. Lifting/hoisting ...................................................... 28 25. Dump truck transportation ................................... 29 26. High pressure ...................................................... 29 27. Safety labels ........................................................ 30

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2. Safety Instructions

1. Dump truck knowledge Learn how to use the control devices, instruments and warning devices. Be sure you understand the meaning of the WARNING signs and other cautionary messages. Always know the dimension and performance limits of your dump truck.

Remember the check points and checking method of fluid levels.

2. General precautions, see also Precautions for Maintenance and Operating Instruction

2.1. Safety rules • ONLY trained and qualified personnel can operate and maintain the dump truck.

• Follow all safety rules, precautions and instructions when operating or performing maintenance on the dump truck.

• ALWAYS USE SEAT BELT DURING DRIVING! If there are instructors or passengers in the cab, be sure that they are seated on the instructor seats and are using their seat belt!

• Never operate the dump truck if you are under the influence of alcohol, medicines or other drugs.

• When working with other operators or persons on work site traffic duty, be sure all personnel understand all hand signals that are to be used.

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2. Safety Instructions

2.2. Clothing and personal protection items Avoid loose clothing, jewellery and loose long hair which may catch on controls or in moving parts and cause serious injury or death. Also, do not wear oily clothing cause it is injurious to health and is flammable.

2.3. Unauthorised modification • Any modification made without authorisation from Moxy Engineering AS can create hazards.

• Before making a modification, consult your local Moxy Dealer. Moxy Engineering AS will not be responsible for any injury or damage caused by any unauthorised modification.

2.4. Getting on and off the dump truck • Always use handles and steps when entering and getting off the dump truck.

• Ensure safety, maintaining at least three-point contact of hands and feet with handles and steps.

• NEVER jump on or off the dump truck. NEVER get on or off a moving dump truck.

• Always clean off grease, oil, ice, snow and dirt to avoid slippery truck surfaces.

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2. Safety Instructions

2.5. Fire prevention for fuel and oil Fuel, oil and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS. • Keep flames away from flammable fluids.

• Stop the engine and do not smoke when refuelling.

• Tighten all fuel and oil caps securely.

• Refuelling and oiling should be carried out in well ventilated areas.

• Spilt fuel and oil must always be cleaned up immediately.

• Keep oil and fuel in a secure place and do not allow unauthorised persons to enter.

2.6. Precautions when handling at high temperatures Immediately after operations are stopped, the engine coolant, engine oil and hydraulic oil are at high temperatures, and are still under pressure. Attempting to remove the cap, drain the oil or coolant, or replace the filters may lead to serious burns.

Always wait for the temperature to fall, and follow the specified procedure when carrying out these operations.

• To prevent hot coolant from spurting out: 1. Turn engine off 2. Allow coolant to cool down.

3. Slowly loosen cap to relieve pressure before removing.

• To prevent hot oil from spurting: 1. Turn engine off 2. Allow oil to cool down.

3. Slowly loosen cap to relieve pressure before removing.

2.7. Fire extinguisher, first aid kit and warning triangle • If any of the safety equipment is missing, contact your local Moxy Dealer.

• Know how to use the fire extinguisher.

Location: Left hand side of driver's seat.

• Keep the first aid kit in its storage place.

Location: Left hand side of the driver's seat (underneath the instructor seat) .

• Keep the warning triangle in its storage place.

Location: Underneath the driver's seat bracket, behind the seat.

• See also Safety equipment in chapter 3.

• Know what to do in case of fire.

• Be sure you know the phone numbers of persons you should contact in case of an emergency.

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2. Safety Instructions

2.8. Precaution for optional accessories • When installing and using optional accessories, read the information related to the equipment in this manual.

• Do not use equipment or parts that are not authorised by Moxy Engineering AS. Use of unauthorised equipment or parts could create a safety problem and adversely affect the proper operation and useful life of the dump truck.

• Any injury, accidents, product failure resulting from the use of unauthorised attachments will not be the responsibility of Moxy Engineering AS.

2.9. Protection against falling objects and roll-over protection The cab on this dump truck is tested and approved to current ROPS (Roll-Over Protective Structure) and FOPS (Falling Object Protective Structure) standards.

ISO 3471 ROPS ISO 3449 FOPS • This cab meets the requirements for objects falling onto the cab roof, and will protect the operator while he is remaining in the cab.

• This cab meets the requirements for roll over protection.

A precondition for protection is that the operator USES THE SEAT BELT and remains in the cab. Therefore, hold onto the steering wheel if the dump truck should roll over.

DO NOT ATTEMPT TO JUMP CLEAR! • The cab is equipped with an approval sign for ROPS/ FOPS. • Structural damage, an overturn, modification, alteration or unpermitted repair can affect the cab strength and thereby void the certification • Consult Moxy Engineering AS or your Moxy Dealer to determine this structure’s limitations without voiding its

2.10. Emergency exit • This dump truck is fitted with three emergency exits.

• Right and left doors and front windscreen.

• If doors are blocked by any means you can get out through the front windscreen.

• Pull the handle under the windscreen backwards.

The rubber seal must be pulled completely off before pushing the front windscreen out.

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Operating & Maintenance Manual

2. Safety Instructions

3. PRECAUTIONS before starting the engine

3.1. Safety at the worksite • Before starting the engine, make sure that the bonnet is closed and throughly check the area for any unusual conditions that could be potentially dangerous.

• Before starting the engine, examine the terrain and soil conditions of worksite. Determine the best and safest method of operation.

3.2. Fire prevention • Throughly remove wood chips, leaves, paper and other flammable material accumulated in the engine compartment, or other places on the dump truck.

THEY COULD CAUSE FIRE! • Marshland, when dry, is highly flammable. Marshland can selfignite even in low temperatures.

Always keep the engine and engine compartment clean!

• Check fuel, lubrication and hydraulic system for leaks.

Have any leaks repaired. Clean up any excess oil, fuel or other flammable fluids. (Check points - see daily maintenance "Walk around check") • Be sure that the fire extinguisher is present and working.

The fire extinguisher shall be located on the left hand side of driver's seat (on the driver's seat bracket).

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2. Safety Instructions

3.3. In operator's cab • Do not leave tools or spare parts laying around in the operator's cab. They may damage or break the control levers or switches. They could also hit the operator and cause serious injury.

Always keep the tools in the tool box (in right hand side fender).

• Keep the cab floor, controls, steps and handrails free of oil, grease, ice, snow and dirt.

3.4. Ventilation for enclosed areas If it is necessary to start the engine within an enclosed area, provide adequate ventilation. Exhaust fumes from the engine can KILL.

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2. Safety Instructions

3.5. Precautions for mirrors, windows and lights • Remove all dirt from the surface of the windows and lights to ensure that you can see well.

• Adjust the rear view mirrors so that you can see clearly from the operator's seat, and always keep the surface of the mirrors clean. If any glass is broken, replace it with a new part.

• Check that the head lights, working lights and all other lights are installed to match the operating conditions.

Check also that they light up properly.

4. When starting the engine • Walk around the dump truck just before you enter it, to check for people and objects that might be in the way.

• When starting the engine, sound the horn as alert.

• Fasten the seat belt and remain seated while in motion. Standing up is dangerous! Concentrate on and evaluate surroundings.

Stop the dump truck if you are uncertain of how to operate safely.

• Slow driving is required to ensure hazard-free operation, especially on curves, narrow roads, hills/cliffs, bumpy or slippery ground. If the visibility is restricted and/or obstructed, designate a person to check and direct the worksite traffic.

• Ensure that you keep a safe distance from other vehicles and nearby people. Be sure that no persons or objects are situated in the articulation area or the overturn area (left and right hand side of the dump truck) before turning or driving.

Also make sure that no persons or objects are situated behind the dump truck before reversing or when tipping the load.

5. Do not go close to high-voltage cables • Going close to high-voltage cables can cause electric shock.

Do not raise the body near high-voltage cables.

• The following actions are effective in preventing accidents: • Wear shoes with rubber or leather soles.

• Use a signalman to give warning if the dump truck approaches too close to the electric cable.

• If the body should touch the electric cable, the operator should not leave the operator's cab.

• When carrying out operation near high-voltage cables, do not let anyone come close to the dump truck.

• Check with the electricity company about the safety zone and voltage of the cables before starting operations.

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2. Safety Instructions

6. Battery hazard prevention • Battery electrolyte contains sulphuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water.

• Battery acid could cause blindness if splashed into the eyes.

If acid gets into the eyes, flush them immediately with large quantities of water and see a doctor at once.

• If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil. Call a doctor or hospital immediately.

• When working with batteries ALWAYS wear safety glasses or goggles.

• Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a small spark or flame.

• Before working with batteries, turn the starter switch to the OFFposition, and the battery main switch must be turned OFF. • Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across the terminals.

• When removing or installing, check which is the positive (+) and negative (-) terminal.

Removing the batteries: 1. Disconnect (-) terminal connected to the earth point.

2. Disconnect the battery cable between the batteries.

3. Disconnect (+) terminal connected to the starter.

When installing the batteries, carry out the procedure in the opposite order, 3 - 2 - 1.

• Tighten the battery caps securely.

• When removing any battery cap, wear rubber gloves to prevent electrolyte contact with the skin.

• Tighten the battery terminals securely, check that the terminals are not loose by trying to move the battery cables by hand.

Loosened terminals can generate sparks and lead to an explosion.

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2. Safety Instructions

7. Rules to follow when filling fuel or oil • Spilt fuel and oil may cause you to slip, so always clean up immediately.

• Slowly loosen the caps to relieve pressure before removing the caps.

• Always check fuel/oil specifications (chapter 6, lubricants) before refilling.

• Always refill fuel and oil in a well-ventilated place.

• Always tighten the cap of fuel and oil fillers securely.

• Never use fuel for washing any parts.

8. Air conditioner system hazard prevention • The air conditioning system is filled with refrigerant (R134a).

• Always use safety glasses or goggles, gloves, boiler suit and protective footwear when inspecting, servicing and repairing the air conditioning system.

• Refrigerant R134a has a property that can cause frostbite if it comes into contact with bare skin or eyes.

• Always work on the air conditioning system in well-ventilated places.

• High concentration of the refrigerant in gaseous form can cause drowsiness, headache, dizziness and at worst unconciousness.

Very high concentration of the gas can even cause cardiac insufficiency.

• Do not smoke when servicing the air conditioning system!

Worker protection rules, refrigerant The following worker protection actions must be taken if there is any contact with escaping refrigerant: • Refrigerant in gaseous form can cause drowsiness, headache, dizziness and at worst unconciousness. Very high concentration of the gas can even cause cardiac insufficiency.

In all cases, get into fresh air and move the affected person from the risk zone. Contact a doctor.

• If larger quantities of fluid refrigerant come into contact with skin (frostbite), the injured area should be carefully warmed with lukewarm running water and covered with a sterile compress.

Contact a doctor.

• If fluid refrigerant comes into contact with a person's eyes (frostbite), rinse the eyes with lukewarm running water, min. 10 min.

Contact a doctor.

• If fluid refrigerant is accidentally swallowed, there can be serious frostbite in the mouth and gullet. Rinse the mouth with water. DO NOT PROVOKE VOMITING. Contact a doctor.

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2. Safety Instructions

9. Expansion tank coolant level 1. If it is necessary to refill coolant to the expansion tank, stop the engine and allow the engine and the expansion tank to cool down before refilling coolant.

2. Slowly loosen the caps to relieve pressure before removing the caps.

3. Always refill using premixed coolant. (see chapter 7, maintenance)

10. Machine turning This articulated dump truck has two frames and the design allows unrestricted turning between front and rear chassis. Overturn of one frame while the other remains level is possible.

It is possible that the operator will not receive warning signs of an overturn, therefore: • Avoid high speed turning and hard braking in curves.

• Reduce speed, avoid sudden turning if travelling across slopes.

• The rear chassis stability decreases when tipping. Be alert when body is raised. Do not under any circumstances drive with raised body!

11. Emergency steering The emergency steering pump will be activated if the engine stops.

It is possible to steer the dump truck when it is in motion, but the steering speed will be slower.

If the emergency steering light illuminates at truck speeds above approx. 5 km/h: • Stop as soon as possible and park in a safe place! Continued driving may result in uncontrollable steering.

• Correct the fault before operating the dump truck again. If necessary, contact your Moxy Dealer.

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2. Safety Instructions

12. Travelling on slopes • Travelling on hills, banks or slopes that are steep, can result in the dump truck starting to slide/slip or roll over.

• Always check ground conditions before travelling on slopes.

• Always travel straight up or down on slopes.

• Do not turn on slopes or travel across slopes.

Always go down to a flat place to perform these operations.

• Keep travel speed very low.

WARNING Ground conditions, gradients, friction, available traction and type of load are of vital importance for safe operation and stability on slopes.

13. Operation of brakes The service brakes must never be applied for long periods due to danger of fading (loss of braking effect due to overheating). To avoid fading, depress the pedal firmly and release it after the speed is reduced.

Select a gear and adjust the speed in a downhill slope so that the speed can be controlled with the engine and/or retarder brake, without the use of the service brake to hold the speed. Never use the service brake for long periods. Avoid racing the engine. See also Operating Instructions.

The max. downhill slope to keep the dump truck at an even speed with the engine and/or retarder brake applied can be read in the brake capacity chart in chapter 8. This depends mainly upon slope (road) conditions

14. Engine overspeed Engine speed above max. allowed rpm is prohibited. It can damage the engine and reduce the safety of the operator.

If the engine speed exceeds 2500 rpm, the engine brake will automatically engage. The retarder brake will automatically engage if the engine speed exceeds 2600 rpm to avoid overspeed of the engine.

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2. Safety Instructions

15. Wading Never drive into water (river beds, ponds, flooded pits, ditches etc.) without knowing the ground surface and depth. The bottom can be slippery, obstacles such as rocks/holes and other dangerous areas can be difficult to determine, and the force of a river current can be substantial. If it is found to be safe, drive slowly to avoid splashing. Do not stop unless absolutely necessary. Be aware of reduced braking effect when brakes are wet.

The brake linings must be checked/replaced more often when driving in wet and swampy areas, because wear of the linings will increase (see 500 hours service for procedure).

The maximum wading depth is: 1.1 metres, i.e. up to the front fenders.

NOTE Under no circumstances let water flow through the grill!

16. Dangerous loads If the body is exhaust heated, dangerous loads such as explosives or inflammable materials like petrols, oils etc. must not be transported.

In some countries there may be special national regulations for transportation of dangerous loads.

To blind off the exhaust heating, do as follows: • Always allow the dump truck to cool down before changing exhaust direction.

1. Remove the clamps on both the vertical exhaust pipe and the pipe which goes to the body.

2. Remove the plate which gives heating to the body (in the vertical exhaust pipe).

3. Remove the ring from the pipe which goes to the body and install it into the vertical exhaust pipe.

4. Install the plate which blind the exhaust to the body (in the pipe which goes to the body) 5. Refit the clamps.

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2. Safety Instructions

17. Welding on the dump truck The transmission and the engine are equipped with electronic control units. Before welding on the dump truck: 1. Disconnect batteries.

2. Unplug the connector on the electronic control units for the engine and the transmission. The units are located under the left hand dashboard panel.

3. Earth point should be less than 1 m from welding point.

4. There should not be sealings and bearings between the welding point and the earth point.

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2. Safety Instructions

Illustration shows MT40B

18. Top tailgate For safe tipping: See Operating Instructions.

If top hinged tailgate is fitted to this dump truck, particular attention should be paid to the material handled in the interest of both safety and efficiency.

The top tailgate is suitable for materials which are both well fragmented and free floating, such as dry earth, gravel, sand, coal, etc.

In such instances, discharge should be continuous during the whole cycle of tipping.

However, if the material is poorly fragmented or adhesive, such as clay, bulky boulders etc., it is imperative that a top tailgate is NOT fitted. Such materials do not have an even discharge and problems could arise during the tipping cycle when the material comes in contact with the top tailgate. Cases have been reported where the tailgate restriction has caused the front wheels of the dump truck to leave the ground. Such a situation creates instability of the front of the dump truck, and results in reduction of operator safety.

WARNING Moxy Engineering AS cannot be held responsible for any damage that may occur through improper use of the top hinged tailgate.

DANGER It is hazardous to work/stand underneath the tailgate while the body is raised!

The tailgate must be removed if any work is to be done inside the body while the body is raised.

Removal of the top tailgate - MT40B: 1. Attach wire or chain to the lifting points.

The tailgate shall be disassembled in three parts, tailgate arms (left and right) and the rear tailgate plate.

Be sure that wire or chain are attached to all three tailgate parts before disassembling.

2. Remove all screws (see arrows) on the tailgate (both sides) and lift off the tailgate parts.

Approx. weight: 1500 kg.

Removal of the top tailgate - MT40B Coal Hauler: 1. Attach wire or chain to the lifting points.

2. Remove screw on body bracket (both sides) and lift the tailgate assembly up. Approx. weight: 1500 kg.

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2. Safety Instructions

19. Engine bonnet Do not open the bonnet when the engine is running.

The bonnet must always be closed and secured with the locks when operating the dump truck.

When the bonnet is open, make sure that the bonnet catcher for open position (on right hand side) secures the bonnet from falling down.

• To open the bonnet: 1. Release the locks at both sides.

2. Push up the bonnet 3. Check that the bonnet catcher engages.

• To close the bonnet: 1. Lift the bonnet catcher.

2. Push the bonnet down.

3. Apply the locks on both sides.

DANGER It is hazardous to work/stand underneath the bonnet without applying the bonnet catcher!

Do not operate the dump truck with a raised and secured bonnet!

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2. Safety Instructions

20. Body support 1

Always secure the raised body with the body support before service/inspection and other work underneath the body. The body support device is intended for empty body only!

• Engagement of the support device: 1. Raise the body.

2. Make sure that the parking brake is on (locked) before leaving the cab.

3. Lift the body support in top position (pos 1).

4. Slowly lower the body towards the support device until firmly positioned.

5. Return the tip control lever to hold position.

6. Stop the engine and remove the starter switch key.

• Disengagement of the support device: 1. Start the engine.

2. Push the tipping system switch (see chapter 3, operating controls) and keep it depressed while the body is lifted slightly.

3. Release the switch when the body is off the body support.

4. Return the tip control lever to hold position.

5. Make sure that the parking brake is on (locked) before leaving the cab.

6. Lower the body support.

7. Lower the body.

DANGER It is hazardous to work/stand underneath the body without applying the body support device!

Do not operate the dump truck with a raised and secured body!

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2. Safety Instructions

21. Service position Prepare the dump truck before service, maintenance and other work on the dump truck. Take every precaution for safe work. If more than one person shall perform work, one person should supervise to maintain the safety.

1. Park on a level ground and apply the parking brake.

2. Apply the articulation lock (see item 23).

Block the wheels (see item 22).

3. Stop the engine and remove starter switch key if not necessary for the work. Disconnect the main switch in the battery compartment in front fender.

4. Secure the dump truck from being operated by accident or by persons unauthorised by attaching a warning label to the steering wheel. Do not allow persons to approach the area unnecessarily.

5. Be aware of hot fluids and components.

6. Drop the air system pressures (see item 26).

7. Block up all lifted components to prevent them from falling during work/stand underneath.

Before starting up after the work, make sure the dump truck is in operationable condition.

22. Wheel chocks Always place wheel chocks under the wheels to avoid spontaneous rolling: • when parking • during maintenance and other work • during transportation.

Operating & Maintenance Manual

27

2. Safety Instructions

23. Articulation lock The lock prevents the dump truck turning when applied.

• Apply the lock: 1. Take out the spring cotter, lift the pin and swing the linkage forward into the hinge ear.

2. Insert the pin through linkage and ear and refit the spring cotter.

• Release the lock: 1. Take out the spring cotter, and remove the pin through the linkage and ear.

2. Swing the linkage backwards, insert the pin through the linkage and ear, and refit the spring cotter.

The lock must always be applied: • During maintenance, greasing and other work.

• When lifting or hoisting the truck, see item 24.

• During dump truck transportation, see item 25.

24. Lifting / hoisting 1. Apply the articulation lock (see item 23).

2. Open and secure (see item 19) the bonnet.

3. Fit suitable lifting wires or chains to the hoisting points at both sides of the body and engine, and use a suitable lifting beam as shown.

Machine net weight: approx. 27,800 kg (MT40B) 28,280 kg (MT40B Coal Hauler).

WARNING Never lift or hoist a loaded truck, the points are intended for an empty dump truck only!

28

Operating & Maintenance Manual

2. Safety Instructions

25. Dump truck transportation 1. Apply the parking brake.

2. Apply the articulation lock.

3. Apply wheel chocks.

Fit suitable wires or chains to the tie down points as shown and tighten them up.

CAUTION Always transport the truck without load in the body!

26. High pressure Be aware of high pressure in the hydraulic system (with running engine), air system, brake fluid system (with operated service brakes) and tyres. Do not strike or bend pressure hoses or tubes. Do not use bare hands for checking leaks, use shield as protection to avoid personal injury. Even a pin-hole size leak can penetrate the skin.

Always release pressure before maintenance or servicing: Hydraulic: Stop the engine. Be aware of possible hot oil.

Air: Stop the engine, drain all air tanks, see chapter 7, Daily maintenance.

Tyres: Release the pressure through the rim nipple before attempting to remove any imbedded objects or removing tyre/rim assembly from the machine. The pressures inside tyres are substantial and an explosion can cause damage and serious personal injury. Never heat or weld on rims or surrounding areas when the tyre is inflated. Stand behind the tread when inflating a tyre.

Operating & Maintenance Manual

29

2. Safety Instructions

27. Safety labels The following labels are related to safety and should always be present and easy to read. Do not cover labels with paint or simular: Cab certification.

The cab has been approved to current ROPS/FOPS standards. Structural damage, an overturn, modification, alteration or unpermitted repair can affect the cab strength and thereby void the certification. Consult your Moxy Dealer to determine this structure’s limitations without voiding its certification.

14 13

Inside 17 battery 9 box

20 Hydr. tank 11

16

5

19

4

15

3

2

1

21

11 Inside door 10 9

8 6 Driver's seat brakcet 7 Underneath instructor seat

21 18 12

12 30

12 Operating & Maintenance Manual

12

2. Safety Instructions

27.1. Warning - operation, inspection and maintenance • Improper operation and maintenance can cause serious injury or death.

• Read the manual and labels before operation and maintenance. Follow instructions and warnings in the manual and on labels on the dump truck.

• Always keep the manual in the cab.

If this manual is lost, please contact your Moxy Dealer for a replacement.

27.2 Warning - never coast in neutral.

• Never coast with the gear selector in the neutral position.

• The braking effect and the operator's safety will be reduced.

27.3 Emergency exit • The emergency exit can be opened by pulling the handle under the windscreen backwards. The rubber seal must be pulled completely off before pushing the front windscreen out.

• Read operating manual (safety instructions, item 2.10) before operation.

27.4 Warning - use of top tailgate.

• Top tailgate is fitted on this dump truck.

• Pay particular attention to the material handled by dump truck with top tailgate.

• Wrong material and improper use of top tailgate can cause a DANGEROUS situation and reduce the operator's safety.

• Read the operating manual (safety instructions, item 18) before operation.

Operating & Maintenance Manual

31

2. Safety Instructions

27.5 Warning - dangerous loads • Must not be used for transport of explosive or inflammable loads!

• Read operating manual (safety instructions, item 16) before operation.

27.6 Fire extinguisher • The fire extinguisher is located on the left hand side of the driver's seat.

• Read operating manual (safety instructions, item 2.7)

27.7 First aid kit • The first aid kit is located on the left hand side of driver's seat (underneath the instructor seat).

• Read operating manual (safety instructions, item 2.7).

27.8 ROPS/FOPS approval cab • Read operating manual (safety instructions, item 2.9).

32

Operating & Maintenance Manual

2. Safety Instructions

27.9 Warning - welding precaution.

• Disconnect the batteries and unplug the connectors on the electronic control units before welding.

• Read operation manual (safety instructions, item 17) before welding.

27.10. Warning - air conditioner.

• Refrigerant R 134a under high pressure.

• Read operating manual (safety instructions, item 8 and chapter 7, maintenance) before servicing

27.11. Warning - system under pressure.

• Always bleed the air pressure before servicing.

• Read operating manual (chapter 7, daily mantenance) about how to bleed the system.

27.12. Note - sling and/or tie down point • Read the operating manual (safety instruction, item 24 and 25) for correct use of the sling and/or tie down point.

Operating & Maintenance Manual

33

2. Safety Instructions

27.13. Warning - limited visibility • Keep out of this area when the engine is running, the operator has limited visibility.

• To prevent serious injury or death, carry out the following before moving the dump truck: • Be sure no one is on or near the dump truck.

• Sound horn to alert people nearby.

27.14. Warning - pinch danger • Keep clear, pinch danger in the articulation area.

• To prevent serious injury or death carry out the following before moving/turning the dump truck: • Be sure no one is on or near the dump truck.

• Sound horn to alert people nearby.

• Always use the articulation lock when servicing!

• Read operating manual (safety instructions, item 23).

27.15. Warning - body support • Do not stand underneath the body without applying the body support device.

• Always use the body support when working underneath the body.

• Empty body before body support is used.

• Read also operating manual (safety instructions, item 20) before operation.

27.16. Warning - engine is running • Never open the bonnet with the engine running.

• To prevent serious injury stop the engine before opening the engine bonnet.

• Wait until all engine parts have completely stopped before touching them.

• Do not touch hot surfaces! Fingers or hands can be burnt.

34

Operating & Maintenance Manual

2. Safety Instructions

27.17. Warning - battery acid and gases • Battery electrolyte contains sulphuric acid and can quickly burn the skin and eat holes in clothing. Flush the area with water if you have spilt acid on yourself.

• Batteries generate hydrogen gas. Hydrogen gas is very explosive, and is easily ignited with a small spark or flame.

• Read operating manual (safety instructions, item 6) before working with batteries.

27.18. Warning - hot coolant can spurt out • If it is necessary to refill coolant to the expansion tank, stop the engine and allow the engine and the expansion tank to cool down.

• Slowly loosen the cap to relieve pressure before removing the cap.

27.19. Note - fuel tank • Read operating manual (safety instructions, item 2.5 and 7) before refilling fuel.

• Always check fuel specification (chapter 6, lubricants ) before refilling.

27.20. Note - hydraulic tank • Read operating manual (safety instructions, item 2.5 and 7) before refilling oil.

• Always check oil specification (chapter 6, lubricants) before refilling.

Operating & Maintenance Manual

35

2. Safety Instructions

27.21. Note - check oil specification • Always check oil specifications before refilling.

• Read operating manual (chapter 6, lubricants) before refilling.

36

Operating & Maintenance Manual

3. Operating controls

Operating Controls

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

37

3. Operating Controls

Contents

3. Operating controls ................................................... 37-78 Overview of the instruments and controls ................. 39 Instruments ................................................................ 40 Warning / Indicator lights ........................................... 46 Switches ..................................................................... 53 Controls ...................................................................... 61 Cab ventilation ........................................................... 69 Other cabin equipment .............................................. 72

* Numbers refer to positions on the electrical circuit diagram 38

Operating & Maintenance Manual

3. Operating controls

Overview of the instrument panels and controls

WARNING Do not drive the dump truck until you are well acquainted with the location and function of instruments and controls. Read the following carefully, together with the chapter about operation.

• Check the instruments now and again. When abnormal values are discovered in time, precautions can be taken to prevent the occurrence of major damage.

• If red lamps light up, stop the dump truck as soon as possible at a safe place and take necessary precautions. If you don't, safety could be endangered or the dump truck could be damaged.

• To be able to check the function of instruments and controls, the battery main switch must be connected and the starting switch key must be in position 1. See item 65.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

39

3. Operating Controls

Instruments Standard extra equipment and optional accessories are also shown and described.

1

2

Pos 1 2 3 4 5 6 7 8 9 10

3

4

5

6

7

Description Page Engine oil pressure gauge 41 Transmission oil temperature gauge 41 Engine coolant temperature gauge 41 Engine revolution counter and hour meter 42 Fuel gauge 42 Gear display 43 Speedometer 45 Air pressure gauge, front service brakes 45 Air pressure gauge, rear service brakes 45 Voltmeter 45

8

9

Remarks Optional

Optional

* Numbers refer to positions on the electrical circuit diagram 40

Operating & Maintenance Manual

10

3. Operating controls

Instruments 1. Engine oil pressure gauge 27* The gauge indicates the engine oil pressure. Normal operating pressure is 3 - 6 bar (above 800 rpm). Minimum pressure at 800 rpm and warm oil is 0.7 bar. Normal pressure when starting with cold engine is above 6 bar.

If the engine oil pressure is too low during operation, the warning light (18) illuminates and the main warning light (19) will flash.

Check and note the error codes on the engine controller, see item 19 for procedure. Then stop the engine immediately and remedy the fault before restart.

2. Transmission oil temperature gauge 28* The gauge indicates the oil temperature in the transmission.

Normal range is 50 - 105°C, max.permitted for a short period 120°C. Normal operation temperature during retarder brake operation is up to 140°C, max. permitted for a short period 150°C. If the oil temperature in the transmission is too high during operation, the following warning light will light up: the warning light (24), main warning light (23), the wrench on the gear display (6) will flash and the display will show the letters WS, WR or WT (See explanation under item 6, gear display). Stop the dump truck immediately, select neutral gear, and run engine at mid-range speed for a while to cool down the oil. One reason for the high temperature could be use of a too high gear range.

3. Engine coolant temperature gauge 29* The gauge indicates the engine coolant temperature. Normal range is 70 - 93°C. Run engine at moderate speed and load until operating temperature is reached (warm-up period).

If the coolant temperature is too high during operation, the warning light (17) and the main warning light (19) will light up, and the engine controller will reduce the engine load. Check and note the error codes on the engine controller, see item 19 for procedure.

If temperature does not drop, stop the engine (possible fault).

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

41

3. Operating Controls

Instruments

4. Engine revolution counter and hour meter 2* The counter indicates the engine rpm.

Normal revolution: • Low idle: 750 + 50 rpm • Max. power and economic area:

1800 - 2200 rpm

• High idle:

2400 ± 50 rpm

• Max. allowed rpm:

2600 rpm

The hour meter is electronic and indicates operated hours of the engine.

5. Fuel gauge 30* The gauge indicates fuel tank level from empty to full. Tank capacity: approx. 430 litres. Fill up with diesel when necessary, and at the end of the shift.

* Numbers refer to positions on the electrical circuit diagram 42

Operating & Maintenance Manual

3. Operating controls

Instruments

1

2

3

4

6. Gear display 250* 1. Shows gear ranges: Manual, 1st gear Manual, 2nd gear Manual, 3rd gear Manual, 4th - 6th gear Automatic modus 1st - 6th gear • The bars will flash when the lock-up is disengaged.

2. Shows engaged gear 1,2,...etc. (in forward and reverse direction). When the pre-selected gear and the engaged gear are different, the digit will flash.

3. Shows driving-direction ("F" for Forward, "R" for Reverse, "N" for Neutral). When pre-selected driving direction gear is not engaged the digit will flash.

4. Starts flashing if error has been detected.

The main warning light for transmission failure (23) will also light.

If this wrench starts flashing: a. Stop the dump truck on a safe place. b. Select neutral gear position and apply the parking brake. c. Check and note the error codes on the display, which will be shown at pos 2 and 3 when the gear selector is in neutral position. If more than one error has been detected, each error code will be shown for about 1 second. d. Contact your Moxy Dealer (a short explanation of the codes is listed under troubleshooting, chapter 5).

NOTE • •

•

If error codes are shown on the display, contact your Moxy Dealer in all cases.

All error codes (also the special features) shown on the display if the wrench is flashing will be stored in the memory of the transmission controller.

Error codes will only be shown when the gear selector is in neutral position.

Special features: "NN" - shown on the display, means "waiting for gear selector neutral position" (Not Neutral). This will be shown if the starter switch is turned on while the gear selector is out of neutral position.

continued overleaf

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

43

3. Operating Controls

Instruments

Gear display continued ...........

1

2

3

4

"EE" - will be shown if the display has a time-out, i.e. gets no data from the EST. Main reason: EST is in a TOTAL RESET MODE (due to output disconnection or external power supply at lines to the gear-solenoid valves) or is without power or data wire is not properly connected. "

"-

will be shown on the display if the oil temperature is below -12°C. The transmission controller will not release any gear before the oil has been warmed up. Keep the gear selector in neutral position during the warm-up period.

"BA" -

will be shown on the display (flashes between BA and the actual gear position) if the transmission filters are clogged and need maintenance. The filter elements must be replaced immediately.

See 1000 hours serivce for procedure.

"WS"-

will be shown on the display (flashes between WS and the actual gear position) if the oil temperature in the transmission sump (after the oil coolers) is too high.

Stop the dump truck immediately, select neutral gear position and run engine at mid-range speed for a while to cool down the oil temperature.

"WR"-

will be shown on the display (flashes between WR and the actual gear position) if the oil temperature on the output of the retarder (before the oil coolers) is too high.

Stop the dump truck immediately, select neutral gear position and run engine at mid-range speed for a while to cool down the oil temperature.

"WT"-

will be shown on the display (flashes between WT and the actual gear position) if the oil temperature on the torque converter is too high.

Stop the dump truck immediately, select neutral gear position and run engine at mid-range speed for a while to cool down the oil temperature.

"WE"-

will be shown on the display (flashes between WE and the actual gear position) if the engine rpm is too high, i.e. WE starts flashing if the engine rpm reaches 2500 rpm.

Reduce the engine speed.

If the engine rpm is further increased the main warning light will illuminate at 2600 rpm and the emergency retarder will automatically engage.

The engine speed must be reduced immediately!

* Numbers refer to positions on the electrical circuit diagram 44

Operating & Maintenance Manual

3. Operating controls

Instruments 7. Speedometer 10* The gauge indicates the dump truck travel speed in kilometres per hour (km/h).

The display on the speedometer counts: • The total travel distance (can not be reset) in kilometres.

• The partial travel distance in kilometres.

Push the button to switch between the total and the partial travel distance.

8. Air pressure gauge, front service brakes 31*

bar

6

The gauge indicates the air pressure in brake circuit 1.

Normal operating pressure is between 6.8 and 7.8 bar. Do not attempt to drive the dump truck at air pressure below 5 bar. Warning light (11) will light when the pressure is below 4.5 - 5 bar.

A warning buzzer will sound if the pressure is too low on the supply line.

9. Air pressure gauge, rear service brakes 32* Same values as in item 8 for the brake circuit 2 (warning light 12).

10. Volt meter 33* The gauge indicates the voltage in the electrical system.

Normal range is between 24 - 30 volts, normal value is 28 volts.

If the gauge shows less than 24 volts, battery charge warning light (20) will illuminate, check V-belts, regulator and alternator.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

45

3. Operating Controls

Warning / indicator lights Standard extra equipment and optional accessories are also shown and described.

Pos 11 12 13 14 15 16 17 18 19 20 21 22

11 12 13

17

18

19

23

24

25

29 30

31

14 15

20

21

22

26

27

28

32 33

34

16

Description Page Front service brakes warning light 47 Rear service brakes warning light 47 Parking brake warning light 47 Brake fluid warning light 47 Emergency steering warning light 47 Parking brake indicator 47 Engine coolant temperature warning light 48 Engine oil pressure warning light 48 Main warning light, engine failure 48 Battery charge warning light 50 Air filter warning light 50 Spare space 50

Pos 23 24 25 26 27 28 29 30 31 32 33 34

Description Page Main warning light, transmission failure 50 Transmission oil temperature warning light 50 Kick-down indicator 50 Hydraulic filter warning light 51 Spare space 51 Lock-up indicator 51 High beam indicator 52 Engine brake indicator 52 Inter axle differential lock indicator 52 Direction light indicator 52 Retarder brake indicator 52 Spare space 52

Note: Indicator lights for "Automatic central lubrication" and "Flame start", see item 46 and 50 under "Switches" in this chapter.

* Numbers refer to positions on the electrical circuit diagram 46

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights

11

12

13

11. Front service brakes warning light, red 6-A1* Lights if air pressure in brake circuit 1 is below approx. 5 bar.

14

15

16

12. Rear service brakes warning light, red 6-B1* Lights if air pressure in brake circuit 2 is below approx. 5 bar.

13. Parking brake warning light, red 6-C1* Lights if air pressure in brake circuit 3 is below approx. 5 bar.

14. Brake fluid warning light, red 6-A2* Lights if there is a failure in a brake fluid circuit when the brakes are operated (too long stroke in a master cylinder due to air in the system or leakage).

15. Emergency steering warning light, red 6-B2* Lights if the emergency steering is activated.

It shall also light when the dump truck is stationary and during slow driving (indicates low oil supply from the emergency steering pump).

16. Parking brake indicator, red 6-C2* Light when the parking brake (64) is engaged. The light will flash and a buzzer will sound if a gear is selected while the parking brake is on.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

47

3. Operating Controls

Warning / indicator lights 17. Engine coolant temperature warning light, red 7-A1* 17

18

19 Lights if the engine coolant rises above 102 °C.

18. Engine oil pressure warning light, red 7-B1* 21

20

22

Lights if oil pressure is lower than 0.7 bar.

19. Main warning light, engine failure, red 7-C1* Lights or flashes if there is an engine /engine controller failure.

Normal operation The main warning light on the instrument panel shall not light during normal operation, but some of the lamps on the engine controller (located under left hand dashboard panel) will / can light or flash.

These lamps are as follows: • • • • • • 1

The The The The The The

Starting lamp.

Running lamp.

Torque limit lamp Boost limit lamp Control Status lamp - flashes during normal operation.

Power + lamp

Engine / engine controller failure 19.1. If this main warning light on the instrument panel lights: The engine controller will reduce the engine load.

Procedure for reading error codes: 1. If possible, adjust the engine rpm to a low idle, check that the engine oil pressure warning light does not illuminate and check the coolant temperature gauges on the instrument panel.

CAN STATUS TORQUE LIMIT SPEED LIMIT

CONTROL STATUS SHUTDOWN STARTING RUNNING TORQUE LIMIT BOOST LIMIT POWER POWER +

2. Stop the dump truck at a safe place as soon as possible.

Do not turn off the starter switch until you have read and noted the error codes on the engine controller, procedure below.

2 3. Select neutral gear position and apply the parking brake.

4. Open left-hand dashboard panel (1).

CONTROL STATUS SHUTDOWN STARTING

CAN STATUS

RUNNING TORQUE LIMIT

TORQUE LIMIT SPEED LIMIT

3

BOOST LIMIT POWER POWER +

5. Press down the test/fault switch (2) and keep it depressed.

6. All lamps (3) on the engine controller and the main warning lamp on the instrument panel will light up for 2 seconds to indicate that they are intact and in working order.

Make a note if any of the lamps are defective.

7. Then an error code will flash for 5 seconds. Note which lamp it is.

8. The operating mode will then be shown for 2 seconds.

9. The first error code that flashes indicates the most serious engine error or operating error. If the test/fault switch is still kept down, the process will be repeated automatically as above. continued overleaf

* Numbers refer to positions on the electrical circuit diagram 48

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights 10.After having read and noted the error code, the test/fault switch can be released, and the starter switch shall be turned off.

11.Contact your Moxy Dealer.

12.When the error has been rectified, the engine can be restarted.

13. If the main warning light still light up, other errors may be registered.

14. The procedure for reading error codes must then be repeated (item 4-11).

• A short explanation of the codes is listed under troubleshooting.

19.2. If this main warning light on the instrument panel flashes, YOU ARE IN A SHUT DOWN CONDITION! Depending of the nature of the error, the engine controller will take various steps to protect the engine: • It can reduce the engine load.

• It can allow the engine to run at a constant low speed.

• If a serious functional error is detected, it can switch of the engine automatically.

Procedure for reading error codes: 1. If possible, adjust the engine rpm to a low idle, check that the engine oil pressure warning light does not illuminate and check the coolant temperature gauges on the instrument panel.

2. Stop the dump truck at a safe place as soon as possible.

Do not turn off the starter switch until you have read and noted the error codes on the engine controller, procedure below.

3. Select neutral gear position and apply the parking brake.

4. Open the left-hand dashboard panel.

5. Follow the same procedure for reading the error codes as mentioned in item 19.1 item 4-14.

6. If the engine is switched off automatically by the Shutdown function and no error code reading can be obtained, there may be an error in the engine speed sensor.

Contact your Moxy Dealer.

• A short explanation of the codes is listed under troubleshooting.

NOTE •

•

•

If the main warning light illuminates / flashes, check and note the error codes on the engine controller and contact your Moxy Dealer in all cases.

Do not turn off the starter switch until you have read and noted the error codes! The codes will be reset to zero, and it will not be possible to read them.

All error codes will be stored in the memory of the engine controller.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

49

3. Operating Controls

Warning / indicator lights

20. Battery charge warning light, red 7-A2* 17

18

19 Lights if the battery charging voltage is too low (alternator or V- belt fault).

21

20

22

21. Air filter warning light, red 7-B2* Lights if the engine air filter is clogged and needs maintenance.

See 1000 hours service for procedure.

22. Spare space

23

24

25

23. Main warning light, transmission failure, red 8-A1* Lights if there is an transmission / transmission controller failure.

Check the gear display (6) for error codes and contact your Moxy Dealer. A short explanation of the error codes is listed under trouble shooting.

26

27

28

24. Transmission oil temperature warning light, red 8B1* Lights if the oil in the transmission rises above 140 °C.

This warning light is only valid for MT40B, not MT40B SERIES II

25. Kick-down indicator, green 8-C1* Lights when the kick-down mode is activated.

This warning light is only valid for MT40B, not MT40B SERIES II

* Numbers refer to positions on the electrical circuit diagram 50

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights

23

24

25

26. Hydraulic filter warning light, red 8-A2* Lights at normal oil operating temperature if the hydraulic filter is clogged and needs to be replaced.

See 2000 hours service for procedure.

26

27

28

Please be aware that the warning light can also light when the dump truck is started and the oil is cold, and at high engine rpm. Check then that the light switches off when the oil has reached normal operating temperature.

CAUTION If the warning light illuminates when the oil has normal operating temperature, replace the filter as soon as possible.

27. Spare space

28. Lock-up indicator, green 8-C2* Lights when the automatic lock-up clutch for transmission is connected.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

51

3. Operating Controls

Warning / indicator lights

29

30

31

29. High beam indicator, blue 9-A1* Lights when high beam (switch 56B) on the headlights are activated.

32

33

34

30. Engine brake indicator, orange 9-B1* Lights when the engine brake is engaged (automatically or switch 54).

31. Inter-axle differential lock indicator, orange 9-C1* Lights when the inter-axle differential lock is engaged (switch 55)

32. Direction light indicator, green 9-A2* Flashes when direction indicator (switch 56 E/F) or hazard light (switch 41) is activated.

• Will flash fast if an external direction indicator bulb is burnt out. (acc. to market demand).

33. Retarder brake indicator, orange 9-B2* Lights when the retarder brake is engaged (automatically or switch 53).

34. Spare space

* Numbers refer to positions on the electrical circuit diagram 52

Operating & Maintenance Manual

3. Operating controls

Switches Standard extra equipment and optional accessories are also shown and described.

35

41

Pos 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

42

43

36

37

44

38

45

39

46

Description Working lights (backwards) Working lights and reversing lights Working lights (forward) Instrument light switch Extra high beam Main light switch Hazard light switch Rotating beacon switch Spare space Test switch for brake warning light Tipping system switch Automatic central lubrication indicator light Mirror heating switch Electrical heated driver's seat switch Cab and engine compartment light

40

47

Page 54 54 54 54 54 54 55 55 55 55 55 56 57 57 57

48

49

Remarks Optional Optional Optional Optional

Optional

Optional Optional Optional

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

53

3. Operating Controls

Switches

35. Working lights (backwards) 91* Push the switch to activate the working lights.

Built-in light.

37 36

36. Working lights and reversing lights 20* Push switch to activated the lights. Built-in light.

The switch has three positions:

35

1. The working lights will light.

2. Neutral, the lights are switched off.

3. The reversing light will light when reverse gear is engaged.

37. Working lights (forward) 19* Push the switch to activate the working lights.

Built-in light.

38. Instrument light switch 4* Push the switch to light all instruments. Built-in light.

The instrument light will be turned off when this switch is off.

40 39 38

39. Extra high beam 21* Push the switch to activate the extra high beam. Will only be activated if the high beam on column switch (56) is switched on.

Built-in light.

40. Main light switch 90* 1st position, Side lights.

When the switch is set to 1st position, the side/marking/licence plate lights illuminates.

2nd position, Headlights.

When the switch is set to 2nd position the headlights (high or low beam according to position of column switch 56) will also illuminate.

Built-in light.

* Numbers refer to positions on the electrical circuit diagram 54

Operating & Maintenance Manual

3. Operating controls

Switches

41. Hazard light switch 89* Push switch to activate the hazard light, all direction indicators will flash at the same time. An indicator light (32) on the instrument panel will flash concurrently. Built-in light.

43

42. Rotating beacon switch 92*

42 41

Push switch to activate the rotating beacon on top of the cab roof.

Built-in light.

43. Spare space

44. Test switch for brake warning light 5* Push the switch and check that the warning light for brake fluid circuit failure (14) lights up.

Or

46 45 44

45. Tipping system switch 716* Push the switch to override the tipping system. For safety reasons, the tipping system is made in such way that it is not possible to tilt the body centre of gravity over the tipping hinges.

• If an empty body shall be raised, it may be necessary to push the switch and keep it depressed while the body is lifted with the tip control lever. Release the switch when the body is raised.

• If the body is resting on the body support, it is necessary to push the switch and keep it depressed while the body is lifted slightly. Release the switch when the body is off the body support and lower the body.

WARNING Do not use this switch when tipping with load!

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

55

3. Operating Controls

Switches 46. Automatic central lubrication indicator light, green or yellow 22* Lights when the automatic central lubrication is activated.

Or

46 45

The system performs all operation automatically. After the starter switch is turned on or is in operation the pump will at 30 minutes interval supply measured quantities of grease to all the lubrication points. The indicator light will then light up once. This pattern will be repeated 4 times.

Blink codes for the indicator light: (the buzzer will sound when the indicator light is flashing)

44

• The light flashes 4 times once (0.5s on/0.5s off) as soon as the starter switch has been turned on: Cause: The automatic central lubrication is activated.

• The light does not flash when the starter switch is turned on: Cause: 1.The system is not powered. Check fuses and connection to earth and replace if necessary.

2. Lamp or wiring to lamp could be defective. Check lamp and wiring and replace if necessary.

• The light flashing for 2 minutes (0.5s on/0.5s off) at the beginning of each cycle: Cause: Minimum grease level in the reservoir has been reached. Refill the reservoir as soon as possible, see 500 hours service for procedure.

• The light continuously light for 2 minutes at the end of the pumping phase: Cause: Insufficient grease pressure. Contact you Moxy Dealer.

Test button

• The light continuously light after starter switch has been turned on: Cause: System out of order! Immediate action is required.

Possible causes: 1. Insufficient grease pressure during 10 consecutive cycles (or 10 consecutive times in the same main pipe channel). Check cause and reset by depressing the test button (on the reservoir) for at least one second while the starter switch is turned on.

2. Reservoir empty; refill the reservoir and after that depress the test button (on the reservoir) for at least one second while the starter switch is turned on.

• The light flashing during one complete cycle (2.0s on/2.0s off): Cause: Single test run being executed (see "test") • The light flashing continuously (0.2s on/0.2s off): Cause: Continuous cycle test run being executed (see "test")

* Numbers refer to positions on the electrical circuit diagram 56

Operating & Maintenance Manual

3. Operating controls

Switches

Test • In order to check the system a single lubrication cycle can be performed.

1. Starter switch turned on.

2. Depress the test button (on the reservoir) for 3 to 5 seconds.

The system will run a single cycle test. During this test the light will flash (2.0s on/2.0s off).

Test button

• In order to provide additional grease to all lubrication points (i.e after cleaning the dump truck) or to vent the system, a continuous lubrication cycle run can be performed.

1. Starter switch turned on.

2. Depress the test button (on the reservoir) for more than 6 seconds.

The system will perform a continuous lubrication cycle run.

During this run the light will flash (0.2s on/0.2s off). The continuous test cycle ends after the starter switch has been turned off.

47. Mirror heating switch 94* Push the switch to heat the external mirrors for ice and condensation removal. Built-in light.

Engage only when necessary!

49 48 47

48. Electrically heated driver's seat switch 205* Push the switch to activate the heating of driver's seat.

Built-in light.

49. Cab and engine compartment light 93* Push the switch to light the cab and the engine compartment lights.

Turn off during operation. Built-in light.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

57

3. Operating Controls

Switches Standard extra equipment and optional accessories are also shown and described.

50

Pos 50 51 52 53 54 55

51

52

53

54

Description Flamestart system indicator Flamestart system preheating switch Flamestart system cancellation switch Retarder brake main switch Engine brake switch Inter axle differential lock

55

Page 59 59 59 60 60 60

* Numbers refer to positions on the electrical circuit diagram 58

Operating & Maintenance Manual

Remarks Optional Optional Optional Optional Optional

3. Operating controls

Switches

50. Flamestart system indicator light, green 407* Lights when glow plugs for the flamestart system are activated.

51. Flamestart system preheating switch 410* 50 51 52

Push the switch and keep it depressed to activate the flamestart system.

1. With the starter switch (65) in position I and the gear selector in neutral position, keep the switch depressed for approx. 15 sec. (max. 20 sec) before starting the engine (pre-heating).

2. Continue to keep the switch depressed while the starter switch (65) is turned to position II and the engine starts.

3. When the engine starter is engaged, the switch can be released and the time relay will automatically keep the system going for 5 minutes, as long as no interruption is made (see item 52).

An indicator light (50) will light as long as the glow plugs are activated.

NOTE To activate the flamestart system the gear selector must be in neutral position and the preheating switch must be kept depressed until the engine starter is engaged.

52. Flamestart system cancellation switch 412* To interrupt the connection to the glow plugs, the cancellation switch must be pushed to break the circuit to the time relay.

Interruption of the connection to the glow plugs will also take place if the gear selector (61) is moved out of neutral position or the starter switch (65) is turned off.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

59

3. Operating Controls

Switches

53. Retarder brake main switch 81* Push the switch to engage the retarder brake.

The retarder brake will only engage when a gear is selected, lockup connected and the throttle pedal released.

Built-in light.

If the switch is not installed, the retarder brake will engage automatically when a gear is selected, lock-up connected and the throttle pedal released.

53 54 55

An indicator light (33) will light when engaged. The retarder brake effect must be controlled by the retarder brake lever (62).

If this lever is in off position, the retarder brake will not function even if the main switch is on.

54. Engine brake switch 80* Push to engage the engine brake.

The engine brake will only engage when a gear is selected, lockup connected and the throttle pedal released.

Built-in light.

If the switch is not installed, the engine brake will engage automatically when a gear is selected, lock-up connected and the throttle pedal released.

An indicator light (30) will light when engaged.

55. Inter-axle differential lock 77* Push the switch to engage the inter-axle differential lock.

Engine power and wheel speed determine when the lock engages. An indicator light (31) will light when the lock is engaged.

Built in light.

NOTE Only to be engaged when the dump truck is stationary.

* Numbers refer to positions on the electrical circuit diagram 60

Operating & Maintenance Manual

3. Operating controls

Controls

Standard extra equipment and optional accessories are also shown and described.

67

56

57

58

Pos 56 57 58 59 60 61 62 63 64 65 66 67 68

59

60

Description Column switch Steering column Steering wheel Brake pedal Throttle pedal (accelerator) Gear selector Retarder brake lever Tip control lever Parking brake lever Starter switch Cigarette lighter Emergency exit Cab ventilation

68

61

66

62

65

63

64

Page 62 64 65 65 66 67 67 67 68 68 68 69

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

61

3. Operating Controls

Controls 56. Column switch 40* The column switch is a multi-function switch for main lights, horn, direction indicators and windscreen wiper/washer.

Main lights (A, B, C):

B

A. Low beam (when switch 40 is in position 2)

C A

B. High beam (when switch 40 is in position 2), indicator 29 will light.

C. High beam flash. Automatic return.

D. Horn, centre button automatic return.

D

E

E. Right turn, all right direction indicators flash.

Indicator light 32 flashes correspondingly.

F. Left turn. All left direction indicators flash.

Indicator light 32 flashes correspondingly.

F

* Numbers refer to position on the electrical circuit diagram 62

Operating & Maintenance Manual

3. Operating controls

Controls

G. Windscreen wiper. Turn handle. Positions: 0 OFF

G

J interval I

low speed

II high speed

H

H. Windscreen washer, push outer ring to activate the washer motor. At the same time, the wiper wipes some times after releasing the ring.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

63

3. Operating Controls

Controls 57. Steering column The steering wheel is fitted on an adjustable column for comfortable reach and easy operation.

• Height adjustment - lift lever up to unlock.

• Tilt adjustment - push lever down to unlock.

• Confirm that the steering column is fixed before operating the truck.

WARNING Do not adjust position while driving!

* Numbers refer to position on the electrical circuit diagram 64

Operating & Maintenance Manual

3. Operating controls

Controls 59. Brake pedal The pedal controls the main brake (service brake). When depressing the pedal, the rear stop light will light. Braking effect depends on pedal position. Depress pedal gradually, and learn to associate braking requirements for loaded and unladen dump truck.

Do not use the pedal for long period retardations, i.e. loaded downhill. This will overheat and damage the disc brake.

59

CAUTION If warning for brake fluid circuit failure lights up (warning light 14), stop the dump truck immediately!

60. Throttle pedal (accelerator) The pedal controls the engine speed electronically.

60

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

65

3. Operating Controls

Controls

61. Gear selector 236* The dump truck is equipped with a fully automatic transmission with 6 forward and 3 reverse speeds. Gear shift pattern is speed and engine load dependent. Preselection of gears is possible. The gear display (6) on the dashboard will always show the engaged gear position.

Pos N: Neutral gear position Depress the knob on top of the gear selector when shifting from neutral to forward or reverse position.

Also, always depress the knob when shifting directly between forward and reverse direction.

Pos V: Forward drive position.

Automatic gear shift between 1st-6th gear according to speed and engine load.

For preselection of gear, push the selector to the right (+) for upshifting or to the left (-) for downshifting. The selected gear will then be engaged when the speed matches the set points.

If the gear selector is pushed either to the left or right, manual gear shifting will take place. The gear selector must then be pushed in order to change gear.

Manual gear shifting will also take place if the knob on the top of the gear selector is depressed while driving in automatic.

To return to automatic gear shifting while driving in manual, depress the knob on top of the gear selector.

Pos R: Reverse drive position: Manual gear shift between 1st-3th gear according to speed and engine load.

The transmission will always select the 1st reverse when the gear selector is set to "R" The selected gear is engaged directly if the dump truck is stationary. The gear selector has to be pushed in order to change gear.

For preselection of gear, push the selector to the right (+) for upshifting or to the left (-) for downshifting.

See also chapter 5, Operating Instructions

NOTE The knob on top of the gear selector has three functions: 1. Depress the knob when shifting from neutral to forward or reverse position.

2. Depress the knob when shifting directly between forward and reverse direction.

3. Depress the knob to change between automatic and manual gear shifting.

* Numbers refer to position on the electrical circuit diagram 66

Operating & Maintenance Manual

3. Operating controls

Controls 62. Retarder brake lever

OFF

The lever controls the retarder brake effect. The effect is infinitely variable between off and max. position.

The retarder main switch (53) has to be switched on to engage the retarder brake. If the switch (53) is not installed, the retarder brake will engage automatically. An indicator light (33) will light when engaged.

MAX.

63. Tip control lever 714*

Lower

The lever controls the body lifting and lowering.

The lever has 3 positions:

Hold

Lock device Lift

1. Lower (body down/power down and floating position).

2. Hold (hold and floating position).

3. Lift (body up).

The lever are mechanically locked in the hold and lower positions.

Lift the lock device to release the lever in these positions. Always keep the lever in hold position during loading and driving. Check that the body is resting on the frame rubber pad during loading and driving. Spring return from lift to hold.

64. Parking brake lever

OFF

ON

The parking brake is on (locked) when the lever is in the backward position. An indicator light (16) will light when the parking brake is on. Lift the lock device to release the parking brake. In the forward position the parking brake is off (released).

The parking brake must not be applied when the dump truck is in motion unless in an emergency situation. Warning light (16) and a buzzer will sound if a gear is selected while the parking brake is on (locked).

CAUTION Do not drive the dump truck if the air pressure is below normal pressure (warning light 13 and buzzer). The parking brake will not be fully released, and the service brakes may not have max. braking effect.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

67

3. Operating Controls

Controls 65. Starter switch 78* The starter switch is key operated, and has 4 positions.

P = Park (key removable) 0 = Power off (key removable) I = Power on (drive position).

II = Starting position (key returns back to pos. I when released).

WARNING Do not turn the key to off position if you do not intend to stop the engine. The engine has a key stop and requires neutral position on the gear selector to start again.

66. Cigarette lighter 79* Push in to activate the heating function. Automatic return when hot.

Can also be utilised as a 24 Volt / 10 amp power source.

67. Emergency exit • This dump truck is fitted with three emergency exits.

• Right and left doors and front windscreen.

• If doors are blocked by any means you can get out through the front windscreen.

• Pull the handle under the window backwards. The rubber seal must be pulled completely off before pushing the front windscreen out.

* Numbers refer to position on the electrical circuit diagram 68

Operating & Maintenance Manual

3. Operating controls

Cab ventilation

68. Cab ventilation 1

2

3

4

1. Ventilation fan switch 37* Turn switch to operate the 3-speed cab fan.

The fan must be used together with both the heater unit and the air conditioner. The fan must be on (1st, 2nd or 3rd speed) to operate the air conditioner.

5

2. Thermostat for the air conditioner. 266* Selects cab temperature during air conditioner operation.

Turning clockwise increases cooling.

Works only together with the air conditioner switch.

3. Heater regulator. 267* Adjust air heating with the knob. The air is heated by the engine coolant. Turning clockwise increases heating.

4. Air conditioner switch 35* Push the switch to activate the air conditioner system.

A compressor (engine mounted) and a cooling element cools the air when the engine is running and this air conditioner switch is set to on. Regulate the efficiency with the thermostat (2).

5. Air conditioner indicator 35* Lights when the air conditioner is activated.

The intake air is filtered before it enters the cab. All nozzles are adjustable, and air may be directed in the desired direction. It is also possible to close the nozzles.

General about heat and ventilation • Keep the doors and window shut.

• Always open the nozzles when operating the dump truck.

• Direct the air flow so that it does not blow straight on uncovered skin.

• Always turn the fan on (1st, 2nd or 3rd speed) when operating the dump truck and adjust fan speed until it feels comfortable in the cab.

• When using air conditioner, do not direct the air flow directly towards the windows, it can cause steamy windows.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

69

3. Operating Controls

Cab ventilation Setting heat and ventilation Without air conditioning How to get...... ......maximum heat: • All nozzles fully open.

• Heater regulator (68.3) on max., i.e right position • Fan switch (68.1) on max, i.e. speed 3.

If condensation forms, see "......remove condensation from all windows.

...... pleasant working temperature: • All nozzles fully open.

• Heater regulator (68.3) on max., i.e. right position • When the correct temperature has been obtained, turn heater regulator (68.3) (left) until you maintain the desired temperature.

• Fan switch (68.1) set to speed 1 or 2.

......fresh air in cab: • All nozzles fully open.

• Heater regulator (68.3) on min., i.e. left position • Fan switch (68.1) on max, i.e. speed 3.

How to get...... ......rid of condensation and ice on all windows: • Direct the nozzles towards the windows.

• Heater regulator (68.3) on max., i.e. right position • Fan switch (68.1) on max, i.e. speed 3

This instruction is a basic recommendation, and each driver should learn to set and regulate the heating/ventilation unit, to give the correct temperature without draughts and achieve best working environment.

CAUTION Ensure good ventilation!

Do not operate the dump truck without ventilation, or with the cab entirely closed, unless the fan is on.

Poor ventilation can cause drowsiness (lack of oxygen). * Numbers refer to position on the electrical circuit diagram 70

Operating & Maintenance Manual

3. Operating controls

Cab ventilation Air conditioner How to get...... ......a pleasant temperature quickly: • • • • •

All nozzles fully open.

Heater regulator (68.3) on min., i.e. left position Thermostat (68.2) on max., i.e. right position Fan switch (68.1) on max, i.e. speed 3.

Switch (68.4) pressed down, i.e. air conditioner engaged.

When the temperature has been lowered to the level you want: • Turn the fan switch (68.1) and the thermostat (68.2) to the position which maintains the desired temperature.

...... rid of air humidity in the cab: • • • • •

All nozzles fully open.

Heater regulator (68.3) on max., i.e right position Thermostat (68.2) on max. , i.e right position Fan switch (68.1) on max., i.e speed 3.

Switch (68.4) pressed down, i.e air conditioner engaged.

• In very cold countries, use of the air conditioner will retain humidity in cab air which may become too dry through heating.

This instruction is a basic recommendation, and each driver should learn to set and regulate the air conditioning unit, to give the correct temperature without draughts and achieve best working environment.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

71

3. Operating Controls

Other cab equipment

Driver's seat The seat is air-sprung and adjustable in height, tilt, back support and lengthwise position. Adjust the seat to the desired position. Always use the safety belt when operating the dump truck.

Seat adjustment.

7 1

1.

Lumbar support adjustment.

Stepless adjustment of the support.

8

2.

Backrest inclination adjustment.

3.

Seat cushion inclination.

Stepless adjustment of seat cushion Forward - clockwise. Backward - counterclockwise.

4.

Forward and backward adjustment.

Lift lever up and slide the seat to a suitable position - release lever.

5.

Height adjustment.

Stepless seat height adjustment.

Elevation - clockwise. Lowering - counter clockwise.

Automatic weight adjustment.

6.

Quick seat lowering.

For comfortable step in and out.

Lower the seat - valve outwards. When seated, press valve in and seat automatically returns to individual setting.

7.

Headrest.

8.

Armrest Can be lifted for easy access, and the inclination of the arm rests are adjustable for comfortable operating position.

9.

Adjustment screw Stepless inclination adjustment.

10.

Backrest.

11.

Suspension height limiter.

I. Lever to the right: Comfort position, max. suspension height, 150 mm.

II. Lever in middle position: Suspension height limited to 90 mm.

III.Lever to the left: Fixed position, no height suspension.

Seat must be in correct position, 75 mm above bottom position when locking.

48.

Electrically heated driver's seat.

2 3 4

10

5/6

11

8 9

The seat can be heated by pushing the switch.

Refer to item 48 in this chapter.

* Numbers refer to position on the electrical circuit diagram 72

Operating & Maintenance Manual

3. Operating controls

Other cab equipment Instructor seat There are one or two seats for instructors, one on the left side of the driver seat and / or one on the right hand side. The seat cushions are spring-loaded and will return to upright position when released. The seats are fitted with safety belt which is recommended for use during driving, both for safety and comfort.

Internal door openers/locks The doors are fitted with lockable door openers.

• Push down handle to open the door.

• The doors can be locked from outside.

• A locked door will be released when using the internal opener.

External door openers/locks The door is fitted with lockable door openers.

• Pull out the handle grip to open the door.

• The doors can be locked from outside by using the door key.

• A locked door will be released when using the internal opener.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

73

3. Operating Controls

Other cab equipment

Door window There are 4 different opening positions by two locking mechanisms at the upper edge of the top windows.

• To open the window: Lift both lock arms to a suitable position.

• To close the window: Push window completely upward and check that the window locks are in the locked position.

Safety equipment The dump truck is originally equipped (Distributor/Dealer fitted) with following safety equipment, which should always be present and in order: • First aid kit.

• Fire extinguisher, 2 kg, ABE class II powder.

* Numbers refer to position on the electrical circuit diagram 74

Operating & Maintenance Manual

3. Operating controls

Other cab equipment

• Warning triangle.

Bottle/cup holder

Ashtray

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

75

3. Operating Controls

Other cab equipment Retractable roller sunblind on front windscreen

Cab light The cab light switch has three positions: • On • Off • Door activated (left hand door)

* Numbers refer to position on the electrical circuit diagram 76

Operating & Maintenance Manual

3. Operating controls

Other cab equipment

Radio/Cassette player 61II* The radio has following security features: Detachable panel, switchable warning light, security warning sticker and identification number.

If any of the security features are missing, contact your local Moxy Dealer.

1.

Detachable panel Take the detachable panel with you when leaving the dump truck. Keep it in its protective cover. Always replace the detachable panel before starting to drive.

• Remove the panel by sliding the "REL" key downwards.

• Replace the panel starting with the left-hand side of the radio. Then push the panel until it clicks into position.

2.

Switchable warning light The red light flashes when the detachable panel is removed.

• Stop or start the light flashing by pressing the "POWER" key.

3.

Security warning stickers • This "security" warning sticker shall be fitted on your dump truck window.

4.

Identification number • This radio has a unique identification number (printed on the "security card"). This card is required as proof of ownership if the radio is stolen, if the detachable panel is lost or if requesting service.

• The "security card" shall be removed before installing the detachable panel.

Do not keep the "security card" in your dump truck.

5.

Operating Manual for the Radio/Cassette player For operation of the radio, see separate Operating Manual.

If the Operating Manual for the radio is missing, contact your local Moxy Dealer.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

77

3. Operating Controls

* Numbers refer to position on the electrical circuit diagram 78

Operating & Maintenance Manual

4. Running-in period

Running-in period

Operating & Maintenance Manual

79

4. Running-in period

Contents

4. Running-in period .................................................... 79-84 1. Running-in operation ............................................ 81 2. Running-in service ............................................... 82

80

Operating & Maintenance Manual

4. Running-in period

1. Running-in operation Each new dump truck requires careful operation the first 100 hours (refer to hour meter) to break in (run-in) all moving parts.

Follow instructions below during this period: 1. Start engine as described in "Operating Instructions"(chapter 5) . Run engine at low idle speed until air pressure in the various circuits is normal.

2. Warm up by operating the dump truck at low load and reduced rpm until all gauges show normal range.

Extend the warming up period in the winter (cold season).

3. During operation do not drive with constant high engine rpm and load, avoid heavy-duty work and high speed travelling.

4. Drive carefully and avoid sudden starts and stops, abrupt acceleration and turns.

5. Carefully perform the running-in services, see next page.

Take special care for the following points: • A warming up period until gauges show normal range is important - also after the dump truck has been run in.

• Operating up to the limit of the dump truck's capacity during the running-in period, may prematurely reduce the performance potential.

Operating & Maintenance Manual

81

4. Running-in period

2. Running-in services Running-in service is to be carried out after operating the dump truck the first 8, 100 and 500 hours. These services are most important for running in a new dump truck.

This is the owner’s responsibility.

2.1

First 8 hours: 1. Wheel nuts.

• Torque setting:

Check tightening of nuts.

450 Nm. Spanner: 30 mm (from serial no. 513001 and up to 513079) Spanner: 32 mm (from serial no. 513080 and up)

2. Lubricating.

Grease all lubricating points.

3. Battery:

Checking electrolyte level in the batteries, see 40 hours/weekly service, item 1.1 Checking battery charge, see 1000 hours service, item 2.3

4. V-belt:

Checking V-belts condition, see 500 hours service, item 1.4

5. Carry on with the normal 8 hours service, listed in chapter 7, maintenance.

Since these points are important for the dump truck to work satisfactorily right from the start they are also listed below.

All items below refer to 8 hours / daily service in chapter 7.

• Walk around check .............................................. item 1.1 • Check operator seat ............................................ item 1.2 • General condition check - look for leakages, ...... item 2.1 • Check oil level, engine ......................................... item 2.2 • Check coolant level .............................................. item 2.3 Coolant should be filled up when the engine is stopped after first stop, see 2000 hours service, item 1.3 check the coolant.

• Check fuel level ................................................... item 2.4 • Function check of the centrifugal cleaner, ........... after first operation ............................................... item 2.5 • Drain air tanks, after first operation ..................... item 2.6 • Check oil level, transmission ............................... item 3.1 • Check oil level, hydraulic system ........................ item 4.1 • Check brake fluid levels ....................................... item 5.1 • Check parking brake capacity, ............................ item 7.1 • Check main brake capacity .................................. item 8.1 • Check main brakes function, ............................... item 8.2 • Check engine brake function ............................... item 9.1 • Check retarder brake function ............................. item 10.1 • Check steering function ....................................... item 11.1

2.2

First 100 hours: 1. Change transmission oil.

20*

See 1000 hours service, item 4.1.

2. Replace transmission filter. 21*

See 1000 hours service, item 4.1.

3. Clean strainer.

22*

See 1000 hours service, item 4.1.

4. Replace hydraulic filter.

43*

See 2000 hours service, item 2.3.

5. Retorque window wiper spindle nuts.

• Torque setting: 35 Nm (M10), 18 Nm (M8) 6. Lubricating. Grease all lubricating points.

* Numbers refers to position on lubrication schedule, chapter 6 82

Operating & Maintenance Manual

4. Running-in period

2.3

First 250 hours: 1. Check brake lining thickness.

See 500 hours service, item 4.1.

How often the brake linings have to be checked/replaced depends on how much the brakes are used and/or application.

After checking the brake linings for the first 250 hours, consider whether or not the brake linings should be checked more often, based on lining wear.

2.4

First 500 hours: 1. Change oil in: • Front differential.

• Rear differential.

• Tandem housings.

• Reduct. gears, front.

30* 31* 32* 33*

See 1000 hours service, item 5.1.

See 1000 hours service, item 6.1.

See 2000 hours service, item 5.1.

See 1000 hours service, item 7.1.

2. Check/adjust: • Valve clearance. Procedure described in 2000 hours service, item 1.2.

• Hydraulic oil pressure. Contact your local Moxy dealer.

3. Lubricating. Grease all lubricating points.

4. Carry on with the normal 500 hours service, listed in chapter 7, maintenance.

• Change oil, engine ............................................... item 1.1 • Clean centrifugal cleaner ..................................... item 1.2 • Replace turbo filter ............................................... item 1.3 • Check V-belt condition ........................................ item 1.4 • Run the AEB-Tester ............................................. item 2.1 • Check brake lining thickness .............................. item 4.1 • Check wheel nuts torque .................................... item 5.1 • Test operation of the air conditioner system ...... item 6.1 • Refill the reservoir for autom. central lubrication item 7.1 • Check the automatic central lubrication system . item 7.2

See chapter 7 for procedures and chapter 6 for fluid specifications.

* Numbers in brackets refer to position on lubrication schedule, chapter 6 Operating & Maintenance Manual

83

4. Running-in period

84

Operating & Maintenance Manual

5. Operating Instructions

Operating Instructions

Operating & Maintenance Manual

85

5. Operating Instructions

Contents

5. Operating instructions ............................................. 85 - 112 Some simple rules to be observed prior to operation 87 1. Starting the engine .............................................. 88 2. Operating the dump truck .................................... 90 3. Parking the dump truck ........................................ 99 4. Stopping the engine ............................................ 100 5. Checks after stopping the engine ....................... 100 6. Loading and tipping ............................................ 101 7. Tyre handling ....................................................... 102 8. Cold weather ........................................................ 104 9. Long term storage ............................................... 105 10. Battery power assistance .................................... 106 11. Towing the dump truck ........................................ 107 12. External air filling ................................................. 107 13. Manual release of parking brake ........................ 108 14. Tyre filling point ................................................... 108 15. Troubleshooting ................................................... 109

86

Operating & Maintenance Manual

5. Operating Instructions

Some simple rules to be observed prior to operation.

• Read and understand this Operating & Maintenance Manual before you begin to operate the dump truck.

• Never operate the dump truck if you are under the influence of alcohol, medicines or other drugs.

• You must wear personal safety equipment, for safe operation.

• Use helmet to increase protection of your head.

• When you climb up or down from the dump truck, always climb with your face towards the dump truck and use steps and handles. Always use two hands and one foot, or one hand and two feet. DO NOT JUMP! • Do not climb on surfaces which are not intended for this, always use the surfaces which are provided with anti-slip coatings.

• When the dump truck is operated, the door should be shut.

• Check that the seat is adjusted for comfortable and safe operation of controls before operation.

• Check that the steering column is adjusted for comfortable operation, and confirm that it is fixed before operation.

DO NOT ADJUST POSITION OF THE STEERING WHEEL WHILE DRIVING! • Always use the seat belt during driving!

If there are instructors or passangers in the cab, be sure that they are seated on the instructor seats and are using seat belts!

• If instructor seats are not fitted, instructors or passengers may not stay in the cab during driving.

• Check the air pressure in the brake system before you start driving.

• The cab is the driver's protection and conforms to the requirements for roll-over protection (ROPS) and falling objects (FOPS), specified in the standard for these. The precondition for providing protection is that the driver uses the seat belt and remains in the cab. Therefore, hold on to the steering wheel if the dump truck should roll over.

• The cab has three exits, two doors and the front windscreen as emergency exit. The front windscreen is opened by pulling the handle under the windscreen backwards. The rubber seal must be pulled completely off before pushing the front windscreen out.

Operating & Maintenance Manual

87

5. Operating Instructions

1. Starting the engine Before starting the engine in the morning, perform the Daily Service, see chapter 7.

Remember to connect the battery main switch in the battery box (if disconnected) otherwise there will be no power supply.

1.1. Confirm that parking brake is ON

1.2. Confirm that gear selector is in neutral position

1.3. Turn the starter switch ON, pos 1 Check warning lights before starting: • engine oil pressure • charging light • parking brake • brake circuits • emergency steering warning light, switches off above 5 km/h.

• depress the test switch for brake warning light to check that the warning light is okay.

If any of these lights do not light up, either the lamp is broken or there is a fault in the electrical system. This should be checked and fixed before starting, if necessary.

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1.4. Start the engine 1. Turn the starter switch key to the right, pos. II to engage the starter.

2. Hold until engine starts (max. 20 sec).

3. Check that warning lights for engine oil pressure and battery charge switch off.

1.5. If engine does not start: 1. Turn starter switch OFF, and wait until engine has stopped completely before attempting to start again.

2. In cold weather, wait 30 sec. before restart.

1.6. Starting in cold weather / at low temperatures Start aids, engine heater and/or flamestart system should be used to avoid starting problems and white smoke.

Below -10 °C it can be absolutely necessary to use engine heater or flamestart system to avoid starting difficulties.

• If a flamestart system is equipped, see Operating Controls (chapter 3), about how to operate the flamestart system.

• If an engine heater is equipped, an external power supply is needed (AC 220 V - 50 Hz).

• See also item 7, Cold weather in this chapter.

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2. Operating the dump truck 2.1. Before operation When the engine is running properly and the air pressures are within operating range: 1. Clean/defrost the windows before driving.

2. Fasten the seatbelt before driving.

3. Check that gauges and warning lights do not indicate any abnormalities.

4. Confirm low idle speed.

5. Check that there are no persons or objects in front of the dump truck, or in the articulation area, before you drive off.

6. Sound the horn as alert.

7. Depress the brake pedal.

8. Release the parking brake and confirm that the indicator light goes off.

9. Select a suitable gear position at low idle (see item 2.3, Gear shifting).

10. Release the brake pedal and increase the engine speed by pressing the throttle pedal downwards.

2.2. Warming up period When driving off with a cold dump truck, operate the dump truck gently with reduced engine load and rpm to warm up until all gauges indicate operating range. This is important to avoid reduction of the dump truck’s performance potential.

2.3. Gear shifting The transmission has automatic gear shift to match the travel speed. The shifting is electronically controlled and a lock-up clutch is fitted in the transmission to increase efficiency in all gears. Connection/disconnection is automatic but speed and engine load related.

Gear position N: Neutral gear position The engine will not start if the gear selector is out of neutral position.

When the gear selector is in neutral position it is always necessary to depress the knob on top of the selector to shift to forward or reverse position.

Also, always depress the knob when shifting directly between forward and reverse direction.

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Gear position V: Forward drive position.

The transmission shifts automatically between 1st and 6th gear, according to dump truck speed and engine load.

The transmission will normally start in 2nd gear, if the conditions are heavy, it will automatically shift down to 1st gear.

Gear shift program: The gear shift program is controlled by the throttle pedal position.

Shifting at low rpm happens when the pedal is partially depressed (part load mode). If the throttle pedal is further depressed, the gear shift will take place at higher rpm (full load mode). With the throttle pedal fully depressed, the gear shift will either be prevented or close to the maximum engine rpm (kick-down mode).

When the throttle pedal is released and the engine and/or the retarder brake is engaged, the down shift will take place at high rpm.

Preselection of gears.

The gears can be preselected by the driver as follows: Push the gear selector to the right (+) for upshifting or to the left (-) for downshifting.

When a gear is preselected and the gear selector is pushed either to the left or right, the gear system will switch to manual gear shifting. The gear selector must then be pushed in order to change gear.

When the selected gear is engaged, the transmission will only operate in this gear until the selector is pushed to another position or changed back to automatic gear shift by depressing the knob on top of the gear selector.

When a gear is preselected and not engaged, the digits on the gear display will flash.

Manual gear shifting To avoid repeated up and down shifting when driving in heavy conditions it is an advantage to use manual gear shift.

When changing from automatic gear shift to manual gear shift, push the gear selector either to the left for downshift or to the right for upshift, or manual gear shift can be obtained by depressing the knob on top of the gear selector while driving in automatic.

In manual gear shift mode the selector must be pushed in order to change gear.

Preselection of gears is also possible in manual gear shift.

When the selected gear is engaged the transmission will only operate in this gear until the selector is pushed to another position.

If the dump truck is stationary, the selected gear will be engaged directly.

To return to automatic gear shift while driving in manual, depress the knob on top of the gear selector.

CAUTION With the dump truck stationary, do not engage a gear at high engine speed.

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Kick-down, KD When the throttle pedal is fully depressed, the kick-down function will be activated, giving a higher rpm before shifting gear.

Kick-down can be used to get a higher engine speed to obtain optimum acceleration and minimum deceleration before shifting gear, or to prevent upshift and to get an earlier downshift.

Engine and retarder brake mode When the engine brake or/and the retarder brake is engaged, the transmission will not shift to a higher gear if the speed increases at downhill driving.

Operating hints Different types of terrain require different operating techniques.

• Use automatic gear shift for normal travel.

• In terrain, before uphill/downhill driving, manually select a suitable position for the estimated speed in the area, avoid repeated up and down shift in hilly terrain.

• When selecting a gear from the neutral position and when shifting between forward and reverse gears: • Stop the truck and release the throttle pedal completely.

• Depress the knob on the top of the gear selector, select the desired gear and wait until the gear is engaged before increasing the engine speed.

• The knob on top of the gear selector is used for: • Shifting from neutral to forward or reverse position.

• Shifting directly between forward and reverse direction.

• Changing between automatic and manual gear shift.

• In manual gear shift mode, always drive allowing the lockup clutch to connect.

• Neutral position must not be selected during driving!

• The starter switch must NEVER be turned off (position 0) during driving, if you do not intend to stop the engine!

The engine has key stop and requires neutral position on gear selector to restart.

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2.4. Reversing (back-up) operations 1. Before reversing, make sure that no persons or objects are behind the dump truck or in the articulation area.

2. Stop the dump truck completely before selecting the reverse gear.

3. Depress the knob on top of the gear selector and place the gear selector in position R with engine running at low idle.

The transmission will always select 1st reverse.

4. Increase the engine speed.

The reverse drive position has manual gear shift between 1st and 3th gear. The selector must be pushed in order to change gear. When a gear is engaged, the transmission will only operate in this gear until the selector is pushed to another position.

If the dump truck is stationary, the selected gear will be engaged directly.

WARNING Be careful when reversing, the rear visibility is limited!

2.5. Normal operation Always operate the dump truck with caution. Careful driving is recommended for safe and comfortable operation.

Regulate dump truck speed in accordance with the ground conditions and surrounding environments.

In manual gear shift mode, always drive allowing the lock-up clutch to connect.

If abnormal noise, vibration, smoke or odours occur during operation, check for possible faults and remedy.

Check at regular intervals that all gauges are indicating normal values, and that no warning lights are on.

• Engine coolant temp.: 70-93°C • Engine oil pressure: 3-6 bar at normal engine temp. (optional instrument) • Transm. oil temp.:

50-105°C, max 120°C for a short period

• Transm. oil temp. at retarder brake operation: up to 140°C max. 150°C for a short period

bar

6

• Air pressures:

6.8 - 7.8 bar.

bar

6

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2.6. Brakes There are four different brake systems on the dump truck.

Check the brakes every day to ensure function.

Service brake (main brake) Air over hydraulic operated dry single disc brake on each wheel. Front and rear axle have separate circuits. If a fault occurs in one of the circuits, the dump truck can still brake with the intact circuit. Self adjusting system.

Engine brake Air operated, speed dependent brake which restricts exhaust flow. Efficient only when lock-up clutch is connected.

Retarder brake Infinitely variable, hydrodynamic, wear resistant and speed dependent oil retarder fitted before transmission torque converter.

Parking brake Spring actuated, air released single disc brake on the rear prop. shaft. Self-adjusting system.

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2.7. Engine and/or retarder brake operation The engine and/or retarder brake operates automatically and is controlled by: • Throttle pedal position • Switches on the instrument panel (optional) • In addition, the retarder brake is controlled by a lever on the instrument panel.

• Throttle pedal position When the throttle pedal is fully released, lock-up conn ected and a gear is selected, both the engine brake and the retarder brake will automatically engage.

• Switches on the instrument panel (optional) The engine brake and the retarder brake can be operated separately by depressing either the engine brake switch or the retarder brake switch, or they can be operated together by depressing both switches.

The engine and/or the retarder brake will then engage if a gear is selected, lock-up connected and the throttle pedal is fully released.

• Always use the engine and/or the retarder brake when driving downhill for constant retardation.

• Both the engine brake and the retarder brake will automatically disconnect if the turbine rpm falls lower than 1200 rpm and will connect again when the turbine rpm rises above 1300 rpm.

• To avoid overspeed of the engine, the engine brake will automatically engage if the engine speed exceeds 2500 rpm. The retarder brake will automatically engage if the engine speed exceeds 2600 rpm!

Reduce the engine speed immediately!

2.8. Braking/stopping the dump truck Learn to associate the braking requirements for loaded and unloaded machine.

See also chapter 2. Safety Instructions 1. Release throttle pedal and apply the engine and retarder brake.

2. Depress the brake pedal gradually, until desired deceleration is obtained.

3. When the dump truck is completely stopped, move the gear selector to neutral.

4. Apply the parking brake.

• Hint: Always use the engine and/or the retarder brake, this will result in increased lifetime of the service brake linings.

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5. Operating Instructions

2.9. Emergency braking If braking effect is lost in both brake circuits, the dump truck can be braked as follows: 1. Release throttle pedal and apply the engine and retarder brake.

2. Set the parking brake to locked (on) position.

3. Move gear selector to 1st gear manually as quickly as possible.

When the dump truck has stopped, immediately put wheel chocks under the wheels.

WARNING After an emergency stop: DO NOT CONTINUE! The parking brake MUST be checked as well as the reason for the service brake failure!

Consult your Moxy Dealer.

2.10. Steering • The dump truck has 2 frames. The steering movement is created by articulation of the frames in relation to each other. The steering is fully hydraulically controlled and there are no mechanical links between the steering column and the steering cylinders. The steering circuit has priority over the tipping circuit, ensuring hydraulic oil available to the steering at any time.

• The dump truck is equipped with an emergency steering system, which will deliver oil when the dump truck is in motion due to a ground-driven pump. It will then be possible to steer the dump truck if the engine stops. The steering movement will then be slower and the warning light for emergency steering will light. Repair the fault before operating the dump truck again!

NOTE Mechanical endstops are fitted in the steering cylinders.

Steering movement that will “hammer” these endstops must be avoided. Continuance of the steering actions against the endstops causes maximum pressure in the system - this must be avoided!

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2.11. Differentials The dump truck has permanent 6-wheel drive with 3 differentials.

1. Front differential, automatic diff. brake (limited slip type).

1

Fitted to the transmission. Transfers the power to left and right front wheels.

The differential will automatically provide highest torque to the wheel which has best grip. The locking ratio is 45%, i.e. the differential is capable of compensating for a 1:2.64 difference in friction between left and right wheels.

2. Inter axle differential, 100% lockable torque divider.

2 Integrated in the transmission. Transfers the torque by 1/3 to the front axle and 2/3 to the rear axle.

The differential lock can improve dump truck performance and should be used to avoid wheel spinning in severe conditions, i.e. slippery surfaces. Engage the differential lock before entering an area with a slippery surface, soft ground, or if the dump truck is stuck in the terrain.

The differential lock must not be used when driving on firm ground!

3

CAUTION Use the interaxle differential lock to avoid spinning on front and rear axle.

3. Rear differential, automatic diff. brake (limited slip type).

Fitted in the rear axle housing. Transfers the power to left and right tandem drive.

The differential will automatically provide highest torque to the wheel which has best grip. The locking ratio is 45%, i.e. the differential is capable of compensating for a 1:2.64 difference in friction between left and right wheels.

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5. Operating Instructions

2.12. Up, down and crossgradient travel.

• When travelling on gradients, consider the ground condition, and maintain a safe speed according to the grade of the path, the surface, degree of curves and road width.

• Before starting downhill, release the throttle pedal and slow down the dump truck to a safe speed for the downhill slope.

Move the gear selector to a suitable position (1st, 2nd or 3rd).

Rule: Select the same gear for operating downhill as you would for operating up the same hill.

• Always use the engine and/or the retarder brake for constant retardation. Long time engagement and unnecessary use of the service brakes can cause excessive wear and a possibility of loss of braking effect due to over-heated brake discs.

• If use of the engine brake and/or retarder brake is insufficient to keep the dump truck within a safe speed, reduce the speed by depressing the brake pedal. The travel must then continue in a lower gear with the engine and/or retarder brake applied.

• Pay attention to the transmission oil temperature when the retarder brake is applied.

• Operate the dump truck sensibly and avoid crossgradient travel. Select a low speed and negotiate the terrain without exagerated steering movements and sudden braking.

• Do not under any circumstances drive the dump truck with raised body.

• Keep engine speed at the upper area, 2000 - 2350 rpm in heavy conditions and at hill travel. Select a manual gear position at steep hill travel.

• Do not park or leave the dump truck on grades or slopes, the risk for spontaneous rolling is high!

• ALWAYS keep the engine speed below max. allowed rpm when travelling downhill!

The engine brake will automatically be engaged if the engine speed exceeds 2500 rpm and the retarder brake will automatically be engaged if the engine speed exceeds 2600 rpm. This is to avoid overspeed of the engine.

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2.13. Important operating instructions • The dump truck must not coast with gear selector in neutral position.

• Engine speed must be reduced, and the dump truck must be stopped completely before changing between reverse and forward gears.

• Do not keep turning against the mechanical endstops, or force it into this point when making maximum turns.

• There is no braking effect from transmission when the engine is stopped.

• Select neutral gear and apply the parking brake when leaving the dump truck. Never leave the dump truck with a gear engaged!

• Engine speed within 1400 - 2200 rpm with engaged lockup is recommended during driving.

• The engine brake will automatically be engaged if the engine speed exceeds 2500 rpm and the retarder brake will automatically be engaged if the engine speed exceeds 2600 rpm, to avoid overspeed of the engine.

• Do not continue to operate the dump truck if a warning lamp lights, a gauge shows abnormal value, or if the warning buzzer sounds.

• Always operate the dump truck within the rated limits and carry out maintenance according to the scheduled program.

Overloading and lack of maintenance reduces safety and the lifetime of the dump truck is reduced.

• In case of problems with the dump truck, stop the vehicle and contact your local Moxy Dealer to amend the fault.

3. Parking the dump truck 1. Avoid parking with loaded body.

P

2. Do not park on grades or slopes.

3. Park on a safe ground, where it will not freeze in place, sink down, etc. A change of weather may affect the ground.

4. Move the gear selector to neutral position.

5. Apply the parking brake.

6. Lower the body completely.

7. Neutralize all operating controls.

8. Secure the dump truck from spontaneous rolling by adding wheel chocks under the wheels before leaving the dump truck.

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5. Operating Instructions

4. Stopping the engine 1. Stop the dump truck 2. Run the engine at low idle for a few minutes to allow it to gradually cool down if the dump truck has been driven with a heavy load for a long period of time.

If engine is stopped suddenly before it cools down, engine life may be shortened.

Never stop the engine immediately after driving except in case of emergency.

3. Before stopping the engine, check that the main warning light for engine failure is not on or flashing. See chapter 3 Operating Controls for procedure if the warning light is on or flashing.

4. Turn the key in starter switch to OFF position.

5. Remove the key from starter switch.

5. Checks after stopping the engine 1. Lock the sliding windows and the cab door.

2. Turn off the battery main switch.

3. Release the air pressure from the air tanks, to drain condensation.

4. Check for leakage of oil or water.

5. Fill up the fuel tank.

Make sure that the filler cap and the area around the filler opening is clean to avoid contamination of the fuel 6. Remove any waste paper or other flammable material which may cause fire in the engine compartment.

7. Remove any mud stuck to the chassis.

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6. Loading and tipping 6.1. Loading • The body must be lowered completely before loading materials. The tip control lever shall stay in hold (float) position.

• When loading large rocks, cover the body bottom with gravel or start with the smallest stones first.

• During loading, the parking brake should be applied and gear selector should stay in neutral position.

• Before driving off, check that no danger can occur during travel. Maintain an even load distribution, avoid unbalanced loads.

• Never overload the dump truck. The operator's safety will be considerably reduced and lifetime of the dump truck will drop.

6.2. Tipping 1. Place the dump truck on a level ground. Check that the tipping may take place safely.

2. The gear selector must be in neutral position, and the parking brake must be applied.

3. Move the tip control lever to body "up" position and increase the engine speed. The body will raise, and the top tailgate, if fitted, opens automatically. The tipping speed is proportional with the engine speed.

4. Reduce the engine speed before the body reaches the top position.

5. To stop the tipping movement, release the tip control lever.

It will then automatically return to hold position.

6. Move the tip control lever to "down", and the body will go down. The top tailgate, if fitted, will then automatically close when the body is completely down.

The tipping cylinders are double acting, on the 3rd stage.

The lowering speed on the 3rd stage is proportional with the engine speed.

7. The tip control lever shall stay in hold (float) position when not operated.

WARNING • • • • • •

Reduce tipping speed when dumping large rocks!

Do not load material into the body if the body is raised!

Do not drive a empty or loaded truck with a raised body!

Do not raise body near electrical power lines! See Chapter 2. SAFETY INSTRUCTIONS Avoid tipping on crossgradients!

Utilisation of top tailgate has safety restrictions!

See Chapter 2. SAFETY INSTRUCTIONS!

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5. Operating Instructions

7. Tyre handling General This is a general instruction for the standard tyres in the table under item 6.2. Contact tyre supplier or your local Moxy Dealer for exact specifications.

Off-road tyres produce more heat during operation than tyres for ordinary cars. Therefore, the tyres must be used correctly to obtain long lifetime and safe operation.

Please note that the following can cause overheating of tyres: • Too low tyre pressure • Overloading • Driving long distances non-stop • Travelling at high speed

CAUTION Extremely low temperature (below -40°C) requires special operation!

7.1. Difference in tyre diameter If it is necessary to change a wheel as a result of puncture or in emergencies, Moxy Engineering AS allows up to 5% difference in the tyre diameter on the same side of the tandem. But the most ideal situation in all cases is to have the same tyre diameter on the same side of the tandem. This is strongly recommended.

7.2. Correct tyre pressures Tyre pressures mainly depend on operation speed and load.

Road configuration, flotation/traction requirements, risk of cutting, hacking, shock damage and ambient temperatures, are also factors to consider.

Both too high and too low tyre pressure may result in damage and shortened lifetime of the tyres.

Tyre pressure checks and corrections must be carried out on cold tyres.

Basic pressure for cold tyres (based on max. load and max. speed): Type Bridgestone VLT ** Michelin XADN/XADT Good Year GP2B/GP4B/RL-2+

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Front bar (psi) 3.0 (44) 3.0 (44) 2.8 (41)

Rear bar (psi) 3.5 (51) 3.5 (51) 3.5 (51)

5. Operating Instructions

7.3. Specified loading Do not overload the dump truck. Maintain an even load distribution, avoid unbalanced loads.

Protect tyres from falling stones during loading.

7.4. Proper maintenance Perform tyre inspections according to Maintenance schedule.

Also roads and driving paths should be maintenanced to achieve max. tyre serviceability.

Damaged, excessively worn or aged tyres should be replaced. Remove foreign objects from the threads, these will sooner or later penetrate into the tyre.

Removal or repairing of tyres should be performed by a tyre specialist to avoid unsafe working conditions.

WARNING Always let the air out of the tyre before removing foreign objects and before demounting or repairing!

See also chapter 2, Safety Instructions (High pressure)

7.5. Transit, long distance drive-away on road This special type of driving requires special operation: • Check and adjust the tyre pressure on cold tyres before starting. Do not reduce pressure during driving.

• Drive only without load.

• Drive 2 hours and stop for minimum 30 minutes.

Drive another 2 hours and stop for minimum 1 hour.

Repeat.

• Upper speed limit for this operation: 32 km/h.

Must not be exceeded!

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5. Operating Instructions

8. Cold weather Cold weather operation (below 0 °C) requires special care to avoid problems and to maintain high comfort and safety.

• The viscosity of oils in engine, transmission, differentials, and hydraulic system should be of a suitable viscosity for the lowest expected ambient temperature, see Oil Specification Sheet.

• The coolant must contain anti-freeze to avoid ice in the cooling system and to protect against corrosion, see chapter 7, maintenance, 2000 hours service.

• As the temperature drops, the battery capacity drops accordingly.

The batteries must be in good condition and fully charged when the dump truck is operated in low temperatures.

• Fuel must be of a low pour point, and the fuel tank must be filled up at the end of the shift. 0.5 - 2 % alcohol (isopropanol) can be added to avoid condensation.

• The washer fluid should contain a mix of alcohol (isopropanol) and water which at least is sufficient to avoid icing in the tubes.

• At very low temperatures (below -10 oC) use of engine heater or flamestart system can be necessary to avoid starting difficulties.

It is recommended to use an engine heater or flamestart system (optional equipment) at low temperatures. The engine heater has an electrical element which heats the engine coolant.

The flamestart system has glow plugs fitted in the intake manifold. Heating of intake air takes place by burning engine fuel. The heating is activated by a pre-heating switch and will continue approx 5 min. after the engine has started.

• Extend the warm-up period to secure that component lubrication is obtained. The dump truck shall be operated with light load and reduced rpm during warming up.

• Pay special attention to the ground surface. In case of snow and ice, use snow chains on the wheels to secure the wheel grip.

• If the dump truck is equipped with exhaust-heated body, this should be connected to avoid material freezing to the body.

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9. Long term storage.

If the dump truck shall be stored for a longer period of time, special preparation must be carried out to avoid deterioration and damage. Store it preferably indoors in a dry and ventilated room or outdoors under shelter.

9.1. Before storage: 1. Neutralise all operating controls, place the gear selector in neutral position, the engine brake switch and the retarder brake switch must be turned OFF and push the retarder control lever to OFF position and apply the parking brake.

2. Release the air pressure in all circuits. (see chapter 7, daily service) 3. Thoroughly wash and clean the dump truck.

4. Completely fill the fuel tank.

5. Replace oil and filters with new and lubricate all nipples.

Check viscosities to match the expected ambient temperature.

6. If the ambient temperature is expected to drop below 0oC, always add antifreeze to the cooling water.

7. Fully charge the batteries and disconnect terminals.

Preferably stored separately in a cold place (0-10oC).

8. Cover all cylinder piston rods with rust protecting fluid.

9. Inflate the tyres to correct pressure. (see chapter 8) 10.Lock the sliding windows, doors, fender hatches and bonnet.

9.2. During storage: Operate the truck once a month by driving it i.e. until engine temperature reaches normal operating temperatures. This will lubricate all moving parts. At the same time check for leakages and recharge the batteries. Grease the nipples.

NOTE Check oil and fluid levels before starting the engine!

Drive slowly and with care the first 5 minutes or 1 km.

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5. Operating Instructions

10. Battery power assistance In case of discharged batteries, the dump truck can be started by connecting charged batteries, 24 volts with capacity approx. equal to the discharged batteries.

• If the batteries have been discharged, check the reason why (are the batteries defect?, is there a short circuit somewhere on the dump truck etc.?)

• Discharged batteries should be charged as soon as possible.

• Check the electrolyte level and density after charging the batteries.

Connection:

6

1 1. Turn off the battery main switch in the battery box.

2. Connect first cable (A) from positive (+) terminal on discharged batteries....

3. .... to the positive (+) terminal on the assisting battery.

3

2

4. Connect second cable (B) from negative (-) terminal on assisting battery....

5. .... to chassis on the dump truck with the discharged batteries, some distance from the batteries.

A

6. Turn on the battery main switch and start the engine in the normal way.

B Disconnection: 4

Disconnect cables in the opposite order, 5 - 4 - 3 - 2.

5

CAUTION • • • • •

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Use cables with min. 25 mm2 cross section.

Connect in sequence described above.

Good clamp contact is essential.

Do not stand near a battery when connecting the cable to the chassis.

Do not disconnect the original battery cables.

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5. Operating Instructions

11. Towing the dump truck.

• The dump truck can be towed by fitting a wire/chain to the eye(s) in front/rear of the dump truck.

• Check that the wire/chain is capable of towing the load.

• The towing distance must not exceed 10 km, and the maximum allowed speed is 10 km/h!

• The engine must run at low idle to steer the dump truck in the normal way. If the engine is stopped, the steering movement will be heavier and slower than normal because there is no oil flow from the main hydraulic pump.

• The maximum towing force is: • Front,90 kN • Rear, 180 kN

CAUTION •

• •

If air pressure is lost, the service brake will not function and the parking brake will be engaged. The air system can be filled from an external air supply, see item 12.

An engaged parking brake can be loosened even if there is no air in the system, see item 13.

It is not possible to start the engine by towing!

12. External air filling Filling of the air system can be done from an external air supply through the air connector fitted to the left side front fender. In the tool kit there is a hose for this purpose. The parking brake must be applied, and wheel chocks placed under the wheels.

1. Remove the protection cap.

2. Connect the hose nipple to the connector.

3. Start filling and check the pressure at the cab gauges.

The dump truck can now be moved if the parking brake can be released.

WARNING 2

1

• •

The pressure will gradually drop when braking. Pay attention to the braking effect!

Make sure that the parking brake is applied (on) before filling from an external air supply. If the parking brake is not engaged, the dump truck may roll spontaneously!

2

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5. Operating Instructions

13. Manual release of parking brake If the parking brake can not be disengaged by the parking brake lever i.e. air pressure has been lost, it may be manually released: 1. Place wheel chocks under the wheels.

2. Raise the body and secure it with the body support (see chapter 2 - safety instructions) 3. Screw the parking brake caliper adjusting screw (1) in an anticlockwise direction until the brake is released.

DANGER All braking systems are now out of function. Extreme care must be taken to avoid spontaneous rolling.

1

14. Tyre filling point The air filling connector (see item 12) can also be used for filling air into the tyres.

1. Connect the hose (1) to the connector (2) and fill air.

1

2. Check the air pressure with a separate gauge.

3. For basic tyre pressure, see chapter 8. Technical Data.

WARNING Be sure to use a self-locking nipple and do not stay in front of the tyre during filling!

2

1

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15. Troubleshooting If the action below does not solve the problem or the fault can not be found, contact your Moxy Dealer.

*= Always contact your Moxy Dealer.

Phenomen

Cause

Action

15.1. Engine: Will not start

Main switch disconnected Out of fuel Low battery current Blown fuse Defective wiring Hydrostatic lock Starter motor defective Electronic controller or sensors defective

Turn on Refill fuel, bleed system Recharge Check circuit, replace fuse Check connections, wires Repair* Replace* Check/repair*

Starts but stops again, runs un-evenly or hunts.

Low output

Fuel system disturbance Condensated water in diesel Bad fuel quality Low fuel level Fuel filters clogged Air filter clogged Fuel tank breather clogged Throttle system disturbance Wrong injection timing Injector defective Turbo charger defective Worn engine or internal damage Electronic controller or sensors defetive

Check fuel lines, bleed system Drain tank Change fuel Refill fuel Replace filters Replace or clean Clean tank cover Adjust/replace/repair Adjust* Repair/replace* Repair/replace* Overhaul* Check/repair*

Overheated (warning light)

Low coolant level Fan belt problem Air in cooling system Dirt inside cooling system Radiator fins clogged/damaged Thermostat faulty Sensor/gauge defective Coolant pump worn

Add coolant, check for leakages Tighten/replace Bleed system Clean and replace coolant Clean Replace Replace Overhaul*

Low coolant temperature

Sensor/gauge defective Thermostat stuck open

Replace Replace

Low oil pressure

Too low oil level Incorrect oil type Sensor/gauge defective Oil pressure red. valve faulty Worn oil pump

Add oil, check for leakage Change to correct oil type Replace Overhaul* Overhaul*

Blue smoke, oil consumed

Too high oil level Incorrect oil type Worn engine or internal damage

Adjust to specified level Change to correct oil type Overhaul*

Black or white smoke

Clogged air filter Fuel pump/injection system worn or faulty Cylinder gasket defective Turbocharger defective

Replace or clean Adjust/repair* Replace* Repair/replace*

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5. Operating Instructions

Phenomen

Cause

Action

Oil in coolant or coolant in oil

Internal leak in transmission cooler Worn engine or internal damage Internal leak on engine oil cooler

Replace* Overhaul* Replace*

Knocking noise

Bad fuel quality Valves incorrectly adjusted Injection pump incorrectly adjusted Injector defective Worn engine or internal damage

Change fuel Adjust Adjust* Replace* Overhaul*

Main warning light illuminates

Engine / engine controller failure

Stop the dump truck at a safe place and check the error codes on the engine controller.

Following error codes can be read on the engine controller: Control status lamp lights Shut down lamp lights Torque limit lamp lights Boost limit lamp lights Power - lamp lights

Main warning light flashes SHUT DOWN CONDITION

Engine controller has detected an internal fault.

Engine temperature has reached a warning threshold or the sensor has failed.

Air inlet temperature has reached a warning threshold or the sensor has failed.

Engine controller has detected a loss of boost pressure.

Speed potentiometer or idle safety switch has failed.

Engine / engine controller failure

Check/repair* Check/repair* Check/repair* Check/repair* Check/repair*

Stop the dump truck at a safe place, stop the engine as soon as possible and check the error codes on the engine controller.

Following error codes can be read on the engine controller: Control status lamp lights

Engine controller has detected an internal fault.

Engine temperature has reached a shut down threshold or the sensor has failed.

Engine has exceeded its overspeed threshold.

Actuator feedback sensor failure.

Oil pressure has dropped below a threshold level or the sensor has failed.

Check/repair*

Too high temperature

Too low oil level Incorrect oil type Cooling circuit failure Lock-up fault Worn oil pump

Add oil, check for leakage Change to correct oil type Check/repair Overhaul* Overhaul*

No drive in any gear or only possible to drive in some gears

Too low oil level Blown fuse Converter prop. shaft Electronic controller detect failure, neutral engaged Electronic controller or sensors defective Flywheel damper separated Drive line failure Internal transmission failure

Add oil, check for leakage Check circuit Replace

Shut down lamp lights Starting lamp lights Running lamp lights Power + lamp lights

Check/repair* Check/repair* Check/repair* Check/repair*

15.2. Transmission:

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Operating & Maintenance Manual

Check/repair* Check/repair* Replace* Check/repair* Overhaul*

5. Operating Instructions

Phenomen

Cause

Action

Low oil pressure

Too low oil level Incorrect oil type Sensor/gauge defective Pressure control valve failure Worn oil pump Internal transmission failure

Add oil, check for leakage Change to correct oil type Replace Check/repair* Overhaul* Overhaul/replace*

Noise

Too high oil level Incorrect oil type in differential(s) Worn transm. or internal damage

Adjust to specified level Change to correct type Overhaul/replace*

Main warning light illuminates

Transmission failure

Stop the dump truck on a safe place, select neutral gear position and check the error codes on the gear display.

Following error codes can be read on the gear display: First digit 1, second digit 1-9 First digit 2, second digit 1-9 or A-C First digit 3,second digit 1-9 or A-E First digit 4,second digit 0-9 First digit 5,second digit 0-9 or A-F First digit 6,second digit 0-9 or A-F First digit 7,second digit 1-9 or A-C First digit 8, second digit 1-9 First digit 9, second digit 1-9 or A-F First digit A, second digit 1-9 or A-F First digit B, second digit 1-9 or A First digit C, second digit 1-9 First digit D, second digit 1-9 First digit E, second digit 1-9 First digit F, second digit 1-9

Digital input signal

Check/repair*

Analog input signal

Check/repair*

Speed signal CAN signal error

Check/repair* Check/repair*

CAN signal error

Check/repair*

CAN signal error

Check/repair*

Analog current output signal Analog current output signal

Check/repair* Check/repair*

Digital output signal

Check/repair*

Digital output signal

Check/repair*

Transmission fault, clutch error Logical fault Power supply High speed signal General fault

Check/repair* Check/repair* Check/repair* Check/repair* Check/repair*

15.3. Brakes: Poor braking effect or truck Low brake fluid level pull to one side when braking Uneven worn brake pads Air in brake fluid circuit Insufficient air pressure A brake caliper is stuck

Add fluid, check for leakage Replace pads Bleed brakes Check charging and system Repair*

15.4. Air system: Low air pressure (all circuits) System leakage Governor problem Compressor failure High air pressure Governor problem

Check circuits Adjust setting/repair Overhaul* Adjust setting/repair

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5. Operating Instructions

Phenomen

Cause

Action

Emergency steering light on when driving

No oil flow from main pump, or no oil flow from emerg. pump Oil flow switch defective

Check and repair* Check and repair* Replace*

Truck will not go straight ahead, uneven steering movement or periodically sticking

Low hydraulic oil level Air trapped in hydraulic system Contaminated oil Incorrect oil type Steering cylinders internal leak Orbitrol or steering valve failure

Add oil, check for leakage.

Bleed system Change oil and flush system Change to correct oil type Overhaul* Check and repair*

Not possible to tip or slow tipping

Low hydraulic oil level Clogged oil filter Insufficient air pressure Clogged tank strainer or breather Low oil pressure Worn oil pump Tip valve failure

Add oil, check for leakage Replace Check charging Replace/clean Check/repair* Check/reapir* Overhaul*

No electrical power

Main switch disconnected Batteries discharged Battery terminals/wiring defective

Turn on Recharge Repair

Charge warning light on

Fan belt problem Defective/worn alternator Defective wiring

Tighten/replace Replace Check connections, wires

Uncomfortable travel (jumping)

Defective shock absorber Defective rubber suspension Articulation turning ring worn

Replace Replace Overhaul*

Vibrations

Engine or transm. mountings Fan or flywheel loose/imbalance Defective elastic coupling Prop. shaft failure Drive line problem

Replace Check/repair* Check/repair* Check/repair* Check/repair*

15.5. Hydraulic system:

15.6. Electrical:

15.7. Chassis:

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6. Lubricants

Lubricants

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113

6. Lubricants

Contents

6. Lubricants ................................................................. 113 - 120 Lubrication schedule .................................................. 115 Oil specification sheet ................................................ 117 Filling capacities ........................................................ 118 Transmission oil list ................................................... 119

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6. Lubricants

Lubrication schedule

1st time

SERVICE INTERVAL

HOURS-->

100 500

POS COMPONENT

8

40

500 1000 2000 4000

Min. once a year

Lubricants filled from producer

ENGINE 1 2 3 4 5

Engine oil Centrifugal cleaner Turbo filter Fuel filters (2) Coolant/cooling system

V V

Shell Rimula Super 15W - 40

R C R R

V

V/R*

ENGINE RELATED 10 Air filter, outer element -Inner element: replace every 3rd year Air filter, prefilter

C/R

C/R*

C/R*

V/C*

11 Batteries (2) 12 Air system/air dryer 13 Fuel tank

V

V

D V

D

R

R D

R R C

R R C

R R

R R

TRANSMISSION 20 Transmission oil 21 Filter (2) 22 Strainer

40% Glycoshell

V/R*

R R C

V

- 513086: Shell Donax TA 513087- : Shell Rimula X10W/30

DRIVE LINE 30 Front differential oil 31 Rear differential oil

R R

V V

32 Tandem housing oil (2)

R

V

33 Front reduction gear oil (2)

R

V

Shell Spirax AX SAE 80W/90

R R

R

HYDRAULIC 40 Hydraulic oil 42 Breather element on tank 43 Filter

V

- 513054: Shell Donax TM 513055- : Shell Tellus T 46

R R* R*

R

Shell Spirax A 90 LS

LUBRICATION POINTS 50 51 52 53 54 55 56 57 59

Articulation turning ring Tip hinges Tandem bearings Articulation bearings Steering cyl. bearings Tip cylinder bearings Tailgate arm hinge (optional) Doors and fender hatches Suspension legs

*5/1 lubric.

2 lubric.

2 lubric.

2 lubric.

4 lubric.

4 lubric.

2 lubric.

8 lubric 4 lubric.

Shell SRS 4000 NLGI - 2

L L L L L L L L L

L L

BRAKES 60 Brake fluid

4 cont.

V

R

R

Shell Donax YB

MISCELLANEOUS 70 Cab ventilation filter R= Replace

V= Check

C/R* C= Clean

L= Lubricate

D= Drain

*= or when required

= Alternatively greased by automatic central lubrication system

*5/1 lubric.: Up to serial number 513086 there are 5 lubrication points on the articulation turning ring From serial number 513087 (SERIES II) there is 1 lubrication point on the articulation turning ring

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115

6. Lubricants

The numbers refer to table on previous page.

116

Operating & Maintenance Manual

6. Lubricants

Oil specification sheet This table presents guidelines for oil, coolant, fuel, lubricants and other fluids best suited for good performance and long life.

COMPONENT

KIND OF FLUID

-4 -20

AMBIENT TEMPERATURE 14 32 50 68 86 °F -10 0 10 20 30 °C SAE 20W-30 SAE 30 SAE 40

Engine oil pan

Engine oil

SAE 50 SAE 5W-30 SAE 10W-30 SAE 15W-40

Diesel fuel

Fuel tank Cooling system

WIN T E R S UM M E R - D IE S E L

Transmission

Dexron -IID/ -III / Mercon -M SAE 10W

Engine oil

The engine oil should at least meet the requirements for one of the following oil classifications: - ACEA E3, E4 or E5 - API CG-4 - Global DHD-1 - The Total Base Number (TBN) should be minimum 12-13 (ASTM 2896).

If fuel contains more than 0.3% (weight) sulphur: reduce the oil change interval.

Make sure the oil can sustain all temperature variations up until next oil change.

Ask your local Moxy Dealer or oil supplier Acc. to: ASTM and ISO standards Cetane number: min. 49.

Sulphure contents: max. 0.3 %.

Max. 2 % isopropanol additive.

30-50 % Nitrite-free glycol anti freeze is recommended.

See 2000 Hours Service .

Water + antifreeze ATF

REMARKS

By changing between AFT and engine oil, it is recommended to run the AEB-Tester.

Only oils in Transmission Oil List , can be used!

SAE 10W-30/10W-40 SAE 15W-40

NOTE! Min. 20 minutes warming up period in neutral position is required when ambient temperature is within this area:

SAE 20W-20

Tandem housing, Planetary red. gear Front diff.

Rear diff.

SAE 85W-90 Gear oil

SAE 80W-90

According to: API GL-5 or MIL-L-2105D (gear oil with EP-additives)

SAE 85W-140 Gear oil with LSadditives

*= max. 2% (weight) VI-Improver and Pour Point Depressant in the basic gear oil.

SAE 90 O t he r ge a r o ils a s a bo v e *

HM ISO VG 32

Hydraulic tank

HV ISO VG

Hydraulic oil

HM ISO VG 46 HV ISO VG

ATF

DEXRON IID

Universal grease

Lithiumsaponfied with EP-additive.

Consistency NLGI-1 / 1,5 / 2.

Optional: Universal Automatic grease Centr. lubr. system Brake system

NLGI 2 NLGI 0/1

Brake fluid

• Contact oil supplier when operating in temp. below -25°C. • Warm up in neutral after starting at temperatures near lower limitation of the oil.

• If using Biological oil contact your Moxy Dealer before use. The oil must be approved by Moxy Engineering AS.

SAE 10W

Engine oil Lubricator

Only mineral based oils.

Viscosity approx. 20 cSt at normal operating temperature.

Range: 10-250 cSt, max. 850 cSt at cold start.

Hydraulic oil: HM or HV oils (ISO 6743/4, CETOP RP 91H) or H-LP oils (DIN 51524).

Grease should not contain graphite or PTFE. Consistency NLGI-2 or synthetic 2, NLGI 0/1 or synthetic 0/1 According to: SAE J1703 (DOT4 or DOT3) or FMVSS 116 DOT 5

CAUTION Remember, Automatic Transmission Fluid must not be mixed with engine or hydraulic oil.

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6. Lubricants

Filling capacities All capacities are measured in litres (dm3), and are approximate values. To achieve correct level: check at dip stick, level eye, level plug etc.

Description: Specified capacity: Total tank/reservoir volume or total capacity from empty.

Refil amount:

Refill volume after normal fluid draining. The differences are fluid left in components, piping etc.

Specified capacity

Refill amount

Engine oil Engine coolant

25 90

24 82

Fuel tank Transmission oil*

430 50

410 33

Rear differential Front differential

53 10

49 10

2 x 140 2 x 7.5

2 x 125 2 x 7.0

Hydraulic system Brake fluid**

200 5.0

180 as req'd

Windscreen washer tank

2.75

2.65

Component/Fluid

Tandem housing, each Front reduction gear, each

*=

Check level when engine runs at low idle.

Do not run engine without oil in the transmission.

** = New pads

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6. Lubricants

Transmission oil list Engine oil

Lubricant class 03A Mineral oil-based engine oil in accordance with Group standard ZFN 13030 (API CD/CE/CF-4/CF/CG-4/SF/SG/SH/SJ or ACEA, categories A, B, E) Viscosity class: SAE 20W-20 / 30 / 10W-30 / 10W-40 / 15W-30 / 15W-40 / 20W-40 Note: All mineral oil-based trade products which satisfy the above specifications may be used.

Lubricant class 03B Engine oil in accordance with Group standard ZFN 13030 (API CD/CE/CF-4/CF/CG-4/SF/SG/SH/SJ or ACEA, categories A, B, E) Viscosity class: SAE 10W / 5W-30 / 5W-40 Manufacturer

Trade name

Manufacturer

Trade name

ADDINOL MINERALÖL GMBH, KRUMPA/D ARAL LUBRICANTS GMBH, BOCHUM/D BUCHER AG, LANGENTHAL/CH CALPAM GMBH, ASCHAFFENBURG/D CALTEX AUSTRALIA PETR., SYDNEY/AUS CALTEX PETROLEUM CORP., LONDON/GB CASTROL BRASIL, RIO DE JANEIRO/BR CASTROL INTERNATIONAL, SWINDON/GB CEPSA LUBRICANTES, MADRID/E CEPSA LUBRICANTES, MADRID/E DEA MINERALÖL AG, HAMBURG/D ELF LUBRIFIANTS, PARIS/F ELF LUBRIFIANTS, PARIS/F ELF LUBRIFIANTS, PARIS/F ELF LUBRIFIANTS, PARIS/F ELLER-MONTAN-COMP., DUISBURG/D ESSO BRASILEIRA, SAO PAULO/BR FINA EUROPE SA, BRÜSSEL/B FL GROUP, VILLASTELLONE/I FUCHS DEA SCHMIERSTOFFE, MANNHEIM/D FUCHS DO BRASIL, JANDIRA/BR FUCHS LUBRICANTS (UK), DERBY/GB FURUKAWA CO LTD, JAPAN GINOUVES GEORGES SA, LA FARLEDE/F HAFA, PARIS/F IGOL FRANCE, PARIS/F ISU CHEMICAL CO. LTD, SEOUL/KOREA ITALIANA PETROLI, GENOVA/I KOMPRESSOL-OEL, KÖLN/D KRAFFT SA, ANDOAIN/E

ADDINOL TURBO DIESEL ARAL BASICTURBORAL MOTOREX EXTRA CALPAM FLEET HD DEULUBE S3 CALTEX DELO 500 TFC 410 CASTROL CRD CEPSA SUPER SERIE 3 ERTOIL SUPER SERIE 3 DEA CRONOS SUPER PERFORMANCE SUPER D ANTAR TRAXOLIA Z PERFORMANCE XR HRD PREXIMA ELLMOTOL HD C3 ESSOLUBE D3+ FINA KAPPA SUPER URANIA C TITAN UNIVERSAL HD (EB) TITAN HD HARDWICK 10 FK 310W YORK 730 HAFA IONODEX 500 IGOL TRANS TURBO 4 MONO TOTAL RUBIA S IP AXIA D KOMPRESSOL-HD-S3-C-OEL MONOGRADO SUPER S-3

KUWAIT PETROLEUM, EUROPOORT/NL LIQUI MOLY GMBH, ULM/D LUBRICATION ENGIN., FORT WORTH/USA MEGUIN GMBH, SAARLOUIS/D MIN.ÖL-RAFFIN. DOLLBERGEN, UETZE/D MOBIL OIL COMPANY LTD., CORYTON/GB MOBIL OIL DO BRASIL, SAO PAULO/BR MORRIS LUBRICANTS, SHREWSBURY/GB NESTE OY, ESPOO/SF NOVA STILMOIL SPA, MODENA/I OEST G. MIN.ÖLWERK, FREUDENSTADT/D OMV AG, SCHWECHAT/A ORLY INTERNATIONAL, VIEUX-THANN/F PAKELO MOTOR OIL, SAN BONIFACIO/I PANOLIN AG, MADETSWIL/CH PETROBRAS, DUOUE DE CAXIAS/BR RAIFFEISEN HG NORD AG, HANNOVER/D SHELL ASEOL AG, BERN/CH SHELL BRASIL SA, RIO DE JANEIRO/BR SHELL INTERNATIONAL, LONDON/GB STATOIL MARKET. LUBR., NYNÄSHAMN/S STRUB+CO AG, REIDEN/CH SUN OIL COMPANY, AARTSELAAR/B TOTAL RAFFINAGE DISTR., PARIS/F TURBOTANK BÖSCHE+BÖDEKER, BREMEN/D VALVOLINE COMPANY, DORDRECHT/NL VEEDOL INTERNATIONAL, SWINDON/GB YACCO SA, ST PIERRE-LES-ELBEUF/F ZENEX OIL, RIVONIA/ZA

Q8 T 400 MONOGRADE THT MOTOROIL HD SAE 30 MONOLEC GFS ENGINE OIL MEGOL MOTORENÖL HD-C3 SG PENNASOL MOTOR OIL EXTRA C MOBIL DELVAC 1300 MOBIL DELVAC DIESEL 1300 MORRIS RING FREE XHD NESTE DIESEL CD ORION PLUS DIMO HDC-MOTORÖL OMV TRUCK ORLY DRACO 3001 PAKELO PKO HD 4 PANOLIN EXTRA DIESEL LUBRAX MD-400 HG UNIVERSAL HD ASEOL MONOGRADE CF SHELL RIMULA D SHELL RIMULA X MONOGRADE DIESELWAY STRUB MOTOR OIL TURBO HD SUNOCO SUPER C TOTAL RUBIA S TURBO HD MOTORENÖL CIII ALL FLEET VEEDOL DIESEL HDC YACCO AS3-SERIE YY, Y, M, X ZENEX SINGLEGRADE

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6. Lubricants

Transmission oil list Automatic Transmission Fluid (ATF)

Lubricant class 03D Automatic Transmission Fluids (ATF) in accordance with Group standard ZFN 13030

Manufacturer

Trade name

Manufacturer

Trade name

AGIP PETROLI SPA, ROM/I AGIP PETROLI SPA, ROM/I ALEXANDRIA CO.FOR PET.ADD. CAIRO/ET ARAL LUBRICANTS GMBH, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BLASER SWISSLUBE, HASLE-RÜEGSAU/CH BP OIL INTERNATIONAL, LONDON/GB BP OIL INTERNATIONAL, LONDON/GB CALPAM GMBH, ASCHAFFENBURG/D CALTEX AUSTRALIA PETR., SYDNEY/AUS CALTEX PETROLEUM CORP., LONDON/GB CASTROL INTERNATIONAL, SWINDON/GB CASTROL INTERNATIONAL, SWINDON/GB CEPSA LUBRICANTES, MADRID/E DE OLIEBRON B.V., ZWIJNDRECHT/NL ELLER-MONTAN-COMP., DUISBURG/D ESSO LUBRICANTS EUROPE, BRÜSSEL/B ESSO SAPA, BUENOS AIRES/RA FINA EUROPE SA, BRÜSSEL/B FINA EUROPE SA, BRÜSSEL/B FL GROUP, VILLASTELLONE/I FL GROUP, VILLASTELLONE/I

AGIP ATF D 309 AGIP ATF IIE ACPA 2000 ARAL GETRIEBEÖL ATF 22 AVIA FLUID ATF 86 BAYWA ATF 3000 BLASOL ATF „GM“ AUTRAN DX II FRONTOL UNIVERSAL-ATF 100 CALPAM PAMATIC FLUID 289 AUTOTRANS FLUID IID CALTEX ATF-HDM CASTROL TQ-D (22765) CASTROL TQ-D (21289) CEPSA ATF 2000 ATF 289 ELLMO-AUTOMATIK-FLUID 22233 ESSO ATF D (21611) ESSO ATF D (22079) FINAMATIC II D-22307 FINAMATIC II D-22233 TUTELA GI/A TUTELA GI/E

KÄPPLER KARL, STUTTGART/D KUWAIT PETROLEUM, EUROPOORT/NL LEPRINCE+SIVEKE GMBH, HERFORD/D MAURAN SA, ODARS/F MIN.ÖL-RAFFIN. DOLLBERGEN, UETZE/D MOL HUNGARIAN OIL, KOMARON/H MORRIS LUBRICANTS, SHREWSBURY/GB NAFTEC, ALGIER/DZ OEST G. MIN.ÖLWERK, FREUDENSTADT/D OMV AG, SCHWECHAT/A PAKELO MOTOR OIL, SAN BONIFACIO/I PETROLEX, KWIDZYN/PL RAFINERIA NAFTY JEDLICZE/PL RAIFFEISEN HG NORD AG, HANNOVER/D SAEL, MADRID/E SHELL ASEOL AG, BERN/CH SHELL INTERNATIONAL, LONDON/GB SHELL INTERNATIONAL, LONDON/GB SLOVNAFT VURUP A.S., BRATISLAVA/SLO SRS SALZBERGEN/D STATOIL MARKET. LUBR., NYNÄSHAMN/S SUN OIL COMPANY, AARTSELAAR/B SUOMEN PETROOLI OY, HAMINA/SF

SELECTOL FLUID GETR.ÖL IID 23 Q8 AUTO 14 LEPRINXOL FLUID CN INTER MATIC ATF D2 PENNASOL FLUID-GETR.ÖL TYP PCN CARRIER ATF LIQUIMATIC DII TASSILIA ATF T 4011 OMV ATF D II (D22427) MULTIPURPOSE TRANSM. FLUID IID VECO MATIC IID HIPOL ATF IID HG AUTOMATIK TF 3000 GULF ATF D IID ASEOL ATF DB UNIVERSAL SHELL DONAX TA (D-21666) SHELL DONAX TA (D-21774) MADIT AUTOMATIC WINTERSHALL ATF D TRANSWAY DX II SUNAMATIC 153 TEBOIL FLUID D

FL GROUP, VILLASTELLONE/I FUCHS DEA SCHMIERSTOFFE, HAMBURG/D FUCHS DEA SCHMIERSTOFFE, HAMBURG/D FUCHS DEA SCHMIERSTOFFE, MANNHEIM/D GINOUVES GEORGES SA, LA FARLEDE/F HANDEL-MIJ NOVIOL B.V., NIJMEGEN/NL HYDROTEX, CARROLLTON/USA IGOL FRANCE, PARIS/F

TUTELA TRUCK GEARLITE DEAFLUID 4011 DEAMATIC TITAN ATF 3000 YORK LT 785 KENDALL ATF DEXRON IID HY-TORQUE Z IGOL ATF 420

TEXACO BELGIUM N.V., BRÜSSEL/B TEXACO BELGIUM N.V., BRÜSSEL/B TOTAL RAFFINAGE DISTR., PARIS/F TURBOTANK BÖSCHE+BÖDEKER, BREMEN/D UNIL DEUTSCHLAND GMBH, BREMEN/D VEBA OEL AG, GELSENKIRCHEN/D VEEDOL INTERNATIONAL, SWINDON/GB YACCO SA, ST PIERRE-LES-ELBEUF/F

TEXAMATIC 7080 TEXAMATIC 4291 TOTAL FLUIDE ATX TURBO UNIV. ATF MERCON 4011 UNIL MATIC CN T 4011 MOVARA ATF-GETRIEBEÖL DIID VEEDOL ATF-M (D-22764) YACCO ATF D

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7. Maintenance

Maintenance

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

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7. Maintenance

Contents

7. Maintenance ............................................................. 121 - 174 Maintenance precaustions ........................................ 123 Maintenance table ..................................................... 124 8 Hours / Daily Service .............................................. 125 40 Hours / Weekly Service ........................................ 135 500 Hours Service ..................................................... 139 1000 Hours Service .................................................. 151 2000 Hours Service .................................................. 159 4000 Hours Service .................................................. 169 Yearly recommended maintenance ......................... 173

* Numbers refer to positions on the lubrication schedule, chapter 6 122

Operating & Maintenance Manual

7. Maintenance

Maintenance precautions • Always prepare the dump truck before starting any maintenance, adjustments or other work on the dump truck, see Service Position in the Safety Instructions chapter (Chapter 2).

• Wear a well-fitting helmet, safety shoes and working clothes. When drilling, grinding or hammering, always wear protective goggles.

• Park the dump truck on firm, flat ground. Apply the Articulation Lock.

• Unless you have special instructions to the contrary, maintenance should always be carried out with engine stopped.

If maintenance is carried out with the engine running, there must be two persons present: One operating the engine, and the other one performing the maintenance. In such a case, never touch any moving part.

• When working with others; Choose a group leader follow the leader's instructions. Do not perform any maintenance beyond the agreed work.

• Fuel and oil are dangerous substances. Never handle fuel, oil, grease or oily clothes in places where there is any fire or flame. As preparation in case of fire, always know the location and the use of fire extinguishers and other firefighting equipment.

• Flames should never be used instead of lamps. Never use a naked flame to check leaks or level of oil, fuel, anti-freeze or electrolyte.

• Always stop the engine when performing maintenance near moving parts.

• During maintenance; Do not allow any unauthorised person to stand near the dump truck.

• Exhaust gas is dangerous. When working inside, be particularly careful to have good ventilation.

• Thoroughly wash the engine. In particular, be careful to clean the filler caps, grease fittings and the area around the dipsticks. Be careful not to let any dirt or dust into the system.

• Always use Moxy genuine parts for replacement.

• Always use the grades of grease and oil recommended by the manufacturer. Choose the viscosity specified for the ambient temperature.

• Always use pure oil or grease, and be sure to use clean containers.

• Before servicing the air system, remember always to drain the air pressure through drain valves.

• When checking or changing the oil, do it in a place free of dust, and prevent any dirt from getting into the oil.

• Before draining the oil, warm it up to a temperature of 30o to 40o C. Be aware of possible internal pressure when opening any drain, level or filling plug. Hot oil can spurt out and inflict personal injury.

• Be particularly careful when removing the expansion tank cap. If this is done immediately after using the engine, there is a danger that boiling water and steam may spurt out.

• After replacing oil, filter element or strainer, bleed the air from the circuit.

• When the strainer is located in the oil filler, the strainer must not be removed while adding oil.

• When adding oil or checking the oil level, check that the oil is at the correct level.

• After greasing up, always wipe off the old grease which was forced out.

• When changing the oil or filter, check the drained oil and filter for any signs of excessive metal particles or other foreign materials.

• When removing parts containing o-rings, gaskets or seals, clean the mounting surface and replace with new sealing parts.

• When washing the dump truck, be careful not to wet electrical components or inside cabin.

• When lubricating oil or cooling water has been drained, keep an eye on the instrument panel so that the dump truck is not operated without oil or cooling water. * In case of difficult maintenance, refer to your Moxy Dealer.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

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7. Maintenance

Maintenance table 8 Hours / Daily Service 1. General 2. Engine

3.

4.

5.

6.

Transmission Hydraulic system Brake system Lubrication: • Artic. turning ring • Tip hinges • Tandem bearings 7. Parking brake 8. Service brake 9. Engine brake 10. Retarder brake 11. Steering

Walk around check ............

Check driver's seat ............

General condition check ...

Check oil level ...................

Check coolant level ...........

Check fuel level .................

Check centrifugal cleaner .

Drain air tanks ...................

Check oil level ...................

Check oil level ...................

Check fluid levels ..............

125 125 126 126 127 127 128 128 129 129 130

5/1 lubricators ....................

2 — “ — .............................

2 — “ — .............................

Check braking capacity .....

Check braking capacity .....

Check function ..................

Check function ..................

Check function ..................

Check function ..................

130 131 131 132 132 133 133 134 134

1000 Hours Service 1. Driver's seat 2. Engine

3. Fuel tank 4. Transmission

5.

6.

7.

8.

Front differential Rear differential Front reduction gears Electrical system

2000 Hours Service 1. Engine

2. Hydraulic system

40 Hours / Weekly Service 1. Engine 2. Cab ventilation 3. Tyres 4. Lubrication: • Artic. bearings • Steering cyl. bearings • Tip cyl. bearings • Tailgate arm hinges

Check batteries .................

Check battery terminals ....

Check filter element ..........

Air conditioner ...................

Check tyre pressure ..........

135 135 135 136 136

2 lubricators .......................

4 — “ — .............................

4 — “ — .............................

2 — “ — ..............................

137 137 137 138

Safety check ...................... 151 Replace fuel filters ............ 151 Bleed fuel system .............. 152 Check batteries ................. 152 Clean/replace air filter ....... 153 Check/clean prefilter ......... 154 Drain condensation ........... 154 Change oil ......................... 155 Replace filter ..................... 155 Clean strainer .................... 155 Change oil ......................... 157 Change oil ......................... 157 Change oil ......................... 158 Check wiring ..................... 158

3. Brake system 4. Parking brake 5. Tandem housings

Check injectors .................. 159 Check/adj. valve clearance 159 Check coolant ................... 160 Replace air dryer filter ....... 163 Change oil ......................... 164 Replace breather element 164 Replace hydraulic oil filter 165 Inspect brake lines ............ 165 Change brake fluid ............ 166 Check breather .................. 167 Change oil ......................... 167

4000 Hours Service 1. Cooling system

External cleaning .............. 169 Internal cleaning ............... 169 Clean charge air cooler .... 170 Changing coolant .............. 171

500 Hours Service 1. Engine

2.

3.

4.

5.

6.

7.

8.

Change oil ......................... 139 Clean centrifugal cleaner .. 139 Replace turbo filter ............ 143 Check V-belts' condition ... 143 Transmission Run the AEB-Tester .......... 144 Drive line Check oil levels ................. 145 Brake system Check linings ..................... 146 Wheels Check wheel nuts torque .. 147 Air conditioner Test operation ................... 148 Automatic central lubr. Refill reservoir ................... 149 Check the system .............. 149 Lubrication: • Doors and fenders 8 — “ — ............................. 150 • Suspension legs 4 — “ — ............................. 150

Yearly recommended maintenance 1.

2.

3.

4.

5.

6.

Transmission Drive line Tanks Hydraulic system Exhaust system Bearings

General condition check ... 173 General condition check ... 173 General condition check ... 173 Inspect the hydr. hoses ..... 174 Safety check ...................... 174 Check clearance ............... 174

* Numbers refer to positions on the lubrication schedule, chapter 6 124

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8th hour of operation or once a day.

1. General 1.1. Walk around check, before start • Check for leaks at the engine (see also item 2.1), transmission, differentials, reduction/tandem housings, tanks, hydraulic hoses and lubrication system.

• General check for loose bolts on the driveline, specially on radiator, engine/transmission brackets and at the prop. shaft flanges.

• Check for damage, wear and other abnormalities on the visible parts of frames, body, tyres, cylinders, etc.

• Check lights. Replace burnt out bulbs.

If leakages, loose bolts, damages or other abnormalities are observed, remedy if necessary (before operation).

If necessary contact your local Moxy Dealer.

1.2. Check driver's seat, before start • Check function.

• Check all seat adjustments for easy operation.

• Check function of the air valve.

• Check safety belt for proper lock functions.

See chapter 3, seat adjustment, for more detailed information.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

125

7. Maintenance

8 Hours / Daily Service To be performed every 8th hour of operation or once a day.

2. Engine 2.1. General condition check - look for leakages Remedy as necessary 1. Start the engine.

2. Look for leakage of oil, coolant, fuel, air and exhaust.

3. Tighten or change leaking connections. Check the overflow holes (1) which show whether the O-rings between the cylinder liner and crackcase are leaking, see drawing. a. If coolant is leaking out, the two upper O-rings are leaking. b. If oil is leaking out, the lower O-ring is leaking.

4. Check that the drain hole (2) on the coolant pump is not blocked, see drawing. If there is leakage, change the pump seal.

5. Check that the drain for the "V" behind the injection pump is open all way through the block and drain pipe so that no fluid can collect in the "V". See drawing.

6. A small amount of leakage from the overflow holes when running-in the engine is normal. (Seals and O-rings are fitted lubricated with soap or oil).

This leakage normally stops after a time.

If there is a large amount of leakage - contact your Moxy Dealer

2.2. Check oil level, before start 1* 1

2

• The correct level shall be between upper and lower mark on the dip stick (dump truck on level ground) (1).

• The dipstick is found on the right hand side of the engine (1).

• If the engine has been running: Let the engine remain stationary for at least 1 minute before checking the oil level.

• Fill up with oil (see oil specification sheet, chapter 6) if level has dropped to the lower mark (2).

Check level correctness.

* Numbers refer to positions on the lubrication schedule, chapter 6 126

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8th hour of operation or once a day.

2.3. Check coolant level, before start 5* • The expansion tank shall be approx. half filled when the dump truck is on level ground.

Refill with coolant of correct mixture if level is lower.

• If large quantities are required to correct the level, check and remedy the cause in such a case.

CAUTION Be careful when removing the filler cap of a hot engine.

Hot coolant can spurt out!

Never add large amounts of cold coolant when engine is hot. The temperature difference can cause cracks in the engine.

2.4. Check fuel level, before start 13* 1. Turn on the starter switch key (to pos. 1) and check on the fuel gauge that there is enough fuel.

2. Fill up with fuel if necessary.

NOTE Always make sure that there is enough fuel in the tank.

NEVER run out of fuel.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

127

7. Maintenance

8 Hours / Daily Service To be performed every 8th hour of operation or once a day.

2.5. Function check of the centrifugal cleaner, after operation 2* The rotor rotates very fast, and will normally carry on rotating after the engine is stopped.

1. Stop the engine when it is warm.

2. Listen for spinning sound from rotor, or feel if cleaner housing vibrates.

3. The rotor normally rotates 30 - 60 seconds after the engine has stopped.

4. If not, dismantle and check the cleaner, see 500 hours service.

2.6. Drain air tanks, after operation 12* • Front chassis: Pull the handle in front of the truck (left hand side) outwards to release air pressures from all front chassis air tanks.

• Rear chassis: Pull the drain chain on the underside of the tank sideways to release the air pressure.

• If condensation is present in the escaping air, release system pressure completely and replace the air dryer cartridge, see 2000 hours service

* Numbers refer to positions on the lubrication schedule, chapter 6 128

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8th hour of operation or once a day.

3. Transmission 3.1. Check oil level, before operation 20* 1. The dump truck must be standing on level ground.

2. The gear selector shall be in neutral and confirm that the parking brake is ON. 3. Run the engine at low idle.

4. Turn the dip stick handle (behind the cab) a few turns to the left to release the seal pressure.

5. Pull out the dip stick and clean it with a clean cloth.

6. Insert dip stick fully and remove it again (at least 2x) 7. Check level:

Cold oil, 40 oC: Hot oil, 80 oC:

lower mark upper mark

8. If necessary correct the level by adding oil according to the transmission oil list (chapter 6) through the dip stick tube.

9. Insert the dip stick again and turn handle clockwise to tighten the sealing.

CAUTION Do not overfill with oil! Both too high and too low level can cause serious internal damage!

4. Hydraulic system 4.1. Check oil level, before start 40* 1. Read the oil level in the oil level gauge.

Level shall be approx. at the middle of the gauge.

2. Fill up with oil (see oil specification sheet, chapter 6) if necessary.

NOTE The dump truck must be horizontal and dump body completely lowered!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

129

7. Maintenance

8 Hours / Daily Service To be performed every 8th hour of operation or once a day.

5. Brake system 5.1. Check brake fluid levels, before start 60* Two containers on right hand side in engine compartment and two containers on rear chassis.

• The containers shall be min. 2/3 filled (see marks).

Fill up with correct brake fluid, if necessary.

• If the containers have to be filled up with brake fluid almost monthly, check the brake system for leaks and/ or worn brake linings. Replace brake linnings if necessary.

• Experiences has shown that if the brake fluid containers are filled up from minimum to maximum 3 times, the brake linnings could have reached the min. thickness.

Therefore, if the level in the containers decreases, the brake linings must be checked /replaced (see 500 hours service for procedure).

CAUTION • •

When refilling, do not overfill!

Use only brake fluid as specified in the specification sheet, chapter 6!

6. Lubrication Grease lubrication points until pure grease is forced out of the components. Wipe off.

6.1. Articulation turning ring Up to serial number 513086 there are 5 lubricators 50* From serial number 513087 (SERIES II) there is 1 lubricator 50* Lubricators located on the distribution block.

• Start with the lowermost points.

* Numbers refer to positions on the lubrication schedule, chapter 6 130

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8th hour of operation or once a day.

6.2. Tip hinges, 2 lubricators 51* One lubricator on each tip hinge.

6.3. Tandem bearings, 2 lubricators 52* One lubricator on rear end of each tandem housing.

Lubricator

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

131

7. Maintenance

8 Hours / Daily Service To be performed every 8th hour of operation or once a day.

7. Parking brake 7.1. Check braking (holding) capacity, before operation 1. Apply the parking brake (indicator light) and make sure that the system pressure is at normal operating pressure which is between 6.8 - 7.8 bar (see air pressure gauge, in chapter 3).

2. With the gear selector in 2nd gear, increase engine speed slowly.

3. The parking brake must be able to keep the dump truck stationary at engine speeds up to 1600 rpm. If not, check parking brake system and contact your Moxy Dealer.

8. Service brake (main brake) 8.1. Check braking (holding) capacity, before operation 1. Apply the parking brake (indicator light) and make sure that the system pressure is at normal operating pressure which is between 6.8 - 7.8 bar (see air pressure gauge, in chapter 3).

2. Depress the brake pedal.

3. Release the parking brake.

4. With the gear selector in 1st gear, increase engine speed slowly.

5. The service brake must be able to keep the dump truck stationary at engine speeds up to 1200 rpm. If not, check the brake system and contact your Moxy Dealer.

* Numbers refer to positions on the lubrication schedule, chapter 6 132

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8th hour of operation or once a day.

8.2. Check function, before operation 1. Apply the parking brake (indicator light) and make sure that the system pressure is at normal operating pressure which is between 6.8 - 7.8 bar (see air pressure gauge, in chapter 3).

2. Stop the engine.

3. Depress brake pedal firmly and listen for leaks in the air system. Also check that the brake fluid warning light (chapter 3) does not illuminate and the air pressure gauge (chapter 3) for large pressure drop.

4. Check for brake fluid leakage at master cylinders, pipes and hoses.

5. Start the engine and release the parking brake.

6. Drive the dump truck slowly on firm, level ground and depress the brake pedal firmly.

7. Check that the braking effect is good and equal.

9. Engine brake 9.1. Check function, before operation 1. Drive the dump truck forwards at approx 10-15 km/h with lock-up engaged.

2. Apply the engine brake by depressing the engine brake switch (if fitted) and release the throttle pedal.

3. Check that the exhaust sound changes.

4. Check the indicator light for function and note the braking power.

5. Depress the throttle pedal again and note that the engine brake goes off (i.e no braking power, exhaust sound changes and the indicator light switches off).

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

133

7. Maintenance

8 Hours / Daily Service To be performed every 8th hour of operation or once a day.

10. Retarder brake 10.1. Check function, before operation 1. Drive the dump truck forwards at approx 10-15 km/h with lock-up engaged.

2. Apply fully the retarder brake by setting the retarder brake lever to max. position (if a retarder brake switch is fitted, it is also necessary to depress this switch) and release the throttle pedal.

3. Check the indicator light for function and note the braking power.

4. Depress the throttle pedal again and notify that the retarder brake goes off (i.e no braking power and the indicator light switches off).

11. Steering 11.1. Check function, before operation 1. Drive slowly forwards (5-10 km/h) and check that the emergency steering light goes off.

2. Turn the steering wheel at an even speed until end stop, both sides.

3. Check that the movement is uniform.

* Numbers refer to positions on the lubrication schedule, chapter 6 134

Operating & Maintenance Manual

7. Maintenance

40 Hours / Weekly Service To be performed every 40th hour of operation or once a week.

1. Engine 1.1. Check batteries 11*

• Checking of batteries shall also be carried out after the first 8 hours of operation.

10 - 15 mm

1. Open right hand side fender cover (key for opening the cover is to be found in the cab, on the seat bracket, left hand side) 2. Undo the plugs and check electrolyte level in all cells.

3. The fluid level in each cell shall be between 10-15 mm above the plates.

4. Refill with distilled water if level is lower.

See also chapter 2, safety instructions.

NOTE Only distilled or chemically cleaned water must be used.

1.2. Check battery terminals for tightness and corrosion Clean if necessary, apply acid-free vaseline on the terminals and retighten the clamps.

2. Cab ventilation 2.1. Check filter element condition 70* 1

5

4

3

2

1. Open 4 clamps (1) and remove outer cover (2).

2. Remove prefilter (3), and clean it with compressed air.

• Replace if necessary.

3. Remove the grid (4) in front of the filter element.

4. Check if the filter element (5) is clogged or damaged.

• Replace if necessary.

5. Reassamble the opposite way.

1

6. Adjust the check interval if another requirement is experienced.

NOTE Never start driving without prefilter. The heater could in worsc case get damaged. * Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

135

7. Maintenance

40 Hours / Weekly Service To be performed every 40th hour of operation or once a week.

2.2. Air conditioner system • The equipment must be used for at least five minutes every week, to distribute oil in the system, this prevent leaks and ensure that the seals are lubricated • See operating controls, chapter 3, cab ventilation, about how to use the air conditioner.

• This must also be done during cold weather operation.

NOTE At ambient temperatures below + 4° C the air conditioner will not engage. Warm up the cab before operating the air conditioner for 10 minutes.

3. Tyres 3.1. Check tyre pressures, before operation When the pressure shall be measured, the dump truck must be unloaded.

Measure the pressure for cold tyres with a tyre pressure gauge and adjust if necessary.

For tyre pressure recommendation, see chapter 8 - Technical data, and chapter 5 - Operating instructions.

WARNING Stand behind the tread when checking the inflation pressure.

Pressures inside tyres are substantial and an explosion can cause damage and serious personal injury.

* Numbers refer to positions on the lubrication schedule, chapter 6 136

Operating & Maintenance Manual

7. Maintenance

40 Hours / Weekly Service To be performed every 40th hour of operation or once a week.

4. Lubrication Grease following lubrication points until pure grease is forced out of the component. Wipe off.

4.1.

Articulation bearings, 2 lubricators 53* Turn the dump truck completely to the right for easy access to the lubricators on the bearing hinge.

4.2.

Steering cylinder bearings, 4 lubricators 54* 2 lubricators on each cylinder (one at each end).

Check the complete length of cylinder rods for scratches and other damage.

4.3.

Tip cylinder bearings, 4 lubricators 55* 2 lubricators on each cylinder (one at each end).

Raise the body to check all cylinder pistons for scratches and other damage.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

137

7. Maintenance

40 Hours / Weekly Service To be performed every 40th hour of operation or once a week.

4.4.

Tailgate arm hinge (optional), 2 lubricators 56* One lubricator on the inner side of each tailgate arm hinge.

5. Continue with all items in 8 Hours / Daily Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 138

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500th hour of operation.

1. Engine 1.1. Change oil 1*

If the dump truck is used for particulary demanding operation, especially in a dusty environment or if the deposits in the centrifugal cleaner are thicker than 20 mm: Change oil more often.

Quick drain plug

1

2

1. Remove the oil pan drain plug and drain the oil when the engine is warm.

Access through the rear drain hole in engine belly plate.

• If a quick drain plug is fitted: Remove the cap on the drain plug, install the draining hose (tool kit) and drain the oil.

2. Clean magnet on plug.

3. Reinstall the plug when all oil is drained.

• Plug torque: 80 Nm. • If quick drain plug is fitted: Remove the draining hose and reinstall the cap.

4. Reinstall the cover for rear drain hole in engine belly plate.

5. Fill oil through filler (2). Do not overfill!

6. Check oil level on dip stick (1).

CAUTION The oil may be hot! Wear protective gloves and eye protection.

1.2. Clean centrifugal cleaner 2* (at the same time as oil change, item 1.1) See next page about how to clean the centrifugal cleaner.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

139

7. Maintenance

500 Hours Service Maintenance to be performed every 500th hour of operation.

1. Unscrew the nut and remove cover.

CAUTION Open the cover with care. The oil and inner parts may be hot!

2. Lift out the rotor assembly and loosen the nut for the rotor cover three turns.

3. If the nut sticks: Secure the nut, absolutely not the rotor, in a vice and turn the rotor three turns by hand or using a screwdriver.

4. Gently tap the nut with the hand or with a plastic hammer to separate the rotor from bottom plate.

* Numbers refer to positions on the lubrication schedule, chapter 6 140

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500th hour of operation.

5. Undo the nut and remove the rotor cover.

6. Carefully prise the strainer loose from the bottom plate.

7. Scrape off the deposits from the inside of rotor cover.

• If there are no deposits, this shows that the cleaner is not working.

• Clean more frequently if deposits are thicker than 20 mm.

8. Clean all parts in diesel fuel.

9. Place the O-ring in the rotor cover.

• The o-ring must be not be damaged.

Change if necessary.

10. Assemble the rotor.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

141

7. Maintenance

500 Hours Service Maintenance to be performed every 500th hour of operation.

11. Tighten rotor nut firmly by hand.

12. Reinstall the rotor.

• Check that it rotates easily.

13. Check that the O-ring in the cover is not damaged.

Hard or damaged O-ring must be replaced.

14. Tighten cover firmly by hand.

15. If the nut is tightened too hard (for instance by using tools), the cover, nut or rotor shaft may be damaged!

16. Replace damaged parts!

17. Function check The rotor rotates very fast, and will normally carry on rotating after the engine is stopped. a. Stop the engine when it is warm. b. Listen for spinning sound from rotor, or feel if cleaner housing vibrates. c. The rotor normally rotates 30 - 60 seconds after the engine has stopped. d. If not, dismantle and check the cleaner.

* Numbers refer to positions on the lubrication schedule, chapter 6 142

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500th hour of operation.

1.3. Replace turbo filter 3* (at the same time as oil change, item 1.1) 1. Remove the old filter and discard it according to enviromental requirements.

2. Oil the rubber gasket on the new genuine filter.

3. Fit the new genuine filter.

4. Tighten the filter by hand as tight as possible.

5. Start the engine and check for leaks.

If the deposits in the centrifugal cleaner exceed 20 mm, the turbo filter must be changed more often, at the same time as cleaning the centrifugal filter and changing the oil.

NOTE • •

Never use tools to tighten the filter. It can be damaged and the circulation obstructed!

Use only genuine filter!

1.4. Check V-belts' condition

• Checking of V-belts' condition shall also be carried out after the first 8 hours of operation.

• Stop the engine to inspect the V-belts.

• Change the belts if damaged or worn (always replace both belts at the same time).

• Correct deflection of the V-belts is approx. 10 mm.

• Adjust tension if necessary: 1. Loosen bolt 1.

2. Adjust for correct tension with bolt 2.

• Do not overtighten the belts!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

143

7. Maintenance

500 Hours Service Maintenance to be performed every 500th hour of operation.

2. Transmission 2.1. Run the AEB-Tester AEB = Automatic Filling Parameter Adjustment

Moxy part no.

8453

To optimize the transmission, run the AEB-Tester.

1. The transmission control unit is located under the left hand side dashboard panel.

2. Follow the procedure described in the table below.

The gear display will show the AEB's actions. ("Display message" in the table).

AEB = Automatic Filling Parameter Adjustment TCU = Transmission Control Unit How to run the AEB-Tester

1 Warm up the transmission oil,

Display message Normal operating messages

Remarks

the oil must have a temperature at 70 - 80 OC

2 - Move the gear selector to

-

Neutral position.

- Engage the parking brake

3 Turn OFF the starter switch

-

4 Plug the AEB-Tester into the

-

diagnostic contact no. 607 5 Start the engine

"PL"

6 Set engine speed to low idle

"PL" if starts condidtions are OK

TCU must recognize "PL" for at least 2 sec. before you can press the button.

rpm

7 Press button on the AEB Tester "ST" if starts conditions are OK

The button must not be released before TCU has started the AEB or quit with an error code.

8 Keep the button depressed until "K1" ……

TCU has started the AEB and goes to (Information about the AEB state) adjusting K1, K2, …, KR. (Button may be released).

the AEB has started

9 Wait until AEB is finished

"OK" (AEB has been successful)

10 Turn OFF the starter switch and unplug the AEB-Tester

11 Remount the dashboard panel -

NOTE • • •

If the oil temperature is too low or too high, following message will apear on the gear display: T or T . Adjust the oil temperature and try again.

If there is a malfunction, turn the starter switch off and start the engine again.

The AEB will not start if any error codes are shown on the gear display, except error code "F6"

* Numbers refer to positions on the lubrication schedule, chapter 6 144

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500th hour of operation.

3. Drive line 3.1. Check oil levels Measurements must be carried out when dump truck is parked on a horizontal ground. Check that oil level is near the bottom edge of the plugs. Refill with oil if level is too low.

If the dump truck tandem housing is angled, the reading will be incorrect.

CAUTION Be aware of possible internal pressure when the oil is hot!

1. Front differential 30* Use a hexagonal key (1) to unscrew the upper filling/level plug (2).

• Plug torque: 80 Nm.

1

2

2. Rear differential 31* 1

2

Use a hexagonal key (1) to unscrew the filling/level plug (2) at the rear of housing.

• Plug torque: 80 Nm.

3. Tandem housings 32* Use a hexagonal key (1) to unscrew the level plugs (2) on the inside of the housings.

• Plug torque: 80 Nm.

2

1

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

145

7. Maintenance

500 Hours Service Maintenance to be performed every 500th hour of operation.

4. Front reduction gears 33* Turn the hubs until level indicator is horizontal (1). Use a hexagonal key (2) to unscrew the plugs (3).

• Plug torque: 80 Nm.

2

3

1

4. Brake system

Service brakes

4.1. Check lining thickness

• Checking of brake lining thickness shall also be carried out after the first 250 hours of operation.

1. Service brakes: Check brake linings. Brake linings should be changed before the thickness of the linings on the most worn areas reaches 3,5 mm.

• How often the brake linings have to be checked/replaced depends on how much the brakes are used and/or application. After checking the brake linings for the first 250 hours, consider whether or not the brake linings should be checked more often, based on lining wear.

• Also if there often (monthly) have to be filled up with brake fluid, the brake linings must be checked and if necessary replaced (see 8 hours/daily service).

Parking brake 1

If the linings have to be replaced, be aware that overflow of brake fluid in the reservoirs can occur.

To avoid this, open the bleeder plug before the old lining is pushed back to give space for the new one.

2. Parking brake: Lift body and apply the body support (1). Check thickness of linings through inspection hole (2) on top of the caliper.

Change when approaching limit.

• After replacement perform adjustment, see next page.

1 2 Standard lining thickness: Service brakes: Parking brake:

22.0 mm 18.0 mm

Min. thickness:

3.5 mm.

3.5 mm.

Service brakes: Parking brake:

CAUTION This applies to normal driving. For rough operating conditions with much braking and/or driving in water, the brake linings should be checked more often! * Numbers refer to positions on the lubrication schedule, chapter 6 146

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500th hour of operation.

4.2. How to adjust the parking brake.

To be performed after replacement of parking brake linings.

1

1. Apply the parking brake and make sure that the system pressure is at normal operating pressure which is between 6.8 - 7.8 bare (see air pressure gauge, in chapter 3).

2. Lift the body.

3. Apply the body support (1) (see also safety instructions, chapter 2).

4. Stop the engine.

1

5. Secure the dump truck with wheel chocks (see also safety instructions, chapter 2)

2 3

6. Release the parking brake.

7. Turn the adjusting screw anticlockwise until a total clearance of 1.5 mm (2) is obtained between outer lining and disk. (Measure at centre of lining when sliding caliper max. outwards.)

8. Place a wrench on the adjusting screw (3), and apply the parking brake in the cab several times. Look out of the rear window to follow the wrench and when no further rotation on the adjusting screw is observed, the brake is correctly adjusted.

9. Remove the wrench and check function and effect.

5. Wheels 5.1

Check wheel nuts torque.

Torque setting 450 Nm. Wheel spanner in the tool box.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

147

7. Maintenance

500 Hours Service Maintenance to be performed every 500th hour of operation.

6. Air conditioner system 6.1. Test operation 1. Start the engine.

2. Press down the air conditioner switch, set the thermostat for air conditioner to maximum cooling, and the fan switch to position 3 (see also chapter 3), and open all nozzles.

3. Check that the indicator light illuminates.

• If the indicator light does not illuminate: • Check whether the indicator bulb or fuse is burnt out, if yes, replace the bulb or fuse and go on to item 4.

• If neither the bulb nor fuse is burnt out, there can be a failure: CONTACT YOUR LOCAL MOXY DEALER. 4. Check that the temperature in the cab decreases.

• If the temperature does not decrease, there can be a failure or too little refrigerant in the system: CONTACT YOUR LOCAL MOXY DEALER

WARNING •

If the air conditioning system does not work properly, contact your Moxy Dealer in all cases!

•

Always use safety glasses or goggles, gloves, boiler suit and protective footwear when inspecting, servicing and repairing the air conditioning system.

•

Refrigerant R134a has a property that can cause frostbite if it comes into contact with bare skin or eyes.

•

Always work on the air conditioning system in well ventilated places.

•

The system contains refrigerant R134a under pressure. Repair and refilling of the refrigerant circuit must only be done by accredited personnel.

•

Dispose of waste oil/fluids in an enviromentally friendly manner!

•

High concentration of the refrigerant in gaseous form can cause drowsiness, headache, dizziness and at worst unconciousness. Very high concentration of the gas can even cause cardiac insufficiency.

Do not smoke when servicing the air conditioning system!

•

Be careful with all hoses connected to the air conditioning system. There is always a certain overpressure in the system. Therefore, never undo hoses or the filler opening on the compressor except during repairs to the system.

•

If there is any suspicion of leakage, the system must not be filled up - leave the leakage site and contact your Moxy Dealer for repairs.

•

Get your Moxy Dealer to check the air conditioning system once per year.

•

See also chapter 2, safety instructions

* Numbers refer to positions on the lubrication schedule, chapter 6 148

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500th hour of operation.

7. Automatic central lubrication 7.1. Refill the reservoir, the reservoir must be refilled if the indicator light flashes for 2 minutes (0.5s on/0.5s off) at the beginning of each cycle.

1. Remove the dust cap from the filler coupling.

2. Carefully clean the filler coupling and the coupling on the filler hose.

3. Fit the filler hose on the filler coupling.

4. Fill the reservoir up to the maximum level indicated on the reservoir.

5. Remove the filler hose and fit the dust cap.

Filler coupling

7.2. Check the system • Check the pump for damage and leakage.

• Check the grease lines for damage and leakage.

• Check, if possible, the condition of the grease points the system serves. Sufficient fresh grease should be present.

• Check the operation of the system. Perform a cycle test (see chapter 3 for how to perform a cycle test).

Note that every time you perform a cycle test, grease is supplied to the grease points.

• Clean the pump-unit and its surroundings.

NOTE •

If you use a high-pressure air or water gun to clean the dump truck, do not spray directly onto the pump unit. Water or dirt might enter the pump-unit through the de-aerating openings.

•

Even if the automatic central lubrication is installed, do not forget that there are still some greasing points that must be greased by hand, these are the doors and fender hatches.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

149

7. Maintenance

500 Hours Service Maintenance to be performed every 500th hour of operation.

8. Lubrication Grease lubrication points until pure grease is forced out of the components.

8.1. Doors and fender hatches, 8 lubricators 57* There are 2 lubricators on each door and hatch (one per hinge)

8.2. Suspension legs, 4 lubricators 59* The lubricators are located on the distribution block (fitted on rear, right side of the front frame).

9. Continue with all items in 40 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 150

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000th hour of operation.

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 2 fuel filters 4* The filter consist of two parallel-coupled filter units.

1. Wash the filters externally and unscrew them, wrench in toolkit. Dispose of filters according to environmental requirements.

2. Tighten the new filters by hand.

• Never use tools to tighten the filters! The filters 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.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

151

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000th hour of operation.

1

2.2

Bleed fuel system: 1. Open the bleeder screw (1) on the main filter.

2. Pump with the hand pump (2) until bubble-free fuel flows out at the main bleeder screw.

3. Close the bleeder screw. Pump a few times using the hand pump.

If the engine is difficult to start after bleeding: • Slacken the injection pump overflow valve (3) one half turn and try starting again.

If the engine still does not start: • Pump the hand pump until bubble-free fuel flows from the overflow valve.

• Tighten the overflow valve when the engine has started.

WARNING The engine may be hot! Use gloves when pumping with the hand pump to avoid burning your hands.

2

3

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, due to tropical version 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.

See also chapter 2, safety instructions.

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! * Numbers refer to positions on the lubrication schedule, chapter 6 152

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000th hour of operation.

2.4. Air filter 10* Outer element: 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 v-clamp and retainer, remove outer element.

Do not remove inner element when cleaning outer element!

2. Clean retainer and inside of filter housing.

3. 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.

4. Check that the element is clean and undamaged, and reinstall it.

Inner element: Replace element every 3rd replacement of the outer element, or at least every 3rd year.

1. Remove outer element. Then remove inner element.

2. Cover the air inlet port.

3. Clean inside of filter housing, and remove inlet cover.

4. Fit a new inner element and the inner element retainer into the housing, and tighten the nut.

5. Install a new or cleaned outer element and outer element retainer, and tighten wing nut.

6. Install cover.

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.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

153

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000th hour of operation.

2.5. Check / clean prefilter of the air filter 10* 2

1. Loosen wing bolt (1) 2. Remove the prefilter (2) and clean with compressed air, if necessary.

3. Reassemble, turn the prefilter so that the dust cap (3) is pointed downwards (max angle: 20°).

4. Check air filter warning light at full engine load.

3

1

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.

2

1. Open engine bonnet.

2. Place a suitable container to catch spillage.

3. Use a hexagonal key (1) to remove the blanking plug (2) from the drainer.

1

4. Install draining hose (3) (tool kit).

3

5. Drain until water/sediment-free fuel comes out.

6. Remove 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 (in the engine compartment) and clean inside of the tank.

* Numbers refer to positions on the lubrication schedule, chapter 6 154

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000th hour of operation.

4. Transmission 4.1. Change oil 20* Replace filter element 21* Clean strainer 22* at least once a year

1

• Changing transmission oil, replacement of transmission filter 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. Unscrew drain plug (2) under the transmission and drain the oil into a suitable container (3).

5. Clean the drain plug with magnetic insert, replace seal if necessary and reinstall the plug.

• Tightening torque: 80 Nm. 2 3

Replace filter elements: 6. Unscrew the filter elements (4).

7. Apply oil to the seals on the new elements.

8. Screw the filter elements in until contact with the sealing surface is obtained. Tighten the elements firmly by hand.

4

Clean stranier: 9. Unscrew the three nuts (5) and washers (6).

5 10. Remove the cover (7) 6

11.Replace the O-ring on the cover, if necessary.

12.Remove the strainer (8) and clean it.

7

13.Reassemble and torque nuts to 23 Nm.

8 continued overleaf

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

155

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000th hour of operation.

Fill new oil: 14.Fill new oil according to the transmission oil list and oil specification sheet (chapter 6) through the dip stick tube.

15.Insert the dip stick again and turn handle clockwise to tighten the sealing.

Check: 16.Start the engine and check oil level (9) (see daily maintenance, for procedure) at low idle. Both too low and too high level can cause serious internal damage!

17.Warm up the oil and check for leaks. Recheck level and adjust if necessary.

NOTE

9

• •

Do not overfill! Both too high and too low level can cause serious internal damage!

For rough operation conditions the oil and the filter element must be changed more often (every 500 hours) and the strainer must be cleaned as well.

* Numbers refer to positions on the lubrication schedule, chapter 6 156

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000th hour of operation.

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. Open level / filling plug (1), special spanner in tool kit.

2. Unscrew drain plug (2).

1

3. Drain the oil into a suitable container.

2 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 filling plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

CAUTION Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening the drain plug.

6. Rear differential 6.1. Change oil, at least once a year 31* 2

1

• 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 filling plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

CAUTION Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening the drain plug. * Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

157

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000th hour of operation.

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 (1).

3. Unscrew the plug.

4. Drain the oil into a suitable container.

5. Turn the hub 90o, so that the level indicator is horizontal.

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.

1

7. Clean plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 8. Recheck oil level after test driving.

CAUTION Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening the drain plug.

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.

9. Continue with all items in 500 Hours Service. * Numbers refer to positions on the lubrication schedule, chapter 6 158

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000th hour of operation.

1. Engine 1.1. Check fuel injectors, at least once a year Contact Moxy Dealer for checking of the fuel injectors.

1.2. Check/adjust valve clearance

• Checking/adjusting valve clearance shall also be carried out after the first 500 hours of operation.

Adjust if necessary: • Inlet: 0,45 mm • Exhaust: 0,80 mm see instruction sign on one of the rocker covers.

Valves should be adjusted when the engine is cold, at least 30 minutes after operation.

FLYWHEEL Cylinder numbering

No. 1 cylinder piston 30° after combustion stroke

induction stroke

Rocker cover gaskets must be changed if necessary.

• Tightening torque: 25 Nm 1. Turn the crankshaft in its direction of rotation until the No. 1 cylinder is at 30° after TDC (Top Dead Centre) on the combustion stroke. There is a mark, ⊥ , at this point.

2. Adjust the following valves: Right hand side

Cyl. 1 Cyl. 2 Cyl. 4

Inlet and exhaust Exhaust Exhaust

Left hand side

Cyl. 5 Cyl. 7 Cyl. 8

Inlet and Exhaust Inlet Inlet

3. Turn the crankshaft one revolution in its direction of rotation to the mark ⊥ . The No. 1 cylinder piston is the at 30° after TDC (Top Dead Centre) in the induction stroke.

FLYWHEEL

4. Adjust the following valves:

Intake valve Exhaust valve

Right hand side

Cyl. 2 Cyl. 3 Cyl. 4

Inlet Inlet and Exhaust Inlet

Left hand side

Cyl. 6 Cyl. 7 Cyl. 8

Inlet and Exhaust Exhaust Exhaust

The readings can only be taken from underneath

WARNING Block the starter device when working on the engine!

If the engine starts out of control, there is a SERIOUS RISK OF INJURY! Covers for reading on flywheel casing

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

159

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000th hour of operation.

1.3. Check the coolant, at least once a year 5*

Coolant: Water + Anti-freeze or Water + Anti-corrosive (see text)

NOTE Coolant composition: If there is a danger of freezing: • at least 30% glycol by volume (27 litres by total volume) • max. 60% glycol by volume (54 litres by total volume) If there is no danger for freezing: • 10% anti-corrosive by volume (9 litres by total volume)

1.3.1 Check the appearance of the coolant, at least once a year • Take a little coolant in a vessel and check that it is clean and clear.

• If the coolant is contaminated or cloudy: Consider changing the coolant.

• The water for the coolant should be free of dirt.

• Use drinking water with a pH of 6 - 9.

* Numbers refer to positions on the lubrication schedule, chapter 6 160

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000th hour of operation.

Freezing point (° C)

Anti - freeze

- 18

30%

27 L

- 24

35%

31.5 L

- 30

40%

36 L

- 38

45%

40.5 L

- 40

50%

45 L

1.3.2 Coolant with glycol only: Check glycol content, at least once a year If there is risk of ambient temperature below 0 °C, use only glycol as protection against corrosion in the coolant.

• Cooling system with glycol must contain at least 27 litres (30%) glycol by volume to offer sufficient protection against corrosion.

• 27 litres (30%) glycol by volume provides anti-freeze protection down to -18 °C. If more protection is required, see the table for calculating the necessary amount of glycol.

The amount of glycol (anti-freeze) is determined acc. to lowest expected temperature.

Always be sure that it is enough glycol (anti-freeze) mixed with the water in the cooling system to avoid freezing, see table.

Total volume: 90 litres

We recommend only nitrite-free glycol anti-freeze with the following supplier designations: • BASF Glysantin G48

• Always fill up the anti-freeze if the content drops below 27 litres (30%) by volume. A glycol content above 54 litres (60%) by volume will not improve the protection against corrosion.

WARNING • •

Ethylene glycol is highly dangerous if consumed and can prove fatal.

Avoid contact with the skin.

NOTE •

•

•

The coolant should be mixed before it is filled into the cooling system. Never top up with only water or only glycol.

The recommended glycols must not be mixed with glycol which has nitrite-based anti-corrosive or with other anti-corrosive. This could cause sludging and reduced cooling capacity.

The coolant should be changed when the cooling system is cleaned. Every 4000 hours or at least every 4th year.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

161

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000th hour of operation.

1.3.3 Coolant with only anti-corrosive: Check protection against corrosion, at least once a year There must always be sufficient anti-corrosive (inhibitor) in the coolant to protect the cooling system against corrosion.

• If there is no danger of freezing use only Anti-corrosive.

• The inhibitor in the Anti-corrosive must be nitrite-free with the following supplier designation: • BASF Glysacorr G93.

• The correct level of Anti-corrosive is 10% by volume (9 litres by total volume).

• Fill with Anti-corrosive as indicated on the packaging.

• Filling up with 1% by volume (0.9 litres by total volume) of Anti-corrosive should be done after every 2000 operating hours.

• Never fill up with water only or Anti-corrosive only. Lost fluid should always be replaced by pre-mixed coolant: water + 10% Anti-corrosive by volume.

• Anti-corrosive content must not be lower than 5% by volume or exceed 30% by volume.

NOTE • • • •

Anti-corrosive must not be mixed with glycol.

Mixing or over concentration can cause sludging and reduced cooling capacity.

Any coolant filter must not contain inhibitor.

The coolant should be changed when the cooling system is cleaned. Every 4000 hours or at least every 4th year.

* Numbers refer to positions on the lubrication schedule, chapter 6 162

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000th hour of operation.

a 1

1.4. Replace air dryer filter, at least once a year 12* Up to serial no. 513086 1. Release air pressure in dryer through air draining point.

2. The air dryer is located inside left hand side fender, together with the air tanks, access through fender hatch.

2

3. Unscrew bolt (1) and remove cover (2) and the spring (3).

4. Remove the filter (4).

3 4

5. Clean all parts, included aluminium filter (5) and bottom plate (6) in a proprietary fluid and dry.

6. Replace the sealings (a-c) with new one.

Grease lightly the new seals.

5

7. Reassemble the parts with new filter and new greased seals (a-c).

b

8. Tighten bolt (1) to 20-25 Nm.

6

9. Start engine end check for air leaks.

c

1.4. Replace air dryer filter, at least once a year 12* From serial no. 513087 (SERIES II) 1. Release air pressure in dryer through air draining point.

2. The air dryer is located inside left hand side fender, together with the air tanks, access through fender hatch.

3. Remove the old air dryer element.

4. Install the new air dryer element.

5. Start engine end check for air leaks.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

163

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000th hour of operation.

2. Hydraulic system 2.1. Change oil 40*

5

1. Open the engine bonnet.

2. Place a suitable container (1) to catch spillage.

3. Remove the cap (2) from drainplug (3) on the main reservoir.

4. Install the draining hose with nipple (4) (tool kit).

5. Drain the main reservoir oil into the container.

2

6. Remove the cap (2) from the drain plug (5) on the emergency steering reservoir.

4

7. Remove the draining hose (4) from the main reservoir drain plug (3), and install it on the the emergency steering reservoir drain plug (5).

8. Drain the oil in the container.

3

9. Remove the draining hose and reinstall both caps (2) 10.Fill new oil through the filler (6), according to the oil specification sheet (chapter 6).

NOTE 4

Remember, ATF oil must not be mixed with engine or hydraulic oil!

1

6

2.2

Replace breather element 42* • Unscrew the old element on the hydraulic tank.

• Check the o-ring for deterioration, apply oil and screw on a new element.

CAUTION Both breather and filter must be replaced if the hydraulic filter warning light illuminates.

Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety. * Numbers refer to positions on the lubrication schedule, chapter 6 164

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000th hour of operation.

2.3. Replace hydraulic oil filter, must be replaced if the hydraulic filter warning light illuminates 43*.

*

Replacement of hydraulic filter shall also be carried out after the first 100 hours of operation.

1. Clean well around the filter housing.

2. Place a suitable container beneath the filter to catch spillage.

3. Unscrew filter housing, spanner in the tool kit.

4. Check for wear particles in the oil.

5. Change O-ring. Check backing ring for damage.

6. Replace the filter element with a new one.

7. Clean the housing and apply oil or grease to threads and O-rings.

8. Fill housing half full with clean oil.

9. Screw filter housing back into place.

• Torque: 141 Nm. 10. Start engine and check for leaks.

11. Check that the hydraulic filter warning light does not light at normal operating temperatures.

CAUTION Both breather and filter must be replaced if the hydraulic filter warning light illuminates.

Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

3. Brake system 3.1. Inspect brake lines, at least once a year.

Replace pipes, hoses and fittings which are corroded (deep seated rust), deteriorated (aged), leaking or otherwise damaged.

CAUTION Check more often when operating in salty condtions or similar environment that may affect the brake system!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

165

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000th hour of operation.

3.2. Change brake fluid, at least once a year 60*

NOTE! Item 1 is only valid for dump trucks with two bleeding plugs as shown on the illustration (from serial no. 513001 and up to 513045). From serial no. 513046, tilting of the tandem housings are not necessary.

1 Park the dump truck in such way that the tandem housings are tilted to max. down position in the front, as shown on the illustration. This must be done to get the air out of the circuits when bleeding is carried out.

2. Apply the parking brake and stop the engine.

Two bleeding plugs

3. Put wheel chocks under the wheel to avoid spontaneous rolling.

4. Drain the fluid from all circuits, pipes included.

5. Refill with new brake fluid acc. to Oil Specification Sheet (chapter 6).

6. Bleed the brake circuits, one at a time: a. First bleed the master cylinder and then the calipers.

Fit a transparent hose to the bleeders and collect the spillage fluid in a container. b. Depress the brake pedal and open bleeder plugs ( ).

Close bleeders before fluid flow stops. c. Refill brake fluid during the bleeding process. d. Bleed until brake fluid appears to be free of air. e. Bleeder torque: 2,9 Nm.

•

Alternatively, other suitable equipment for bleeding the brake circuits can be used.

7. Fill up to correct container level, see filling capacities (chapter 6).

8. Perform brake function test and check for leakage.

WARNING • 2

1

• 1. Brake fluid container

•

Contact your Moxy Dealer for performing the fluid replacement.

Always follow the applicable governmental regulations for work on the brake system.

Make sure that the parking brake is on and put wheel chocks under the wheels before performing brake fluid replacement.

2. Master cyl. bleeder plug

* Numbers refer to positions on the lubrication schedule, chapter 6 166

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000th hour of operation.

4. Parking brake 4.1. Check breather, at least once a year 1. Loosen the circlip (1).

2. Remove cover plate (2).

3. Take out the breather element (3).

4. Remove the sealing (4).

5. Check if the breather element is clogged or damaged.

Clean the breather element and the other parts with solvent or cleaning fluid. Dry with compressed air.

6. Check the rubber bellow for wear and damages.

• Replace parts if necessary.

4

7. Reassemble the opposite way.

3

Adjust the check interval according to the surroundings (dusty/muddy conditions, etc.)

2 1

5. Tandem housings 5.1. Change oil 32*

• Change of tandem housing oil shall also be carried out after the first 500 hours of operation.

1. The dump truck and tandem housings must be horizontal.

2. Unscrew drain plugs (1) on the inside of the housings. Both front and rear.

3. Drain the oil into a suitable container.

4. Clean plugs, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 5. Fill new oil, according to the oil specification sheet (chapter 6), through the filler plugs (2) to correct level.

2

6. Clean filler plugs, replace seals if necessary and reinstall.

• Tightening torque: 80 Nm. 7. After test driving, check that level is at lower edge of the level plug (3).

3

CAUTION 1

Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

6. Continue with all items in 1000 Hours Service. * Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

167

7. Maintenance

* Numbers refer to positions on the lubrication schedule, chapter 6 168

Operating & Maintenance Manual

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000th hour of operation.

1. Cooling system If necessary, the cooling system should be cleaned more often.

1.1. External cleaning, at least every 4th year 5* 1. Clean externally the radiator fins and hoses.

2. Check that the radiator is not blocked on the air side and that the fins are not damaged.

3. Carefully scrape the deposit away from the radiator fins.

If necessary, a paraffin-based engine cleaner may be used.

4. Check the fins, rubber hoses, clamps and pipes for corrosion, damage and leakages.

5. Bent fins can be carefully straightened, e.g. using a steel wire brush.

CAUTION The cooling system must not be cleaned using caustic soda. It can damage aluminium parts.

1.2

Internal cleaning, at least every 4th year 5* Removing deposits 1. If possible, run the engine until it is warm and then drain the cooling system, see changing coolant, item 1.4 2. Remove the thermostats.

3. Fill the system with clean, hot water mixed with one of the commercially available radiator cleaners based on sulphamin acid and containing dispersing agents. Follow the manufacturer's instructions (on the packaging) for mix ratios and cleaning times.

4. Run the engine for the specified time.

5. Drain the cooling system by removing a low hose or pipe.

Do not use the drain cocks, the loosened deposits can clog them!

6. Refit the hose which was used as drain hose.

7 Fill the system again with hot water and run the engine for about 20 -30 minutes.

8. Drain the water from the cooling system in the usual way, use the drain cocks.

9. Refit the thermostats.

10.Fill the system with coolant as described in the specifications in item 1.3 at 2000 hours service.

WARNING When handling cleaners for the cooling system: Study the warning on the packaging. * Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

169

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000th hour of operation.

1.3. Charge air cooler 5* 1. Drain the coolant from the engine, see changing coolant, item 1.4.

2. Detach the upper part of the inlet manifold.

3. Detach the charge air cooler hose and pipe connections.

4. Disassemble the charge air cooler as illustrated.

Take care not to damage the element's water connections.

1.

2.

3.

4.

5.

6.

Inlet manifold, lower part Gasket Radiator element Gasket Inlet manifold, upper part V-ring seal

5. Clean the outside of the element. Use a paraffin-based engine cleaner.

6. Reassemble the charge air cooler. Change all seals and gaskets.

7. Refit hose and pipe connections.

8. Fill coolant as described in the specifications in item 1.3 at 2000 hours service.

9. Connect the inlet manifold from the turbo.

* Numbers refer to positions on the lubrication schedule, chapter 6 170

Operating & Maintenance Manual

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000th hour of operation.

Filler cap

1.4

Change coolant, at least every 4th year 5* 1. Remove the filler cap from the expansion tank.

2. Drain the coolant in two places: • drain cock on the engine.

• drain cock underneath the oil coolers.

3. Close the cocks.

4. Fill with correct mixture, pre-mixed coolant through the expansion tank filler hole. See item 1.3 at 2000 hours service.

2. Continue with all items in 2000 Hours Service. * Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

171

7. Maintenance

* Numbers refer to positions on the lubrication schedule, chapter 6 172

Operating & Maintenance Manual

7. Maintenance

Yearly recommended maintenance Maintenance recommended to be performed once a year.

1. Transmission 1.1. General condition check 1. Check tightness of lubrication system when engine is running.

• Tighten or change defective connections.

2. Check transmission rubber mountings and replace if necessary.

Inspect the mounting bolts.

2. Drive line 2.1. General condition check Check the general condition and mountings, joints, bearings, etc. for general deterioration, wear, damages and leakages.

• Replace or recondition if necessary.

1. Rear axle and tandem housings.

2. Articulation hinge and turning ring.

3. Suspension:

• shock absorbers • rubber dampers • arms and rods

4. All prop. shafts, universal joints included.

3. Tanks 3.1. General condition check Check the hydraulic and the diesel tank bolts/mountings.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

173

7. Maintenance

Yearly recommended maintenance Maintenance recommended to be performed once a year.

4. Hydraulic system 4.1. Inspect the hydraulic hoses Replace hoses which are deteriorated, leaking or otherwise damaged.

5. Exhaust system 5.1. Safety check • Check fastening brackets, muffler, pipes and joints for leaks, damages and insecurity.

• If body is exhaust heated, check also that the channels in the body not are clogged by any means.

CAUTION Be aware of hot parts when engine has been running!

6. Bearings 6.1. Check clearance Contact your local Moxy Dealer for checking of the bearing clearance: • Tandem bearing • Tip bearings • Turning ring and articulation bearings • Wheel bearings

* Numbers refer to positions on the lubrication schedule, chapter 6 174

Operating & Maintenance Manual

8. Technical Data

Technical Data

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8. Technical Data

Contents

8. Technical data .......................................................... 175 - 188 Measurements ........................................................... 177 Engine ........................................................................ 178 Transmission ............................................................. 178 Hydraulic system ....................................................... 179 Air system .................................................................. 179 Tyre pressures ........................................................... 179 Electrical system ........................................................ 180 Metering conversion table ......................................... 182 Toolkit content ........................................................... 182 Performance chart ..................................................... 183 Engine and retarder brake capacity chart ................ 184 Torque limit tables ..................................................... 185 Reference information (fill in table) .......................... 185 Product signs ............................................................. 186 Periodic service (fill in table) ..................................... 187

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8. Technical Data

Measurements Machine dimensions (mm): ..................................... MT 40B

MT40B Coal Hauler

Total length ................................................................ 9868 Total width ................................................................. 3495 Total height ................................................................ 3780 (cab) Total height, loaded .................................................. 3720 (cab) Overhang, front .......................................................... 2340 Overhang, rear ........................................................... 1210 Wheelbase ................................................................. 4358/1960 Body upper height (rear edge) ................................... 3212 Body floor height (rear edge) ..................................... 2325 Total height, raised body ........................................... 6362 Ground clearance, raised body ................................. 815 Min. ground clearance ............................................... 680 (front) loaded ........................................................................ 620 (front) Turning radius (ISO 7457) ......................................... 9450 Body tipping angle ..................................................... 70° Steering angle, both sides ......................................... 45° Standard tyre dimension ............................................ 29,5R25 Tyre load/speed index ............................................... 200B (2-stars)

12135 < 3933 (body) 3858 (body) 2760 1586 5828/1960 3533 1630 7857 490 < < 10741 55° < < <

Machine weights (kg): Empty weight .............................................................. 27800 Gross weight .............................................................. 64100 Maximum payload ...................................................... 36300

28280 64280 36000

Weight distribution (kg): Front axle, empty ....................................................... 13050 Rear axle, empty ........................................................ 14750

13240 15040

Body capacity (m³): Struck ......................................................................... 17,7 (18,6*) Heaped, SAE 2:1 ....................................................... 22,1 (23,7*)

33,0 (with standard top tailgate fitted) 40,0 (with standard top tailgate fitted)

Machine speed (km/h): Forward speeds 6 ...................................................... 6 - 9 - 15 - 23 - 34 - 53 Reverse speed 3 ....................................................... 6 - 15 - 34 Towing load on hooks (kN): Front ........................................................................... 90 Rear ............................................................................ 180 Sound power level, dB(A): According to ISO 6393 (external) ............................. 113

Sound pressure level, dB(A): According to ISO 6394 (in cab) ................................. 75

Ambient operating temperature (°C): Min. (-) ........................................................................ 20 Max. (+) ...................................................................... 40

The measurements are valid for a standard, unloaded machine if nothing else is given. *= with top tail gate fitted

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8. Technical Data

Engine Water cooled, 4-stroke, direct injected diesel engine with turbo charger and intercooler Type ........................................................................... Scania DI 14 81 A Cylinder volume ......................................................... 14.2 litres Bore x stroke .............................................................. 127 x 140 mm No. of cylinders .......................................................... V8, 90° Power rating (ISO 3046) at 2200 rpm ....................... 330 kW (448hp) Power rating (ISO 9249) at 2200 rpm ....................... 316 kW (430hp) Max. torque ................................................................ 1854 Nm at 1200 rpm Engine speed, low idle ............................................... 750 + 50 rpm Engine speed, high idle ............................................. 2400 ± 50 rpm Max. allowed engine speed ....................................... 2600 rpm

1 kW = hp 1,36

Oil capacity (min./max.) ............................................. 25/30 litres Oil pressure, warm engine at 2200 rpm .................... 3.0-6.0 bar Oil pressure, warm engine at 800 rpm ...................... min. 0.7 bar Specific oil consumption ............................................ 0.3 g/hph Coolant volume .......................................................... 90 litres (approx.)

Normal temperature ................................................... 70-93 oC, max. 98 oC Thermostats (2) .......................................................... 79 oC Max. system pressure ................................................ 0.5 bar Compression ratio ...................................................... 15 : 1 Firing order ................................................................. 1-5-4-2-6-3-7-8 Engine rotation, seen from rear ................................. Counterclockwise Valve clearance (cold engine) ................................... 0.45 mm, inlet valves .............................................................................. 0.80 mm, exhaust valves Pump timing (see rocker cover sign) ......................... 14o before TDC Opening pressure, injectors ....................................... 300 bar

Transmission Automatic transmission. Integrated in the gearbox: torque converter, automatic lock-up clutch, retarder brake and lockable inter axle differential.

Type ........................................................................... ZF 6WG 310 No. of forward gears .................................................. 6 No. of reverse gears .................................................. 3 Oil capacity ................................................................ 33 litres (approx.)

Oil pressure, clutches ................................................ 12 +2 bar / 1500 rpm Normal temperature ................................................... 50-105 oC Max. permitted temperature ....................................... 120 oC (short period only) Max. permitted temp. when using retarder brake ...... 150°C (short period only) Lock-up clutch ............................................................ in all gears Lock-up in/out ............................................................ acc. to engaged mode Inter axle diff. distribution .......................................... 1/3 to front axle, 2/3 to rear axle, lockable

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8. Technical Data

Hydraulic system Applied for steering and work equipment. The steering circuit has priority above the work circuit. The main and emergency steering pumps are fitted on the transmission.

Tank capacity ............................................................. 180 litres (approx.)

Normal oil temperature .............................................. 40-90 oC (at tank) Filter ........................................................................... Full flow pressure filter w/ indicator Main pump (double) ................................................... Gear pump, engine speed dependent Pump delivery ............................................................ 345 l/min at 2200 rpm Emergency steering pump ......................................... Piston pump, ground driven, speed dependent Pump delivery ............................................................ Max. 50 l/min Pressure setting- main safety valves: Tipping circuit - up ..................................................... 150 bar Tipping circuit - down ................................................. 45 bar End stop for tip cylinders ........................................... 145 bar (shock valve) Steering circuit ........................................................... 175 bar Tipping cylinders ........................................................ 2 x 3-stage, double acting on the third stage Tipping time ............................................................... 15 sec.

Steering cylinders ...................................................... 2 x double acting w/ 1 piston Steering wheel turns .................................................. Approx. 5

Air system Applied for brakes, tip control, differential lock and driver seat. The air dryer is fitted with heater, thermostat and silencer.

System pressure ........................................................ 6.8-7.8 bar Safety valve (compressor) ......................................... 19.0 bar Safety valve, supply circuit ........................................ 9.3 bar Low pressure indication (buzzer) .............................. Below 4.8 bar Air pressure reduction valve, retarder brake ............. 4 bar Air tanks ..................................................................... 7 (1x 30 L, 2x 20 L, 3x 10 L and 1x 3 L) Air compressor ........................................................... Piston, 1 cylinder, single acting Heater element, air dryer ........................................... 100 W Thermostat range, air dryer ....................................... 2-33 oC

Tyre pressures Basic pressure for cold tyres (based on max. load and max. speed):

Type Bridgestone VLT ** Michelin XADN/XADT Good Year GP2B/GP4B/RL-2+

Front bar (psi) 3.0 (44) 3.0 (44) 2.8 (41)

Rear bar (psi) 3.5 (51) 3.5 (51) 3.5 (51)

Regarding tyre pressure: Contact your Moxy Dealer or tyre supplier to get further information.

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8. Technical Data

Electrical system System voltage .......................................................... 24 V Battery ........................................................................ 2x 12 V, 230 Ah Grounding .................................................................. Negative earth cable Alternator .................................................................... 28 V, 65 A Starter motor .............................................................. 9,1 hp (6.7 kW) Fuses: The fuses are located in the fuse boxes inside the left side of the dashboard. Be sure to use fuses of correct size. Never install larger fuses than specified! If a certain fuse blows several times, the circuit must be checked and failure corrected.

98

228

85

A

B

C

D

E

1

1

1

1

1

2

2

2

2

2

3

3

3

3

3

4

4

4

4

4

5

5

5

5

5

6

6

6

6

6

107

108

109

110

251

252

253

254

255

87

88

99

100

101

103

104

105

106

A 1 / 20A • Side light s

FUSE BOXES AND RELAYS

B 1 / 15A • Engine cont roller

2 / 20A

2 / 15A

• Low beam

• Fuel valve

C

D

1 /10A • High beam, left h. s.

1 / 5A • Side light , lef t , f ront

• Cont rol light

• M arking light, lef t

2 / 10A • High beam, right h. s.

2 / 5A • Side light , right , f ront • M arking light, right

3 / 20A • High beam

3 / 15A • Reverse light

• High beam f lash

• Reverse alarm

E 1 / 10A • Radio 30 2 / 10A • Aut omat ic cent ral lubricat ion

3 / 10A • Low beam, lef t h. s.

3 / 5A • Side light , lef t , rear

3 / 10A • Inst rument s light s

4 / 10A • Low beam, right h. s.

4 / 5A • Side light , right , rear

4 / 10A • Tipping syst em • Radio 15

• Working / reverse light on f enders

4 / 20A • Working light , roof

4 / 15A • Air dryer

• Wiper / washer

• Heat ed seat swit ch

• Horn

• Heat ed mirrors swit ch

5 / 20A

5 / 15A

5 / 10A

5 / 10A

5 / 10A

• Heated seat

• Ext ra high beam

• Brake lights

• Gear selector

• Controller, head light

• Heated mirrors

• Rot ating beacon

• Cab light

• Transm. cont roller 15

• Control light

• Engine compart ment

• Parking brake alarm

• Light er

light

• Ret arder brake • Engine brake • Int er axle diff . lock • Cont roller, reverse light

6 / 20A • Direct ion indicators

6 / 15A • Hazard light

6 / 10A • St art er

6 / 10A • Transm. cont roller 30

6 / 10A • Inst rument s

• Heater

• Low pressure alarm

• Air conditioner

• Controller, relay • Swit ch lights

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8. Technical Data

Relays: The relays are located inside the left side of the dashboard (together with the fuse boxes).

98

228

85

A

B

C

D

E

1

1

1

1

1

2

2

2

2

2

3

3

3

3

3

4

4

4

4

4

5

5

5

5

5

6

6

6

6

6

107

108

109

110

251

252

253

254

255

87

88

99

100

101

103

104

105

106

85 • Wiper / washer

87 • Engine cont roller

FUSE BOXES AND RELAYS

88 • Air dryer

98 • Direct ion indicators

99 • Working light , roof (backwards)

• Hazard light 100 • Start er

101 103 • Work. light, roof (forw.) • Supply relay 99/101

104 • Low beam

105 • High beam

106 • Reverse light

107 • Heated seat

109 • Parking brake alarm

110 • Direction indicat ors • Heat er

108 • Ext ra high beam

• Heated mirrors

• Air condit ioner 228 • Parking brake alarm

251 • Tipping syst em

252 • Transm. cont roller 15

253 • Wiper / washer

• Relay cont rol, reverse

• Horn

254 • Tipping syst em

light

255 • Working / reverse light on f enders

The fuses and relays for the flamestart system are located underneath the right hand side dashboard plate where the flamestart switches are installed.

404

1

1 / 10A • Flamest art syst em

FLAMESTART

2 / 10A • Flamest art syst em

2

401A

3 4

401B

FUSE BOXES AND RELAYS

3 / 20A • Flamest art syst em 4 / 20A • Flamest art syst em

5 6

5

400 6

404 • Flamestart syst em, t imer

401A • Flamestart syst em, glow plug I

401B • Flamest art system, glow plug II

400 • Flamest art syst em, cancellat ion

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8. Technical Data

Bulbs: Light ........................................................................... Watts Head lights (H4) ......................................................... 75/70 Side lights in head light .............................................. 4 Direction indicators .................................................... 21 Stop lights .................................................................. 21 Marking lights ............................................................. 5 Licence plate lights .................................................... 5 Work light on roof ....................................................... 70 Reverse light .............................................................. 70 Rotating beacon (H1) ................................................. 70 Rear lights .................................................................. 5 Engine compartment light .......................................... 18 Cab light ..................................................................... 5 Instrument lights ......................................................... 1.2 Warning/indicator lights ............................................. 1.2 Switch lights ............................................................... 1.2

Socket P 45t BA 9s BA 15s BA 15s S 8,5 S 8,5 Pk 22s Pk 22s P 14,5s BA 15s S 8,5 S 8,5 W2x4,6d W2x4,6d

Metering conversion table Length:

1m 1 km

= =

1.094 yd 1000 m

= =

3.281 ft 0.621 mile

=

39.37 in

Volume:

1 dm3 1 dm3 1 m3

= = =

1 litre 0.0353 ft3 35.32 ft3

= =

0.264 gal (US) 61.02 in3

=

0.220 gal (UK)

Weight:

1 kg = 1000 kg =

2.20 lb 1 ton (metric)

= =

35.27 oz 0.984 ton (UK) =

0.902 ton (US)

Power:

1 hp

=

0.746 kW

=

1.015 hk.

Torque:

10 Nm =

1.02 kpm

=

7.38 lbf ft (pound-force foot)

Pressure:

1 bar

=

1.02 kp/cm2

=

14.5 p.s.i.

Temperature:

o

= =

5/9 x (oF- 32) (9/5 x oC)+32

C F

o

Speed:

1 km/h =

0.62 mph

Tool kit content

Hex. socket 19 mm Hex. bit front hub Wrench 22 mm Wheel-spanner Arm, wheel-spanner Draining hose Grease gun Tool bag

182

Wrench 12 mm Fire extinguisher Warning triangle First aid kit Operation manual Driver instruction Parts catalogue

Operating & Maintenance Manual

=

100 kPa

8. Technical Data

Performance chart Below diagram gives guidelines for calculation of the dump truck gradeability performance related to rolling + grade resistance. The traction capabilities depend on the ground conditions and surroundings, i.e. available wheel grip (friction), tyre pattern, weight on the wheels, etc.

How to find gradeability perfomance: 1. Read from actual dump truck weight (A) up to the percentage grade (B).

(Rolling resistance is not included in the percentage grade).

2. From this point, read horizontally to the curve with highest speed range (C).

3. Then down to maximum speed (D).

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8. Technical Data

Engine and retarder brake capacity chart Below diagram gives guidelines for calculation of the dump truck engine and retarder brake performance related to rolling + grade. The traction capabilities depend on the ground conditions and surroundings, i.e. available wheel grip (friction), tyre pattern, weight on the wheels, etc. If the driving conditions (f.ex curves) requires hard decellerating by using the main brake, driving in a lower gear is advised.

How to find downhill gradeability capacity: 1. Read from actual dump truck weight (A) up to the percentage grade (B) (Rolling resistance is not included in the percentage grade).

2. From this point, read horizontally to the curve with highest speed range (C).

3. Then down to maximum speed (D).

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8. Technical Data

Torque limits for bolts This tables indicates standard torque limits in Nm for the various screw and bolt qualities and dimensions.

The torques are valid for screws on the outside of the components.

Metric Threads

Dim./Class

8.8

Fine Metric Threads

10.9

12.9

Dim./Class

8.8

10.9

12.9

M8 M10 M12

24 47 81

33 65 114

40 79 136

M8 x 1 M10 x 1.25 M10 x 1

25 48 49

35 68 70

42 81 84

M14 M16 M18

128 197 275

181 277 386

217 333 463

M12 x 1.5 M12 x 1.25 M14 x 1.5 M16 x 1.5

83 85 135 204

117 120 190 287

140 144 228 344

M20 M22 M24

385 518 665

541 728 935

649 874 1120

M27 M30 M33 M36

961 1310 1770 2280

1350 1840 2480 3210

1620 2210 2980 3850

M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2

294 408 546 696

413 574 768 979

496 688 921 1170

1000 1390 1860 2350

1410 1950 2610 3310

1690 2340 3130 3970

M27 x 2 M30 x 2 M33 x 2 M36 x 3

Reference information Machine model:

Serial no.:

Prod. year:

In operation:

Engine s/no.:

Transm. s/no.:

Dealer:

Consumeable parts Part no.

Q'ty

Description

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8. Technical Data

Product signs

Type Variant Engine no.

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Operating & Maintenance Manual

DSI 14 81 A 40 E 55 65 81 4

8. Technical Data

Periodic service DELIVERY Hrs: ________ Date: _____________ Stamp / Sign.:

Fill in the boxes according to the maintenance performed on the dump truck serial no.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

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8. Technical Data

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

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9. Index

Index

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9. Index

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9. Index

Index 1000 Hours Service ........................................................ 151 2000 Hours Service ........................................................ 159 40 Hours Service ............................................................ 135 4000 Hours Service ........................................................ 169 500 Hours Service .......................................................... 139 8 Hours Service .............................................................. 125 AEB ................................................................................. 144 Air conditioner system ........................................... 136, 148 Air conditioner system hazard prevention ....................... 19 Air dryer filter .................................................................. 163 Air filter ............................................................................ 153 Air filter warning light ........................................................ 50 Air pressure gauge, front service brakes ......................... 45 Air pressure gauge, rear service brakes .......................... 45 Air system ....................................................................... 179 Articulation lock ................................................................ 28 Ashtray .............................................................................. 75 Automatic central lubrication .......................................... 149 Automatic central lubrication indicator light ..................... 56 Automatic Transmission Fluid (ATF) ............................... 120 Batteries ................................................................. 135, 152 Battery charge warning light ............................................ 50 Battery hazard prevention ................................................ 18 Battery power assistance ............................................... 106 Bearings ......................................................................... 174 Before operation ............................................................... 90 Bleed fuel system ........................................................... 152 Body capacity ................................................................. 177 Body support .................................................................... 26 Bottle/cup holder .............................................................. 75 Brake fluid ....................................................................... 166 Brake fluid warning light ................................................... 47 Brake lines ...................................................................... 165 Brake pedal ...................................................................... 65 Brake system ................................................ 130, 146, 165 Brakes ........................................................................ 21, 94 Braking/stopping the dump truck ...................................... 95 Breather element ............................................................ 164 Bulbs ............................................................................... 182 Cab and engine compartment light .................................. 57 Cab certification ................................................................ 30 Cab light ........................................................................... 76 Cab ventilation ........................................................ 69, 135 Central lubrication ................................................... 56, 149 Centrifugal cleaner ......................................................... 139 Change brake fluid ......................................................... 166 Change coolant .............................................................. 171 Change oil, engine ......................................................... 139 Change oil, front differential ........................................... 157 Change oil, front reduction gears ................................... 158 Change oil, hydraulic system ......................................... 164 Change oil, rear differential ............................................ 157 Change oil, tandem housings ........................................ 167 Change oil, transmission ................................................ 155 Charge air cooler ............................................................ 170 Check batteries ...................................................... 135, 152 Check battery terminals .................................................. 135 Check brake fluid levels ................................................. 130

Check braking (holding) capacity .................................. 132 Check cab ventilation filter element ............................... 135 Check clearance of bearings ......................................... 174 Check coolant level ........................................................ 127 Check driver's seat ......................................................... 125 Check fuel injectors ........................................................ 159 Check fuel level .............................................................. 127 Check function, engine brake ........................................ 133 Check function, main brake ............................................ 133 Check function, retarder brake ....................................... 134 Check function, steering ................................................. 134 Check glycol content in the coolant ............................... 161 Check lining thickness ................................................... 146 Check of the centrifugal cleaner .................................... 128 Check oil level, drive line ............................................... 145 Check oil level, engine ................................................... 126 Check oil level, front differential ..................................... 145 Check oil level, front reduction gears ............................. 146 Check oil level, hydraulic system ................................... 129 Check oil level, rear differential ...................................... 145 Check oil level, tandem housings .................................. 145 Check oil level, transmission .......................................... 129 Check parking brake breather ....................................... 167 Check protection against corrosion in the coolant ......... 162 Check the appearance of the coolant ............................ 160 Check the coolant ........................................................... 160 Check tyre pressures ...................................................... 136 Check V-belts condition .................................................. 143 Check wheel nuts torque ................................................ 147 Check wiring ................................................................... 158 Check/adjust valve clearance ........................................ 159 Checks after stopping the engine .................................. 100 Cigarette lighter ................................................................ 68 Clean centrifugal cleaner ............................................... 139 Clean strainer ................................................................. 155 Clothing and personal protection items ........................... 12 Cold weather .................................................................. 104 Column switch .................................................................. 62 Consumeable parts ........................................................ 185 Controls ............................................................................ 61 Coolant .................................................................. 160, 171 Cooling system ............................................................... 169 Correct tyre pressures .................................................... 102 Daily Service .................................................................. 125 Dangerous loads .............................................................. 22 Difference in tyre diameter ............................................. 102 Differentials ....................................................................... 97 Direction light indicator ..................................................... 52 Do not go close to high-voltage cables ............................ 17 Door window .................................................................... 74 Drain air tanks ................................................................ 128 Drain condensation, fuel tank ........................................ 154 Drive line ............................................................... 145, 173 Driver's seat ............................................................. 72, 151 Dump truck knowledge ..................................................... 11 Dump truck transportation ................................................ 29 Electrical system .................................................... 158, 180 Electrically heated driver's seat switch ............................. 57 Emergency braking .......................................................... 96

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9. Index

Emergency exit .......................................................... 14, 68 Emergency steering ......................................................... 20 Emergency steering warning light ................................... 47 Engine ............................... 126, 135, 139, 151, 159, 178 Engine and retarder brake capacity chart ...................... 184 Engine and retarder brake mode ..................................... 92 Engine and/or retarder brake operation .......................... 95 Engine bonnet .................................................................. 25 Engine brake ........................................................... 94, 133 Engine brake indicator ..................................................... 52 Engine brake switch ......................................................... 60 Engine controller .............................................................. 48 Engine coolant temperature gauge ................................. 41 Engine coolant temperature warning light ....................... 48 Engine, general condition check .................................... 126 Engine oil ........................................................................ 119 Engine oil pressure gauge ............................................... 41 Engine oil pressure warning light .................................... 48 Engine overspeed ............................................................ 21 Engine revolution counter and hour meter ...................... 42 Exhaust heating ................................................................ 22 Exhaust system ............................................................... 174 Expansion tank coolant level ........................................... 20 External air filling ............................................................ 107 External cleaning, cooling system ................................. 169 External door openers/locks ............................................ 73 Extra high beam on mirror arms ....................................... 54 Filling capacities ............................................................. 118 Filling fuel or oil ................................................................ 19 Fire extinguisher ............................................................... 13 Fire prevention ................................................................. 15 Fire prevention for fuel and oil ......................................... 13 First 100 hours .................................................................. 82 First 250 hours .................................................................. 83 First 500 hours .................................................................. 83 First 8 hours ...................................................................... 82 First aid kit ......................................................................... 13 Flamestart system cancellation switch ............................. 59 Flamestart system indicator light ...................................... 59 Flamestart system preheating switch ............................... 59 FOPS ................................................................................ 14 Foreword ............................................................................ 5 Forward drive position ...................................................... 91 Front differential ....................................................... 97, 157 Front reduction gears ...................................................... 158 Front service brakes warning light ................................... 47 Fuel filters ....................................................................... 151 Fuel gauge ....................................................................... 42 Fuel injectors .................................................................. 159 Fuel tank ......................................................................... 154 Fuses .............................................................................. 180 Gear display ..................................................................... 43 Gear position N ................................................................. 90 Gear position V ................................................................. 91 Gear selector .................................................................... 66 Gear shift program ............................................................ 91 Gear shifting ..................................................................... 90 General condition check, drive line ................................ 173 General condition check, tanks ...................................... 173 General condition check, transmission .......................... 173 General description ............................................................ 7 General precautions ......................................................... 11 192

General safety check, driver's seat ................................. 151 Getting on and off the dump truck .................................... 12 Hazard light switch ........................................................... 55 High beam indicator ......................................................... 52 High pressure ................................................................... 29 High temperatures ............................................................ 13 High-voltage cables ......................................................... 17 Hoisting ............................................................................. 28 How to adjust the parking brake .................................... 147 Hydraulic filter warning light ............................................. 51 Hydraulic oil filter ............................................................ 165 Hydraulic system ................................. 129, 164, 174, 179 Important operating instructions ....................................... 99 Indicator lights .................................................................. 46 Inspect the hydraulic hoses ........................................... 174 Inspect brake lines ......................................................... 165 Instructor seat ................................................................... 73 Instrument light switch ...................................................... 54 Instruments ....................................................................... 40 Intended use ....................................................................... 7 Inter axle differential ......................................................... 97 Inter-axle differential lock ................................................. 60 Inter-axle differential lock indicator .................................. 52 Internal cleaning, cooling system ................................... 169 Internal door openers/locks .............................................. 73 Introduction ......................................................................... 7 Kick-down ......................................................................... 92 Kick-down indicator .......................................................... 50 Labels ............................................................................... 30 Lifting ................................................................................ 28 Loading ........................................................................... 101 Lock-up indicator .............................................................. 51 Long term storage .......................................................... 105 Lubricants ....................................................................... 113 Lubrication .................................................... 130, 137, 150 Lubrication, articulation bearings ................................... 137 Lubrication, articulation turning ring .............................. 130 Lubrication, doors and fender hatches .......................... 150 Lubrication schedule ...................................................... 115 Lubrication, steering cylinder bearings .......................... 137 Lubrication, tailgate arm hinge ....................................... 138 Lubrication, tandem bearings ........................................ 131 Lubrication, tip cylinder bearings ................................... 137 Lubrication, tip hinges .................................................... 131 Lubrication,suspension legs .......................................... 150 Machine dimensions ...................................................... 177 Machine speed ............................................................... 177 Machine turning ................................................................ 20 Machine weights ............................................................ 177 Main light switch ............................................................... 54 Main warning light, engine failure .................................... 48 Main warning light, transmission failure .......................... 50 Maintenance ................................................................... 121 Maintenance precautions ............................................... 123 Maintenance table .......................................................... 124 Manual gear shifting ......................................................... 91 Manual release of parking brake ................................... 108 Measurements ................................................................ 177 Metering conversion table .............................................. 182

Operating & Maintenance Manual

9. Index

Mirror heating switch ........................................................ 57 Neutral gear position ........................................................ 90 Normal operation .............................................................. 93 Oil specification sheet .................................................... 117 Operating Controls ........................................................... 37 Operating hints ................................................................. 92 Operating Instructions ...................................................... 85 Operating the dump truck ................................................. 90 Operation of brakes .......................................................... 21 Operator's cab .................................................................. 16 Optional accessories ........................................................ 14 Other cab equipment ........................................................ 72 Parking brake ........................................ 94, 132, 147, 167 Parking brake indicator .................................................... 47 Parking brake lever .......................................................... 67 Parking brake warning light ............................................. 47 Parking the dump truck ..................................................... 99 Performance chart .......................................................... 183 Periodic service .............................................................. 187 Precautions before starting the engine ............................ 15 Precautions for mirrors, windows and lights .................... 17 Precautions for optional accessories ............................... 14 Precautions when handling at high temperatures ........... 13 Prefilter of the air filter ..................................................... 154 Preselection of gears ........................................................ 91 Product signs .................................................................. 186 Proper maintenance ....................................................... 103 Protection against falling objects ..................................... 14 Radio/Cassette player or Radio/CD player ..................... 77 Rear differential ....................................................... 97, 157 Rear service brakes warning light ................................... 47 Reference information .................................................... 185 Refrigerant ........................................................................ 19 Relays ............................................................................. 181 Replace air dryer filter .................................................... 163 Replace breather element ............................................. 164 Replace fuel filters .......................................................... 151 Replace hydraulic oil filter .............................................. 165 Replace transmission filter element ............................... 155 Replace turbo filter ......................................................... 143 Retarder brake ........................................................ 94, 134 Retarder brake capacity chart ........................................ 184 Retarder brake indicator .................................................. 52 Retarder brake lever ........................................................ 67 Retarder brake main switch ............................................. 60 Retarder brake mode ....................................................... 92 Retractable roller sunblind on front window .................... 76 Reversing (back-up) operations ...................................... 93 Roll-over protection .......................................................... 14 ROPS ................................................................................ 14 Rotating beacon switch .................................................... 55 Rules to follow when filling fuel or oil ............................... 19 Run the AEB-Tester ........................................................ 144 Running-in operation ....................................................... 81 Running-in period ............................................................ 79 Running-in services ......................................................... 82 Safety at the worksite ........................................................ 15 Safety check, exhaust system ........................................ 174 Safety equipment .............................................................. 74

Safety information ............................................................... 6 Safety instructions .............................................................. 9 Safety labels ..................................................................... 30 Safety rules ....................................................................... 11 Service brake ........................................................... 94, 132 Service position ................................................................ 27 Some simple rules to be observed prior to operatio ........ 87 Specified loading ............................................................ 103 Speedometer .................................................................... 45 Starter switch .................................................................... 68 Starting in cold weather .................................................... 89 Starting the engine ........................................................... 88 Steering ................................................................... 96, 134 Steering column ............................................................... 64 Stopping the engine ....................................................... 100 Switches ........................................................................... 53 Tandem housings ........................................................... 167 Tanks .............................................................................. 173 Technical Data ................................................................ 175 Test switch for brake warning light ................................... 55 Throttle pedal .................................................................... 65 Tip control lever ................................................................ 67 Tipping ............................................................................ 101 Tipping system switch ...................................................... 55 Tool kit content ................................................................ 182 Top tailgate ....................................................................... 24 Torque limits for bolts ...................................................... 185 Towing the dump truck ................................................... 107 Transit, long distance drive-away on road ..................... 103 Transmission .............................. 129, 144, 155, 173, 178 Transmission controller .................................................... 50 Transmission filter element ............................................. 155 Transmission oil list ........................................................ 119 Transmission oil temperature gauge ................................ 41 Transmission temperature warning light .......................... 50 Transportation ................................................................... 29 Travelling on slopes ......................................................... 21 Troubleshooting .............................................................. 109 Turbo filter ....................................................................... 143 Tyre filling point ............................................................... 108 Tyre handling .................................................................. 102 Tyre pressures ....................................................... 102, 179 Tyres ............................................................................... 136 Unauthorised modification ............................................... 12 Up, down and crossgradient travel .................................. 98 Valve clearance .............................................................. 159 Ventilation for enclosed areas .......................................... 16 Volt meter .......................................................................... 45 Wading ............................................................................. 22 Walk around check ......................................................... 125 Warming up period ........................................................... 90 Warning / indicator lights .................................................. 46 Warning triangle ............................................................... 13 Weekly Service ............................................................... 135 Weight distribution .......................................................... 177 Welding ............................................................................. 23 Wheel chocks ................................................................... 27 Wheels ............................................................................ 147 When starting the engine ................................................. 17 Worker protection rules, refrigerant .................................. 19

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193

9. Index

Working lights (backwards) .............................................. 54 Working lights (forward) ................................................... 54 Working lights and reversing lights .................................. 54 Yearly recommended maintenance ............................... 173

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Operating & Maintenance Manual