Daewoo Doosan MT25 MT26 MT31 Operation and Maintenance Manual MX515442 - PDF DOWNLOAD

MX515442 August 2014

ADT

Operation & Maintenance Manual MT25 / MT26 / MT31 MT25 / MT26 / MT31 - Serial Number 710655 and Up

Operation & Maintenance Manual MT25 / MT26 / MT31 ADT MT25 / MT26 / MT31 - Serial Number 710655 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

MX515442 August 2014 Copyright Doosan 2011

1. Foreword

MT25/MT26/MT31 E

OPERATING & MAINTENANCE MANUAL

Serial no.

710655 and up

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.:515442 Edition: March 1 2006

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 - 40 3. Operating controls ............................................. 41 - 78 Overview of the instruments and controls ................. 43 Instruments ................................................................ 44 Warning / indicator lights ........................................... 49 Switches ..................................................................... 57 Controls ...................................................................... 61 Cab ventilation ............................................................ 69 Other cabin equipment .............................................. 73

Tool kit content .......................................................... 201 Performance chart .................................................... 202 Engine and retarder brake chart .............................. 204 Torque limit tables .................................................... 205 Reference information (fill in tables) ....................... 205 Consumeable parts .................................................. 205 Product signs ............................................................ 206 Periodic service (fill in tables) .................................. 207 9. Alphabetical Index ......................................... 209 - 214

4. Running-in period ............................................... 79 - 84 Running-in operation ................................................. 81 Running-in services ................................................... 82 5. Operating instructions ...................................... 85 -122 Precautions on worksites ........................................... 87 Some simple rules to be observed prior to operation 90 Starting the engine ..................................................... 91 Operating the dump truck ........................................... 93 Parking the dump truck ............................................ 105 Stopping the engine ................................................. 105 Checks after stopping the engine ............................ 106 Loading and tipping ................................................. 106 Tyre handling ............................................................ 108 Cold weather ............................................................ 110 Long term storage .................................................... 111 Battery power assistance ......................................... 112 Towing the dump truck ............................................. 113 External air filling ...................................................... 113 Manual release of parking brake ............................. 114 Manual release of the tip valve ................................ 115 Tyre filling point ........................................................ 115 Troubleshooting ....................................................... 116 6. Lubricants ....................................................... 123 - 130 Lubrication schedule ................................................ 125 Oil specification sheet .............................................. 127 Filling capacities ....................................................... 128 Transmission oil list .................................................. 129 7. Maintenance ................................................... 131 - 194 Maintenance precautions ........................................ 133 Maintenance table .................................................... 135 8 Hours / Daily service ............................................. 137 40 Hours / Weekly service ........................................ 151 500 Hours Service .................................................... 153 1000 Hours Service ................................................. 169 2000 Hours Service ................................................. 183 4000 Hours Service ................................................. 191 Yearly recommended maintenance ........................ 193 8. Technical data ................................................ 195 - 208 Measurements .......................................................... 197 Engine ....................................................................... 198 Transmission ............................................................ 198 Hydraulic system ...................................................... 199 Air system ................................................................. 199 Tyre pressures .......................................................... 199 Electrical system ....................................................... 200 Metering conversion table ........................................ 200

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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 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 98/37/EC with amendments and 89/336/EC 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 MT25, MT26 and MT31 are articulated, 6-wheel drive dump trucks. 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 Dump body Engine bonnet

Hydraulic tank

Head and side light

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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

Content

2. Safety instructions................................................................. 9 - 40 1. Dump truck knowledge ............................................... 11 2. General precautions ...................................................... 11 3. Precautions before starting the engine .................. 16 4. When staring the engine ............................................. 18 5. Do not go close to high-voltage cables.................. 18 6. Battery hazard prevention........................................... 19 7. Air conditioning system hazard prevention ......... 20 8. Rules to follow when filling fuel or oil ..................... 21 9. Expansion tank coolant level...................................... 21 10. Machine turning ............................................................. 21 11. Emergency steering ....................................................... 22 12. Travelling on slopes ....................................................... 22 13. Operation of brakes ....................................................... 22 14. Engine over speed (Emergency retarder) .............. 23 15. Wading ............................................................................... 23 16. Dangerous loads (exhaust heated body) ............... 24 17. Welding on the dump truck........................................ 25 18. Top tailgate ....................................................................... 26 19. Engine bonnet ................................................................. 27 20 Tiltable cab ........................................................................ 27 21. Body support.................................................................... 29 22. Service position ............................................................... 30 23. Wheel chocks ................................................................... 30 24. Articulation lock .............................................................. 31 25. Lifting/hoisting ................................................................ 31 26. Dump truck transportation ......................................... 32 27. High pressure ................................................................... 32 28. Safety labels ...................................................................... 33

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Operating & Maintenance Manual

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 lev-

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 is instructor or passenger in the cab, be sure that they are seated on the instructor seat 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 because it is hazardous to your 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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Operating & Maintenance Manual

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 out: 1. Turn engine off 2. Allow oil to cool down.

3. Slowly loosen cap to relieve pressure before removing.

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2. Safety Instructions

2.7. Fire extinguisher, first aid kit and warning triangle (optional equipment) • Know how to use the fire extinguisher (Distributor/ Dealer fitted).

If the fire extinguisher is missing, contact your local Moxy Dealer.

Location: Left hand side in the cab.

• If the first aid kit is present in the cab, keep it in its storage place.

Location: Left hand side in the cab, below the rear side window.

• If the warning triangle is present, keep it in its storage place.

Location: Toolbox in the right hand side fender.

• 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.

2.8. Precautions 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.

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Operating & Maintenance Manual

2. Safety Instructions

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 approval sign for ROPS/FOPS is located on the fire wall underneath the bonnet.

• Structural damage, an overturn, modification, alteration or not permitted repair can affect the cab strength and there by void the certification • Consult Moxy Engineering AS or your Moxy Dealer to determine this structure’s limitations without voiding its certification.

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

A

• Left door and front side window on right hand side.

• If door is blocked, you can get out through the front side window.

• Remove hammer (A) from storage location and break front side window.

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2. Safety Instructions

3. PRECAUTIONS before starting the engine

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

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

3.2. Fire prevention • Thoroughly 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!.

• Marsh land, when dry, is highly flammable. Marsh land can self ignite 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 left hand side in the cab.

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Operating & Maintenance Manual

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 work site 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.

The operator should remain in the cab until it has been confirmed that the electricity has been shut off.

• 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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Operating & Maintenance Manual

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 OFF position, 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 (see figure): 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.

1

2

3

Battery main switch (OFF)

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2. Safety Instructions

7. Air conditioning 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 unconsciousness. 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 unconsciousness. 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 luke warm running water and covered with a sterile com press. 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 INDUCE VOMITING. Contact a doctor.

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2. Safety Instructions

8. 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.

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 pre-mixed 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!

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2. Safety Instructions

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.

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 is 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 brake or engine and 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.

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2. Safety Instructions

14. Engine over speed (Emergency retarder) When the operator releases there foot off the accelerator, the exhaust brake is automatically engaged. Driving downhill with the accelerator pedal released, the engine rpm’s will increase, when the engine rpm's reach 2,200 the transmission retarder is activated, this will disengage when rpm’s drop to 1,800, the exhaust brake will continue to operate.

It’s called emergency retarder because the cooling capacity is not designed for continuous operation.

If the truck is on a downhill slope and the operator does not release there foot off the accelerator pedal, the exhaust brake is activated at 2,450 rpm’s to override the operator error. The transmission emergency retarder brake will be activated at 2,500 rpm.

To prevent engine damage due to the over-speed situation, the transmission control unit (TCU) will perform an automatic up-shift to the next gear, if engine reach's 2,700 rpm’s.

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: MT25/MT26/MT31 - 780mm, i.e. up to the front fenders MT31 - 1100mm, i.e. up to the front fenders MT41 - 1250mm, i.e. up to the front fenders

NOTE Under no circumstances let water flow through the grill!

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2. Safety Instructions

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

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

To blank 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 will blank 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 connectors on the electronic control units for the engine and the transmission. The units are located behind the cover on the back wall (behind the instructor seat back rest, if that is fitted).

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.

OFF

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2. Safety Instructions

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: 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.

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2. Safety Instructions

19. Engine bonnet Do not open the bonnet when the engine is running. The bonnet is fitted with lockable bonnet opener on left hand side. The bonnet must always be closed and secured with the lock when operating the dump truck.

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

• To open the bonnet: 1. Depress the button on the handle grip on left hand side.

2. Lift the bonnet catcher.

3. Push up the bonnet.

4. Check that the bonnet catcher engages.

• To close the bonnet: 1. Push the bonnet forward.

2. Lift the bonnet catcher.

3. Push down the bonnet and see to that the lock engages.

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

Do not operate the dump truck

20. Tiltable cab Always secure the tilted cab with the support before service/inspection and other work/stand underneath the cab. The cab must always be closed and secured with the locks when operating the dump truck.

Before tilting the cab, check that there are no loose objects in the cab.

When the cab is tilted, make sure that the support secures the cab from falling down. To tilt the cab.

• To tilt the cab: 1. Lift the body and secure it with the body support (see item 21).

2. Stop the engine.

3 Open the bonnet and apply the bonnet catcher (see item 19).

4. Put a plastic bag or similar around the brake fluid reservoirs before the cab is tilted. To prevent brake fluid spillage.

5. The cab has two tilted positions: • Service position - Must be secured with the safety support, see below (item 8) • Top position - The cover behind the hydraulic tank has to be removed before tilting the cab to top position.

Operating & Maintenance Manual

27

2. Safety Instructions

- If exhaust heating is fitted, this must also be removed.

- The cab must be fastened to a crane or similar when tilted for safety reason.

6. Remove one bolt on each side of the cab.

Spanner: 46 mm 7. Push up the cab by using the hydraulic pump (a) on left hand side. If hydraulic pump is not installed, crane has to be used.

• Make sure that the handle for up-and down pushing (b) is in the up-position (the illustration shows the down-position).

8. In service position: Fasten the safety support (c) to the anchorage point at the cab and front frame, by using the bolts removed in item 6.

The safety support is to be found in the toolbox.

• To lower the cab: 1. Unscrew the safety support (c). Put it back to its storage place in the tool box.

2. Lower the cab by using the hydraulic pump (a) on left hand side. If hydraulic pump is not installed, crane has to be used.

• Make sure that the handle for up-and down pushing (b) is in the down-position (the illustration shows the downposition).

3. Refit the bolt on each side of the cab. a

4. Remove the plastic bags on the brake fluid reservoirs.

5. Close the bonnet.

6. Lower the body.

7. Refit the cover behind the hydraulic tank and the exhaust heating, if this was removed.

b

DANGER It is hazardous to work/stand underneath the cab without applying the safety support!

Do not enter the cab while it is tilted!

Do not operate the dump truck with a tilted and secured cab!

c

28

Operating & Maintenance Manual

2. Safety Instructions

21. Body support 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.

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. Lift the body slightly.

3. Return the tip control lever to hold position when the body is off the body support.

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

5. Lower the body support.

6. 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

Operating & Maintenance Manual

29

2. Safety Instructions

22. 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 24).

Block the wheels (see item 23).

3. Stop the engine and remove starter switch key if not necessary for the work. Disconnect the main switch on the front fender (left hand side).

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

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

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

30

Operating & Maintenance Manual

2. Safety Instructions

24. 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 link age 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 25.

• During dump truck transportation, see item 26.

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

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: MT25: approx. 22,500 kg MT26 : approx. 23,500 kg MT31: approx. 25,150 kg MT36: approx. 28,800 kg MT41: approx. 29,200 kg incl. tailgate

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

Operating & Maintenance Manual

31

2. Safety Instructions

26. 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!

27. High pressure Be aware of high pressure in the hydraulic system (with running engine and 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: Accumulators contain oil under high pressure!

Always empty the accumulators before working on or opening the hydraulic system.

Procedure: • Stop the engine.

• Operate the brake pedal repeatedly until the accumulators are empty.

Accumulators can also be emptied through the accumulator test connectors.

Be aware that the accumulators will be recharged with oil when the engine is re-started.

Tyres: Release the pressure through the rim nipple before attempting to remove any embedded objects or removing tyre/rim assembly from the machine. The pressure inside the tyres is 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.

32

Operating & Maintenance Manual

2. Safety Instructions

28. 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 similar: Cab certification.

The cab has been approved to current ROPS/FOPS standards. Structural damage, an overturn, modification, alteration or not permitted 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.

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.

Warning - dangerous loads 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.

Operating & Maintenance Manual

• Explosive or inflammable loads must not be transport if the body is exhaust heated.

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

33

2. Safety Instructions

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

Emergency exit • The emergency exit can be used by removing the hammer from the storage location and break front side window.

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

34

Operating & Maintenance Manual

• 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.

2. Safety Instructions

Fire extinguisher • The fire extinguisher is located on the left hand side in the cab.

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

Warning - accumulators contain oil under high pressure • Always empty the accumulators before working on or opening the hydraulic system • Read the operating manual (safety instructions, item 27 and chapter 7, maintenance) before servicing

Warning - air conditioner • Refrigerant R 134a under high pressure.

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

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

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

Operating & Maintenance Manual

35

2. Safety Instructions

First aid kit • The first aid kit (if fitted) is located on the left hand side in the cab, below the rear side window.

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

36

Operating & Maintenance Manual

2. Safety Instructions

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.

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.

Note - sling and/or tie down point • Read the operating manual (safety instruction, item 25 and 26)for correct use of the sling and/or tie down point.

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 the operating manual (safety instructions, item 24).

Operating & Maintenance Manual

37

2. Safety Instructions

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 the operating manual (safety instructions, item 21) before operation.

Note - sling and/or tie down point • Read the operating manual (safety instruction, item 25 and 26) for correct use of the sling and/or tie down point.

Warning - accumulators contain oil under high pressure • Always empty the accumulators before working on or opening the hydraulic system • Read the operating manual (safety instructions, item 27 and chapter 7,maintenance) before servicing.

MT25/MT26/MT31/MT36/MT41

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

Note - sling and/or tie down point • Read the operating manual (safety instruction, item 25 and 26) for correct use of the sling and/ or tie down point.

38

Operating & Maintenance Manual

2. Safety Instructions

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

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

Note - use correct type of grease • Always check grease specifications before refilling.

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

Warning - hot coolant can spurt out

• The exhaust pipes and nearby area may be hot. Fingers and hands can be burnt!

• 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.

• Use gloves when checking the transmission oil level or filling oil.

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

Warning - hot area!

Operating & Maintenance Manual

39

2. Safety Instructions

(Behind the hydr. tank)

(Behind the cab)

Note - transmission

Note - fuel tank

Note - hydraulic tank

• Read the operating manual (safety instructions, item 2.5 and 8) before refilling oil.

• Read the operating manual (safety instructions, item 2.5 and 8) before refilling fuel.

• Read the operating manual (safety instructions, item 2.5 and 8) before refilling oil.

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

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

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

(Inside battery compartment) (Inside battery compartment) Warning - battery acid and gases Warning - welding precaution • Disconnect the batteries and unplug the connectors on the electronic control units before welding.

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

40

Note - sling and/or tie down point • Read the operating manual (safety instruction,item 25 and 26) for correct use of the sling and/ or tie down point.

Operating & Maintenance Manual

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

3. Operating controls

Operating Controls

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

41

3. Operating Controls

Contents

3. Operating controls ................................................... 41-78 Overview of the instruments and controls ................ 43 Instruments ............................................................... 44 Warning / indicator lights .......................................... 49 Switches .................................................................... 57 Controls ..................................................................... 61 Cab ventilation ........................................................... 69 Other cab equipment ................................................ 73

* Numbers refer to positions on the electrical circuit diagram 42

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 88.

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

43

3. Operating Controls

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

2

1

Pos 1 2 3 4 5

3

4

Description Page Fuel gauge 45 Engine revolution counter and hour meter 45 Gear display 45 Speedometer 48 Transmission oil temperature gauge 48

5

Remarks

* Numbers refer to positions on the electrical circuit diagram 44

Operating & Maintenance Manual

3. Operating controls

Instruments 1. Fuel gauge 30* The gauge indicates fuel tank level from empty to full.

Tank capacity: MT25, approx. 290 litres MT26, approx. 320 litres MT31, approx. 350 litres.

Fill up with diesel when necessary, and at the end of the shift.

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

Normal revolution: • Low idle: 600 rpm ± 50 • Max. economic area:

1500 - 1900 rpm

• High idle:

2430 rpm ± 50

• Max. allowed rpm:

2600 rpm

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

3. Gear display 250* A. 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.

continued overleaf

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

45

3. Operating Controls

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

B. 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.

C. 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.

D. Starts flashing if error has been detected.

The main warning light for transmission failure (30) will also light.

If this wrench starts flashing: 1. Stop the dump truck on a safe place.

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

3. Check and note the error codes on the display, which will be shown at pos B and C 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.

4. 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.

continued overleaf

* Numbers refer to positions on the electrical circuit diagram 46

Operating & Maintenance Manual

3. Operating controls

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

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.

"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 engine rpm above 1200 rpm and 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 2600 rpm. The main warning light (30) will also illuminate, and the emergency retarder will automatically engage.

The engine speed must be reduced immediately!

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

47

3. Operating Controls

Instruments

4. 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.

5. 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 warnings will show up: the main warning light (30), the wrench on the gear display (3) will flash and the display will show the letters WS, WR or WT (see explanation under item 3, 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.

* Numbers refer to positions on the electrical circuit diagram 48

Operating & Maintenance Manual

3. Operating controls

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

21

22

30 31

13 14 15 23 24

25

33 34 35 43 44 45

12 20 10 11

Pos 10 11 12 13 14 15 20 21 22 23 24 25

Description Page Brake system warning light 50 Spare space 50 Spare space 50 Brake fluid warning light 50 Emergency steering warning light 50 Parking brake indicator 50 Engine coolant temperature warning light 51 Engine oil pressure warning light 51 Main warning light, engine failure 51 Battery charge warning light 53 Air filter warning light 53 Spare space 53

Pos 30 31 32 33 34 35 40 41 42 43 44 45

32 40 41 42

Description Page Main warning light, transmission failure 53 Spare space 53 Spare space 53 Spare space 54 Spare space 54 Lock-up indicator 54 High beam indicator 55 Engine brake indicator 55 Inter axle differential lock indicator 55 Direction light indicator 55 Retarder brake indicator 55 Automatic central lubrication indicator 55

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

49

3. Operating Controls

Warning / indicator lights

10

11

12

10. Brake system warning light, red 6-A1* Lights if the air pressure in front or/and rear brake circuit is below approx. 5 bar. Do not attempt to drive the dump truck at air pressure below 5 bar.

Lights also when the starter switch is turned on, switches off when the air pressure is above 5 bar.

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

13

14

15

11. Spare space

12. Spare space

13. 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) or if the level in one of the brake fluid reservoirs has dropped to minimum.

Check for leaks and/or worn brake linings (see 500 hours service).

Replace brake linings if necessary.

14. 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).

15. Parking brake indicator, red 6-C2* Lights when the parking brake (87) is engaged.

Will also light if the air pressure in the parking brake circuit is below approx. 5 bar.

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 50

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights

20

21

22

20. Engine coolant temperature warning light, red 7-A1* Lights if the engine coolant rises above 102 °C. Additional the main warning light (22) will start flashing. Check and note the error codes on the engine controller, see item 22 for procedure. Then stop the engine (possible fault) immediately.

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

23

24

25

Lights if oil pressure is lower than 0.7 bar. Additional the main warning light (22) will start flashing. Check and note the error codes on the engine controller, see item 22 for procedure. Then stop the engine (possible fault) immediately.

22. 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 will / can light or flash. These lamps are as follows: • • • • • •

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

The engine controller is located behind the cover on the backwall (behind the instructor's seat back rest, if that is fitted).

Engine / engine controller failure 22.1. Main warning light on the instrument panel lights: The engine controller will reduce the engine load.

22.2. 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 (1200 - 1500 rpm).

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

Action when the main warning light illuminate and procedure for reading error codes, see next page.

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

51

3. Operating Controls

Warning / indicator lights

Action when the main warning light flashes or lights up: 1. If possible, adjust the engine rpm to a low idle, check that the engine oil pressure warning light and the engine coolant temperature warning light does not illuminate.

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.

Procedure for reading error codes: 1. Open the cover on the back wall (1) (remove the instructor's seat back rest, if that is fitted).

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

3. 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.

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

1

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

6. 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.

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

8. Contact your Moxy Dealer.

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

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

3

11.The procedure for reading error codes must then be repeated (item 1-8).

Error codes

2

12.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 52

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights

20

21

22

23. Battery charge warning light, red 7-A2* Lights if the battery charging voltage is too low (less than 24 volts).

Check alternator, multi-groove belt and regulator.

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

See 1000 hours service for procedure.

23

24

25 25. Spare space

30

31

32

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

Check the gear display (3) for error codes and contact your Moxy Dealer.

A short explanation of the error codes are listed under trouble shooting, chapter 5.

31. Spare space

33

34

35 32. Spare space

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

53

3. Operating Controls

Warning / indicator lights

30

31

32

33. Spare space

34. Spare space

35. Lock-up indicator, green 8-C2*

33

34

35

Lights when the automatic lock-up clutch for transmission is connected.

* Numbers refer to positions on the electrical circuit diagram 54

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights

40

41

42

40. High beam indicator, blue 9-A1* Lights when high beam (switch 80B) on the headlights are activated.

41. Engine brake indicator, orange 9-B1* Lights when the engine brake is engaged (throttle pedal released).

43

44

45 42. Inter-axle differential lock indicator, orange 9-C1* Lights when the inter-axle differential lock is engaged (switch 76)

43. Direction light indicator, green 9-A2* Flashes when direction indicator (switch 80 E/F) or hazard light (switch 63) is activated.

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

44. Retarder brake indicator, orange 9-B2* Lights when the retarder brake is engaged (switch 61)

45. Automatic central lubrication indicator, yellow 9-C2* Lights if there is a failure in the system, blink codes for the indicator, see next page.

Lights also when the starter switch is turned on. Switches off when the automatically test cycle is done.

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.

Blink codes for the indicator, see next page.

NOTE If there is a failure in the system, it is only possible to run the dump truck in 2. gear until the failure is corrected.

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

continued overleaf 55

3. Operating Controls

Warning / indicator lights

Blink codes for the automatic central lubrication indicator:

Blink codes

Cause/Meaning

The light flashes 4 times once (0.5s on/0.5s off) The automatic central lubrication is activated. as soon as the starter switch has been turned on: The light does not flash when the starter switch is turned on:

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:

Minimum grease level in the reservoir has been reached. Refill the reservoir as soon as possible, see 40 hours service.

The light continuously light for 2 minutes at the end of the pumping phase:

Insufficient grease pressure. Contact your Moxy Dealer.

The light continuously light after starter switch has been turned on:

System out of order! Immediate action is required.

Possible causes: • 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.

• 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):

Single test run being executed (see "test")

The light flashing continuously (0.2s on/0.2s off):

Continuous cycle test run being executed (see "test")

Located under the cover

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.

* Numbers refer to positions on the electrical circuit diagram 56

Operating & Maintenance Manual

3. Operating controls

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

50

51

52

53

54

55

63

60

76

64

61

65 62 70

71

72

Pos 50 51 52 53 54 55 60 61 62 63 64 65 70 71 72 73 74 75 76

73

74

75

Description Main light switch Cab light Rotating beacon switch Working light and extra high beam Spare space Working and back-up lights Spare space Retarder brake switch Spare space Hazard light switch Spare space Test switch for brake warning light Mirror heating switch Electrically heated driver's seat switch Spare space Spare space Spare space Spare space Inter-axle differential lock

Page 58 58 58 58 58 58 59 59 59 59 59 59 60 60 60 60 60 60 60

Remarks

Optional Optional Optional

Optional Optional

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

57

3. Operating Controls

Switches

50

51

50. Main light switch 90*

52

1st position, Side lights.

When the switch is set to 1st position, the side/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 (80)) will also illuminate. Built-in light.

51. Cab light 93* Push the switch to light the cab.

Turn off during operation. Built-in light.

52. Rotating beacon switch 92* Push switch to activate the rotating beacon on top of the cab roof.

Built-in light.

53

I

54

53. Working lights and extra high beam 20*

55

I

0

0

II

II

Push the switch to activate the lights.

Will only be activated if the main light switch (50) is switched on to 2nd. position. Built-in light.

The switch has three positions: I. The extra high beam will light when the high beam on the column switch (80) is switched on.

0. Neutral, the lights are switched off.

II. The working lights will light.

54. Spare space

55. Working and back-up lights 38* Push the switch to activate the lights.

Will only be activated if the main light switch (50) is switched on.

Built-in light.

The switch has three positions: I. The back-up light will light when the reverse gear is engaged.

0. Neutral, the lights are switched off.

II. The working lights will light.

* Numbers refer to positions on the electrical circuit diagram 58

Operating & Maintenance Manual

3. Operating controls

Switches

60

61

62

60. Spare space

61. Retarder brake switch 47* The retarder brake will engage automatically if: - the engine rpm exceeds 2100 rpm and the throttle pedal is fully released. This will happen regardless to the switch position. The brake will then disengage at 1950 rpm.

- the brake pedal is depressed. The retarder brake will then be engaged until the throttle pedal is depressed or the lock-up is disconnected or the gear selector is moved out of gear position.

This will happen regardless to the switch position.

- the engine rpm exceeds 2600 rpm, to avoid overspeed of the engine. This will happen regardless to the throttle pedal and switch position.

Push the switch to engage the retarder brake.

The retarder brake will only engage if the throttle pedal is fully released, lock-up connected and a gear is selected. Built-in light.

Indicator light (44) will light when the retarder brake is engaged.

62. Spare space

63

64

65

63. Hazard light switch 89* Push switch to activate the hazard light, all direction indicators will flash at the same time. An indicator light (43) on the instrument panel will flash concurrently. Built-in light.

64. Spare space

65. Test switch for brake warning light 5* Push the switch and check that the warning light for brake fluid circuit failure (13) lights up.

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

59

3. Operating Controls

Switches

70

71

72

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

Engage only when necessary!

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

Built-in light.

72. Spare space

73

74

75

73. Spare space

74. Spare space

75. Spare space

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

To engage the inter-axle differential lock, the dump truck must be stationary and the gear selector must be set to neutral (N) position.

An indicator light (42) will light when the lock is engaged.

Built in light.

NOTE Engage only: • when the dump truck is stationary.

• when necessary!

* 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.

80

81

82

86

85

90 91 87 83

89

84

88

Pos 80 81 82 83 84 85 86 87 88 89 90 91

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

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

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

61

3. Operating Controls

Controls 80. Column switch 16* 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 50 is in position 2)

C

B. High beam (when switch 50 is in position 2), indicator 40 will light.

C. High beam flash. Automatic return.

A

D. Horn, centre button automatic return.

D

E. Right turn, all right direction indicators flash.

Indicator light 43 flashes correspondingly.

E

F. Left turn. All left direction indicators flash.

Indicator light 43 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 82. 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 83. 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.

CAUTION If warning for brake fluid circuit failure lights up (warning light 13), stop the dump truck immediately!

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

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

65

3. Operating Controls

Controls

85. 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 (3) 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 86. Tip control lever 1

The lever controls the body lifting and lowering.

The lever has 3 positions:

2

1. Lower (body down/power down).

2. Hold (hold and floating position).

3. Lift (body up).

3

The lever are electronically locked in the lower position, and have spring return from lower to hold.

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.

87. Parking brake lever OFF

ON

The parking brake is on (locked) when the lever is in the backward position. An indicator light (15) 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. Indicator light (15) 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 (indicator light 13 and buzzer). The parking brake will not be fully released, and the service brakes may not have max. braking effect.

88. Starter switch 50* 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.

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

67

3. Operating Controls

Controls

89. Cigarette lighter 51* Push in to activate the heating function. Automatic return when hot.

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

90. Emergency exit • This dump truck is fitted with two emergency exits.

• Left door and front sidewindow on right hand side.

• If the door is blocked by any means you can get out through the front sidewindow.

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

* Numbers refer to position on the electrical circuit diagram 68

Operating & Maintenance Manual

3. Operating controls

Cab ventilation

91. Cab ventilation

For machines up to serial no. 710124 1

4

3

2

1. Ventilation fan switch 55* 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. Air flow regulator 55* Selects direction of the air flow, either towards the driver's feet or towards the windows (front windscreen, side windows and back window).

Turning counter clockwise to increase the air flow towards the driver's feet.

Turning clockwise to increase the air flow towards the windows.

3. Heater regulator 55* Adjust air heating with the knob. The air is heated by the engine coolant. Turning clockwise increases heating.

4. Air conditioner switch 55* Push the switch to activate the air conditioner system.

For machines from serial no. 710125 1

2

3

4

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.

5. Only installed on machines up to serial no. 710124: Recirculation switch 55* The switch has two positions: Pos I: Fresh air in cab. Air intake is fully open.

Pos. II:Recirculation of the internal air. The ventilation fan must be used to circulate the air.

The intake air is filtered before it enters the cab. All nozzles, except nozzles for the front windscreen, 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 door 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

- 710124

How to get...... ......maximum heat: • • • • •

710125 -

All nozzles fully open.

Heater regulator (91.3) on max., i.e right position Fan switch (91.1) on max, i.e. speed 3.

Air flow regulator (91.2) to driver's feet i.e. left position.

Recirculation switch (91.5) on pos II, recirculation (- 710124).

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

- 710124 ...... pleasant working temperature:

710125 -

• All nozzles fully open.

• Heater regulator (91.3) on max., i.e. right position • When the correct temperature has been obtained, turn heater regulator (91.3) (left) until you maintain the desired temperature.

• Air flow regulator (91.2) turned to the position which feels most comfortable.

• Recirculation switch (91.5) on pos I, fresh air (- 710124).

• Fan switch (91.1) set to speed 1 or 2.

- 710124 ......fresh air in cab:

710125 -

• All nozzles fully open.

• Heater regulator (91.3) on min., i.e. left position • Air flow regulator (91.2) on max. air flow towards the driver's feet, i.e. left position.

• Recirculation switch (91.5) on pos I, fresh air (- 710124).

• Fan switch (91.1) on max, i.e. speed 3.

* Numbers refer to position on the electrical circuit diagram 70

Operating & Maintenance Manual

3. Operating controls

Cab ventilation Setting heat and ventilation Without air conditioning - 710124

710125 -

How to get...... ......rid of condensation and ice on all windows: • Nozzles towards the windows fully open.

• Heater regulator (91.3) on max., i.e. right position • Air flow regulator (91.2) on max. air flow towards the windows, i.e. right position.

• Recirculation switch (91.5) on pos I, fresh air (- 710124).

• Fan switch (91.1) 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 positions on the electrical circuit diagram Operating & Maintenance Manual

71

3. Operating Controls

Cab ventilation Air conditioner - 710124

710125 -

How to get...... ......a pleasant temperature quickly: • Nozzles towards the driver's feet fully open.

• Heater regulator (91.3) on min., i.e. left position • Air flow regulator (91.2) on max. air flow towards the driver's feet, i.e. left position.

• Fan switch (91.1) on max, i.e. speed 3.

• Switch (91.4) pressed down, i.e. air conditioner engaged.

- 710124 When the temperature has been lowered to the level you want: • Turn the fan switch (91.1) to the position which maintains the desired temperature.

• Turn the air flow regulator (91.2) to the position which feels most comfortable.

• Adjust the nozzles towards the driver to a comfortable position.

710125 -

- 710124 ...... rid of air humidity in the cab:

710125 -

• All nozzles fully open.

• Heater regulator (91.3) on max., i.e right position • Air flow regulator (91.2) on max. air flow towards the windows, i.e. right position.

• Fan switch (91.1) on max., i.e speed 3.

• Switch (91.4) 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 position on the electrical circuit diagram 72

Operating & Maintenance Manual

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.

1

Seat adjustment.

2

1.

Lumbar support adjustment.

Stepless adjustment of the support.

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.

71.

Electrically heated seat.

3 5/6

4

7 8

9 8

10

11

70

71

72 The seat can be heated by pushing the switch.

Refer to item 71 in this chapter.

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

73

3. Operating Controls

Other cab equipment

Instructor seat There is one seat for instructor, on the left side of the driver seat.

The seat cushions are spring-loaded and will return to upright position when released. The seat are fitted with safety belt which is recommended for use during driving, both for safety and comfort.

Internal door opener • Push up handle to open the door.

External door opener/lock The door is fitted with lockable door opener.

• Depress the button on the handle grip to open the door.

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

* Numbers refer to position on the electrical circuit diagram 74

Operating & Maintenance Manual

3. Operating controls

Other cab equipment

Side 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 If the safety equipment is present, always keep it on its storage place and make sure that it is in order: • First aid kit (optional equipment)

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

(Distributor / Dealer fitted)

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

75

3. Operating Controls

Other cab equipment

• Warning triangle (located in right hand side fender). (optional equipment)

Ashtray

Retractable roller sunblind on front windscreen

Cab light The cab light switch has three positions: • On • Off • Door activated (or switch on the insturment panel)

* Numbers refer to position on the electrical circuit diagram 76

Operating & Maintenance Manual

3. Operating controls

Other cab equipment

Radio/Cassette player 201,212* 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

Content

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 (i.e. brake system warning light switched off, also see chapter 3).

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: 32 mm

2. Lubricating.

Grease all lubricating points.

3. Battery:

Checking electrolyte level in the batteries, see 500 hours service, item 1.4.

Checking battery charge, see 1000 hours service, item 2.3.

4. Multi-groove belt:

Checking multi-groove belt condition, see 1000 hours service, item 2.4.

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 driver's 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.

It is recommended to fill up with the same mixture as filled from the producer - 40% glycol / 60% water, see also 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 steering function ....................................... item 9.1.

• Check engine brake function ............................... item 10.1.

• Check engine and retarder brake function .......... item 11.1.

2.2

First 100 hours: 1. Change transmission oil.

20*

See 1000 hours service, item 3.1.

2. Replace transmission filter.

21*

See 1000 hours service, item 3.1.

3. Clean strainer.

22*

See 1000 hours service, item 3.1.

4. Replace hydraulic filter.

43*

See 1000 hours service, item 4.2.

5. Run the AEB Tester.

See 1000 hours service, item 3.2.

6. Multi-groove belt: Checking multi-groove belt condition, see 1000 hours service, item 2.4.

7. Expander bolts:

Checking torque setting on expander bolts on tip- and steering cylinders, see 500 hours service, item 5.1

8. Retorque window wiper spindle nuts.

• Torque setting: 35 Nm (M10), 18 Nm (M8) 9. 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

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 4.1.

See 1000 hours service, item 8.1.

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

• Hydraulic oil pressure. Contact your local Moxy dealer.

3. Run the AEB Tester. Procedure described in 1000 hours service, item 3.2.

4. Lubricating. Grease all lubricating points.

5. 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 oil filter ................................................... item 1.3.

• External cleaning of the radiator ......................... item 1.4.

• Check batteries .................................................... item 1.5 • Check battery terminals ....................................... item 1.6.

• Check brake lining thickness .............................. item 3.1.

• Check wheel nuts torque .................................... item 4.1.

• Check expander bolts, tip- and steering cyl. ...... item 5.1.

• Air conditioner system, test operation ................ item 6.1.

• Check cab ventilation filter element .................... item 6.2.

• Check the automatic central lubrication system . item 7.1.

.

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

Content

5. Operating instructions ............................................. 85 - 122 Precautions on worksites .......................................... 87 Some simple rules to be observed prior to operation 90 1. Starting the engine .............................................. 91 2. Operating the dump truck .................................... 93 3. Parking the dump truck ........................................ 105 4. Stopping the engine ............................................ 105 5. Checks after stopping the engine ....................... 106 6. Loading and tipping ............................................ 106 7. Tyre handling ....................................................... 108 8. Cold weather ........................................................ 110 9. Long term storage ............................................... 111 10. Battery power assistance .................................... 112 11. Towing the dump truck ........................................ 113 12. External air filling ................................................. 113 13. Manual release of parking brake ........................ 114 14. Manual release of the tip valve ........................... 115 15. Tyre filling point ................................................... 115 16. Troubleshooting ................................................... 116

86

Operating & Maintenance Manual

5. Operating Instructions

Precautions on worksites There are many different types of worksites, some of them could be: • • • •

Dusty areas Rocky areas Wet, swampy or muddy areas Seashore or salty areas

• • • •

Altitude above 1000 m Steep driving Extremely hot areas Extremely cold areas

• Underground areas (mines) • Transit, long distance drive-away (more than 2 km)

Rules and guidelines are listed below to increase the lifetime of the dump truck. Pay attention to these guidelines and let the safety always get first priority.

General • On worksites where extra heavy-duty operations are occuring, reduce the maintenance intervals and carry out greasing more frequently.

• Clean the machine regulary. Keep grease fittings, breathers and oil level gauges clean and avoid dirt to enter these items.

Dusty areas/Underground areas (mines) • When working in dusty/sandy worksites or worksites where the service brake (foot brake) is frequently used, check the brake lining more often, at least every 250 hours (see 500 hours service for procedure).

• Remember to check the brake fluid level daily, and fill up if necessary (see also 8 hours/daily service).

• Watch the air filter warning light, to see whether the engine air filter is clogged. Clean/replace the engine air filter at shorter intervals than specified, clean as often as necessary (see 1000 hours service for procedure).

Extremly dusty applications may require to clean the air filter every day!

• Clean the radiator core frequently, every week if necessary, to avoid clogging (see 500 hours service for procedure).

• Clean and replace the fuel filter frequently (see 1000 hours service for procedure).

• Check daily the cab ventilation filter and prefilter. These filters will very soon be clogged in dusty areas, therefore it is necessary to clean and replace the cab ventilation filter and prefilter more frequently than usual (see 40 and 500 hours service for procedure).

Never remove a filter element/prefilter without replacing it with a new one!

• Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.

Rocky areas • Inspect the pinion bearings more often when working in rocky areas (see 1000 hours service for procedure), and replace the bearings as often as necessary, i.e. if the bearings shows signs of wear, cracks or damages.

• Check for damage to the undercarriage and for looseness, flaws, wear and damage in wheelbolts and nuts.

• Check tyres for damage and wear. Remove foreign object from the threads as soon as possible, these will sooner or later penetrate into the tyre. Also protect the tyres from falling stones during loading.

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Wet, swampy or muddy areas (see also chapter 2, item 15 - Wading) • Be aware of that the braking effect will be reduced when the brakes are wet.

• The brake linings must be checked more often, at least every 250 hours, when driving in wet or swampy areas (see 500 hours service for procedure), the wear of the lining will increase.

• The wear of the sealings will also increase when driving in wet or swampy areas, check and replace sealings as often as necessary.

• If mud sticks to the calipers or discs, and the brakes are left in that condition, the wear of the lining will increase, therefore always wash the area well with water after operations. E.g. clay dryed up is hard as concrete, this will cause breakage and wear of the machine.

• Do not let the water flow through the grill or into the different breathers and air filters.

• Do not operate the dump truck in water/rivers permanently for a long period.

And do not under no cicumstances let the water flow through the grill.

Seashore or salty areas • Before start working, check plugs and valves for tightness.

• Spray exposed areas with anti-corrosive.

• Check the brake system (see 2000 hours service) and the brake linings more often (see 500 hours service for procedure).

When driving in wet salty/sandy areas the wear of the lining will increase.

• Check also the sealings more often, the wear will increase in salty/sandy areas.

• Lubricate components more frequently than usual.

• Do not operate the dump truck in water permanently for a long period.

And do not under no cicumstances let the water flow through the grill.

• It is important to wash the machine immediately after the work to protect the components for rusting and to remove dirt and sand. See also item above "Wet, swampy or muddy areas"

High altitude (above 1000 m) • Be aware of that the engine power and torque will be reduced due to low air pressure.

Contact your Dealer for possible remedy.

• Do not remove the air filter!

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Steep driving • Always when driving downhill and loaded, use only the exhaust and retarder brake for retarding. The service brake (foot brake) must only be used for complete stop. (see also chapter 2, item 13 - Operation of brakes and chapter 5, item 2.12 - Up, down and crossgradient travel) • See also engine and retarder brake capacity chart at chapter 8.

Extremely hot areas • Watch the engine coolant temperature gauge, the engine coolant temperature warning light and the transmission oil temperature gauge. If the temperatures are at the limit, check the engine radiator for clogging (see 500 hours service) • Watch the air filter warning light, to see whether the engine air filter is clogged. Clean/replace the engine air filter at shorter intervals than specified, clean as often as necessary (see 1000 hours service for procedure).

Extremly cold areas (see also chapter 5, item 7 - Cold weather) • Use engine heater • Check that the correct oils are used (see oil specification sheet, chapter 6) • Check that there is enough glycol in the coolant (see 2000 hours service for freezing point and correct coolant)

Transit, long distance drive-away (more than 2 km) • Check and adjust the tyre pressure on cold tyres before starting. Do not reduce pressure during driving.

• Generally replace the mineral based oil with fully synthetic oil.

A mineral based oil have a rapid break down of lubrication ability and cooling ability when operated at high temperatures (120OC). Replacing mineral based oil with a synthetic oil will improve the cooling capacity by 15%.

• Make sure that the interaxle differential is disconnected when roading, as the 50/50 torque split will generate a lot of heat.

• Drive only without load.

• Drive 2 hours and stop for minimum 30 min. Drive another 2 hours and stop for minimum 1 hour. Repeat.

• Upper speed limit for this operation: 2000 rpm at 6. gear. Must not be exceeded!

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Some simple rules to be observed prior to operation.

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

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

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

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

• You must wear personal safety equipment, for safe 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!

• Use helmet to increase protection of your head.

• Always use the seat belt during driving!

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

• 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!

• If instructor seat is not fitted, instructor or passenger may not stay in the cab during driving.

• Do not climb on surfaces which are not intended for this, always use the surfaces which are provided with anti-slip coatings.

• Check that both the brake system warning light and the brake fluid warning light are not lighted before 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 two exits, one door and the front sidewindow on the right hand side as emergency exit. The front sidewindow is opened by pulling the handle under the window backwards. The rubber seal must be pulled completely off before pushing the front sidewindow out.

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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 compartment (if disconnected) otherwise there will be no power supply.

1.1. Confirm that parking brake is ON

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, switches off when the air pressure is above 5 bar • emergency steering warning light, switches off above 5 km/h.

• automatic central lubrication - switches off when the automatically test cycle is done.

• 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. 30 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 2 minutes before restart.

2 min.

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

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

• 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.

6. Sound the horn as alert.

2. Fasten the seatbelt before driving.

7. Depress the brake pedal.

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

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

OFF

4. Confirm low idle speed.

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

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

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

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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.

Gear position V: Forward drive position.

Automatic gear shift

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 brake or the engine and retarder brake is engaged, the down shift will take place at high rpm.

continued overleaf

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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 Manual gear shift

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.

Engine and retarder brake mode When the engine brake or the engine and retarder brake is engaged, the transmission will not shift to a higher gear if the speed increases at downhill driving, unless the throttle pedal is depressed (disengagement of engine and retarder brake).

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Operating hints Different types of terrain require different operating techniques.

Automatic gear shift

• Use automatic gear shift, for normal travel.

• 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.

Manual gear shift

• Changing between automatic and manual gear shift.

• 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:

N

OFF

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

• Stop the truck and release the throttle pedal completely.

• Neutral position must not be selected during driving.

• 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 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.

• Do not operate the gear selector with the throttle pedal depressed. This will cause a big shock, and will also reduce the life of the dump truck.

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5. Operating Instructions

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 only manual gear shift between 1st, 2nd 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.

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.

• Transm. oil temp.:

50 - 105°C, max 120°C a short period

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

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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. There are two 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. The braking effect of the retarder brake depends on the engine rpm. High engine rpm gives high retarder braking effect.

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 retarder brake operation The engine and retarder brake operates automatically and are controlled by: • Throttle pedal position • Switch on the instrument panel • Throttle pedal position When the throttle pedal is fully released, lock-up connected and a gear is selected, the engine brake will automatically engage.

• Switch on the instrument panel The retarder brake can be operated by depressing the retarder brake switch.

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

The retarder brake will engage automatically if: - the engine rpm exceeds 2100 rpm and the throttle pedal is fully released. This will happen regardless to the switch position. The brake will then disengage at 1950 rpm.

- the brake pedal is depressed. The retarder brake will then be engaged until the throttle pedal is depressed or the lock-up is disconnected or the gear selector is moved out of gear position. This will happen regardless to the switch position.

- the engine rpm exceeds 2600 rpm, to avoid overspeed of the engine. This will happen regardless to the throttle pedal and switch position.

NOTE •

Always use the engine brake or engine and 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 retarder brake will automatically engage if the engine speed exceeds 2600 rpm. This will happen ragardless to the throttle pedal an switch position.

Reduce the engine speed immediately!

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5. Operating Instructions

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 the throttle pedal.

2. Apply the engine brake or the engine and retarder brake.

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

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

5. Apply the parking brake.

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

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

2. Apply the engine and retarder brake.

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

4. Move the gear selector to 1st gear manually as quickly as possible.

5. 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.

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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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5. Operating Instructions

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

1. Front differential, automatic diff. brake (limited slip type) Fitted to the transmission. Transfers the power to left and right front wheels.

1

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 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!

2

CAUTION

3

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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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.

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

• 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.

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

• Always use the engine brake or the engine and 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.

• Keep engine speed at the upper area, 1500 - 1900 rpm in heavy conditions and at hill travel. Select a manual gear position at steep hill travel.

• If use of the engine brake or engine and 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 brake or the engine and retarder brake applied.

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

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

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

The retarder brake (emergency retarder) will automatically be engaged if the engine speed exceeds 2600 rpm.

This is to avoid overspeed of the engine.

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5. Operating Instructions

2.13. Important operating instructions

• The dump truck must not coast with gear selector in neutral position.

N

104

• Engine speed within 1500 1900 rpm with engaged lockup is recommended during driving.

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

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

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

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

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

• 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 life time of the dump truck is reduced.

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

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

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5. Operating Instructions

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

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.

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.

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5. Operating Instructions

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.

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.

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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 (check that the top tailgate, if fitted, opens).

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. The lowering speed is proportional with the engine speed.

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

NOTE For safety reasons, the tipping system is equipped with an automatic tip stop, to prevent the loaded body from tipping over.

Vibrations caused by the automatic tip stop may help to loosen material from the body.

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 7.2. 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 carry 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

108

MT25 (20,5R25) 30 km-version bar (psi) 4.0 (58) 3.5 (51) 3.5 (51)

Front MT25 (20,5R25) MT26 (23,5R25) MT31 (23,5R25) 50 km-version bar (psi) bar (ps i) bar (psi) 5.0 (73) 4.0 (58) 4.5 (65) 4.5 (65) 3.5 (51) 3.75 (54) 4.5 (65) 3.5 (51) 3.75 (54)

MT25 (20,5R25) 30 km-version bar (ps i) 4.0 (58) 3.5 (51) 3.5 (51)

Operating & Maintenance Manual

Rear MT25 (20,5R25) MT26 (23,5R25) MT31 (23,5R25) 50 km-version bar (psi) bar (psi) bar (psi) 5.0 (73) 4.0 (58) 4.75 (69) 4.5 (65) 3.5 (51) 4.0 (58) 4.5 (65) 3.5 (51) 4.0 (58)

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 min. Drive another 2 hours and stop for minimum 1 hour. Repeat.

• Upper speed limit for this operation: 2000 rpm at 6th gear.

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 can be necessary to avoid starting difficulties.

It is recommended to use an engine heater (optional equipment) at low temperatures. The engine heater has an electrical element which heats the engine coolant.

• 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 retarder brake switch must be turned OFF 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, door, 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: A

1. Turn off the battery main switch in the battery compartment.

3

4

2. Connect first cable (A) from positive (+) terminal on discharged batteries....

2

3. .... to the positive (+) terminal on the assisting battery.

Good batteries

B

Low batteries

4. Connect second cable (B) from negative (-) terminal on assisting battery....

5

Chassis of vehicle with low battery

5. .... to chassis on the dump truck with the discharged batteries, some distance from the batteries.

6. Turn on the battery main switch and start the engine in the normal way.

Disconnection: Disconnect cables in the opposite order, 5 - 4 - 3 - 2.

CAUTION • • • • •

112

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,100 kN (each) • Rear, 200 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 which is fitted on the firewall, between the air tanks (below the window wiper engine).

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 and start filling.

The dump truck can now be moved if the parking brake can be released.

WARNING • •

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!

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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. mm 82,6

2. Raise the body and secure it with the body support (see chapter 2 - safety instructions) 3. Remove the dust plug on the air cylinder.

4. Insert and lock the release bolt into piston.

• The release bolt, washer and nut are to be found under the air cylinder.

5. Tighten the nut against the washer, until the bolt extends 82,6 mm.

DANGER All braking systems are now out of function. Extreme care must be taken to avoid spontaneous rolling.

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14. Manual release of the tip valve If the body is lifted and cannot be lowered by the tip control lever, i.e. hydraulic pressure has been lost, the tip valve may be manually released.

1. The bolt for manual release are to be found on the underside of the tip valve. The tip valve is located on the back of the cab on left hand side.

2. Before doing the following procedure, make sure to measure the length of the protruding bolt.

3. Screw in the bolt until the body is in the lowered position.

4. Then unscrew the bolt to its original length as measured on beforehand.

CAUTION It is very important for the function of the tip valve that the length of the protruding bolt is exactly the same after the procedure as it was before the procedure was carried out.

15. Tyre filling point The air filling connector (see item 12) can also be used for filling air into the tyres.

1. Connect the hose to the connector and fill air.

2. Check the air pressure with a separate gauge.

3. For basic tyre pressures, 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!

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5. Operating Instructions

16. Troubleshooting If the action below does not solve the problem or the fault cannot be found, contact Moxy dealer.

*= Always contact your Moxy Dealer.

Symptom

Cause

Action

Engine: • • • • • • • •

Main switch disconnected Out of fuel Low battery current Blown fuse Defective wiring Hydrostatic lock Starter motor defective Electronic controller or sensors defective

• • • • • • • • • • • • •

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 defective

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

• • • • •

Add oil, check for leakage Change to correct oil type Replace Overhaul* Overhaul*

Will not start

Starts but stops again, runs un-evenly or hunts.

Low output

116

Too low oil level Incorrect oil type Sensor/gauge defective Oil pressure red. valve faulty Worn oil pump

Operating & Maintenance Manual

• Turn on Refill fuel, bleed system Recharge Check circuit, replace fuse Check connections, wires Repair* Replace* Check/repair*

5. Operating Instructions

Symptom

Cause

Action

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

• • • •

Replace or clean Adjust/repair* Replace* Repair/replace*

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

• • • • •

Change fuel Adjust Adjust* Replace* Overhaul*

Main warning light illuminates

Clogged air filter Fuel pump/injection system worn or faulty Cylinder gasket defective Turbocharger defective

Bad fuel quality Valves incorrectly adjusted Injection pump incorrectly adjusted Injector defective Worn engine or internal damage

• Engine / engine controller failure

Following error codes can be read on the engine controller: • Control status lamp lights • Engine controller has detected an internal fault.

• Shut down lamp lights • Engine temperature has reached a warning threshold or the sensor has failed.

• Torque limit lamp lights • Air inlet temperature has reached a warning threshold or the sensor has failed.

• Power - lamp lights • Speed potentiometer or idle safety switch has failed.

Operating & Maintenance Manual

Stop the dump truck at a safe place and check the error codes on the engine controller.

Check/repair* Check/repair* Check/repair* Check/repair*

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5. Operating Instructions

Symptom

Main warning light flashes SHUT DOWN CONDITION

Cause

Action

• Engine / engine controller failure

Following error codes can be read on the engine controller: • Control status lamp lights • Engine controller has detected an internal fault.

• Shut down lamp lights • Engine temperature has reached a shut down threshold or the sensor has failed.

• Starting lamp lights • Engine has exceeded its overspeed threshold.

• Running lamp lights • Actuator feedback sensor failure.

• Boost limit lamp lights • Engine controller has detected a loss of boost pressure.

• Power + lamp lights • Oil pressure has dropped below a threshold level or the sensor has failed.

Stop the dump truck at a safe place, check the error codes on the engine controller and stop the engine as soon as possible.

Check/repair* Check/repair* Check/repair* Check/repair* Check/repair* Check/repair*

Transmission:

• • • • •

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*

• • • •

Add oil, check for leakage Check circuit Replace Check/repair*

• • • • •

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 Automatic central lubrication failure

Check/repair* Replace* Check/repair* Overhaul* Check/repair*

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

Too high temperature

No drive in any gear or only possible to drive in some gears

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Adjust to specified level Change to correct type Overhaul/replace*

5. Operating Instructions

Symptom

Cause

Action

• Transmission / transmission controller failure Main warning light illuminates

Following error codes can be read on the gear display: • First digit 1, second digit 1-9 • Digital input signals • First digit 2, second digit 1-9 • Analog input signals • First digit 3, second digit1-9 • Speed signals or A-E • First digit 5, second digit 1-9 • CAN signal error • First digit 6, second digit 1-9 • CAN signal error or A-F • First digit 7, second digit 1-9 • Analog current output signals or A-C • Analog current output signals • First digit 8, second digit 1-9 • First digit 9, second digit 1-9 • Digital output signals or A-F • Digital output signals • First digit A, second digit 1-9 • First digit B, second digit 1-9 • Clutch errors or A-F • Power supply • First digit D, second diget 1-9 • High speed signals • First digit E, second digit 1-9 • General errors • First digit F, second digit 1-9

Stop the dump truck at a safe place, select neutral gear position and check the error codes on the gear display.

Check/repair* Check/repair* Check/repair* Check/repair* Check/repair* Check/repair* Check/repair* Check/repair* Check/repair* Check/repair* Check/repair* Check/repair* Check/repair*

Brakes:

Poor braking effect or truck pull to one side when braking

• • • • •

Low brake fluid level 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*

Air system:

Low air pressure (all circuits)

• System leakage • Governor problem • Compressor failure

Check circuits Adjust setting/repair Overhaul*

High air pressure

• Governor problem

Adjust setting/repair

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5. Operating Instructions

Symptom

Cause

Action

Hydraulic system:

Emergency steering light on when driving

• No oil flow from main pump, or no oil flow from emergency 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/repair* Overhaul*

Electrical system:

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

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5. Operating Instructions

Symptom

Cause

Action

Chassis:

Uncomfortable travel (jumping)

• Defective shock absorber • Defective rubber suspension • Articulation turning ring worn

Replace Replace Overhaul*

Vibrations

• • • • •

Replace Check/repair* Check/repair* Check/repair* Check/repair*

Engine or transm. mountings Fan or flywheel loose/imbalance Defective elastic coupling Prop. shaft failure Drive line problem

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5. Operating Instructions

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6. Lubricants

Lubricants

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6. Lubricants

Content

6. Lubricants ................................................................. 123 - 130 Lubrication schedule ................................................. 125 Oil specification sheet ............................................... 127 Filling capacities ........................................................ 128 Transmission oil list ................................................... 129

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6. Lubricants

Lubrication schedule 1st time

POS COMPONENT ENGINE 1 2 3 4 5

HOURS-->

100 500

Engine oil Centrifugal cleaner Engine oil filter Fuel filter (2) Coolant / cooling system

SERVICE INTERVAL 8

40

500 1000 2000 4000

V V

Lubricants filled from producer

Shell Rimula Super 15W-40

R C R

D V

R C/V/R* C/R

ENGINE RELATED 10 Air filter, outer element -Inner element: replace every 2th year 11 Batteries (2) 13 Fuel tank

Min. once a year

V

C/V/R*

C/R*

C/R*

V

V

R R C

R R C

R R

R R

40% Glycoshell

V

TRANSMISSION 20 Transmission oil 21 Filter (2) 22 Strainer

R R C

V

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

R R

R

Shell Rimula X 10W-30

Shell Spirax A 90 LS Shell Spirax AX SAE 80W-90 Shell Spirax AX SAE 80W-90

HYDRAULIC 40 Hydraulic oil 42 Breather element on tank 43 Filter (2)

V

R

R

LUBRICATION POINTS 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65

Articulation turning ring Tip hinges Tandem bearings Articulation bearings Steering cyl. bearings Tip cylinder bearings Tailgate arm hinge (optional) Door and fender hatches Cab hinges Suspension legs Cardan shaft Cardan shaft Cardan shaft Cardan shaft Park break Tilt support

4+2 lub.

2 lubric.

2+2 lub.

2 lubric.

4 lubric.

4 lubric.

2 lubric.

8 lubric 4 lubric.

2 lubric.

2 lubric.

2 lubric.

2 lubric.

2+2 lub.

1 lubric.

1 lubric.

Shell Tellus T 46

R R Shell SRS 4000 NLGI - 2

L-6 L-2 L-6 L-3 L-2 L-2 L-1 L L L-1 L-2 L-2 L-2 L-2 L L

MISCELLANEOUS 70 Cab ventilation filter

C/R* V/R*

80 Hydr. pump, tiltable cab

Shell Tellus T15

R= Replace V= Check C= Clean L= Lubricate D= Drain *= or when required L-X = The number after the L means number of pump stroke per lubricator (1 stroke = 1-1 1/2 cm3) = Alternatively greased by automatic central lubrication system (optional)

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6. Lubricants

The numbers refer to table on previous page.

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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

Fuel tank Cooling system

Diesel fuel

S UM M E R - D IES E L

Dexron -IID/ -III / Mercon -M

SAE 10W-30/10W-40

SAE 20W-20

Front diff.

Rear diff.

Gear oil

SAE 80W-90

By changing between AFT and engine oil, it is recommended to run the AEB-Tester.

Only oils in the Transmission oil list can be used!

NOTE! Min. 20 minutes warming up period in neutral position is required when ambient temperature is within this area:

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 *

HV ISO VG

Hydraulic oil

HM ISO VG 46 HV ISO VG

ATF

DEXRON IID

Lubricator

Universal grease

Optional: Automatic

Universal grease

Centr. lubr. system

Lithiumsaponfied with EP-additive.

Consistency NLGI-1 / 1,5 / 2.

NLGI 2 NLGI 0/1

Brake fluid

Hydr. pump, Hydraulic oil tiltable cab

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).

• Contact oil supplier when operating in temp. below -25°.

• 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

Brake system

Acc. to: ASTM and ISO standards Cetane number: min. 49.

Sulphure contents: max. 0.3 %.

Max. 2 % isopropanol additive.

SAE 85W-90

HM ISO VG 32

Hydraulic tank

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

SAE 10W Engine oil

SAE 15W-40

Tandem housing, Planetary red. gear

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).

30-50 % Nitrite-free glycol anti freeze is recommended. See 2000 Hours Service .

Water + antifreeze ATF

ZF Transmission

WIN T E R

REMARKS

Grease should not contain graphite, teflon or molybdenum.

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

ISO VG 15 See remarks

NOTE! If the cab should be tilted by use of the hydr. pump at temperatures below -20OC, use oil Fluid 4 Aero Shell or similar.

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 33

Component/Fluid Engine oil Engine coolant

45

38

Fuel tank - MT25

290

as req'd

Fuel tank - MT26

320

as req'd

Fuel tank - MT31

350

as req'd

Transmission oil*

57

29

Rear differential

32

29

Front differential (-710484)

9,5

9,5

Front differential (710485-)

13,2

13,2

2 x 75

2 x 67,5

Front reduction gear, each

2x3

2x3

Hydraulic system - MT25

128

101

Hydraulic system - MT26

138

111

Hydraulic system - MT31

150

123

Windscreen washer tank

4,5

4,5

Tandem housing, each

*=

128

Refill amount 33

Check level when engine runs at low idle.

Do not run engine without oil in the transmission.

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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/CH-4/CI-4/SF/SG/SH/SJ/SL 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/CH-4/CI-4//SF/SG/SH/SJ/SL or ACEA, categories A, B, E) Viscosity class: SAE 10W / 5W-30 / 5W-40 Manufacturer

Trade name

ARAL AG, BOCHUM/D BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH CASTROL INTERNATIONAL, PANGBOURNE READING/GB COMP.BRASIL. D. PETRO. IPIRANGA, RIO DE JANEIRO/BR FL ITALIA S.P.A., VILLASTELLONE/I FL ITALIA S.P.A., VILLASTELLONE/I FL ITALIA S.P.A., VILLASTELLONE/I FUCHS LUBRICANTS (UK) PLC, HANLEY/GB FUCHS PETROLUB AG, MANNHEIM/D GINOUVES GEORGES SA, LA FARLEDE/F KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL LIQUI MOLY GMBH, ULM/D LUBRICATION ENGINEERS, INC., FORT WORTH, TEXAS/USA MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MORRIS LUBRICANTS, SHREWSBURY/GB ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH REPSOL LUBRICANTES, MADRID/E SHELL ASEOL AG, BERN 5/CH SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STATOIL LUBRICANTS, STOCKHOLM/S TOTAL LUBRIFIANTS S.A., PARIS/F VALVOLINE EUROPE, DORDRECHT/NL VEEDOL INTERNATIONAL, PANGBOURNE READING/GB

ARAL BASICTURBORAL SAE 10W BLASOL 10W20 CASTROL ENDURON PLUS 5W-40 ULTRAMO TURBO 10W AKCELA SUPER 10 (SAE 10W) AMBRA SUPER 10 (SAE 10W) URANIA C SAE 10 W TITAN TXE 10 FUCHS TITAN UNIVERSAL HD SAE 10W YORK 730 SAE 10W Q8 T 400 SAE 10W TOURING HIGH TECH SAE 10W MONOLEC GFS ENGINE OIL SAE 10 MEGOL MOTORENOEL HD-C3 SG SAE 10W PENNASOL MOTOR OIL EXTRA C SAE 10W RING FREE XHD 10W ORLY DRACO 3001 SAE 10W PAKELO PKO HD 4 SAE 10W PANOLIN EXTRA DIESEL 10W TELEX W SAE 10W ASEOL MONOGRADE CF 10W SHELL RIMULA X 10W WINTERSHALL REKORD 10W DIESELWAY 10W TOTAL RUBIA S 10W ALL FLEET PLUS 10W VEEDOL DIESEL HDC SAE 10W

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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

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CYCLON HELLAS S.A., MAROUSSI ATHENS/GR DE OLIEBRON B.V., ZWIJNDRECHT/NL DE OLIEBRON B.V., ZWIJNDRECHT/NL EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FL ITALIA S.P.A., VILLASTELLONE/I FL ITALIA S.P.A., VILLASTELLONE/I FL ITALIA S.P.A., VILLASTELLONE/I FL ITALIA S.P.A., VILLASTELLONE/I FUCHS PETROLUB AG, MANNHEIM/D FUCHS PETROLUB AG, MANNHEIM/D GENOL GMBH & CO., WIEN/A GINOUVES GEORGES SA, LA FARLEDE/F GINOUVES GEORGES SA, LA FARLEDE/F HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL HUILES BERLIET S.A., SAINT PRIEST/F HYDROTEX, CARROLLTON, TEXAS/USA IGOL FRANCE SA, AMIENS/F KRAFFT S.A., ANDOAIN/E KRAFFT S.A., ANDOAIN/E KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL LIQUI MOLY GMBH, ULM/D MAZIVA ZAGREB D.O.O, ZAGREB/HR MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MORRIS LUBRICANTS, SHREWSBURY/GB MORRIS LUBRICANTS, SHREWSBURY/GB OEL-BRACK AG, HUNZENSCHWIL/CH OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PETROGAL S.A., LISBOA/P PETROL OFISI A.S, MASLAK-ISTANBUL-TURKEY/TR PRZEDSIEBIORSTWO MODEX-OIL, KWIDZYN/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL S.A.E.L., MADRID/E S.A.E.L., MADRID/E SHELL ASEOL AG, BERN 5/CH SHELL DEUTSCHLAND OIL GMBH, HAMBURG/D SHELL DEUTSCHLAND OIL GMBH, HAMBURG/D SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SLOVNAFT VURUP A.S., BRATISLAVA/SK SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STATOIL LUBRICANTS, STOCKHOLM/S STATOIL LUBRICANTS, STOCKHOLM/S SUN OIL COMPANY (BELGIUM) N.V., AARTSELAAR/B SYNECO SPA, SAN GIULIANO MILANESE/I TEDEX OIL SP.Z.O.O., PIASECZNO/PL TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F UNIL S.A., SAUMUR CEDEX/F VALVOLINE EUROPE, DORDRECHT/NL VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL INTERNATIONAL, PANGBOURNE READING/GB YACCO, ST PIERRE LES ELBEUF/F ZELLER + GMELIN GMBH & CO., EISLINGEN/D

ADDINOL ATF D II D ADDINOL ATF D III ARAL GETRIEBEÖL ATF 22 ARAL GETRIEBEÖL ATF 55 F-30589 AVIA FLUID ATF 86 AVIA FLUID ATF 98 BAYWA ATF 3000 ATF GM BP AUTRAN DXIII BP AUTRAN MBX MOTOREX ATF SUPER CASTROL TQ DEXRON III (F-30520) CASTROL TQ-D (22256) CEPSA ATF 70 TEXAMATIC 4291 TEXTRAN PSM ATF TYPE D TOR ATF 289 TOR ATF DMM ESSO ATF D2 MOBIL ATF 220 AKCELA TRANS XHD AMBRA HYDRODEX 3 TUTELA CAR GI/E TUTELA GI/A TITAN ATF 3000 TITAN ATF 4000 GENOL ATF MULTIFLUID YORK 686 YORK 785 KENDALL ATF DEXRON II D HRD STARMATIC 3 HY-TORQUE Z (ATF) ATF 430 ATF SYNTHETIC D3 KRAFFT ATF 21247 Q8 AUTO 14 Q8 AUTO 15 LIQUI MOLY ATF DEXRON IID INA ATF SUPER MEGOL HYDRAULIKOEL ATF DEXRON II D PENNASOL FLUID GETRIEBEOEL TYP P/CN LIQUIMATIC D II LIQUIMATIC SUPER ATF QUAKER STATE ATF Q3 PLUS OMV ATF D II (D22427) OMV ATF III PAKELO MULTIPURPOSE TRANSMISSION FLUID II D PANOLIN ATF DEXRON III HEAVY DUTY SYNTHETIC BLEND ATF MERCON V ATF SYNTHETIC BLEND ATF GALP TRANSMATIC D II PO ATF-2 VECO MATIC IID HIPOL ATF II D HIPOL ATF III GULF ATF D II D GULF ATF HIGH TECH ASEOL ATF DB UNIVERSAL DEAFLUID 4011 DEAMATIC SHELL DONAX TA (D-21631) SHELL DONAX TA (D-21666) SHELL DONAX TA (D-21774) SHELL DONAX TX (G-32003) SHELL DONAX TX (G-34077) MADIT AUTOMATIC WINTERSHALL ATF III STATOIL TRANSWAY DX II STATOIL TRANSWAY DX III SUNAMATIC 153 ATF PLUS TEDEX ATF DEXRON II D ELFMATIC G3 FINAMATIC HP FINAMATIC II D TOTAL FLUIDE AT 42 TOTAL FLUIDE ATX MATIC D VALVOLINE ATF TYPE D VEEDOL ATF DEXRON III (F-30521) VEEDOL ATF-M (22764) YACCO ATF III DIVINOL FLUID III F

130

Operating & Maintenance Manual

7. Maintenance

Maintenance

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

131

7. Maintenance

Contents

7. Maintenance ............................................................. 131 - 194 Maintenance precaustions ........................................ 133 Maintenance table ..................................................... 135 8 Hours / Daily Service .............................................. 137 40 Hours / Weekly Service ........................................ 151 500 Hours Service ..................................................... 153 1000 Hours Service .................................................. 169 2000 Hours Service .................................................. 183 4000 Hours Service .................................................. 191 Yearly recommended maintenance ......................... 193

* Numbers refer to positions on the lubrication schedule, chapter 6 132

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).

• 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.

• Wear a well-fitting helmet, safety shoes and working clothes. When drilling, grinding or hammering always wear protective goggles.

• 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.

• Park the dump truck on firm, flat ground. Apply the Articulation Lock.

• Exhaust gas is dangerous. When working inside, be particularly careful to have good ventilation.

• When working with others; Choose a group leader, follow the leader's instructions. Do not perform any maintenance beyond the agreed work.

• 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 stop the engine when performing maintenance near moving parts.

• Wash the dump truck, be careful not to wet electrical components or inside cab.

• During maintenance; Do not allow any unauthorised person to stand near the dump truck.

• Always use Moxy genuine parts for replacement.

• 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 parts.

• Always use the grades of grease and oil recommended by the manufacturer. Choose the viscosity specified for the ambient temperature.

See chapter 6.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

133

7. Maintenance

• When adding oil or checking the oil level, check that the oil is at the correct level.

• 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.

• After greasing up, always wipe off the old grease which was forced out.

• When checking or changing the oil, do it in a place free of dust, and prevent any dirt from getting into the oil.

• When changing the oil or filter, check the drained oil and filter for any signs of excessive metal parti cles or other foreign materials.

• 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.

• When removing parts containing Orings, gaskets or seals, clean the mounting surface and replace with new sealing parts.

• 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 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.

• When the strainer is located in the oil filler, the strainer must not be removed while adding oil.

• In case of difficult maintenance, refer to your Moxy Dealer.

* Numbers refer to positions on the lubrication schedule, chapter 6 134

Operating & Maintenance Manual

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 • Suspension legs • Artic. bearings • Steering cyl. bearings • Tip cyl. bearings • Tailgate arm hinges • Tip hinges • Tandem bearings • Door and fenders • Cab rear hinges 7. Parking brake 8. Service brake

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 ...........................................................

137 137 138 138 139 139 140 140 141 142 143

1 lubricator ...................................................................... 144 2 lubricators ................................................................... 144 2 — “ — ........................................................................... 144 4 — “ — .......................................................................... 144 4 — “ — .......................................................................... 144 2 — “ — ........................................................................... 145 2 — “ — .......................................................................... 145 2 — “ — .......................................................................... 146 8 — “ — .......................................................................... 146 2 — “ — .......................................................................... 147 Check braking capacity .................................................. 147 Check braking capacity .................................................. 148 Check function ................................................................ 148 9. Steering Check function ................................................................ 148 10. Engine brake Check function ................................................................ 149 11. Engine and retarder brake Check function ................................................................ 149

40 Hours / Weekly Service 1. Cab ventilation 2. Tyres 3. Automatic central lubr.

Clean prefilter .................................................................

Air conditioner ................................................................

Check tyre pressure .......................................................

Check grease level, refill if necessary ...........................

151 151 152 152

500 Hours Service 1. Engine

2.

3.

4.

5.

6.

Drive line Brake system Wheels Tip- and steering cyl.

Cab ventilation

7. Automatic central lubr.

Change oil ...................................................................... 153 Clean centrifugal cleaner ............................................... 154 Replace oil filter .............................................................. 157 External cleaning of the radiator .................................... 158 Check batteries ............................................................... 159 Check battery terminals .................................................. 159 Check oil levels .............................................................. 160 Check linings .................................................................. 162 Check wheel nuts torque ................................................ 164 Check expander bolts .................................................... 164 Test of air conditioner ..................................................... 165 Check cab ventilation filter ............................................. 166 Check the system ........................................................... 167

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

135

7. Maintenance

Maintenance table 1000 Hours Service 1. Driver's seat 2. Engine

3. Transmission

4. Hydraulic system 5.

6.

7.

8.

9.

Front differential Rear differential Pinion bearing Front reduction gears Electrical system

Safety check ................................................................... 169 Replace fuel filter ............................................................ 169 Bleed the fuel system ..................................................... 170 Check batteries ............................................................... 170 Check multi-groove belt ................................................. 171 Clean/replace air filter .................................................... 172 Change oil ...................................................................... 174 Replace filter elements ................................................... 174 Clean strainer ................................................................. 175 Run the AEB-Tester ........................................................ 176 Replace breather element ............................................. 178 Replace hydr. return filter ............................................... 179 Change oil ...................................................................... 180 Change oil ...................................................................... 181 Inspect the bearing ......................................................... 181 Change oil ...................................................................... 182 Check wiring ................................................................... 182

2000 Hours Service 1. Engine

2. Hydraulic system 3. Brake system 4. Tandem housings

Check fuel injectors ........................................................ 183 Check/adj. valve clearance ............................................ 183 Check coolant ................................................................. 184 Replace air dryer ............................................................ 187 Change oil ...................................................................... 188 Inspect brake lines ......................................................... 188 Change brake fluid ......................................................... 189 Change oil ...................................................................... 190

4000 Hours Service 1. Cooling system

Internal cleaning ............................................................. 191 Changing coolant ........................................................... 192

Yearly recommended maintenance 1.

2.

3.

4.

5.

6.

Transmission Drive line Tanks Hydraulic system Exhaust system Bearings

General condition check ................................................ 193 General condition check ................................................ 193 General condition check ................................................ 193 Inspect the hydr. hoses ................................................... 194 Safety check ................................................................... 194 Check clearance ............................................................ 194

* Numbers refer to positions on the lubrication schedule, chapter 6 136

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

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.

Breather, front differential Breather, front differential

The breather for the front differential is located under the cab, on the right hand side of the transmission.

CAUTION Do not fill any oil or other fluid into the breather reservoir!

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

137

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

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 crankcase 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. A small amount of leakage from the overflow holes during the engine's running-in period is normal. (Seals and O-rings are lubricated with soap or oil when fitted).

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* • If the engine has been running: Let the engine remain stationary for at least 1 minute before checking the oil level.

2

• The dipstick (1) is found on the left hand side of the engine.

• The correct level shall be between upper and lower mark on the dip stick (1) (dump truck on level ground).

• Fill up with oil (2) if level has dropped to the lower mark.

See oil specification sheet, chapter 6 for correct oil type.

• Check level correctness.

1

* Numbers refer to positions on the lubrication schedule, chapter 6 138

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

2.3. Check coolant level, before start 5* • The level in the expansion tank shall be between minimum and maximum when the dump truck is on level ground. See marks.

Refill with coolant of correct mixture if level is lower than minimum.

• 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 and steam can spurt out!

Never add large amounts of cold coolant when engine is hot. The temperature difference can cause cracks in the engine.

Always top up with pre-mixed coolant.

2.4. Check fuel level, before start 13*

1

1. Turn on the starter switch key (to pos. 1) and check on the fuel gauge that there is enough fuel (1).

2. Fill up with fuel if necessary (2).

NOTE Always make sure that there is enough fuel in the tank.

NEVER run out of fuel.

2

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

139

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

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 hot.

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* • Two air tanks are located on the fire wall under the bonnet.

• From serial no 710353 - an additional air tank is located inside the fender, right hand side.

• Pull the drain chain on the underside of the tanks sideways to release the air pressure.

• If condensation is present in the escaping air, release system pressure completely and replace the air dryer, see 2000 hours service.

From serial no 710353 - an additional air tank is located inside the fender, right hand side.

* Numbers refer to positions on the lubrication schedule, chapter 6 140

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

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, right hand side) 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 °C: Hot oil, 80 °C:

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 Use gloves when checking the oil level or filling oil. The exhaust pipes and nearby area may be hot and fingers and hands could be burnt.

Do not overfill with oil! Both too high and too low level can cause serious internal damage!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

141

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

4. Hydraulic system 4.1. Check oil level, before start 40* 1. Read the oil level in the oil level gauges (located on the back of the hydraulic tank).

• The upper gauge shows max. level at warm oil • The lower gauge shows min. level at cold oil.

2. Fill up with oil (see oil specification sheet, chapter 6) if necessary.

Oil filler located on the top of the hydraulic filter.

NOTE The dump truck must be horizontal and dump body completely lowered!

* Numbers refer to positions on the lubrication schedule, chapter 6 142

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

5. Brake system 5.1. Check brake fluid levels, before start 60* Two reservoirs on the fire wall under the bonnet.

• The reservoirs shall be min. 2/3 filled (see marks).

Fill up with correct brake fluid, if necessary.

• If the reservoirs have to be filled up with brake fluid often (i.e. montly), check the brake system for leaks and/ or worn brake linings. Replace brake linings if necessary.

• If the brake fluid level drops to minimum, the brake fluid warning light will illuminate. Check the brake linings and replace them if necessary (see 500 hours service).

Fill up the brake fluid reservoirs with correct brake fluid.

CAUTION • •

When refilling, do not overfill!

Use only brake fluid as specified in the specification sheet, chapter 6!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

143

7. Maintenance

8 Hours / Daily Service To be performed every 8 hourr of operation or daily.

6. Lubrication Grease lubrication points until pure grease is forced out of the components. Wipe off.

6.1. Articulation turning ring, 1 lubricator 50* Lubricator located on the distribution block behind the hydraulic tank (left hand side).

• By Manual lubrication: 6 pump strokes (1 stroke = 1-1 1/2 cm3)

6.2. Suspension legs, 2 lubricators 59* The lubricators are located on the distribution block behind the hydraulic tank (left hand side).

• By Manual lubrication: 1 pump stroke (1 stroke = 1-1 1/2 cm3)

6.3.

Articulation bearings, 2 lubricators 53* Lubricators are located on the distribution block besides the steering cylinder on left hand side.

59 59

54

50

54

• By Manual lubrication: 3 pump strokes (1 stroke = 1-1 1/2 cm3)

54 54

6.4.

Steering cylinder bearings, 4 lubricators 54* Lubricators are located on the distribution block besides the steering cylinder on left hand side.

55 53

• By Manual lubrication: 2 pump strokes (1 stroke = 1-1 1/2 cm3)

53 55

Check the complete length of cylinder rods for scratches and other damage.

6.5.

Tip cylinder bearings, 4 lubricators 55* Lubricatos for the lower tip cylinder bearings are located on the distribution block besides the steering cylinder on left hand side.

• By Manual lubrication: 2 pump strokes (1 stroke = 1-1 1/2 cm3)

Upper tip cylinder bearings

Lubricators for the upper tip cylinder bearings are located on the upper end of the tip cylinder.

• By Manual lubrication: 2 pump strokes (1 stroke = 1-1 1/2 cm3) Raise the body to check all cylinder pistons for scratches and other damage.

* Numbers refer to positions on the lubrication schedule, chapter 6 144

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hourr of operation or daily.

6.6. Tailgate arm hinge (optional), 2 lubricators 56* One lubricator on the inner side of each tailgate arm hinge.

• By Manual lubrication: 1 pump stroke (1 stroke = 1-1 1/2 cm3)

6.7. Tip hinges, 2 lubricators 51* One lubricator located on each tip hinge.

• By Manual lubrication: 2 pump strokes (1 stroke = 1-1 1/2 cm3)

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

145

7. Maintenance

8 Hours / Daily Service To be performed every 8 hourr of operation or daily.

6.8. Tandem bearings, 2 lubricators 52* Lubricators located on the distribution block between the tip hinges (on the rear frame).

• By Manual lubrication: 6 pump strokes (1 stroke = 1-1 1/2 cm3)

52

6.9. Door and fender hatches, 8 lubricators 57* There are 2 lubricators on the door, 2 lubricators on right hand side fender, 2 lubricators on left hand side fender and 2 lubricators on the cover upon the hydraulic tank (one per hinge) These lubricators must be manually greased, even if the automatic central lubrication is fitted.

* Numbers refer to positions on the lubrication schedule, chapter 6 146

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

6.10. Cab rear hinges, 2 lubricator 58 * There is one lubricator on each side of the cab.

These lubricators must be manually greased, even if the automatic central lubrication is fitted.

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 (i.e. no warning lights on).

2. Set the gear selector in 1st gear.

3. Increase the engine speed slowly.

4. The parking brake must be able to keep the dump truck stationary at engine speeds up to 1400 rpm. If not, check parking brake system and contact your Moxy Dealer.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

147

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

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 (i.e. no warning lights on).

2. Depress the brake pedal.

3. Release the parking brake.

4. Set the gear selector in 1st gear.

5. Increase the engine speed slowly.

6. The service brake must be able to keep the dump truck stationary at engine speed up to 1100 rpm. If not, check the brake system and contact your Moxy Dealer.

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 (i.e. no warning lights on).

2. Stop the engine.

3. Depress brake pedal firmly and listen for leaks in the air system.

4. Also check that the brake fluid warning light and the brake system warning light (chapter 3) does not illuminate.

5. Check for brake fluid leakage at master cylinders, pipes and hoses.

6. Start the engine and release the parking brake.

7. Drive the dump truck slowly on firm, level ground and depress the brake pedal firmly.

8. Check that the braking effect is good and equal.

9. Steering 9.1. 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 6 148

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

10. Engine 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 the engine brake by releasing 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).

11. Engine and retarder brake 11.1. Check function, before operation 1. Drive the dump truck forwards at approx 10-15 km/h with lock-up engaged.

2. Apply the retarder brake by depressing the retarder brake switch and release the throttle pedal. The engine brake will also then apply.

3. Check that the exhaust sound changes.

4. Check the indicator lights for function, both engine and retarder brake and note the braking power.

5. Depress the throttle pedal again and notify that both the engine and retarder brake goes off (i.e no braking power and the indicator lights switches off).

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

149

7. Maintenance

* Numbers refer to positions on the lubrication schedule, chapter 6 150

Operating & Maintenance Manual

7. Maintenance

40 Hours / Weekly Service To be performed every 40 hours of operation or weekly.

1. Cab ventilation 1.1. Clean prefilter 70* 1. Open 2 clamps and remove the cover (1).

2. Remove the prefilter (2), and clean it with compressed air.

• Replace if necessary 3. Reassamble the opposite way.

2 1

4. Adjust the check interval if another requirement is experienced.

NOTE Never start driving without prefilter. The heater could in worsc case get damaged.

1.2. 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.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

151

7. Maintenance

40 Hours / Weekly Service To be performed every 40 hours of operation or weekly.

2. Tyres 2.1. 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.

3. Automatic central lubrication Located under the cover

3.1. Check the grease level in the reservoir.

Refill the reservoir if the level has dropped to a minimum The reservoir must also 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. Use only grease as specified in chapter 6, lubricants.

5. Remove the filler hose and fit the dust cap.

Filler coupling

NOTE •

Do NOT use grease which contains graphite, teflon or molybdenum

•

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 door, fender hatches and the cab rear hinges.

4. Continue with all items in 8 Hours / Daily Service. * Numbers refer to positions on the lubrication schedule, chapter 6 152

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours 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.

1. Remove the cap on the drain plug, install the draining hose (tool kit) and drain the oil when the engine is hot.

Access through the drain hole in engine bottom guard (1).

1

2. When all oil is drained, remove the draining hose and reinstall the cap.

4. Reinstall the cover for drain hole in engine bottom guard.

5. Fill oil through filler (2). Do not overfill!

6. Check oil level on dip stick (3).

CAUTION The oil may be hot! Wear protective gloves and eye protection.

3

2

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

153

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1.2. Clean centrifugal cleaner 2* (at the same time as oil change, item 1.1)

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.

* Numbers refer to positions on the lubrication schedule, chapter 6 154

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

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.

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.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

155

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

9. Place the O-ring in position in the rotor cover.

• The O-ring must not be damaged.

Change if necessary.

10. Assemble the rotor.

11. Tighten rotor nut firmly by hand.

12. Reinstall the rotor.

• Check that it rotates easily.

* Numbers refer to positions on the lubrication schedule, chapter 6 156

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

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.

1.3. Replace oil filter 3* (at the same time as oil change, item 1.1) 1. The filter is located on the right hand side of the engine.

2. Remove the old filter and discard it according to enviromental requirements.

3. Oil the rubber gasket on the new genuine filter.

4. Fit the new genuine filter.

5. Tighten the filter by hand as tight as possible.

6. Start the engine and check for leaks.

If the deposits in the centrifugal cleaner exceed 20 mm, the oil 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!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

157

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1.4. External cleaning of the radiator, at least once a year 5* If necessary, the cooling system should be cleaned more often.

1. Clean externally the radiator fins and hoses by using a brush.

The radiator can also be washed with water from the backside.

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.

* Numbers refer to positions on the lubrication schedule, chapter 6 158

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1.5. Check batteries 11* 10 - 15 mm

• Checking of batteries shall also be carried out after the first 8 hours of operation.

1. Open left hand side fender cover (open the bonnet first and then the fender cover) 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.

NOTE Only distilled or chemically cleaned water must be used.

1.6. Check battery terminals for tightness and corrosion Clean if necessary, apply acid-free vaseline on the terminals and retighten the clamps.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

159

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

2. Drive line 2.1. 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 to unscrew the upper filling/ level plug.

• Plug torque: 80 Nm

2. Rear differential 31* Use a hexagonal key to unscrew the filling/level plug at the rear of housing.

• Plug torque: 80 Nm.

* Numbers refer to positions on the lubrication schedule, chapter 6 160

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

3. Tandem housings 32* Use a hexagonal key to unscrew the level plugs on the inside of the housings.

• Plug torque: 80 Nm.

4. Front reduction gears 33* Turn the hubs until level indicator is horizontal. Use a hexagonal key to unscrew the plugs.

• Plug torque: 80 Nm.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

161

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

Service brake

3. Brake system 3.1. 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 applications.

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 (also see 8 hours/daily service).

• 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.

Remove the protection on the top of the parking brake and check thickness of linings. Change when approaching limit.

• In connection with replacement perform adjustment, see next page.

Parking brake

Standard lining thickness: Service brakes: Parking brake:

22.0 mm 20.0 mm

Min. thickness:

3.5 mm.

5.1 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 6 162

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

3.2. How to adjust the parking brake.

To be performed in connection with replacement of parking brake linings.

• Before removing the parking brake linings, do as follows:

1

1. Apply the parking brake.

2. Lift the body.

3. Apply the body support (1) (see also safety instructions, chapter 2).

4. Stop the engine.

Washer-adjuster plug

5. Secure the dump truck with wheel chocks (see also safety instructions, chapter 2) 6. Release the parking brake by the parking brake lever.

Adjuster plug Bolt for manual release

Allen wrench

7. Manually release the parking brake as described in item 13 in chapter 5 (This must be done for safety reason i.e if the air pressure should be lost during the replacement of the linings).

8. Remove the adjuster plug and washer from the chamber bracket.

9. Use a 6 mm allen wrench to de-adjust the brake (turning the allen wrench in counter clockwise direction). Stop turning the allen wrench when you feel resistance, which indicates that the adjuster pistons are fully retracted.

• When you de-adjust the brake (increase disc clearance) you will hear a "clicking" sound and feel a "pulsing" sensation during the adjsutment.

• To ensure that the automatic adjustment will occur: Adjust the brake an additional 1/4 turn after you reach the resistance point.

• Do not use an air gun to adjust or de-adjust the parking brake! Components could be damaged.

10. The parking brake linings can now be replaced.

• After installation of new parking brake linings, do as follows: 1. Adjust the caliper by reducing the caliper-to-disc clearance to ZERO (turning the allen wrench in clockwise direction).

2. Check that the load plate fully contacts the lining backing plate.

3. To increase the disc clearance, turn the allen wrench SEVEN CLICKS in counter clockwise direction, which sets the initial clearance.

4. Install the adjuster plug and washer.

• Tightening torque: 11-17 Nm 5. Remove the bolt for manually releasing of the parking brake. Install this bolt, nut and washer on its storage position under the air cylinder.

6. Apply and release the parking brake 15-20 times to allow the adjuster to set the final caliper clearance.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

163

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

4. Wheels 4.1

Check wheel nuts torque.

Torque setting 450 Nm.

5. Tip- and steering cylinders 5.1

Check expander bolts.

• Checking of the expander bolts torque setting shall also be carried out after the first 100 hours of operation.

Torque setting: • Tip cylinder bolt: • Steering cylinder bolt:

250 Nm 380 Nm

• The torque must be checked on on both sides of the bolts.

• Be aware of the lubrication nipples on the bolts when checking the torque.

* Numbers refer to positions on the lubrication schedule, chapter 6 164

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

6. Cab ventilation 6.1. Air conditioner system, test operation 1. Start the engine.

2

2. Press down the air conditioner switch, set the fan switch to position 3 (see also chapter 3) and open all nozzles.

1

3. Check that the temperature in the cab decreases.

• If the temperature does not decrease: • Check whether the fuse is burnt out, if yes, replace the fuse.

• If the fuse is not burnt out, 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.

•

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 yearly and refill refrigerant, if necessary.

•

See also chapter 2, Safety Instructions * Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

165

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

6.2. Check cab ventilation filter element condition 70* 1. Remove the rear panel on the right hand side inside the cab (behind the driver's seat).

2. Open the cover (1) with a screw driver.

3. There is two filter elements (2).

4. Check if the filter elements are clogged or damaged.

• Replace if necessary.

5. Reassamble the opposite way.

1

6. Adjust the check interval if another requirement is experienced.

2

* Numbers refer to positions on the lubrication schedule, chapter 6 166

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

Located under the cover

7. Automatic central lubrication 7.1. 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.

8. Continue with all items in 40 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

1000 Hours Service Maintenance to be performed every 1000 hours 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 fuel filter 4* The filter consist of one filter unit.

It is located on the left hand side of the engine (on the rear end).

1. Wash the filter externally and unscrew it.

Discard the filter according to environmental requirements.

2. Fit the new genuine filter and tighten it by hand.

• Never use tools to tighten the filter! The filter may be damaged and the fuel flow hampered.

3. Bleed the fuel system, procedure on next page, item 2.2.

4. Start engine and check for leaks.

CAUTION Observe extreme cleanliness when working with the fuel system. Otherwise may operational interruption easily occur and the injection equipment may be damaged.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

169

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.2 1

Bleed the 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 bleed 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.

2

3

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. Check batteries, at least once a year 11*

• Checking battery charge shall also be carried out after the first 8 hours of operation.

Use a hydrometer to check the density of the electrolyte. The density of a fully charged battery should be: 1.240 at higher than +20 oC 1.280 at +20 oC, 1.294 at 0 oC, 1.308 at -20 oC. Recharge the battery if the density is lower than 1.20.

A discharged battery freezes at -5 oC.

WARNING The electrolyte level must be correct when charging!

During recharge a explosive gas is emitted. Open cell plugs and ventilate properly to avoid explosion!

* Numbers refer to positions on the lubrication schedule, chapter 6 170

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.4. Check multi-groove belt condition, at least once a year

• Checking of multi-groove belt condition shall also be carried out after the first 8 and 100 hours of operation.

2 • Stop the engine to inspect the multi-groove belt (1), see item 2.4.1 for procedure.

• Change the belt (1) if damaged or worn, see figures 1-3 below.

1

• Check that the automatic belt tensioner (2) is in proper working order and keeps the multi-groove belt sufficiantly tightened.

2.4.1

Inspect the multi-groove belt.

• Loosen the multi-groove belt from the belt pulleys but leave it around the fan shaft so that the direction of rotation for the multi-groove belt is not changed.

• Check the multi-groove belt carefully. If the multi-groove belt has one or more cracks, as shown in fig. 1, it should be replaced.

• Also check the wear on the multi-groove belt as shown in fig. 2 and 3.

NOTE Small superficial cracks in the belt can be accepted

Do not change the direction of rotation of the multi-groove belt if it is refitted.

Fig. 2 The multi-groove belt shows signs of wear.

Can be refitted.

Fig. 1 At large and deep cracks or if small pieces are missing, the belt should be replaced.

Fig. 3 The wear is down to the chord. The multi-groove belt must be replaced.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

171

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.5. Air filter 10* The air filter is located on the top of the engine, under the bonnet.

• Always stop the engine before servicing the air filter.

• Open the bonnet and apply the bonnet catcher.

• Cleaning and replacement of outer and inner element, see this page and next page.

Outer element: Clean element every 1000 hours of operation or if the air filter warning light illuminates at full load on the engine.

• Replace the outer element after 5 times of cleaning, or at the latest after 2 years.

Dust cap

Fig. 1

Fig. 2

1. Loosen all clamps and remove the cover (fig. 1).

2. Remove outer element with a light turning movement (fig. 2).

Do not remove inner element when cleaning outer element!

3. To blow out the filter element, use tube with a bent end which is attached to a compressed air gun; the end of the tube must be bent by approx. 90°. It must be of sufficient length to reach down to the bottom of the filter element.

Blow out the filter element using dry compressed air (max. 5 bar) by moving the tube up and down inside the filter element until there is no more dust coming out (fig. 3).

• Never wash out or brush out the outer element. When blowing out make sure that no dust is allowed to enter the inside area of the outer element.

4. Punch a mark in the edge of the inner element each time the outer element is cleaned.

5. Check the cleaned element for damage of the paper element and of the rubber seals.

• Cracks and holes in the paper element can be discovered by shining through light from an electric bulb (fig. 4).

Fig. 3

6. Never carry on using a damaged outer element. In case of doubt, always fit a new outer element.

7. Reinstall the outer element, the cover, and fasten all the clamps. Turn the cover so that the dust cap is pointed downwards (max angle: 15°).

See also precautions on next page

Fig. 4

* Numbers refer to positions on the lubrication schedule, chapter 6 172

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Servicing the dust cap The dust cap require very little maintenance.

Possible dust packs to be removed by squeezing the cap (fig. 5).

Fig. 5

Inner element: • Replace element every 5th cleaning of the outer element, or at the latest after 2 year.

• Do not clean the inner element and do not reuse it after it has been taken out. Only open the seal in order to replace the inner element.

1. Loosen all clamps and remove the cover.

2. Remove outer element.

Fig. 6

3. Remove the inner element; Use a suitable tool (e.g. screw driver) to push through the seal of the inner element from the inside to the outside and pull both the straps upwards (fig. 6).

4. Use both straps to take hold of the inner element and then pull out with a light turning movement (fig. 7).

5. Install a new inner element into the housing.

6. Install a new or cleaned outer element.

7. Reinstall the cover, and fasten all the clamps.

Turn the cover so that the dust cap is pointed downwards (max angle: 15°).

Fig. 7

CAUTION • • •

• • • •

Do not attempt to reinstall a cleaned inner element.

Do not clean or replace the elements when the engine is running.

Replace the outer element if small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning.

Do not use an element in which folds, gasket or seal are damaged.

When cleaning the element, do not hit or hammer it.

Do not dismantle the inner element unnecessarily.

Punch a mark in the edge of the inner element each time the outer element is cleaned.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

173

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

3. Transmission 3.1. Change oil 20* Replace filter element 21* Clean strainer 22* , at least once a year

• 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 (located behind the cab).

4. Access to the drain plug through transmission bottom guard (rear cover).

5. Unscrew drain plug, at the bottom of the transmission and drain the oil into a suitable container.

6. Clean the drain plug with magnetic insert, replace seal if necessary and reinstall the plug.

• Tightening torque: 80 Nm.

Rear cover

CAUTION Use gloves when checking the oil level or filling oil. The exhaust pipes and nearby area may be hot and fingers and hands could be burnt.

Drain plug

Replace filter elements (located in the engine compartment, left hand side, at the rear end of the engine): 7. Clean well around the filters.

8. Place a suitable container beneath the filters to catch spillage.

9. Unscrew the filter elements.

10. Check for wear particles in the oil.

11. Apply oil to the seals on the new elements.

12. Screw the filter elements in until contact with the sealing surface is obtained. Tighten the elements firmly by hand.

continued overleaf

* Numbers refer to positions on the lubrication schedule, chapter 6 174

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Clean stranier: Access to remove the strainer

13. The strainer is located on the left hand side of the drain plug.

14. Unscrew the three nuts (1) and washers (2).

15. Remove the cover (3).

16. Replace the O-ring on the cover, if necessary.

17. Remove the strainer (4) and clean it.

Rear cover

18. Reassemble and torque nuts to 23 Nm. 1

2

3

4

Fill new oil: 19. Fill new oil, according to the transmission oil list and oil specification sheet (chapter 6), through the dip stick tube.

20. Insert the dip stick again and turn handle clockwise to tighten the sealing.

Check: 21. Start the engine and check oil level (see daily maintenance, for procedure) at low idle. Both too low and too high level can cause serious internal damage!

22. Warm up the oil and check for leaks. Recheck level and adjust if necessary.

NOTE • •

Do not overfill! Both too high and too low level can cause serious internal damage!

For rough operation conditions the oil 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 Operating & Maintenance Manual

175

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

3.2. Run the AEB-Tester AEB = Automatic Filling Parameter Adjustment

The AEB-Tester should also be run after the first 100 and first 500 hours of operation.

To optimize the transmission, run the AEB-Tester.

1. Remove the cover on the backwall (remove the instructor's seat back rest, if that is fitted).

2. Follow the procedure described in the table on next page.

The gear display will show the AEB's actions. ("Display message" in the table on the next page).

TCU = Transmission Control Unit

* Numbers refer to positions on the lubrication schedule, chapter 6 176

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Run the AEB-Tester continued..............

Moxy part no.

8453

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 O

70 - 80 C

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 rpm

"PL" if starts condidtions are OK

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" ……

(Information about the AEB state)

TCU has started the AEB and goes to adjusting K1, K2, …, KR. (Button may be released).

the AEB has started

9 Wait until AEB is finished 10 Turn OFF the starter switch and

TCU must recognize "PL" for at least 2 sec. before you can press the button.

"OK" (AEB has been successful) -

unplug the AEB-Tester

11 Remount the cover on the

-

backwall

• • •

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 Operating & Maintenance Manual

177

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

4. Hydraulic system 4.1. Replace breather element 42* • Unscrew the old element on the hydraulic tank (under the cover).

• Check the o-ring for deterioration, apply oil and screw on a new element.

CAUTION 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 6 178

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

4.2. Replace hydraulic return filter element 43*.

•

Replacement of hydraulic return filter element shall also be carried out after the first 100 hours of operation.

1. The filter is located on the back of the hydraulic tank.

Remove the cover to get into the filter.

2. Clean well around the filter housing.

3. Place a suitable container beneath the draining hose to catch spillage.

4. Use a filter key to unscrew the old filter (counterclockwise). Remove also the old O-ring.

The old filter contains 4 litres oil. Discard the filter element, and oil according to environmental requirements.

5. Check for wear particles in the oil.

6. Clean the O-ring groove, apply oil to the new O-ring and install it.

7. Apply oil or grease to the threads and install a new filter element by turning it clockwise until seals make contact.

Then tighten by hand 1/4 to 1/3 turn more.

8. Fill 4 litres hydraulic oil, as specified in chapter 6, lubricants, through the oil filler on the top of the filter unit (under the cover on the top of the hydraulic tank).

9. Screw the oil plug back into place and clean off any oil spill.

10. Start engine and check for leaks.

CAUTION Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

Fill 4 litres hydraulic oil throguh the oil filler.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

179

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours 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. Access to the drain plug through transmission bottom guard.

2. Open level / filling plug (1), special spanner in tool kit.

3. Unscrew drain plug (2).

4. Drain the oil into a suitable container.

5. Clean the drain plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 6. Fill new oil, according to the oil specification sheet (chapter 6), through the level / filling plug, level shall be at lower edge of hole when dump truck is horizontal.

1

7. Clean the 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.

2

* Numbers refer to positions on the lubrication schedule, chapter 6 180

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

6. Rear differential 6.1. Change oil, at least once a year 31*

• Change rear diff. oil shall also be carried out after the first 500 hours of operation.

1. Open level/filling plug (1).

2. Unscrew drain plug (2) underneath the housing.

3. Drain the oil into a suitable container.

4. Clean the drain plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 5. Fill new oil, according to the oil specification sheet (chapter 6), through the level/filling plug, level shall be at lower edge of hole when dump truck is horizontal.

1

6. Clean the plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

CAUTION

2

Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening the drain plug.

Inspection cover

7. Pinion bearing 7.1. Inspect the pinion bearing, on both sides of the tandem housings 1. Remove the inspection cover.

2. Check the general condition of the pinion bearing.

Check for wear, cracks, deterioration, damages .

• Replace the bearing if necessary.

3. Reinstall the inspection cover.

NOTE For rough operating conditions, the pinion bearing should be checked more often.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

181

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

8. Front reduction gears 8.1. 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 (1).

4. Drain the oil into a suitable container.

5. Turn the hub 90o, so that the level indicator is horizontal (2).

6. Fill new oil, according to the oil specification sheet (chapter 6), through level/filling plug, level shall be at lower edge of hole when dump truck is horizontal.

7. Clean plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

2

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.

9. Electrical system 9.1. 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.

10. Continue with all items in 500 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 182

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours 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.

• The air filter and air filter bracket has to be removed before adjustment takes place.

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 TDC position No. 6 cylinder

TDC position No. 1 cylinder

Rocker cover gaskets must be changed if necessary.

• Tightening torque: 25 Nm 1. Set no. 1 cylinder to TDC (Top Dead Centre) by turning the engine in its direction of rotation until both valves are closed.

2. Adjust the following valves: Cylinder

1 2 3 4 5

Inlet and exhaust Inlet Exhaust Inlet Exhaust

3. Set no. 6 cylinder to TDC (Top Dead Centre) by turning the engine one revolution in its direction of rotation.

4. Adjust the following valves: Cylinder FLYWHEEL Intake valve Exhaust valve

2 3 4 5 6

Exhaust Inlet Exhaust Inlet Inlet and exhaust

WARNING The readings can only be taken from underneath

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

183

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours 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 (11 litres by total volume) • max. 60% glycol by volume (21.5 litres by total volume) If there is no danger for freezing: • 10% anti-corrosive by volume (3.6 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 6 184

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

Freezing O

point ( C)

Antifreeze

- 16

30 % 11 L

- 22

35 % 12.5 L

- 27

40 % 14.5 L

- 36

45 % 16 L

- 46

50 % 18 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 30% glycol by volume (11 litres by total volume) to offer sufficient protection against corrosion.

• 30% glycol by volume (11 litres by total volume) provides anti-freeze protection down to -16 °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: 36 litres

We recommend only nitrite-free anti-freeze glycols with the following supplier designation: • BASF Glysantin G48

• Always fill up the anti-freeze if the glycol content drops below 30% by volume (11 litres by total volume). A glycol content above 60% by volume (21.5 litres by total 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 nor 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

185

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours 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 (3.6 litres by total volume).

• Fill with Anti-corrosive as indicated on the packaging.

• Filling up with 1% by volume (0.4 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 6 186

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

1.4. Replace air dryer, at least once a year 12* 1. Release air pressure in dryer through air draining point.

2. The air dryer is to be found on left hand side fender (together with the batteries) 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

187

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

2. Hydraulic system 2.1. Change oil 40* 1. The drain plugs both for the main reservoir and the emergency steering reservoir are to be found on the right hand side of the hydraulic tank (on the bottom).

Remove the cover to get into the drain plugs.

2. Place a suitable container to catch spillage.

3. Remove the cap from both drain plugs.

4. Install the draining hose with nipple to the first drain plug and drain the oil into the container.

5. Install the draining hose to the second drain plug and drain the oil into the container.

6. Remove the draining hose and reinstall both caps.

7. The oil filler is located on the top of the hydraulic filter unit under the cover on the top of the hydraulic tank.

8. Fill new oil through the oil filler, according to the oil specification sheet, chapter 6.

Oil filler

Drain plug

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 6 188

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

3.2. Change brake fluid, at least once a year 60* 1. Apply the parking brake and stop the engine.

2. Put wheel chocks under the wheel to avoid spontaneous rolling.

3. Drain the old fluid from all circuits, pipes included.

4. Refill with new brake fluid acc. to Oil Specification Sheet (chapter 6).

5. 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.

Brake fluid reservoirs

c. Refill brake fluid during the bleeding process.

Brake fluid reservoirs

d. Bleed until brake fluid appears to be free of air. e. Bleeder torque: 2,9 Nm.

• Master cylinder

Alternatively, other suitable equipment for bleeding the brake circuits can be used.

6. Fill up to correct reservoir level, see filling capacities (chapter 6).

Master cylinder

7. Perform brake function test and check for leakage.

WARNING • • •

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.

Bleeder plugs ( • )

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

189

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

4. Tandem housings 4.1. 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.

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.

6. Clean 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.

2

1

CAUTION Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

5. Continue with all items in 1000 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 190

Operating & Maintenance Manual

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation.

1. Cooling system 1.1

Internal cleaning, at least every 4th year 5* Removing deposits, oil and grease

For internal cleaning use liquid dishwasher detergent designed for household use. Alternative BASF Glycacorr G93 or Texaco Havoline XLI can be used.

Important: The cleaning agent must not foam.

1. If possible, run the engine until it is warm and then drain the cooling system, see changing coolant, item 1.2 2. Remove the thermostat housing (1) and replace it with a hose. Plug the by-pass.

3. Fill the system with clean, hot water mixed with liquid dishwasher designed for household use.

Concentration 1% (0.1 L by 10 L water).

Alternative BASF Glycacorr G93 or Texaco Havoline XL can be used.

1

4. Run the engine for about 20-30 minutes.

NOTE! Do not forget the cab heater system.

5. Drain the cooling system.

6. Fill the system again with hot water and run the engine for about 20 -30 minutes.

7. Drain the water from the cooling system.

8. Refit the thermostat housing and the connections.

9. Fill the system with coolant as described in the specifications in item 1.3 at 2000 hours service.

WARNING Handling cleaning agents for the cooling system: Read the warning label on the container

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

191

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation.

1.2

Change coolant, at least every 4th year 5* 1. Remove the filler cap from the expansion tank.

2. Drain the coolant in two places: • the "lowest point" on the engine block, see ill.

• the "lowest point" of the cooling system (1), under the oil cooler on left hand side. Access through the engine bottom guard.

3. Close the cocks.

4. Fill with correct mixture, pre-mixed coolant through the expansion tank filler hole (2). See item 1.3 at 2000 hours service.

2 1

2. Continue with all items in 2000 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 192

Operating & Maintenance Manual

7. Maintenance

Yearly recommended maintenance Maintenance recommended to be performed yearly.

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

193

7. Maintenance

Yearly recommended maintenance Maintenance recommended to be performed yearly.

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 6 194

Operating & Maintenance Manual

8. Technical Data

Technical Data

Operating & Maintenance Manual

195

8. Technical Data

Contents

8. Technical data .......................................................... 195 - 208 Measurements ........................................................... 197 Engine ........................................................................ 198 Transmission ............................................................. 198 Hydraulic system ....................................................... 199 Tyre pressures ........................................................... 199 Electrical system ........................................................ 200 Metering conversion table ......................................... 201 Tool kit content ........................................................... 201 Performance chart ..................................................... 202 Engine and retarder brake chart ............................... 204 Torque limit tables ..................................................... 205 Reference information (fill in table) .......................... 205 Consumable parts ..................................................... 205 Product signs ............................................................. 206 Periodic service (fill in table) ..................................... 207

196

Operating & Maintenance Manual

8. Technical Data

Measurements Machine dimensions (mm): ..................................... MT25

MT26

MT31

Total length ................................................................ 9488 Total width w/ standard tyres .................................... 2545 (20,5R25) Total width w/ optional tyres (750/65 R25) ............... Total height ................................................................ 3420 Total height, loaded .................................................. 3365 Overhang, front .......................................................... 2650 Overhang, rear ........................................................... 1028 Wheelbase ................................................................. 4040/1770 Body upper height (rear edge) .................................. 2745 Body floor height (rear edge) .................................... 1975 Total height, raised body ........................................... 5680 Total height, raised body incl. spillguard ................. 6075 Ground clearance, raised body ................................ 490 Min. ground clearance .............................................. 490 (front) Min. ground clearance, loaded ................................. 435 Turning radius (ISO 7457) ......................................... 7500 Body tipping angle ..................................................... 70° Steering angle, both sides ........................................ 45° Standard tyre dimension ........................................... 20.5R25 Tyre load/speed index ............................................... 177B (2-stars)

< 2750 (23,5R25) 2995 3530 3475 < 1029 4041/1768 2864 2100 5855 6250 610 565 (front) 510 7560 < < 23.5R25 185B (2-stars)

< 2990 (23,5R25) 3235 < < < < < 2946 < 5885 6280 < 571 516 7680 < < < <

22000 45500 23500

22650 50650 28000

10950 11050

11150 11500

11.4 (11.9*) 14.1 (14.8*)

13.6 (14.2*) 16.8 (17.8*)

Forward speeds 6 ..................................................... 6 - 8 - 13 - 20 - 30 - 46 Forward speeds 6 - MT25-30 km-version ................ 6 - 8 - 13 - 20 - 30 - 30 Reverse speed 3 ...................................................... 6 - 13 - 30

6 - 9 - 14 - 22 - 33 - 51 6 - 14 - 33

< <

Towing load on hooks (kN): Front ........................................................................... 100 (each) Rear ........................................................................... 200

< <

< <

Sound power level, dB(A): According to ISO 6395 (external) .............................. 111

<

<

Sound pressure level, dB(A): According to ISO 6394 (in cab) ................................. 74

<

<

Ambient operating temperature (°C): Min. (-) ........................................................................ 20 Max. (+) ....................................................................... 40

< <

< <

Machine weights (kg): Empty weight ............................................................. 20950* Gross weight .............................................................. 43550* Maximum payload ..................................................... 22600* Weight distribution (kg): Front axle, empty ....................................................... 10500* Rear axle, empty ........................................................ 10450* Body capacity (m³): Struck ......................................................................... 10.7 (11.1*) Heaped, SAE 2:1 ....................................................... 13.0 (13.7*) Machine speed (km/h):

The measurements are valid for a standard, unloaded machine if nothing else is given. *= with top tail gate fitted Operating & Maintenance Manual

197

8. Technical Data

Engine

1 kW = hp 1,36

Water cooled, 4-stroke, direct injected diesel engine with turbo charger and intercooler MT25

MT26

MT31

Type ........................................................................... Scania DC 9 EMS Cylinder volume ......................................................... 9.0 litres Bore x stroke .............................................................. 127 x 140 mm No. of cylinders .......................................................... 5 (in line) Power rating (ISO 3046) ............................................ 234 kW (318 hp) Power rating (ISO 9249) ............................................ 230 kW (313 hp) Engine speed, low idle .............................................. 700 rpm ± 50 Engine speed, high idle ............................................ 2430 rpm ± 50 Max. allowed engine speed ...................................... 2600 rpm

< < < < 228 kW (310 hp) 224 kW (305 hp) < < <

< < < < 243 kW (331 hp) 234 kW (324 hp) < < <

Oil capacity ................................................................ 33 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/kWh

< < < <

< < < <

Coolant volume ......................................................... 45 litres (approx.)

Normal temperature .................................................. 70-90 oC Thermostat ................................................................. 83 oC Max. system pressure ............................................... 0.5 bar

< < < <

< < < <

Compression ratio ..................................................... 18 : 1 Firing order ................................................................ 1-2-4-5-3 Engine rotation, seen from rear ................................ Counterclockwise Valve clearance (cold engine) .................................. 0.45 mm, inlet valves .............................................................................. 0.70 mm, exh. valves Pump timing (see rocker cover sign) ....................... 13o 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 6WG260 No. of forward gears .................................................. 6 No. of reverse gears .................................................. 3 Oil capacity ................................................................ 57 litres (approx.)

Normal temperature ................................................... 50-105 oC Max. permitted temp. when using retarder brake ...... 150 oC (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

198

Operating & Maintenance Manual

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 - MT25 ................................................ 101 litres (approx.)

Tank capacity - MT26 ................................................ 111 litres (approx.)

Tank capacity - MT31 ................................................ 123 litres (approx.)

Normal oil temperature ............................................. 40-90 oC (at tank) Filter ........................................................................... One return flow filter and high-pressure filter Main pump (double) .................................................. Gear pump, engine speed dependent Pump delivery ............................................................ 230 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 ..................................................... 280 Tipping circuit - down ................................................ 280 End stop for tip cylinders ........................................... 300 Steering circuit ........................................................... 210

bar bar bar (up), 80 bar (down) (shock valve) bar

Tipping cylinders ....................................................... single stage, double acting Tipping time ............................................................... 11 sec.

Steering cylinders ..................................................... 2 x double acting w/ 1 piston Steering wheel turns ................................................. Approx. 5

Tyre pressures Basic pressure for cold tyres (based on max. load and max. speed):

Type

Bridgestone VLT ** Michelin XADN/XADT Good Year GP2B/GP4B

MT25 (20,5R25) 30 km-version bar (psi) 4.0 (58) 3.5 (51) 3.5 (51)

Front MT25 (20,5R25) MT26 (23,5R25) MT31 (23,5R25) 50 km-version bar (psi) bar (psi) bar (psi) 5.0 (73) 4.0 (58) 4.5 (65) 4.5 (65) 3.5 (51) 3.75 (54) 4.5 (65) 3.5 (51) 3.75 (54)

MT25 (20,5R25) 30 km-version bar (psi) 4.0 (58) 3.5 (51) 3.5 (51)

Rear MT25 (20,5R25) MT26 (23,5R25) MT31 (23,5R25) 50 km-version bar (psi) bar (psi) bar (psi) 5.0 (73) 4.0 (58) 4.75 (69) 4.5 (65) 3.5 (51) 4.0 (58) 4.5 (65) 3.5 (51) 4.0 (58)

Regarding tyre pressure: Contact your Moxy Dealer or tyre supplier to get further information.

Operating & Maintenance Manual

199

8. Technical Data

Electrical system System voltage .......................................................... 24 V Battery ........................................................................ 2x 12 V, 140 Ah Grounding .................................................................. Negative earth cable Alternator ................................................................... 28 V, 100 A Starter motor .............................................................. 4.0 kW (5.4 hp) Fuses and relays: The fuses and relays are located behind the cover on the backwall.

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.

Relays: 98

98 B

2 28

252

2 53

254

• Directio n light • Direction light • P arking brake • Transmission • Supply wiper, • Hazard light alarm contro ller washer, horn

105

10 6

• High beam

• Reverse light

107

10 8

• Heated seat

87

• Wo rking light, • Wiper/washer • Engine rear contro ller

109

118

• P arking brake • P ark brake alarm alarm

85

• Heated mirro rs

119

99 • Charging activated

12 0

• Engine coo ler • Co ntrol, retarder

100

10 2

• Starter

121

104

• Working light • High beam

• Lo w beam

129

• P arking brake • B rake alarm

130 lights

Fuses: Fusebox A (Natural) 1/ 15A • Ignition

2 / 15A • Low beam

3 / 15A • High beam

4 / 15A • Supply, wiper

Fusebox B (Yellow) 5/ 15A

6 / 15A

• Flamestart • Direct ion light • Heater

1/ 10 A

2 / 10 A

• Engine cont roller

• Transm. cont roller

3 / 10 A • Reverse light • Reverse alarm

4 / 10 A • Heated mirrors • Heated seat

Fusebox C (Green) 5/ 10 A

• Parking light

6 / 10 A • Hazard light

Fusebox D (Black) 1/ 10 A

2 / 10 A

• Direction • Radio light • Swit ch • Inst r. light light

3 / 10 A • Cont rol light

4 / 10 A • Engine cooler

• Radio memory

2 / 10 A • Air dryer

3 / 10 A • Brake light

4 / 10 A • Lighter • Cab light

Fusebox E (Red) 5/ 10 A • Transm.

• Parking brake alarm

6 / 10 A • Parking brake alarm • Ret arder • Engine brake

1/ 10 A

2 / 10 A

3/20A

• Autom.

• Head light • Starter central lubricat ion • Flamestart

Bulbs: Light ........................................................................... Watts Socket Head lights (H3/H7) .................................................. 75/70 P 43t/38 Side lights in head light ............................................ 4 BA 9s Direction indicators ................................................... Diode light Stop lights .................................................................. Diode light Licence plate lights ................................................... 5 S 8,5 Work light ................................................................... 70 Pk 22s Reverse light .............................................................. 70 Pk 22s Rotating beacon (H1) ................................................ 70 P 14,5s Rear lights ................................................................. Diode light Cab light .................................................................... 10 BA 15s Instrument lights ....................................................... 2 Warning/indicator lights ............................................ 1.2 W2x4,6d Switch lights .............................................................. 1.2 W2x4,6d

200

1/ 10 A

Operating & Maintenance Manual

4 / 5A

5/ 5A

• Parking • Parking light, r.h.s. light l.h.s.

6 / 10 A -

5/ 10 A

6 / 10 A

• Ext ra • Working high beam light, rear • Working light, roof

8. Technical Data

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 kW

1.34 hp (British) 1.36 hk (Metric)

Torque:

10 Nm =

=

7.38 lbf ft (pound-force foot)

=

14.5 p.s.i.

= =

1.02 kpm 2

Pressure:

1 bar

=

1.02 kp/cm

Temperature:

o

= =

5/9 x (oF- 32) (9/5 x oC)+32

C F

o

Speed:

1 km/h =

=

100 kPa

0.62 mph

Tool kit content (standard)

Operation manual Driver instruction Parts catalogue

Arm, hydraulic pump (tiltable cab) - only High Line Safety support (tiltable cab) Draining hose

Tool kit content (optional) Hex. socket 12 mm Hex. bit front hub Diagonal wrench

Wheel-spanner Grease gun Arm, wheel-spanner

Operating & Maintenance Manual

201

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 performance: 1. Read from actual dump truck weight (A) up to the percentage gradient (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).

MT25 100 70 50 40 30

50%

20

40% 35% 30% 25% 20%

10

C

B

15%

B Grade

Rimpull (kp x 1000)

C

10% 5

5%

3% 2% 1

D Weight (kgx1000) A 10

0

20

30

A

40

50

60

Travel Speed (km/h) D

MT26 100 70 50 40 30

50%

20

40% 35% 30% 25% 20%

10

C

B

15% 10%

5

5%

3% 2% 1

D

A Weight (kgx1000) A

0

10

20

30

40

50

Travel Speed (km/h) D

202

Operating & Maintenance Manual

60

B Grade

Rimpull (kp x 1000)

C

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 downhill gradeability performance: 1. Read from actual dump truck weight (A) up to the percentage gradient (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).

MT31 100 70 50 40 30

50%

20

40% 35% 30% 25% 20%

10

C

B

15%

B Grade

Rimpull (kp x 1000)

C

10% 5

5%

3% 2% 1

D

A Weight (kgx1000) A

0

10

20

30

40

50

60

Travel Speed (km/h) D

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203

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 up to the percentage gradient (Rolling resistance is not included in the percentage grade).

2. From this point, read horizontally to the curve with highest speed range.

3. Then down to maximum speed.

MT25 30

50

25

20

35

30 15

25

Gradient (%)

Brake Brake capacity (kpx1000) capacity (kpx1000)'

40

20 10

15

10 5

5

0 0

10

20

30

40

50

speed (km/h), Weight (kgx1000) Travel Travel speed (km/h), Weight (kgx1000)

MT26 & MT31 30

50

25

40

35

30 15

25

20 10

15

10 5

5

0 0

10

20

Travel

204

30

40

Travel speed (km/h), Weight (kgx1000) speed (km/h), Weight (kgx1000)

Operating & Maintenance Manual

50

Gradient (%)

Brake capacity (kpx1000 Brake capacity (kpx1000)

20

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

UNF - Threads 10.9

12.9

Dim./Class

8.8

10.9

12.9

M8

24

33

40

M8 x 1

25

35

42

3/8" UNF

41

59

73

M10

47

65

79

M10 x 1.25

48

68

81

7/16" UNF

66

93

115

M12

81

114

136

M10 x 1

49

70

84

1/2" UNF

99

141

175

M14

128

181

217

M12 x 1.5

83

117

140

9/16" UNF

142

201

250

M16

197

277

333

M12 x 1.25

85

120

144

5/8" UNF

197

279

347

M18

275

386

463

M14 x 1.5

135

190

228

3/4" UNF

344

486

606

M20

385

541

649

M16 x 1.5

204

287

344

7/8" UNF

547

772

963

M22

518

728

874

M18 x 1.5

294

413

496

1" UNF

814

1150

1430

M24

665

935

1120

M20 x 1.5

408

574

688

1 1/8" UNF

1170

1660

2060

M27

961

1350

1620

M22 x 1.5

546

768

921

1 1/4" UNF

1620

2290

2850

M30

1310

1840

2210

M24 x 2

696

979

1170

1 3/8" UNF

2170

3070

3820

M33

1770

2480

2980

M27 x 2

1000

1410

1690

1 1/2" UNF

2840

4000

5000

M36

2280

3210

3850

M30 x 2

1390

1950

2340

M33 x 2 M36 x 3

1860 2350

2610 3310

3130 3970

Reference information Machine model:

Serial no.:

Prod. year:

In operation:

Engine s/no.:

Transm. s/no.:

Dealer:

Consumeable parts Part no.

Q'ty

Description

Operating & Maintenance Manual

205

8. Technical Data

Product signs

(EPA)

206

Operating & Maintenance Manual

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.:

Operating & Maintenance Manual

207

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.:

208

Operating & Maintenance Manual

9. Index

Index

Operating & Maintenance Manual

209

9. Index

210

Operating & Maintenance Manual

9. Index

Index 1000 Hours Service ........................................................ 169 2000 Hours Service ........................................................ 183 40 Hours Service ............................................................ 151 4000 Hours Service ........................................................ 191 500 Hours Service .......................................................... 153 8 Hours Service .............................................................. 137 AEB-Tester ...................................................................... 176 Air conditioner system ......................... 151, 152, 165, 167 Air conditioning system hazard prevention ...................... 20 Air dryer .......................................................................... 187 Air filter ............................................................................ 172 Air filter warning light ........................................................ 53 Air system ....................................................................... 199 Articulation lock ................................................................ 31 Ashtray .............................................................................. 76 Automatic central lubrication ................................. 152, 167 Automatic central lubrication indicator ............................. 55 Automatic Transmission Fluid (ATF) ............................... 130 Batteries ................................................................. 159, 170 Battery charge warning light ............................................ 53 Battery hazard prevention ................................................ 19 Battery power assistance ............................................... 112 Bearings ......................................................................... 194 Before operation ............................................................... 93 Bleed fuel system ........................................................... 170 Body capacity ................................................................. 197 Body support .................................................................... 29 Brake fluid ....................................................................... 189 Brake fluid warning light ................................................... 50 Brake lines ...................................................................... 188 Brake pedal ...................................................................... 65 Brake system ................................................ 143, 162, 188 Brake system warning light .............................................. 50 Brakes ........................................................................ 22, 98 Braking/stopping the dump truck .................................... 100 Breather element ............................................................ 178 Bulbs ............................................................................... 200 Cab and engine compartment light .................................. 58 Cab certification ................................................................ 33 Cab light ........................................................................... 76 Cab ventilation ............................................... 69, 151, 165 Central lubrication ................................................. 152, 167 Centrifugal cleaner ......................................................... 154 Change brake fluid ......................................................... 189 Change coolant .............................................................. 192 Change oil, engine ......................................................... 153 Change oil, front differential ........................................... 180 Change oil, front reduction gears ................................... 182 Change oil, hydraulic system ......................................... 188 Change oil, rear differential ............................................ 181 Change oil, tandem housings ........................................ 190 Change oil, transmission ................................................ 174 Check batteries ...................................................... 159, 170 Check battery terminals .................................................. 159 Check brake fluid levels ................................................. 143 Check braking (holding) capacity .................................. 147 Check cab ventilation filter element ............................... 166

Check clearance of bearings ......................................... 194 Check coolant level ........................................................ 139 Check driver's seat ......................................................... 137 Check fuel injectors ........................................................ 183 Check fuel level .............................................................. 139 Check function, engine and retarder brake ................... 149 Check function, engine brake ........................................ 149 Check function, main brake ............................................ 148 Check function, steering ................................................. 148 Check glycol content in the coolant ............................... 185 Check lining thickness ................................................... 162 Check multi-groove belt ................................................. 171 Check of the centrifugal cleaner .................................... 140 Check oil level, drive line ...................................... 160, 176 Check oil level, engine ................................................... 138 Check oil level, front differential ..................................... 160 Check oil level, front reduction gears ............................. 161 Check oil level, hydraulic system ................................... 142 Check oil level, rear differential ...................................... 160 Check oil level, tandem housings .................................. 161 Check oil level, transmission .......................................... 141 Check protection against corrosion in the coolant ......... 186 Check the appearance of the coolant ............................ 184 Check the coolant ........................................................... 184 Check tyre pressures ...................................................... 152 Check wheel nuts torque ................................................ 164 Check wiring ................................................................... 182 Check/adjust valve clearance ........................................ 183 Checks after stopping the engine .................................. 106 Cigarette lighter ................................................................ 68 Clean centrifugal cleaner ............................................... 154 Clean prefilter, cab ventilation ........................................ 151 Clean strainer ................................................................. 174 Clothing and personal protection items ........................... 12 Cold weather .................................................................. 110 Column switch .................................................................. 62 Consumeable parts ........................................................ 205 Controls ............................................................................ 61 Coolant .................................................................. 184, 192 Cooling system ............................................................... 191 Correct tyre pressures .................................................... 108 Daily Service .................................................................. 137 Dangerous loads .............................................................. 24 Difference in tyre diameter ............................................. 108 Differentials ..................................................................... 102 Direction light indicator ..................................................... 55 Do not go close to high-voltage cables ............................ 18 Drain air tanks ................................................................ 140 Drive line ............................................................... 160, 193 Driver's seat ............................................................. 73, 169 Dump truck knowledge ..................................................... 11 Dump truck transportation ................................................ 32 Electrical system .................................................... 182, 200 Electrically heated driver's seat switch ............................. 60 Emergency braking ........................................................ 100 Emergency exit .......................................................... 15, 68 Emergency retarder .......................................................... 23 Emergency steering ......................................................... 22

Operating & Maintenance Manual

211

9. Index

Emergency steering warning light ................................... 50 Engine ........................................ 138, 153, 169, 183, 198 Engine and retarder brake ............................................. 149 Engine and retarder brake capacity chart ...................... 204 Engine and retarder brake mode ..................................... 95 Engine and retarder brake operation ............................... 99 Engine bonnet .................................................................. 27 Engine brake ........................................................... 98, 149 Engine brake indicator ..................................................... 55 Engine controller .............................................................. 51 Engine coolant temperature warning light ....................... 51 Engine, general condition check .................................... 138 Engine oil pressure warning light .................................... 51 Engine overspeed ............................................................ 23 Engine revolution counter and hour meter ...................... 45 Exhaust heating ................................................................ 24 Exhaust system ............................................................... 194 Expansion tank coolant level ........................................... 21 External air filling ............................................................ 113 External cleaning of the radiator .................................... 158 External door opener/lock ................................................ 74 Filling capacities ............................................................. 128 Filling fuel or oil ................................................................ 21 Fire extinguisher ............................................................... 14 Fire prevention ................................................................. 16 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 ......................................................................... 14 FOPS ................................................................................ 15 Foreword ............................................................................ 5 Forward drive position ...................................................... 94 Front differential ..................................................... 102, 180 Front reduction gears ...................................................... 182 Fuel filter ......................................................................... 169 Fuel gauge ....................................................................... 45 Fuel injectors .................................................................. 183 Fuses .............................................................................. 200 Gear display ..................................................................... 45 Gear position N ................................................................. 94 Gear position V ................................................................. 94 Gear selector .................................................................... 66 Gear shift program ............................................................ 94 Gear shifting ..................................................................... 94 General condition check, drive line ................................ 193 General condition check, engine ................................... 138 General condition check, tanks ...................................... 193 General condition check, transmission .......................... 193 General description ............................................................ 7 General precautions ......................................................... 11 General safety check, driver's seat ................................. 169 Getting on and off the dump truck .................................... 12 Hazard light switch ...........................................................

High beam indicator .........................................................

High pressure ...................................................................

High temperatures ............................................................

High-voltage cables .........................................................

Hoisting .............................................................................

212

59 55 32 13 18 31

How to adjust the parking brake .................................... 163 Hydraulic return filter element ........................................ 179 Hydraulic system ........................ 142, 178, 188, 194, 199 Important operating instructions ..................................... 104 Indicator lights .................................................................. 49 Inspect the hydraulic hoses ........................................... 194 Inspect brake lines ......................................................... 188 Instructor seat ................................................................... 74 Instruments ....................................................................... 44 Intended use ....................................................................... 7 Inter axle differential ....................................................... 102 Inter-axle differential lock ................................................. 60 Inter-axle differential lock indicator .................................. 55 Internal cleaning, cooling system ................................... 191 Internal door opener ......................................................... 74 Introduction ......................................................................... 7 Labels ............................................................................... 33 Lifting ................................................................................ 31 Loading ........................................................................... 106 Lock-up indicator .............................................................. 54 Long term storage .......................................................... 111 Lubricants ....................................................................... 123 Lubrication ...................................................................... 144 Lubrication, articulation bearings ................................... 144 Lubrication, articulation turning ring .............................. 144 Lubrication, cab rear hinges .......................................... 147 Lubrication, door and fender hatches ............................ 146 Lubrication schedule ...................................................... 125 Lubrication, steering cylinder bearings .......................... 144 Lubrication, tailgate arm hinge ....................................... 145 Lubrication, tandem bearings ........................................ 146 Lubrication, tip cylinder bearings ................................... 144 Lubrication, tip hinges .................................................... 145 Lubrication,suspension legs .......................................... 144 Machine dimensions ...................................................... 197 Machine speed ............................................................... 197 Machine turning ................................................................ 21 Machine weights ............................................................ 197 Main light switch ............................................................... 58 Main warning light, engine failure .................................... 51 Main warning light, transmission failure .......................... 53 Maintenance ................................................................... 131 Maintenance precautions ............................................... 133 Maintenance table ................................................. 135, 136 Manual gear shifting ......................................................... 95 Manual release of the tip valve ..................................... 115 Manual release of parking brake .......................... 114, 115 Measurements ................................................................ 197 Metering conversion table .............................................. 201 Mirror heating switch ........................................................ 60 Neutral gear position ........................................................ 94 Normal operation .............................................................. 97 Oil specification sheet .................................................... 127 Operating Controls ........................................................... 41 Operating hints ................................................................. 96 Operating Instructions ...................................................... 85 Operating the dump truck ................................................. 93 Operation of brakes .......................................................... 22

Operating & Maintenance Manual

9. Index

Operator's cab .................................................................. 17 Optional accessories ........................................................ 14 Other cab equipment ........................................................ 73 Parking brake ................................................. 98, 147, 163 Parking brake indicator .................................................... 50 Parking brake lever .......................................................... 67 Parking the dump truck ................................................... 105 Performance chart ................................................. 202, 203 Periodic service .............................................................. 207 Pinion bearing ................................................................ 181 Precautions before starting the engine ............................ 16 Precautions for mirrors, windows and lights .................... 18 Precautions for optional accessories ............................... 14 Precautions on worksites ................................................. 87 Precautions when handling at high temperatures ........... 13 Preselection of gears ........................................................ 95 Product signs .................................................................. 206 Proper maintenance ....................................................... 109 Protection against falling objects ..................................... 15 Radiator .......................................................................... 158 Radio/Cassette player ...................................................... 77 Rear differential ..................................................... 102, 181 Reference information .................................................... 205 Refrigerant ........................................................................ 20 Relays ............................................................................. 200 Replace air dryer ............................................................ 187 Replace breather element ............................................. 178 Replace fuel filter ............................................................ 169 Replace hydraulic return filter element .......................... 179 Replace transmission filter element ............................... 174 Replace turbo filter ......................................................... 157 Retarder brake ........................................................ 98, 149 Retarder brake capacity chart ........................................ 204 Retarder brake indicator .................................................. 55 Retarder brake mode ....................................................... 95 Retarder brake switch ...................................................... 59 Retractable roller sunblind on front window .................... 76 Reversing (back-up) operations ...................................... 97 Roll-over protection .......................................................... 15 ROPS ................................................................................ 15 Rotating beacon switch .................................................... 58 Rules to follow when filling fuel or oil ............................... 21 Run the AEB-Tester ........................................................ 176 Running-in operation ....................................................... 81 Running-in period ............................................................ 79 Running-in services ......................................................... 82 Safety at the worksite ........................................................ 16 Safety check, exhaust system ........................................ 194 Safety equipment .............................................................. 75 Safety information ............................................................... 6 Safety Instructions .............................................................. 9 Safety labels ..................................................................... 33 Safety rules ....................................................................... 11 Service brake ........................................................... 98, 148 Service position ................................................................ 30 Side window ..................................................................... 75 Specified loading ............................................................ 109 Speedometer .................................................................... 48 Starter switch .................................................................... 67 Starting in cold weather .................................................... 92

Starting the engine ........................................................... 91 Steering ................................................................. 101, 148 Steering column ............................................................... 64 Stopping the engine ....................................................... 105 Switches ........................................................................... 57 Tandem housings ........................................................... 190 Tanks .............................................................................. 193 Technical Data ................................................................ 195 Test switch for brake warning light ................................... 59 Throttle pedal .................................................................... 65 Tiltable cab ....................................................................... 27 Tip control lever ................................................................ 67 Tip- and steering cylinders ............................................. 164 Tipping ............................................................................ 107 Tool kit content ................................................................ 201 Top tailgate ....................................................................... 26 Torque limits for bolts ...................................................... 205 Towing the dump truck ................................................... 113 Transit, long distance drive-away on road ..................... 109 Transmission ....................................... 141, 174, 193, 198 Transmission oil list ........................................................ 130 Transmission oil temperature gauge ................................ 48 Transportation ................................................................... 32 Travelling on slopes ......................................................... 22 Troubleshooting .............................................................. 116 Turbo filter ....................................................................... 157 Tyre filling point ............................................................... 115 Tyre handling .................................................................. 108 Tyre pressures ....................................................... 108, 199 Tyres ............................................................................... 152 Unauthorised modification ............................................... 12 Up, down and crossgradient travel ................................ 103 Valve clearance .............................................................. 183 Ventilation for enclosed areas .......................................... 17 Wading ............................................................................. 23 Walk around check ......................................................... 137 Warming up period ........................................................... 94 Warning / indicator lights .................................................. 49 Warning triangle ............................................................... 14 Weekly Service ............................................................... 151 Weight distribution .......................................................... 197 Welding ............................................................................. 25 Wheel chocks ................................................................... 30 Wheels ............................................................................ 164 When starting the engine ................................................. 18 Worker protection rules, refrigerant .................................. 20 Working and back-up lights .............................................. 58 Working lights and extra high beam ................................ 58 Yearly recommended maintenance ............................... 193

Operating & Maintenance Manual

213

9. Index

214

Operating & Maintenance Manual

Industrial & Marine Engines

In order for the Scania organisation to be able to handle the engine, it is required that the engine is registered as put into operation. This registration means that preparedness to take care of service and spare parts matters can be built up and that a correct warranty handling can take place.

It is you as the user of the engine who should report when the engine is put into operation.

The easiest way for you is to report the start-up via the INTERNET: http://www.scania.com/products/engines/Start_up_report_ASURIM/start_up_report.asp An alternative with longer handling time: Fill in the information below, tear off the page, fold it, tape it, stamp it and send it to Scania.

The address is already printed. Or send it by telefax: +46 8 553 858 20.

Normally the warranty is valid for one year from the date of start-up.

If the start-up report is not submitted to us - within 12 months from the date of delivery the warranty period will be regarded as having started on the date of delivery from Scania.

Operator’s manual DC9 EMS with S6/PDE Industrial engine: opm05-9a en 2005-11:1

START-UP REPORT (From end user)

Engine No. Start-up date Name of company Contact person Address (street)

Postal code Name of town State or Territory Country

1 715 020

START OF WARRANTY = START-UP REPORT

Start of Warranty - Start-up Report

Industrial & Marine Engines

IMPORTANT INFORMATION

!

When working on the engine, for example adjusting drive belts, changing the oil or adjusting the clutch, it is important not to start the engine. The engine may be damaged and there is

SERIOUS RISK OF INJURY. For this reason, always secure the starting device or disconnect a battery cable before working on the engine. This is especially important if the engine has a remote starter or automatic starting.

This warning symbol and text is reproduced beside those maintenance points where it is especially important to consider the risk of injury.

Operator's Manual DC9 EMS with S6/PDE Industrial engine: opm05-9a en

1 715 020

2005-11:1

START-UP REPORT - WARRANTY When the start-up report has been filled in and sent to Scania or you have reported commissioning via Internet, you have a 1 year guarantee from the commissioning date. Also fill in the particulars below as this can make things easier if you need to contact for example a service workshop.

Engine number Commissioning date User's name and address

Signature Engine type Variant Engine type and variant are indicated on the engine type plate

PREFACE This Operator's Manual describes the handling and maintenance of Scania DC9 Industrial Engines with EMS S6/PDE injection systems.

The engines are of direct-injection, liquid-cooled, four-stroke, 5-cylinder inline diesel type. These engines have turbochargers and charge air coolers: see page 10.

Common applications are as power units in construction machines, generator sets, earth-moving, railway and forestry machines as well as in irrigation systems.

The engines can have different output and speed settings.

The normal output setting of the engine (performance code) is indicated on the type plate, see page 10.

Note: Only standard components are described in the Operator's Manual. Regarding special equipment, refer to the instructions of the relevant manufacturer.

In order to obtain the best value and service life from your engine, there are several points you should bear in mind: - Read the manual before starting to use the engine. Even though you may be experienced with Scania engines you may find new information in this Operator's Manual.

- Follow the maintenance instructions. Good working order and service life are ensured if maintenance is carried out according to the instructions.

- In particular, read the safety information starting on page 6.

- Get to know your engine so that you know what it can do and how it works.

During the warranty period, - Whenever necessary, always contact an authorised Scania workshop.

They have special tools, genuine Scania parts and staff with training and only genuine Scania parts may practical experience of Scania engines. be used during service and Note: Always use genuine Scania parts during service and repair so as to keep your engine in the best possible working order.

repair otherwise the warranty will be invalidated.

The information in this manual was correct at the time of going to press.

However, we reserve the right to make alterations without prior notice.

Scania CV AB Industrial and Marine Engines S-151 87 Södertälje, Sweden

2

© Scania Industrial & Marine Engines

2005-11:1

CONTENTS PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENVIRONMENTAL RESPONSIBILITY . . . . . .4 CERTIFIED ENGINES . . . . . . . . . . . . . . . . . . . .5 SAFETY INFORMATION . . . . . . . . . . . . . . . . . .6 Safety precautions for running the engine . . . .7 Safety precautions for handling materials . . . . .8 Safety precautions for care and maintenance . .8

TYPE DESIGNATIONS . . . . . . . . . . . . . . . 10 ENGINE MANAGEMENT SYSTEM, EMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Troubleshooting using flashing codes for the EMS control unit . . . . . . . . . . . . . . . . . . . .14 Overview of flashing codes for EMS control unit . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Troubleshooting using flashing codes for the EMS coordinator . . . . . . . . . . . . . . . . . . . .16 Overview of flashing codes for EMS coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . .17

STARTING AND RUNNING . . . . . . . . . . . 18 AT FIRST START . . . . . . . . . . . . . . . . . . . . . . .18 CHECKS BEFORE RUNNING . . . . . . . . . . . . .19 STARTING THE ENGINE . . . . . . . . . . . . . . . .19 Starting at low temperatures . . . . . . . . . . . . . .20 DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Rotation speed . . . . . . . . . . . . . . . . . . . . . . . . .20 Limp-home mode . . . . . . . . . . . . . . . . . . . . . .21 Coolant temperature . . . . . . . . . . . . . . . . . . . .21 Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .22 STOPPING THE ENGINE . . . . . . . . . . . . . . . . .23 CHECKS AFTER RUNNING . . . . . . . . . . . . . .23

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 24 ENGINES WITH FEW HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .24 MAINTENANCE SCHEDULE . . . . . . . . . . . . .25

LUBRICATING OIL SYSTEM . . . . . . . . . 26 OIL GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . .26 CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . .27 OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . .27 Maximum angles of inclination during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 CLEANING THE OIL CLEANER . . . . . . . . . .29 CHANGING THE OIL FILTER . . . . . . . . . . . .31 CHANGING THE FILTER FOR OPEN OR CLOSED CRANKCASE VENTILATION . . . .31

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COOLING SYSTEM . . . . . . . . . . . . . . . . . . 32 CHECKING COOLANT LEVEL . . . . . . . . . . .32 CHECKING THE COOLANT . . . . . . . . . . . . . .33 Checking protection against corrosion . . . . . .35 Changing the coolant . . . . . . . . . . . . . . . . . . .35 CLEANING THE COOLING SYSTEM . . . . . .36 Internal cleaning . . . . . . . . . . . . . . . . . . . . . . .37

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 38 READING THE VACUUM INDICATOR . . . .38 CLEANING THE AIR CLEANER COARSE CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 CLEANING OR CHANGING THE FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 CHANGING THE SAFETY CARTRIDGE . . . .39

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 40 CHECKING THE FUEL LEVEL . . . . . . . . . . . .40 CHANGING THE FUEL FILTER . . . . . . . . . . .40

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 42 CHECKING THE ELECTROLYTE LEVEL IN BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 CHECKING STATE OF CHARGE IN BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 CLEANING BATTERIES . . . . . . . . . . . . . . . . .42

CHANGING THE BATTERY . . . . . . . . . . 43 CHECKING THE COOLANT LEVEL MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

MISCELLANEOUS . . . . . . . . . . . . . . . . . . . 44 CHECKING THE DRIVE BELT . . . . . . . . . . . .44 CHECK FOR LEAKS, RECTIFY AS NECESSARY . . . . . . . . . . . . . . .45 CHECKING/ADJUSTING VALVE CLEARANCES . . . . . . . . . . . . . . . . . .46 CHECKING/ADJUSTING THE PDE INJECTOR ROCKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

PREPARING THE ENGINE FOR STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Preservative fuel . . . . . . . . . . . . . . . . . . . . . . .50 Preservative oil . . . . . . . . . . . . . . . . . . . . . . . .51 Preparations for storage . . . . . . . . . . . . . . . . .51 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Taking out of storage . . . . . . . . . . . . . . . . . . .52

TECHNICAL DATA . . . . . . . . . . . . . . . . . . 53 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 ALPHABETICAL INDEX . . . . . . . . . . . . . . 57

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3

ENVIRONMENTAL RESPONSIBILITY Scania has always been very much at the leading edge when it comes to developing and producing engines which are as environmentally friendly as possible.

Major progress has been made on reducing harmful exhaust emissions as required to be able to meet the stringent environmental standards stipulated on almost all markets.

At the same time, we have been able to maintain high quality in terms of performance and operating economy for Scania Industrial and Marine Engines.

To preserve these qualities throughout the entire service life of the engine, it is important for the operator/owner to follow the instructions on running, maintenance and the choice of fuel and oil as outlined in the manual.

Other efforts to preserve the environment we all share are possible by ensuring that the person carrying out servicing and maintenance always makes sure that environmentally hazardous waste after servicing and repairs (oil, fuel, coolant, filters, batteries, etc.) is dealt with and disposed of in accordance with applicable environmental standards.

On a number of pages, this Operator's Manual contains specially highlighted text with instructions to help protecting our environment during certain Always use suitable containers servicing and maintenance work. to avoid spillage when bleeding See example

systems or renewing components.

4

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CERTIFIED ENGINES Emissions-certified engines have been approved in accordance with a special certification standard. The certified engines supplied by Scania meet the most stringent emissions standards which apply on European (EU) and nonEuropean (USA) markets.

Scania guarantees that all the engines it supplies of a certified type are equivalent to the engine approved for certification.

The engine comes with a special certification plate which indicates the certification rules (standard) to which the engine has been approved. See page 10.

The following is required for the certified engine to meet emissions standards once it has been commissioned: - Servicing and maintenance must be carried out in accordance with the instructions in this manual.

- Only genuine Scania parts are to be used.

- Injection equipment is to be serviced by an authorised Scania workshop.

- The engine must not be modified with equipment not approved by Scania.

- Seals may be broken and setting data edited only once approval has been granted by Scania in Södertälje. Changes may be made by authorised personnel only.

- Changes which affect the exhaust system and intake system must be approved by Scania.

Otherwise, the instructions in the manual in respect of running, care and maintenance of the engine shall apply. The safety precautions described over the next four pages must also be observed.

Important! If servicing and maintenance are not carried out as specified above, Scania can no longer guarantee that the engine will comply with the certified design, nor can it take responsibility for any damage that occurs.

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© Scania Industrial & Marine Engines

5

SAFETY INFORMATION General This Operator's Manual contains safety information which is important so as to avoid both personal injury and damage to the product/other property. See also page 1.

The text highlighted in text boxes on the right of a number of pages is important for engine function and in order to avoid damage to the engine.

If these instructions are not followed, your warranty may be invalidated.

See example.

Only use Scania genuine fuel filter.

Similar text may also appear in the text column, and in this instance it will be marked Note: or Important!

The warning text found in text boxes on the right of a number of pages which is marked with a warning triangle and starts with WARNING is extremely important and warns you of serious engine faults or incorrect handling which may lead to injury.

See example

Immobilise the starting device when working on the engine.

If the engine starts out of control, there is a SERIOUS RISK OF INJURY.

A list of the safety precautions to be followed when running and maintaining Scania engines can be found on the next three pages. Similar text can often be found at the relevant maintenance points, and here different levels of importance are attached to such text in accordance with the above description.

All points are marked !, so as to indicate how important it is to read through each point in this section.

For safety reasons, smoking is not allowed:

6

•

In the vicinity of the engine and in the engine room

•

When fuelling and close to the filling station

•

When working on the fuel system

•

In the vicinity of inflammable or explosive material (fuel, oils, batteries, chemicals, etc.)

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Safety precautions for running the engine Daily inspection

Starter lock

Always carry out a visual check of the engine and engine room before starting the engine and once you have stopped the engine after running.

If the control panel is not fitted with a key operated switch, there should be a lock on the engine room to prevent unauthorised starting of the engine.

This will enable you to easily detect and fuel, oil or coolant leaks, or any other abnormalities which may require rectification.

Alternatively, a lockable on/off master switch or battery master switch can be used.

Starting spray Refuelling There is a risk of fire and explosion when refuelling. The engine must be stopped and smoking is not allowed.

Do not overfill the tank due to a risk of expansion, and close the filler cap properly.

Use only fuel recommended in the service literature. Fuel of the wrong quality can cause the engine to malfunction or stop by preventing the injection pump and injectors from operating as they should.

This can cause damage to the engine and, possibly, injury.

Hazardous gases Start the engine only in a well ventilated area.

The exhaust fumes contain carbon monoxide and nitric oxides, which are toxic.

Never use starting spray or similar to help you start the engine. This can cause an explosion in the intake manifold and possible injury.

Journey The engine must not be run in environments where there is a risk for explosion as all of the electrical or mechanical components can generate sparks.

Approaching a running engine always poses a safety risk. Parts of the body, clothes or dropped tools can get caught in rotating parts such as the fan and cause injury.

Therefore, all rotating parts and hot surfaces must be shielded as much as possible to aid personal safety.

When running the engine in a closed area, there must be an efficient device for dissipating exhaust fumes and crankcase gases.

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7

Safety precautions for handling materials Fuel and oil All fuels and lubricants and many chemicals are inflammable. Always follow the instructions on the relevant packaging.

All work on the fuel system must be done with the engine cold. Fuel leaks and spillage on hot surfaces can cause fire.

Store soaked rags and other inflammable materials safely so as to avoid spontaneous combustion.

Batteries The batteries contain and emit oxyhydrogen gas, particularly during charging, and this gas is inflammable and highly explosive. Therefore, there must be no smoking, naked flames or sparks near the batteries or the battery compartment.

Incorrect connection of a battery cable or jump lead can cause a spark, which in turn can cause the battery to explode.

Chemicals Most chemicals such as glycol, corrosion inhibitors, preservative oils, degreasing agents, etc. are hazardous to health. Always follow the safety precautions on the relevant packaging.

Some chemicals, such as preservative oil, are also inflammable.

Store chemicals and other materials which are hazardous to health in approved containers, marking them clearly and storing them where they are inaccessible to unauthorised persons.

Always hand in leftover or used chemicals to an authorised waste disposal contractor.

Safety precautions for care and maintenance Stop the engine Always stop the engine before maintenance and servicing unless stated otherwise.

8

Prevent unwanted starting by taking out the ignition key where applicable and disconnecting the power using the master switch or battery master switch and locking them. Also put up a warning sign somewhere appropriate, indicating that work is in progress on the engine.

Working with a running engine always poses a safety risk. Parts of the body, clothes or dropped tools can get caught in rotating parts and cause injury.

Hot surfaces and fluids There is always a risk of sustaining burns when an engine is hot. Therefore, take care not to come into contact with manifolds, the turbo, the sump, hot coolant and oil in pipes and hoses.

Lifting the engine The engine lifting eyes must be used when lifting the engine. Check first that your lifting devices are in good condition and of the correct size to lift the weight.

Extra equipment on the engine can alter the centre of gravity, which is why you may need additional lifting devices to balance the engine correctly and lift it safely.

Never work underneath a suspended engine!

Batteries The batteries contain a highly corrosive electrolyte (sulphuric acid). Take care to protect your eyes, skin and clothes when charging or handling batteries. Wear protective gloves and goggles.

If the acid splashes on your skin, wash it off with soap and copious amounts of water. If acid splashes in your eyes, flush them immediately with copious amounts of water and contact a doctor.

Dispose of used batteries through an authorised waste disposal contractor.

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Electrical system

Cooling system

The engine must be stopped and the power disconnected using the master switch or battery master switch before working on the electrical system.

External power supplies to extra equipment on the engine must also be disconnected.

Electric welding When carrying out welding work close to and on the engine, remove the battery leads and the leads to the alternator. Also remove the multi-pin connector to the control unit.

Never open the coolant filler cap if the engine is hot. Hot coolant or steam may spray out and cause burns.

If you have to open or remove a cooling system component when the engine is hot, open the cap very carefully and slowly to relieve the system pressure before removing the cap.

Wear gloves as the coolant is still very hot.

Dispose of used coolant through an authorised waste disposal contractor.

Fuel system

Connect the weld clamp to the component to be welded and close to the welding point, never to the engine or in such a manner that the current can pass over to a mounting.

Always wear gloves when looking for leaks or carrying out any other work on the fuel system.

Also wear protective goggles when testing injectors.

When you have finished welding, connect the leads to the alternator and control unit before connecting the batteries.

Fuel escaping at high pressure can penetrate tissues and cause serious injury.

Lubrication system

Never use non-genuine parts in the fuel and electrical systems as genuine parts are designed and manufacture to minimise the risk of fire and explosion.

Hot oil can cause burns and skin irritation.

Therefore, avoid skin contact with hot oil.

Make sure that there is no pressure in the lubricating system before starting work on it.

Never start or run the engine with the oil filler cap removed, as this may cause oil to be thrown out.

Dispose of used oil through an authorised waste disposal contractor.

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Before starting Fit all removed shields before starting the engine again. Check that you have not left any tools or other objects on the engine.

Never start the engine without the air filter fitted. There is a risk of objects being sucked into the impeller or of injury if you come into contact with it.

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9

TYPE DESIGNATIONS The engine type designation indicates, in the form of a code, the type of engine, its size and applications, etc.

The type designation and engine serial number are specified on a type plate affixed to the right-hand side of the flywheel housing. The engine number is in addition stamped on the right side of the engine block. See the arrow in illustration.

DC 9 60 A 01 P Type DC

Supercharged diesel engine with air-cooled charge air cooler.

Displacement in whole dm3 Performance and certification code Indicates, together with the application code, the normal gross engine output.

The actual output setting of the engine is indicated on the engine card.

Application A

For general industrial use

Variant 01-99 Type of regulator P

10

EMS engine management system with PDE and S6

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9

10

11

12

2 1

3 4

5 6 7

8

13

18 17 16

15

14

The illustrations show a normal version of a DC9 engine.

Your engine may have different equipment from that illustrated.

1. Type plate 2. Engine number, 3.

4.

5.

6.

7.

stamped into the engine block Coolant pump Automatic belt tensioner Draining, coolant Oil filter Oil cleaner

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8.

9.

10.

11.

12.

13.

14.

15.

Draining, engine oil Crankcase ventilation Oil top up Turbocharger Oil cooler Fuel filter Fuel pump with hand pump Starter motor

© Scania Industrial & Marine Engines

16. Oil dipstick 17. S6 control unit 18. Alternator

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ENGINE MANAGEMENT SYSTEM, EMS This engine has an electronic management system, EMS (Engine Management System) with unit injectors (PDE) which provide each cylinder with the right amount of fuel at the right time in all operating situations.

The EMS system consists of a control unit (S6) and sensors for speed, charge air temperature and pressure, coolant temperature, oil pressure, accelerator pedal/throttle actuation which constantly emit signals to the control unit.

With the aid of this input data and the programmed control software, the correct fuel amount and correct injection time are calculated for each unit injector (PDE) under the specific operating conditions.

The EMS system sensors can also be used to emit signals to the instruments in the instrument panel.

The control unit constantly checks the sensors to make sure they are operational.

The control unit contains monitoring functions to protect the engine in the event of a fault which would otherwise damage it. In the event of a fault, e.g. alarm level for low oil pressure or high coolant temperature, the S6 control unit sends a CAN message to a coordinator.

The main task of the coordinator is to pass on data by means of CAN communication from the engine control unit to other control units and signals to gauges and lamps in the instrument panel. The coordinator also has monitoring functions.

When the EMS control unit or the coordinator detects a fault, the diagnostics lamp on the instrument panels(s) comes on, and it stays on as long as the fault is active. A fault code is at the same time set which can be read via the coordinator on the diagnostics lamp as a flashing code when the diagnostics switch is activated. A flashing code may consist of a number of different fault codes.

Diagnosis and troubleshooting using Scania EMS Display is described in the Operator's Manual for Scania EMS Instrumentation.

If the torque reducing function is activated, the fuel amount and the engine power output are reduced to 70%, and if the engine shutoff function is activated, the engine is shut off at programmed alarm levels.

A separate PC-based diagnostics program is used to read off the contents of the flashing codes. For in-depth analysis of fault codes, contact an authorised Scania dealer.

Reading off the fault codes, and descriptions of these, are also covered in a separate document in the Service manual, Engine Management System EMSS6: Troubleshooting.

Only authorised personnel are allowed to carry out diagnostic procedures and program changes.

The positions of the sensors which emit signals to the control unit are shown in the illustrations on page 13.

See pages 14 and 16 for a description of how to read off flashing codes.

See pages 15 and 17 for a list of flashing codes for the control unit and coordinator.

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Positions of sensors for EMS with S6 on DC9

1

2

3

4

1. Coolant temperature sensor 2. Oil pressure sensor 3. Sensor for charge air temperature and pressure 4. Engine speed sensor (2) 5. Coolant level monitor (located in the expansion tank)

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© Scania Industrial & Marine Engines

13

Troubleshooting using flashing codes for the EMS control unit •

The diagnostics lamp on the instrument panel always comes on for two seconds when the system is powered up.

•

As soon as a fault is detected by the control unit, it is stored in the EEPROM fault code memory and the diagnostics lamp on the instrument panel comes on.

•

The diagnostics lamp will stay on for as long as a fault is active. Even if the lamp has gone off and the fault is no longer active, the code can generally be read off in accordance with the instruction below.

Reading fault codes for the control unit for engines with Scania electrical systems 1. Turn on the ignition.

2. Activate the diagnostics switch to the left to view the flashing codes for the control unit (EMS).

3. A fault code will then flash on the diagnostics lamp. This flashing code consists of long flashes (approximately 1 second long) and short flashes (0.3 seconds long). Long flashes are equivalent to units of 10, and short flashes are equivalent to units of 1.

Example: long - short - short = fault code 12.

4. Repeat this procedure until the first flashing code is repeated. This means that the entire fault code memory has been flashed out. If the fault code memory is empty, only one long flash approx. 4 seconds long will be given.

5. See the flashing code table on the next page for a description and localisation of the fault.

6. In order to obtain further information on the fault code, the PC-based diagnostics tool or Scania EMS Display must be used. Contact an authorised Scania workshop.

7. When a fault has been rectified the fault code can be erased as described below.

Deleting fault codes for engines with Scania electrical systems 1. Turn the ignition off.

2. Activate the diagnostics switch in the same direction as the flashing codes indicate, i.e. to the right for the coordinator (COO) or to the left for EMS.

3. Switch on the ignition and keep at the same time the diagnostics switch activated, to the right (COO) or to the left (EMS), for 3 seconds.

4. This will erase passive fault codes which can be read off via flashing code for the relevant system. The rest of the fault code will remain in the EEPROM and can only be deleted using the PC tool.

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Overview of flashing codes for EMS control unit Code

Description

Code

Description

0

No fault detected.

53

PDE in cylinder 3: The solenoid valve does not work correctly.

11

Overspeed. One or both engine speed sensors are displaying speeds in excess of 3000 r/min.

54

PDE in cylinder 4: The solenoid valve does not work correctly.

12

Engine speed sensor 1 faulty, or incorrect signal.

55

PDE in cylinder 5: The solenoid valve does not work correctly.

13

Engine speed sensor 2 faulty, or incorrect signal.

59

Incorrect signal in extra analogue input.

14

Coolant temperature sensor faulty, or incorrect signal.

61

Incorrect control unit shutdown.

15

Charge air temperature sensor faulty, or incorrect signal.

66

Shut-off due to coolant level.

16

Charge air pressure sensor faulty, or incorrect signal.

68

Alternator charging incorrectly.

17

Oil temperature sensor faulty, or incorrect signal.

69

Starter motor function interrupted or not activated.

18

Oil pressure sensor faulty, or incorrect signal.

82

Engine speed above ref. speed at start

21

Coolant level sensor faulty.

83

Fault in memory circuit (EEPROM) in control unit.

23

Fault code internally in the coordinator.

84

Data transfer to the control unit memory (EEPROM) has been interrupted.

24

Accelerator/brake. If the accelerator and brake have been operated simultaneously.

85

Incorrect temperature internally in the control unit.

25

Accelerator sensor/idle switch Accelerator sensor/kickdown switch

86

Internal fault in the control unit: Fault in hardware control.

27

Engine shutdown bypassed.

87

Fault in control unit RAM.

28

Shut-off due to oil pressure.

88

Internal control unit fault: Memory fault

31

Torque limitation due to oil pressure

89

Incorrect seal: Prohibited changes in software.

32

Incorrect parameters for limp home function.

93

Engine speed sensors faulty or not connected.

33

Battery voltage incorrect or no signal.

94

Shutdown due to high coolant temperature.

37

Emergency shutdown switch activated in accordance with CAN message from coordinator.

96

Torque limitation due to high coolant temperature.

43

CAN circuit faulty in the control unit.

98

Incorrect voltage supply to one of the sensors.

47

Immobiliser function. Ignition key code incorrect.

99

Internal hardware fault in the processor (TPU).

48

There is an incorrect CAN message or no CAN message from the coordinator.

49

Incorrect CAN version in control unit or coordinator.

51

PDE in cylinder 1: The solenoid valve does not work correctly.

52

PDE in cylinder 2: The solenoid valve does not work correctly.

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© Scania Industrial & Marine Engines

15

Troubleshooting using flashing codes for the EMS coordinator •

The diagnostics lamp on the instrument panel always comes on for two seconds when the system is powered up

•

As soon as a fault is detected by the coordinator, it is stored in the EEPROM fault code memory and the diagnostics lamp on the instrument panel/s comes on.

•

Even if the lamp has gone off and the fault is no longer active, the code can generally be read off in accordance with the instruction below.

Reading fault codes for the coordinator on engines with Scania electrical systems 1. Turn on the ignition.

2. Activate the diagnostics switch to the right for 1 second to view the flashing codes for the coordinator (COO).

3. A fault code will then flash on the diagnostics lamp. This flashing code consists of long flashes (approximately 1 second long) and short flashes (0.3 seconds long). Long flashes are equivalent to units of 10, and short flashes are equivalent to units of 1.

Example: long - short - short = fault code 12.

4. Repeat this procedure until the first flashing code is repeated. This means that the entire fault code memory has been flashed out. If the fault code memory is empty, only one long flash approx. 4 seconds long will be given.

5. See the flashing code table on the next page for a description and localisation of the fault.

6. In order to obtain further information on the fault code, the PC-based diagnostics tool or Scania EMS Display must be used. Contact an authorised Scania workshop.

7. When a fault has been rectified the fault code can be erased as described below.

Deleting fault codes for engines with Scania electrical systems 1. Turn the ignition off.

2. Activate the diagnostics switch in the same direction as the flashing codes indicate, i.e. to the right for the coordinator (COO) or to the left for EMS.

3. Switch on the ignition and keep at the same time the diagnostics switch activated, to the right (COO) or to the left (EMS), for 3 seconds.

4. This will erase passive fault codes which can be read off via flashing code for the relevant system. The rest of the fault code will remain in the EEPROM and can only be deleted using the PC tool.

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Overview of flashing codes for EMS coordinator Flashing code

Fault description

111)

Incorrect signal from the nominal speed signal fine adjustment.

112)

Incorrect signals from the accelerator pedal sensor.

121)

Incorrect signal from the resistor module for governor setting.

122)

Incorrect signal from the resistor module for idle and fixed speed setting.

13

No communication with the engine.

14

Short-circuit in the tachometer signal circuit.

15

Faulty atmospheric pressure sensor.

17

Short-circuit in the coolant temperature gauge signal cable.

18

Short-circuit in the oil pressure gauge signal circuit.

19

Short-circuit in the oil pressure lamp signal circuit.

21

Different versions of the communications protocol between the coordinator and EMS.

22

Faulty start switch or short circuit.

23

The supply voltage is too high.

24

The supply voltage is too low.

25

Check value from End of line (EOL) is incorrect.

26

Speed sensor signal missing or incorrect.

27

The signals from the RCB (Remote Control Box) switches are implausible.

28

Incorrect signals from the droop-setting switches.

29

Faulty remote start switch or short circuit.

31

No communication from the slave coordinator or the master coordinator.

32

Short circuit in the signal cable to the coolant temperature warning lamp.

33

Short circuit in the signal cable to the charge indicator lamp.

34

Incorrect signal from the Fixed speed switches.

35

Fault in CAN communication.

1) Single speed engine 2) All-speed engine

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17

STARTING AND RUNNING AT FIRST START When the engine is started for the first time, the maintenance points listed under "First start" in the maintenance schedule should be followed, see page 25.

Since the points are important for satisfactory operation of the engine right from the outset, they are also listed below.

1. Checking the oil level (see page 27).

6. Checking the coolant level (see page 33).

The coolant should contain corrosion inhibitor to protect the cooling system from corrosion.

Coolant composition: If there is a danger of freezing: minimum 30% glycol by volume maximum 60% glycol by volume If there is no danger of freezing: 8-12% by volume Scania corrosion inhibitor (no glycol)

If there is a danger of freezing: - Only anti-freeze glycol should be used in the coolant as protection against corrosion. We recommend only nitrite-free anti-freeze glycol with the following supplier designations: BASF G48 or BASF D542

Ethylene glycol and corrosion inhibitor are toxic if ingested.

Avoid contact with the skin.

- The concentration of glycol should be 30 - 60% by volume depending on the ambient temperature. 30% glycol by volume provides anti-freeze protection down to -16°C. See page 33.

- Never top up with only water or only glycol. Fluid losses must always be replaced with pre-mixed coolant having the same glycol concentration as that in the engine. If the glycol content drops, both anti-freeze protection and protection against corrosion are impaired.

Note: A glycol concentration below 30% by volume will not provide sufficient protection against corrosion. Glycol concentrations The recommended glycols higher than 60% do not improve anti-freeze protection and have should not be mixed with glycol a negative effect on engine cooling capacity.

containing nitrite-based corrosion inhibitor.

If there is no danger of freezing: - Only Scania Corrosion Inhibitor should be used in the coolant as protection against corrosion. The correct concentration of corrosion inhibitor is 8-12% by volume, and this must never drop below 8% by volume. The inhibitor in Scania Corrosion Inhibitor is free of nitrite.

- First filling: Fill up the system with water + 10% by volume Scania Corrosion Inhibitor. Use drinking water with a pH of 6 - 9.

- Never top up with only water or only corrosion inhibitor!

Fluid losses must always be replaced with blended coolant: water + 10% Scania Corrosion Inhibitor by volume.

Overdosing with Scania Corrosion Inhibitor and mixing with glycol can cause sludge to be formed.

Coolant filter (not standard equipment) Only coolant filter without inhibitor may be used. The use of coolant filters increases the life of the coolant and reduces the risk of deposition corrosion.

If a coolant filter has been fitted it must not contain inhibitor.

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12. Checking the fuel level (see page 40).

14. Checking the electrolyte level in batteries (see page 42).

15. Checking the state of charge in batteries (see page 42).

18. Checking the drive belt tension (see page 44).

CHECKS BEFORE RUNNING

Immobilise the starting device when working on the engine.

If the engine starts out of control, there is a SERIOUS RISK OF INJURY.

Before running, "Daily maintenance" as described in the maintenance schedule should be carried out, see page 25.

STARTING THE ENGINE If the fuel tank has been run dry or if the engine has not been used for a long time, bleed the fuel system (see page 41).

Out of consideration for our common environment, your Scania engine has been designed to use a smaller amount of fuel when starting. Unnecessarily high levels of fuel supply when starting the engine always results in the discharge of unburnt fuel.

- Open the fuel cock, if fitted.

Only Start start the engine the engine only in in aa well well ventilated ventilated area. area.

If it If it is is run run in in aa enclosed enclosed space, space, there there should should be be an an effective effective device to device to draw draw off off exhaust exhaust gases gases and crankcase and crankcase gases. gases.

- Disengage the engine.

- Engines with battery master switch: Switch on the power by means of the battery master switch.

- Start the engine with the key on the control panel (SCP).

- S6: All lamps should go out after around 2 seconds after starting (applies only to all-speed engines).

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Never use starting spray or similar as a starting aid.

An explosion may occur in the intake manifold with a risk of personal injury.

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Starting at low temperatures Local environmental requirements must be complied with. Starting aids, engine heaters and/or flame start devices should be used to avoid starting problems and white smoke.

To limit white smoke, the engine should be run at low speed and under moderate load. A light load on a cold engine gives better combustion and faster heating than warming up with no load.

The starter motor may only be connected for a maximum of At temperatures below 0°C: 30 seconds. There is risk of overheating. Allow the engine to Note: Only use starting aids recommended by Scania. rest for 2 minutes between each - The starter motor may only be used for 30 seconds at a time. After that attempt to start it.

Avoid running it longer than necessary at idling speed.

time it must rest for 2 minutes.

DRIVING Check instruments and warning lamps at regular intervals.

Rotation speed The Scania tachometer is divided into sectors of different colours, as follows:

0-500 rpm

red area:

prohibited engine speed, passed through when stopping and starting.

500-700 rpm

yellow area:

slow idle. Engine idling is controlled by the S6 control system. See page 20.

700-2200 rpm

green area:

normal operating speed.

The engine operating speed range is controlled by the S6 control system.

2200-2600 rpm

yellow/green striped:

unsuitable operating speed.

May occur when switching off.

2600-3000 rpm

red area:

prohibited engine speed

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Limp-home mode If there is a fault on the normal accelerator pedal or if CAN communication is interrupted, the following limp-home option is provided: CAN interruption or accelerator pedal fault on all-speed engines (both signal and idling switch): - The accelerator pedal value is 0% and the engine is running at normal idling speed.

- The accelerator pedal value is 0% and the engine is running at raised idling speed (750 rpm) if this function is activated.

Accelerator pedal fault but the idling switch is working: - The accelerator pedal value can be increased slowly between 0% - 50% by using the idling switch.

CAN interruption: - The engine is switched off if the shutdown function is activated.

Coolant temperature Normal coolant temperature when the engine is running should be 70 - 90°C. The S6 control system has the following alarm levels: - If the temperature is high, 95°C -105°C (standard value, other values can be programmed), for a certain period (1 second), S6 will send a CAN message which switches on the warning lamp and diagnostics lamp via the coordinator.

- If the temperature exceeds 105°C, the warning lamp and diagnostics lamps will come on. If torque reduction is activated, the control system will reduce the fuel quantity to 70%. A fault code is generated in the control unit.

- At temperatures exceeding 105°C and with engine shutdown activated, the warning lamp and diagnostics lamp come on and the engine is switched off. If the override function is activated, only torque reduction takes place when this function is activated. A fault code is generated in the control unit.

After an alarm, approved values should be registered for more than 2 seconds to reset the alarm.

Excessively high coolant temperature can damage the engine.

If run for extended periods under an extremely light load, the engine may have difficulty in maintaining normal operating temperature. However, the temperature will rise to a normal level again when the load on the engine is increased.

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Oil pressure Max. oil pressure: warm engine running at a speed above 800 rpm

6 bar

Normal oil pressure: warm engine running at an operating speed of

3 - 6 bar

Min. oil pressure: hot engine above 1000 rpm

2.3 bar

High lubricating oil pressure (above 6 bar) is normal when starting a cold engine.

The control system has the following alarm levels: - at a speed of less than 1000 rpm and an oil pressure of less than 1.0 bar - at a speed of more than 1000 rpm and an oil pressure of less than 2.3 bar for longer than 5 seconds.

The following functions are available if there is an alarm: - Alarm which only switches on the warning lamp and diagnostics lamp.

- Alarm which switches on the warning lamp and diagnostics lamp as well as torque reduction if this function is activated (70% of fuel quantity).

A fault code is generated in the control unit.

- Alarm which switches on the warning lamp and diagnostics lamp. The engine is switched off if engine shutdown is activated. If the override function is activated, only torque reduction takes place when this function is activated.

A fault code is generated in the control unit.

After an alarm, approved values should be registered for more than 1 second to reset the alarm.

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Charging indicator lamp If the lamp comes on during operation: - Check/adjust the alternator drive belts as described under the maintenance point. See page 44.

- If the charging indicator lamp is still on, this could be due to an alternator fault or a fault in the electrical system.

STOPPING THE ENGINE 1. Run the engine without a load for a few minutes if it has been run continuously with a heavy load.

2. Engines with Scania electrical systems: Stop the engine with the stop button. Keep the stop button depressed until the engine is completely stationary.

There is danger of turbo damage and post boiling if the engine is stopped without cooling.

3. Engines with battery master switch: Switch the power off with the battery master switch.

The power must not be switched off before the engine has stopped.

4. Set the control switch to "0".

CHECKS AFTER RUNNING - Check that the power is cut from the battery master switch and that the control switch is in the "0" position.

Immobilise the starting device when working on the engine.

If the engine starts out of - If there is a risk of freezing, the cooling system must contain enough control, there is a glycol. See pages 18 and 33.

SERIOUS RISK OF - At temperatures below 0°C: Prepare for the next start by connecting the INJURY engine heater (if fitted).

- Fill the fuel tank. Make sure that the filler cap and the area round the filler opening are clean to avoid contamination of the fuel.

Coolant should be topped up when the engine is stopped after the first start.

Hot engine with pressurised cooling system: Risk of burn injuries.

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MAINTENANCE The maintenance programme covers 20 points, divided into the following main groups: Lubricating oil system . . . . . . . . . . . . . . . . . page 26 Cooling system . . . . . . . . . . . . . . . . . . . . . . . page 32 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . page 38 Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . page 40 Electrical system, batteries, etc . . . . . . . . . . page 42 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . page 44 The maintenance points are divided into intervals as follows: Daily maintenance Maintenance before the first start

Immobilise the starting device when working on the engine.

If the engine starts out of control, there is a SERIOUS RISK OF INJURY

Maintenance after the first 400 hours of operation Periodic maintenance every 200 hours of operation (carried out after 200, 400, 600, 800, etc. hours) Periodic maintenance every 400 hours of operation (carried out after 400, 800, 1200, 1600, etc. hours) Periodic maintenance every 1200 hours of operation (carried out after 1200, 2400, 3600, etc. hours) Periodic maintenance every 2400 hours of operation (carried out after 2400, 4800, etc. hours) Periodic maintenance every 4800 hours of operation (carried out after 4800, 9600 etc. hours) Annual Maintenance Maintenance every 5th year

ENGINES WITH FEW HOURS OF OPERATION For engines with few operating hours that do not receive periodic maintenance according Run the engine until it reaches operating temperature and then carry out the to the maintenance schedule on page 25, maintenance should be maintenance points below: carried out in accordance with 1. Checking oil level. the schedule: 5. Checking coolant level.

"Annually" 8. Checking low pressure indicator.

"Every 5th year" Emergency generator sets and the like that are not used regularly should be run on test and checked in accordance with the generator set manufacturer's instructions.

12. Checking fuel level.

14. Checking electrolyte level in batteries.

15. Checking state of charge in batteries.

16. Cleaning batteries.

19. Check for leaks, rectify as necessary

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MAINTENANCE SCHEDULE

LUBRICATING OIL SYSTEM, page 26 1. Checking oil level 2. Oil change 3. Cleaning oil cleaner 4. Changing the oil filter and filter for crankcase ventilation COOLING SYSTEM, page 32 5. Checking coolant level 6. Checking coolant 7. Cleaning cooling system AIR CLEANER, page 38 8. Test reading low pressure indicator 9. Cleaning the coarse cleaner 10. Cleaning or changing filter element 11. Changing safety cartridge FUEL SYSTEM, page 40 12. Checking fuel level 13. Changing the main filter and water separating filter ELECTRICAL SYSTEM, page 42 14. Checking electrolyte level in batteries 15. Checking state of charge in batteries 16. Cleaning batteries 17. Checking coolant level monitor MISCELLANEOUS, page 44 18. Checking drive belt 19. Check for leaks, rectify as necessary 20. Checking/adjusting valve clearances 21. Checking/adjusting PDE injector rocker arms

Every 5th year

Annually

4800 h

At least

2400 h

1200 h

400 h

Interval

200 h

400 h

First start

Daily

First time at

1 1 1

3 1

1 2

1

1. More often if required 2. Earlier if low pressure indicator shows red.

3. If inhibitor has not been topped up for five years, the coolant should be changed.

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LUBRICATING OIL SYSTEM OIL GRADE The engine oil must at least meet the requirements for one of the following oil classifications:

- ACEA E3, E4 or E5 - The Total Base Number (TBN) should be minimum 12-13 (ASTM 2896).

- Check with your oil supplier that the oil meets these requirements.

Additives must not be used.

- The oil change intervals stated apply provided that the sulphur content of the fuel is not in excess of 0.3% by weight. If the sulphur content is The oil should be suitable for all greater than 0.3% but no more than 1.0%, the oil change interval must temperature variations until the be halved (200 h). next oil change.

- Viscosities are shown in the figure below.

- For operation at extremely low ambient temperature: Consult your nearest Scania representative on how to avoid starting difficulties.

Oil analysis Some oil companies can offer analysis of the engine oil. Such analysis measures the oil's TBN (Total Base Number), TAN (Total Acid Number), fuel dilution, water content, viscosity and the quantity of wear particles and soot in the oil.

The result of a series of analyses is used as the basis for establishing a suitable oil change interval.

If the conditions are changed, a new oil analysis programme must be carried out to establish the new change interval.

-40

-30

-20

-10

0

10

20

30

40 °C

SAE 20W-30 SAE 30 SAE 40 SAE 50 SAE 5W-30 SAE 10W-30 SAE 15W-40

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1. Daily: CHECKING OIL LEVEL Note: Before checking oil level: Allow the engine to remain stationary for at least 1 minute.

- The oil is at the correct level when it comes to between the marks on the dipstick. Top up when the oil level is at the lower mark on the dipstick.

- Correct type, see "Oil grade" on page 26.

Checking oil level during operation On some engines the oil level can be checked during operation.

- Remove the oil filler cap to release the pressure in the crankcase.

- Check the level on the dipstick. Correct oil level: 10 mm below the Min. or Max. mark.

Max.

Min.

2. Every 400 hours: OIL CHANGE Note: If the engine is used for especially demanding operations, particularly in a dusty environment or if the deposits in the centrifugal cleaner are thicker than 20 mm: Change the oil at more frequent intervals.

- Unscrew the plug and drain the oil when the engine is hot.

Max. 37 dm3 Min. 32 dm3

- In certain engines the oil is pumped out by means of a bilge pump.

- Clean the magnet on the plug.

- Refit the plug.

Max. 34 dm3 Min. 27 dm3 1 liter = 1 dm3

- Fill up with oil.

- Check the level on the dipstick.

WARNING The oil may be hot.

Wear protective gloves and goggles

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Use a container to avoid spillage when changing the oil. Dispose of used oil through an authorised waste disposal contractor.

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Maximum angles of inclination during operation Maximum permissible angles during operation vary, depending on the type of oil sump, see illustration.

Note: Specified angle may only occur intermittently.

25° 25° 35°

35°

35°

35°

25° 25°

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3. Every 400 hours: CLEANING THE OIL CLEANER (in connection with oil change) - Clean the cover. Unscrew the nut and remove the cover.

Open the cap carefully. The oil may be hot.

- Lift out the rotor and wipe the outside. Unscrew the rotor bowl nut about one and a half turns.

- If the rotor nut is jammed: Turn the rotor upside down and fasten the nut, absolutely not the rotor, in a vice, and turn the rotor one and a half turn anti-clockwise by hand, or use M20 bolt and nuts as illustrated. The grip distance should be 30 mm.

- Hold the rotor and tap lightly on the rotor nut with a plastic mallet or against the workbench, so that the rotor bowl comes loose from the bottom plate. Never strike on the rotor directly as this may damage the bearings.

- Unscrew the nut and remove the rotor bowl.

- Remove the strainer. If the strainer has seized in the rotor bowl, pry carefully with a screwdriver between the rotor bowl and the strainer.

- If the strainer has seized in the rotor, pry carefully between the rotor and the strainer.

- Scrape off the deposits from the inside of the rotor bowl. If there are no deposits, this indicates that the cleaner is not working properly.

- If the deposits are thicker than 28 mm: Clean more often.

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- Wash all parts in diesel oil.

- Make sure the nozzles on the rotor are not blocked or damaged.

- Make sure the bearings are not damaged. If they are damaged the entire rotor must be renewed.

- Fit a new O-ring on the rotor and fit the strainer.

- Reassemble the rotor.

- Tighten the rotor nut firmly by hand.

- Make sure the shaft is not loose. If it is loose, use locking compound 561 200 and tighten it to 34 Nm using tool 98 421.

- In order to tighten the rotor shaft, it is necessary to modify socket wrench 98 421: - Drill out the threads from a M20 nut so that it fits on the square drive of the socket wrench.

- Weld on the nut.

- Refit the rotor.

- Check that it rotates easily by rotating it manually.

- Fit a new O ring on the bowl and fit the bowl.

- Screw the bowl on and tighten the lock nut to 15 Nm. Tighten the nut carefully so as not to damage the rotor shaft, nut or bowl.

Functional inspection The rotor rotates very fast and should continue to rotate when the engine has stopped.

- Stop the engine when it is warm.

- Listen for a whirring sound from the rotor or feel whether the cleaner housing is vibrating.

The rotor normally continues spinning for 30 - 60 seconds after the engine has stopped.

If not: Dismantle and check.

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4. Every 400 hours: CHANGING THE OIL FILTER (in connection with oil change) - Remove the old filter.

- Oil the rubber gasket and fit a new genuine Scania filter.

- Tighten the filter by hand.

Never use tools for this. The filter could sustain damage, obstructing circulation.

- Start the engine and check for leaks.

Important! If the deposits in the centrifugal cleaner are more than 20 mm thick, the oil filter has to be replaced more often. The same is true for cleaning the centrifugal filter and changing the oil.

Use a container to avoid spillage when changing the filter.

Dispose of used filters through an authorised waste disposal contractor.

CHANGING THE FILTER FOR OPEN OR CLOSED CRANKCASE VENTILATION For engines with both opened and closed crankcase ventilation, the filter element must be changed at the same time as the main oil filter as described below: - Remove the speed coupling on the bleed pipe connection 1 to the filter housing and pull the pipe off the filter housing cover.

- Remove the filter housing lid 2 and remove the filter element 3.

- Clean the filter housing and fit a new he filter element as shown in picture.

- Note that the filter element should be fitted so that the path of crankcase gases through the filter is the longest possible route. The text on the filter will then run vertically.

- Pour approx. 1 dl of oil into the filter housing oil outlet so as to ensure that there is sufficient oil in the liquid seal.

- Fit the cover to the filter housing.

- Check that there is an O-ring on the bleed pipe connection. Press the pipe on and fit the speed coupling.

3 2

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COOLING SYSTEM 5. Daily: CHECKING COOLANT LEVEL - Open the expansion tank filler cap and check the coolant level.

- Correct level: (Scania plastic expansion tank) - Cold engine: Coolant level must be approx. 50 mm below the filler neck.

- Hot engine:

Coolant level must be approx. 25 mm below the Full line.

- Other types of expansion tank according to the instructions of the fitter.

Hot engine with pressurised cooling system: Open the cap carefully.

Water and steam may spray out.

Risk of burn injuries.

- Top up the coolant as necessary, see point 6.

Note: When filling large amounts of coolant: Never pour cold coolant into a hot engine.

This could crack the cylinder block and cylinder head.

Always top up with ready mixed coolant.

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6. Every 2400 hours: CHECKING THE COOLANT Coolant should be checked as follows:

a) Check the appearance of the coolant. b) Coolant with glycol only: Check the glycol content. c) Coolant with Scania Corrosion Inhibitor only:

Coolant composition:

If there is a danger of freezing: minimum 30% glycol by volume The composition of the coolant is described in more detail under maximum 60% glycol by "Starting and running" volume a) If there is no danger of freezing: 8-12% by volume Checking the appearance of the coolant Scania corrosion inhibitor - Pour a small amount of coolant in a container, and check that the coolant Check the corrosion protection.

is pure and clear.

- If the coolant is contaminated or cloudy: Consider changing the coolant - Water for the coolant must be clean and free from contamination.

- Use drinking water with a pH of 6 - 9.

b) Checking the glycol content If there is a danger of freezing, use only glycol as an anti-corrosive in the coolant.

- Cooling systems with glycol should contain at least 30% glycol by volume to provide acceptable protection against corrosion.

Ethylene It is highly glycol dangerous is highly to consume poisonouscorrosion and can be inhibitor. fatal if ingested.

Avoid skin contact Avoid skinwith contact glycol. with glycol.

- 30% glycol by volume provides protection against freezing to -16°C. If additional protection against freezing is required, see the table on the next page to help you calculate how much glycol you need.

We recommend only nitrite-free anti-freeze glycol with the following supplier designations:

The coolant should be ready mixed when it is poured into the BASF G48 or BASF D542 cooling system.

- Always top up the anti-freeze if its glycol content drops below 30% by Never top up with only water or volume. A glycol content above 60% by volume will not provide greater only glycol. protection against freezing.

- The table shows the temperature at which ice starts to form. The engine will freeze and break at appreciably lower temperatures, see diagram.

- Ice forming in the coolant often causes malfunctioning without any risk of damage. The engine should not be subjected to heavy loads when ice starts to form.

Note: The coolant should be changed when the cooling system is cleaned: every 4800 hours or at least every 5th year.

Important! If a coolant filter is used in the cooling system it must not

The recommended glycol must not be mixed with glycol having nitrite-based anti-corrosive.

Risk for build up of sludge and reduced cooling capacity.

contain an inhibitor.

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Anti-freeze glycol, % by volume

Characteristics of glycol at low temperatures: - Example with 30% glycol by volume - Ice slush starts to form at -16°C - There is risk for malfunctions at -30°C - No risk of damage by freezing with a minimum content of 30% glycol by volume

Curve A: Ice formation starts (ice slush) Curve B: Temperature at which there is a risk of damage by damage freezing by freezing 1. Safe area 2. Malfunctions may occur (ice slush) 3. There is risk of damage by freezing

A % glycol by volume

15

20

25

Ice slush starts to form at °C

-6

-9

-12 -16 -22 -27 -36 -46 -55

Glycol dm3 (litres)

5 6 8 9 11 12 14 15 17 18 20 21 23 24 26 27 29 30

6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40

8 10 13 15 18 20 23 25 28 30 33 35 38 40 43 45 48 50

30

9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60

35

11 14 18 21 25 28 32 35 39 42 46 49 53 56 60 63 67 70

40

12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80

45

50

14 15 18 20 23 25 27 30 32 35 36 40 41 45 45 50 50 55 54 60 59 65 63 70 68 75 72 80 77 85 81 90 86 95 90 100

60

18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120

Cooling system volume, dm3 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

A = Area to be avoided. Only for calculating glycol mix.

Coolant freezing temperature, when ice starts to form, for different glycol mixes 34

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c) Checking protection against corrosion There must always be sufficient corrosion inhibitor in the coolant to protect the cooling system against corrosion.

If there is no danger of freezing, only Scania Corrosion Inhibitor should be used in the coolant.

The inhibitor in Scania Corrosion Inhibitor is free of nitrite.

Corrosion inhibitor is highly dangerous if ingested and can prove fatal.

Avoid contact with the skin.

The correct proportion of corrosion inhibitor is 8-12%by volume.

- Topping up with 1.0% Scania Corrosion Inhibitor by volume should be Mixing with glycol or the use of done after every 2400 hours of operation.

- Never top up with only water or only corrosion inhibitor!

Fluid losses must always be replaced with blended coolant: water + 10% Scania Corrosion Inhibitor by volume.

too much corrosion inhibitor can lead to build up of sludge and reduced cooling capacity.

Note: The coolant should be changed when the cooling system is cleaned: every 4800 hours or at least every 5th year.

If a coolant filter has been fitted it must not contain inhibitor.

Changing the coolant 1. Remove the filler cap from the expansion tank.

2. The coolant is drained at two points: - the "lowest point" of the engine block, see illustration.

- the "lowest point" of the cooling system.

3. Close the drain taps.

4. Fill up with coolant through the expansion tank's filler hole.

Mix coolant as described on page 33.

Use a container to avoid spills when changing the coolant.

Dispose of used coolant through an authorised waste disposal contractor.

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7. Every 4800 hours: CLEANING THE COOLING SYSTEM Note: If necessary, the cooling system should be cleaned more often.

External cleaning Radiator and charge air cooler - Check that the radiator and the charge air cooler are not clogged on the air side and that the cooling fins are not damaged.

- Carefully scrape the deposit off the radiator's cooling fins. If necessary, a paraffin-based engine cleaner can be used.

- Bent fins can be straightened using a wire brush, for example, and exercising care.

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The cooling system must never be cleaned with caustic soda.

There is a risk of damage to aluminium parts.

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Internal cleaning Removing oil and grease - If possible, run the engine until it has reached operating temperature and then drain the cooling system.

- Remove the thermostats.

- Fill the system with clean, hot water mixed with liquid dishwasher detergent designed for household use.

Concentration 1% (0.1/10 l).

- Run the engine until warm for about 20-30 minutes. Do not forget the cab heating system (if fitted).

Handling cleaning agents for the cooling system: Carefully read the warning label on the container.

- Drain the cooling system.

- Fill the system again using clean, hot water and run the engine for about 20-30 minutes.

- Drain the water from the system.

- Refit the thermostats.

- Top up the system with new coolant according to the specification on page 33.

Removing deposits

Use a container to avoid spills when changing the coolant.

- If possible, run the engine until it has reached operating temperature and then drain the cooling system.

Dispose of used coolant through an authorised waste disposal - Remove the thermostats. contractor.

- Fill the system with clean, hot water mixed with one of the commercially available radiator cleaners based on sulphamic acid and containing dispersing agents. Follow the manufacturer's instructions for mixing proportions and cleaning times.

- Run the engine for the specified time and then drain the cooling system.

- Refill the system with hot water and run the engine for about 20-30 minutes.

- Drain the water from the system.

- Refit the thermostats.

- Top up the system with new coolant according to the specification on page 33.

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AIR CLEANER 8. Daily: READING THE VACUUM INDICATOR If the red indicator telltale is entirely visible, change or clean the air cleaner filter element, point 10. This is particularly important if the engine is run at high loads and high speed.

9. Every 200 hours: CLEANING THE AIR CLEANER COARSE CLEANER 1. Remove the cover from coarse cleaner 2.

2. Remove the conical coarse separator. Empty out the particles of dirt and

The coarse cleaner must always be fitted in an upright position.

1

2

clean it.

3. Fit the coarse cleaner as shown in the figure and screw the cover in place.

10. Every 1200 hours: CLEANING OR CHANGING THE FILTER ELEMENT Note: Earlier if the vacuum indicator shows red

Dismantling 1. Remove the side cover from the air cleaner.

2. Change or clean the element.

3

4

1.

2.

3.

4.

Filter element Coarse cleaner Cover Vacuum indicator Air cleaner with coarse cleaner

Note: Cleaning the element always entails a risk of damaging it. The element can only be cleaned a maximum of four times. After cleaning, it has poorer dust capacity than a new element.

3. Mark the filter when it has been cleaned.

Cleaning the element - Carefully blow the filter element clean using dry compressed air from the inside.

Note: This filter element must not be washed with water.

Only use Scania genuine air filter.

Change the filter element if it is damaged.

Danger of engine damage if the filter element is damaged.

Never start the engine without the air filter.

There is a risk of injury or serious engine damage.

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Checking - Insert a torch into the element and check from the outside that there are no holes or cracks in the filter paper.

- Change the filter element if it has the slightest damage. Danger of engine damage.

Assembly 1. Assemble the air cleaner in reverse order.

2. Reset the red plunger in the vacuum indicator by depressing the button.

11. Every 2400 hours: CHANGING THE SAFETY CARTRIDGE

Do not remove the safety cartridge unnecessarily.

Note: Not all filters are equipped with a safety cartridge. When changing the safety cartridge, take great care to ensure that no dirt or other impurities can get into the engine.

1.

2.

3.

4.

5.

6.

Remove the side cover from the air cleaner.

Remove the filter element.

1

Remove the safety cartridge.

Fit a new genuine Scania safety cartridge.

Change or clean the filter element, see point 10.

Assemble the air cleaner.

1. Safety cartridge Air cleaner with safety cartridge

Never clean the safety cartridge

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FUEL SYSTEM

Observe the utmost cleanliness when working on the fuel system.

There is a risk of engine malfunction and damage to the injection equipment.

12. Daily: CHECKING THE FUEL LEVEL - Top up with fuel if necessary.

- If the tank has been run dry, bleed the fuel system, see point 13.

13. Every 1200 hours: CHANGING THE FUEL FILTER Fuel tanks - Drain any water from the fuel tanks.

Main filter - Unscrew the filter lid with a closed tool with hexagon driver, e.g. socket 587 637, so as not to damage the lid.

- Lift out the filter lid and filter element. At the same time, the filter housing will drain automatically. This applies only if the fuel tank is lower than the engine. The fuel shut off valve must otherwise be first shut off.

- Undo the removed filter element from the lid by carefully bending it to one side. Discard the filter according to environmental requirements.

- Renew the O-ring in the cover. Lubricate the new O-ring with a suitable grease.

- Check that the filter housing is drained of fuel. Contaminated fuel may enter the injectors if the drainage does not work.

- Press a new filter element into the snap fastener in the lid.

- Fit the lid with the filter element in the housing. Tighten the lid to 25 +/-5 Nm. Use a closed tool with hexagon driver.

- After changing the water separating filter, bleed the fuel system as instructed on the next page.

Only use Scania genuine fuel filters.

Use a container to avoid spillage when bleeding and changing components.

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Water separating filter - Drainage must be carried out when filling fuel.

- The filter must be changed at the same replacement interval as the main filter.

- Close the drain tap 1 before the filter.

- Unscrew the container and drain valve 3.

- Unscrew and change the filter 2. Lubricate the seal before tightening the new filter by hand.

1. Shut-off cock 2. Filter 3. Drain valve

- Screw the container and drain valve into position.

- Open the drain tap 1.

- Bleed the fuel system after changing both filters.

Bleeding the fuel system A - Attach a clear plastic hose to the bleeder nipple 1 on the fuel filter housing, to lead fuel into a container.

- Open the bleeder nipple and pump with the hand pump 2 until fuel comes out of the hose. When the fuel system is empty, approximately 100 pump strokes will be needed to draw fuel up to the bleeder nipple.

Use a container to avoid spillage when bleeding and changing components.

- Pump until fuel without air bubbles comes out, approximately 20 strokes.

- Close the bleed nipple and remove the hose.

B

A 4

B

1

3

- Transfer the plastic hose to the fuel manifold bleeder nipple 3.

- Open the fuel manifold bleeder nipple and pump with the hand pump until the fuel is free from air bubbles (approx. 50 strokes).

- Close the bleeder nipple on the fuel manifold and remove the plastic hose.

2

- Pump approx. 20 hand pump strokes until the overflow valve 4 opens.

You will hear a creaking sound when it opens.

If the engine fails to start after bleeding. . . . . . .

- Open the bleeder nipple again and pump the hand pump until fuel without air bubbles flows out.

- Tighten the bleeder nipple. Start the engine and check for leaks.

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ELECTRICAL SYSTEM 14. Every 200 hours: CHECKING THE ELECTROLYTE LEVEL IN BATTERIES

Avoid naked flames or sparks near the batteries.

When the batteries are charged, 1. Unscrew the plugs and check the electrolyte level in all cells. oxyhydrogen gas is formed 2. Top up with distilled water until the level is 10-15 mm above the plates. which is inflammable and explosive.

15. Every 1200 hours: CHECKING STATE OF CHARGE IN BATTERIES - Check the density with an acid tester.

Wear gloves and protective goggles when charging and handling batteries The batteries contain a highly corrosive acid.

In a fully-charged battery it should be: 1.280 at +20°C 1.294 at 0° 1.308 at -20°C - If the density is below 1.20, the battery must be charged. A discharged battery freezes at -5°C. Do not rapid-charge the battery. This will damage the battery in the long run.

16. Every 1200 hours: CLEANING BATTERIES 1. Clean batteries, cables and cable terminals.

2. Check that all cable terminals are firmly tightened.

3. Grease battery terminal posts and cable terminals with vaseline.

42

Do not connect the terminals up incorrectly.

This can cause serious damage to the electrical system.

If the terminals are shorted, sparking will occur.

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CHANGING THE BATTERY Removal 1. Disconnect the negative cable (-) from the battery (cable connected to earth).

2. Disconnect the positive cable (+) from the battery (cable connected to starter motor).

Fitting 1. Connect the positive cable (+) to the battery (cable connected to starter

Do not connect the terminals up incorrectly.

This can cause serious damage to the electrical system.

If the terminals are shorted, sparking will occur.

motor).

2. Connect the negative cable (-) to the battery (cable connected to earth).

Dispose of used batteries through an authorised waste disposal contractor.

17. Every 1200 hours: CHECKING THE COOLANT LEVEL MONITOR (optional equipment) 1. Start the engine.

2. Lower the coolant level in the expansion tank.

2-pin level monitor installed in the 3. Automatic stop in the event of a fault: The engine stops, fault code, the expansion tank for radiators indicator lamp comes on and the buzzer (if fitted) sounds if there is no level monitor fault.

supplied by Scania

4. No automatic stop in the event of a fault: The indicator lamp comes on and the buzzer (if fitted) sounds if there is no fault in the level monitor.

5. Top up coolant to the correct level, see page 32.

Use a container to avoid spills when draining the coolant.

Dispose of used coolant through an authorised waste disposal contractor.

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MISCELLANEOUS 18. Every 1200 hours: CHECKING THE DRIVE BELT - If the drive belts (1), which are poly-V belts, are worn or damaged they must be changed.

- Also check that the automatic belt tensioners (2) are in proper working order and keep the drive belts correctly tensioned.

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19. Daily: CHECK FOR LEAKS, RECTIFY AS NECESSARY - Start the engine.

- Check for oil, coolant, fuel, air and exhaust leaks.

- Tighten or change leaking connections. Check the overflow holes (1) (below the side covers) which show whether the O-rings between the cylinder liners and crankcase are leaking, see figure.

Take care to ensure that any leaks do not cause pollution.

a) If coolant is running out, the O-ring is leaking. b) If lubricating oil is running out, the liner shelf is leaking.

- Check that the coolant pump drain hole (2) is not clogged, see figure. If there is leakage, change the pump seal or the complete coolant pump.

A small amount of leakage from the overflow holes during the engine running-in period is normal. (Seals and O-rings are lubricated with soap or oil when fitted).

If serious leakage occurs, contact your nearest Scania workshop.

- This leakage normally stops after a time.

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20. Every 2400 hours: CHECKING/ADJUSTING VALVE CLEARANCES Note: Checking/adjusting valve clearances should also be done after the first 400 hours of operation.

Valve clearances should be adjusted when the engine is cold, at least 30 minutes after running.

WARNING Immobilise the starting device when working on the engine.

If the engine starts out of control, there is a SERIOUS RISK OF INJURY.

The rocker cover gaskets should be changed as necessary.

Tightening torque: 26 Nm. Intake valve clearance: 0.45 mm.

Exhaust valve clearance: 0.70 mm.

Tightening torque for locknut: 35 Nm

Order of adjustment To make sure you adjust on the correct revolution, proceed as follows: - Rotate the flywheel using tool 99 309 so that the 72° mark on the flywheel can be seen in the lower window of the flywheel housing and there is valve overlap on cylinder 5. Refer to table.

- Then turn the flywheel clockwise so that it passes TDC Down (0°) by about 20° and then turn it anticlockwise until TDC Down (0°) is visible in the bottom window on the flywheel housing. The reason for turning past TDC down (0°) and then back is to counteract any backlash.

- You are now on the first revolution and can adjust the valves as shown in the table on the next page.

- Measure the valve clearance using a feeler gauge. Correct valve clearances are also given on the instruction plate on one of the rocker covers.

- Continue to turn the flywheel anticlockwise so that the marking on the flywheel is visible in the lower window on the flywheel housing and adjust the valves as shown in the table on the next page.

1 2 3 4 5 FLYWHEEL

Cylinder numbering

- Check/adjustment of the rockers for the PDE injectors should be done together with the valve clearance check/adjustment. See step 21

Important! The flywheel marking is only correct if the reading is taken through the lower opening.

Flywheel seen from the rear of the engine. * Direction of rotation when adjusting.

The continuous line show which sequence the angles should be measured on revolution 1 and the dashed line show the sequence for revolution 2 46

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Mark on flywheel (reading taken through the lower opening)

Revolution

Valve overlap on cylinder

Adjust the valves on cylinder

1

-

1

2

1

-

144°

1

-

2

504°

2

2

-

288°

1

-

4

648°

2

4

-

72°

1

5

-

432°

2

-

5

216°

1

3

-

576°

2

-

3

TDC Down (0°)

If reading cannot be taken from underneath: - Turn the flywheel with tool 99 309 to valve overlap on cylinder 1 (which corresponds to TDC down (0°) in the lower opening). Then turn the flywheel anti-clockwise 144° at a time and observe the valve overlap. Adjust the valves according to the table below.

Valve overlap on cylinder

Adjust the valves on cylinder

Adjust unit injector rocker arm on cylinder

TDCdown (0°)

1

5

5

(144°)

2

3

3

(288°)

4

1

1

(432°)

5

2

2

(576°)

3

4

4

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21. Every 2400 hours: CHECKING/ADJUSTING THE PDE INJECTOR ROCKERS Note: Checking/adjusting the rockers for the PDE injectors should also be done together with the valve clearance check/adjustment after the first 400 hours of operation.

Important! The unit injectors are adjusted using setting tool 99 414 or a digital sliding caliper.

This adjustment is important as incorrect positioning of the unit injector can lead to poor performance and possible damage.

Order of adjustment - Follow the work description on page 49 and the table below at check/adjustment of the unit injectors.

- The table below is only valid if the reading is taken in the lower opening.

Revolution

Valve overlap on cylinder

Adjust unit injector rocker arm on cylinder

1

-

2

2

1

-

144°

1

-

4

504°

2

2

-

288°

1

-

5

648°

2

4

-

72°

1

5

-

432°

2

-

3

216°

1

3

-

576°

2

-

1

Mark on flywheel (reading taken through the lower opening) TDC Down (0°)

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Measurement A= PDE32: 69,9±0,1 mm Measurement B= PDE32: 38,8 mm

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PDE32: 1. See page 46 for a description of how the engine should be turned to access TDC down (0°) to be able start checking and adjusting the injectors.

2. You are now on the first revolution and can check/adjust the injectors as specified in the table on the previous page.

3. Firstly, measure the distance A between plane a and the top edge of the valve spring washer on the PDE injector using a digital sliding caliper.

See figure.

4. Measurement A should be 69.9 mm for PDE31 (measurement B = 38.8 mm).

5. The dimension is adjusted by undoing the lock nut and screwing the rocker arm adjusting screw 1 to the correct measurement.

WARNING! Take care when carrying out the adjustment if the dimension is well outside the adjustment dimension. The spring is pre-tensioned and can cause personal injury if it is released.

6. Position setting tool 99 442 with the metal plate around the injector spring.

7. Finely adjust dimension A by simultaneously using a finger to sense that the small piston 2 is level with the flat upper surface of the tool. It is possible to sense differences of less than a tenth of a millimetre.

8. If the setting tool is not available, a digital sliding caliper can also be

used for fine adjustment. The rocker position is adjusted by means of the adjusting screw to 69.9 +/-0.1 mm as stated above.

9. Tighten the adjusting screw lock nut to 39 Nm and remove the tool.

10. Continue to turn the flywheel anticlockwise so that the marking on the 99 442

69.9

flywheel is visible in the lower window on the flywheel housing and adjust the valves as shown in the table on the previous page.

If the reading cannot be taken from underneath:

Piston above or below the flat surface. Adjustment necessary

- Turn the flywheel with tool 99 309 to valve overlap on cylinder 1 (which corresponds to TDC down (0°) in the lower opening). Then turn the flywheel anti-clockwise 144° at a time and observe the valve overlap. Adjust the unit injectors according to the table in page 47 and the work decsription above.

Piston level with the flat surface.

The adjustment is correct

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PREPARING THE ENGINE FOR STORAGE If the engine is not to be used for a lengthy period of time, special measures should be taken to protect the cooling system, fuel system and combustion chamber from corrosion and the exterior from rusting.

The engine can normally stand idle for up to six months. If it remains unused for longer than this the following measures, which provide protection for about four years, should be adopted. An alternative to preparing the engine for long-term storage is to start the engine and warm it up every 6 months.

Preparing for storage means: - Thoroughly cleaning the engine - Running the engine for a certain time using special preservative fuel, oil and coolant.

- Otherwise preparing the engine for storage (filter changes, lubrication, etc.).

Preservative coolant If the engine is stored with coolant in the system, the coolant should contain 50% glycol by volume. Glycol without nitrite-based inhibitor should be used.

For example BASF G48 or BASF D542.

Ethylene glycol is highly dangerous if imbibed and can prove fatal.

Avoid contact with the skin.

Preservative fuel - Use diesel fuel oil mixed with Lubrizol 560H or equivalent.

- Mix 1 cm3 (ml) Lubrizol 560H in 10 dm3 (l) of fuel.

!

HANDLING LUBRIZOL 560H Hazardous!

Contains aromatic hydrocarbons Use spot extractors where there is a danger of vapour build-up.

Wear protective gloves and goggles when handling Lubrizol. Do not use contaminated clothing.

If it gets in your eyes: Rinse with a gentle stream of water (at least 15 minutes). Seek medical attention.

If it gets on your skin: Wash the affected area with soap and water

50

If inhaled:

Fresh air, rest and warmth

Inflammable:

Fire class 2A. Flashpoint + 27°.

In case of fire: Extinguish with carbon dioxide, powder or foam.

Storage:

In well-sealed receptacle in a dry, cool place. Keep out of reach of children.

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Preservative oil Suitable preservative oils are supplied by most oil suppliers.

E.g. Dinitrol 40 or equivalent.

Preparations for storage - Drain and flush the cooling system. Top up with preservative coolant.

- Warm up the engine on regular fuel. Stop the engine and drain the oil.

- Renew the fuel filter.

- Fill the engine with preservative oil up to the minimum level on the dipstick.

- Mix preservative fuel in a can. Detach the fuel pipe at the feed pump suction line and connect a hose from the can.

- Detach the fuel pipe at the overflow valve and connect a return hose to the can.

- Start the engine and run it at about 1000 rpm for 20 - 25 minutes.

Use a container to avoid spills when draining the oil and coolant.

Dispose of used oil and coolant through an authorised waste disposal contractor.

- Stop the engine, remove the hoses and connect the regular fuel lines.

- Remove the rocker covers and lubricate the valve mechanisms and PDE mechanisms with preservative oil. Refit the rocker covers.

Note: The PDE injectors should not be removed.

- Drain the preservative oil from the engine. Fresh engine oil can be filled directly or when the engine is taken out of storage.

- Drain the coolant if the engine is not to be stored with coolant in the system. Plug and tape over all coolant connections (if the cooling system is not completely assembled).

- Air cleaner: Clean or change the filter element.

- Cover air intakes and exhaust pipes.

- Alternator and starter motor: - Spray with water-repellent anti-corrosive oil, CRC 226, LPS1 or the equivalent.

- Spray the outside of bright engine parts with penetrating preservative oil, for example Dinitrol 25B, and then with Dinitrol 112 or equivalent.

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- Attach a label to the engine, clearly stating the storage preparation date and that the engine must not be started or cranked.

ENGINE PREPARED FOR LONG-TERM STORAGE Date . . . . . . . . . . .

Batteries Remove the batteries for trickle charging at the battery charging station.

(Does not apply to batteries which according to the manufacturer do not require any maintenance). The same is applicable for short-term storage, even if the engine has not been prepared for storage as above.

Storage After the preparations, the engine should be stored in a dry and warm place (room temperature).

Wear gloves and protective goggles when charging and handling batteries The batteries contain a highly corrosive acid.

Taking out of storage (Procedure when the engine is to be put into operation) - Remove plugs and tape from coolant connections, air intakes and exhaust pipes.

- Fill the system with coolant, see page 18.

- Check the oil level in the engine or fill up with fresh motor oil.

- Lubricate the valve mechanisms and their pushrods and valve tappets as well as the PDE injector mechanisms.

- Drain the preservative fuel from the fuel manifold and fuel filter.

- Connect and bleed the fuel system, see page 41.

- Wash off any externally applied preservative oil, using white spirit.

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TECHNICAL DATA GENERAL

DC9 EMS

Number of cylinders

5 in line

Cylinder diameter

mm

127

Stroke

mm

140

dm3 (litres)

8.87

Displacement No. of main bearings

6

Firing order

1-2-4-5-3

Compression ratio

18:1

Engine direction of rotation viewed from rear

Anticlockwise

Fan direction of rotation viewed from front

Clockwise

Cooling Valve clearances, cold engine intake valve exhaust valve Weight, without coolant or oil *With charge air cooler, radiator, expansion tank and pipes

Liquid mm mm

0.45 0.70

kg

887

LUBRICATION SYSTEM Max. oil pressure hot engine at engine speeds above 1000 r/min

bar (kp/cm2)

Normal oil pressure: hot engine at operating speed

bar (kp/cm2)

3-6

Min. oil pressure: hot engine under 1000 rpm hot engine above 1000 rpm

bar (kp/cm2)

0.7 2.3

6

Oil volume, see page 27 Crankcase pressure with closed crankcase ventilation

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-55 - +20 mm VP

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FUEL SYSTEM

DC9 EMS

Low idle speed

rpm

700 (adjustable 500-800)

Maximum full load speed

See engine card Diesel fuel oil1

Fuel 1

see page 55

COOLING SYSTEM Number of thermostats

1 (dual thermostat)

Thermostat, opening temperature

°C

83

Coolant temperature: system at atmospheric pressure system at overpressure

°C °C

83 - 95 83 - approx. 100

Volume, including radiator, engine and expansion tank with 1.0 m2 radiator

dm3 (litres)

57

System voltage

V

24

Alternator, current

A

80 or 100

kW (hp)

5.5 (7.5)

ELECTRICAL SYSTEM

Starter motor output Monitors, threshold values: oil pressure monitor temperature monitor

54

bar (kp/cm2) °C

1,0 ± 0,15 Programmed in S6

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FUEL Diesel fuel oil The composition of the diesel fuel oil has a great influence on the functioning and the service life of the engine and the injection system. The engine output and exhaust emissions are also dependent on the fuel quality. The requirements and testing standards for the most important properties are described in the service manual in sections which can be ordered from Scania dealers or directly from Scania. The address of Scania is printed on the cover.

Diesel fuel must comply with the following standard: EN 590 (European standard).

The table below shows the requirements for some of the most important properties:

Property Viscosity at 40°C Density at 15°C Sulphur (concentration by mass) Ignitability (CET rating) Flashpoint

Requirement 2.0 - 4.5 mm2/s (cSt) 0.82 - 0.86 kg/dm3 max. 0.3% min. 49 56°C

Environmentally favourable fuels (low sulphur fuels) There are three classes of so called environmentally favourable fuels (SS15 54 35).

Class 1 is sulphur-free and class 2 is low in sulphur. Compared with class 3 (normal fuel), these fuels are less dense and this reduces engine power output.

Only class 1 fuel should be used with a catalytic converter.

Short term use of fuel with a higher sulphur content than 0.05% by weight will not cause permanent damage to the catalytic converter.

The catalytic converter may, however, require fuel with low sulphur content for some time after this to regain its normal efficiency.

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Temperature dependence of diesel fuel At temperatures lower than those specified for the diesel fuel, paraffin wax may precipitate from the fuel and block filters and pipes. The engine can then loose power or stop.

The diesel fuel is adapted for use in the specific climate of each country. If a It is not permitted to mix vehicle or an engine is to be operated in a temperature zone with lower kerosene with diesel fuel that is temperature than normal, first identify the temperature properties of the already adapted for the climate fuel concerned.

concerned. This can damage the PDE injectors. All use of paraffin other than kerosene is - If the fuel concerned cannot cope with the expected temperatures, and forbidden, as it causes engine diesel fuel is not available with the correct temperature properties, we damage.

The properties of the fuel when cold can be improved by adopting one of the following measures before the temperature drops:

recommend that an electric fuel heater is installed as a preventative measure.

- The low temperature properties of diesel fuel may be improved by adding kerosene as a preventative measure. A maximum of 20% may be added. When refuelling, the kerosene should be added first, so that it mixes thoroughly with the diesel fuel.

It is not permissible to mix petrol with diesel fuel. In the some countries. long term, petrol may cause - To prevent water in the fuel from freezing and forming ice, a maximum wear to the PDE injectors and it of 0.5-2% alcohol (isopropanol) may be added. may also cause damage to the Drain fuel tanks and drain or change fuel filters regularly. engine.

Note: It is prohibited to use kerosene in engine fuel in

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ALPHABETICAL INDEX

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air cleaner, prefilter . . . . . . . . . . . . . . . . . . . .

Air cleaner, safety cartridge . . . . . . . . . . . . . .

Air cleaner, vacuum indicator . . . . . . . . . . . . .

Air filter, element . . . . . . . . . . . . . . . . . . . . . .

38 38 39 38 38

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Bleeding, fuel system . . . . . . . . . . . . . . . . . . . 41 Certified engines . . . . . . . . . . . . . . . . . . . . . . . . 5 Changing the battery . . . . . . . . . . . . . . . . . . . . 43 Changing the fuel filter . . . . . . . . . . . . . . . . . . 40 Checks after running . . . . . . . . . . . . . . . . . . . . 23 Checks before running . . . . . . . . . . . . . . . . . . 19 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Coolant level monitor . . . . . . . . . . . . . . . . . . . 43 Coolant temperature . . . . . . . . . . . . . . . . . . . . 21 Coolant, changing . . . . . . . . . . . . . . . . . . . . . . 35 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 32 Cooling system, cleaning . . . . . . . . . . . . . . . . 36 Corrosion inhibitor . . . . . . . . . . . . . . . . . . . . . 35 Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electrical system . . . . . . . . . . . . . . . . . . . . . . . 42 EMS engine management system . . . . . . . . . . 12 EMS sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Environmental responsibility . . . . . . . . . . . . . . 4 Filter, air cleaner . . . . . . . . . . . . . . . . . . . . . . .

Filter, closed crankcase ventilation . . . . . . . . .

Filter, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .

First start . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flashing codes, control unit . . . . . . . . . . . . . .

Flashing codes, coordinator . . . . . . . . . . . . . .

Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel specifications . . . . . . . . . . . . . . . . . . . . .

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel system, bleeding . . . . . . . . . . . . . . . . . . .

38 31 40 18 15 17 40 55 40 41

Lubricating oil pressure . . . . . . . . . . . . . . . . . . 22 Lubricating oil system . . . . . . . . . . . . . . . . . . . 26 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Maintenance Schedule . . . . . . . . . . . . . . . . . . 25 Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Oil volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 PDE injectors . . . . . . . . . . . . . . . . . . . . . . . . . 48 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Prefilter, air cleaner . . . . . . . . . . . . . . . . . . . . . 38 Preparations for storage . . . . . . . . . . . . . . . . . . 50 Safety cartridge, air cleaner . . . . . . . . . . . . . . . 39 Safety information . . . . . . . . . . . . . . . . . . . . . . . 6 Safety precautions for care and maintenance . . 8 Safety precautions for handling materials . . . . . 8 Safety precautions for running the engine . . . . 7 Starting the engine . . . . . . . . . . . . . . . . . . . . . . 19 Stopping the engine . . . . . . . . . . . . . . . . . . . . . 23 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Taking out of storage . . . . . . . . . . . . . . . . . . . 52 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 53 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 14 Troubleshooting, control unit . . . . . . . . . . . . . 14 Troubleshooting, coordinator . . . . . . . . . . . . . 16 Type designations . . . . . . . . . . . . . . . . . . . . . . 10 Vacuum indicator . . . . . . . . . . . . . . . . . . . . . . 38 Valve clearances . . . . . . . . . . . . . . . . . . . . . . . 46 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 2005-11:1

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