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:

Will not start •Main switch disconnected •Turn on •Out of fuel Refill fuel, bleed system •Low battery current Recharge •Blown fuse Check circuit, replace fuse •Defective wiring Check connections, wires •Hydrostatic lock Repair* •Starter motor defective Replace* •Electronic controller or sensors defective Check/repair*

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

Low output •Fuel system disturbance Check fuel lines, bleed system •Condensated water in diesel Drain tank •Bad fuel quality Change fuel •Low fuel level Refill fuel •Fuel filters clogged Replace filters •Air filter clogged Replace or clean •Fuel tank breather clogged Clean tank cover •Throttle system disturbance Adjust/replace/repair •Wrong injection timing Adjust* •Injector defective Repair/replace* •Turbo charger defective Repair/replace* •Worn engine or internal damage Overhaul* •Electronic controller or sensors defective Check/repair*

Overheated (warning light) •Low coolant level Add coolant, check for leakages •Fan belt problem Tighten/replace •Air in cooling system Bleed system •Dirt inside cooling system Clean and replace coolant •Radiator fins clogged/damaged Clean •Thermostat faulty Replace •Sensor/gauge defective Replace •Coolant pump worn Overhaul*

Low coolant temperature •Sensor/gauge defective Replace •Thermostat stuck open Replace

Low oil pressure •Too low oil level Add oil, check for leakage •Incorrect oil type Change to correct oil type •Sensor/gauge defective Replace •Oil pressure red. valve faulty Overhaul* •Worn oil pump Overhaul*

Blue smoke, oil consumed

Black or white smoke

Oil in coolant or coolant in oil •Too high oil level Adjust to specified level •Incorrect oil type Change to correct oil type •Worn engine or internal damage Overhaul*

•Clogged air filter Replace or clean •Fuel pump/injection system worn or faulty Adjust/repair* •Cylinder gasket defective Replace* •Turbocharger defective Repair/replace*

•Internal leak in transmission cooler Replace* •Worn engine or internal damage Overhaul* •Internal leak on engine oil cooler Replace*

Knocking noise •Bad fuel quality Change fuel •Valves incorrectly adjusted Adjust •Injection pump incorrectly adjusted Adjust* •Injector defective Replace* •Worn engine or internal damage Overhaul*

Main warning light illuminates •Engine / engine controller failure Stop the dump truck at a safe place and check the error codes on the engine controller.

Following error codes can be read on the engine controller: • Control status lamp lights •Engine controller has detected an internal fault. Check/repair* • Shut down lamp lights •Engine temperature has reached a warning threshold or the sensor has failed. Check/repair* • Torque limit lamp lights •Air inlet temperature has reached a warning threshold or the sensor has failed. Check/repair* • Power - lamp lights •Speed potentiometer or idle safety switch has failed. Check/repair*

Main warning light flashes SHUT DOWN CONDITION •Engine / engine controller failure Stop the dump truck at a safe place, check the error codes on the engine controller and stop the engine as soon as possible.

Following error codes can be read on the engine controller: • Control status lamp lights • Engine controller has detected an internal fault. Check/repair* • Shut down lamp lights •Engine temperature has reached a shut down threshold or the sensor has failed. Check/repair* • Starting lamp lights • Engine has exceeded its overspeed threshold. Check/repair* • Running lamp lights •Actuator feedback sensor failure. Check/repair* • Boost limit lamp lights •Engine controller has detected a loss of boost pressure. Check/repair* • Power + lamp lights •Oil pressure has dropped below a threshold level or the sensor has failed. Check/repair*

Transmission:

Too high temperature

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

Low oil pressure •Too low oil level Add oil, check for leakage •Incorrect oil type Change to correct oil type •Cooling circuit failure Check/repair •Lock-up fault Overhaul* •Worn oil pump Overhaul*

•Too low oil level Add oil, check for leakage •Blown fuse Check circuit •Converter prop. shaft Replace •Electronic controller detect failure, neutral engaged Check/repair* •Electronic controller or sensors defective Check/repair* •Flywheel damper separated Replace* •Drive line failure Check/repair* •Internal transmission failure Overhaul* •Automatic central lubrication failure Check/repair*

•Too low oil level Add oil, check for leakage •Incorrect oil type Change to correct oil type •Sensor/gauge defective Replace •Pressure control valve failure Check/repair* •Worn oil pump Overhaul* •Internal transmission failure Overhaul/replace*

Noise •Too high oil level Adjust to specified level •Incorrect oil type in differential(s) Change to correct type •Worn transm. or internal damage Overhaul/replace*

Main warning light illuminates •Transmission / transmission controller failure Stop the dump truck at a safe place, select neutral gear position and check the error codes on the gear display.

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

Brakes:

Poor braking effect or truck pull to one side when braking

Air system:

•Low brake fluid level Add fluid, check for leakage •Uneven worn brake pads Replace pads •Air in brake fluid circuit Bleed brakes •Insufficient air pressure Check charging and system •A brake caliper is stuck Repair*

Low air pressure (all circuits) •System leakage Check circuits •Governor problem Adjust setting/repair •Compressor failure Overhaul*

High air pressure •Governor problem Adjust setting/repair

Hydraulic system:

Emergency steering light on when driving • No oil flow from main pump, or no oil flow from emergency pump

Check and repair* Check and repair* •Oil flow switch defective Replace*

Truck will not go straight ahead, uneven steering movement or periodically sticking

Not possible to tip or slow tipping

Electrical system:

No electrical power •Low hydraulic oil level Add oil, check for leakage. •Air trapped in hydraulic system Bleed system •Contaminated oil Change oil and flush system •Incorrect oil type Change to correct oil type •Steering cylinders internal leak Overhaul* •Orbitrol or steering valve failure Check and repair*

•Low hydraulic oil level Add oil, check for leakage •Clogged oil filter Replace •Insufficient air pressure Check charging •Clogged tank strainer or breather Replace/clean •Low oil pressure Check/repair* •Worn oil pump Check/repair* •Tip valve failure Overhaul*

•Main switch disconnected Turn on •Batteries discharged Recharge •Battery terminals/wiring defective Repair

Charge warning light on •Fan belt problem Tighten/replace •Defective/worn alternator Replace •Defective wiring Check connections, wires

Chassis:

Uncomfortable travel (jumping) •Defective shock absorber Replace •Defective rubber suspension Replace •Articulation turning ring worn Overhaul*

Vibrations •Engine or transm. mountings Replace •Fan or flywheel loose/imbalance Check/repair* •Defective elastic coupling Check/repair* •Prop. shaft failure Check/repair* •Drive line problem Check/repair*

Lubricants

6.Lubricants .................................................................123 - 130

Lubrication schedule.................................................125

Oil specification sheet ...............................................127 Filling capacities........................................................128 Transmission oil list...................................................129