Daewoo Doosan MT27 MT30 (RS) ADT Operation & Maintenance Manual – PDF DOWNLOAD

MX159345-1 August 2014

ADT

Operation & Maintenance Manual MT27 / MT30 (R/S) Serial Number 353934 and Up

Operation & Maintenance Manual MT27 / MT30 (R/S) ADT Serial Number 353934 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

MX159345-1 August 2014 Copyright Doosan 2011

OPERATING & MAINTENANCE MANUAL MT27 / MT30 (R/S) Serial no. 353934 and up

Part no.:159345 Edition: 10. April 1997 Manufacturer:

Dealer:

N-6440 ELNESVÅGEN - NORWAY

Printed in Norway

CONTENTS 1. Foreword ..................................................... 1-4 2. Safety instructions...................................... 2-1 - 2-14 3. Operating controls ..................................... 3-1 - 3-20 Dashboard .................................................... 3-3 Instruments................................................... 3-4 Warning / Indicator lights ............................ 3-7 Switches ....................................................... 3-9 Controls ........................................................ 3-12 Other cabin equipment ................................. 3-18 4. Running in period ...................................... 4-1 - 4-6 Running in operation ................................... 4-3 Running in services ...................................... 4-4 5. Operating instructions ............................... 5-1 - 5-22 Starting the engine ....................................... 5-3 Operating the machine ................................. 5-4 Stopping the engine ..................................... 5-12 Parking the machine ..................................... 5-12 Loading and tipping ..................................... 5-13 Tyre handling ............................................... 5-14 Cold weather ................................................ 5-15 Long term storage ........................................ 5-15 Battery power aid ......................................... 5-16 Towing the machine ..................................... 5-16 External air filling ........................................ 5-17 Manual release of parking brake .................. 5-17 Tyre filling point .......................................... 5-17 Trouble shooting .......................................... 5-18 6. Lubricants................................................... 6-1 - 6-10 Lubrication schedule .................................... 6-3 Oil specification sheet .................................. 6-5 Filling capacities .......................................... 6-6 Transmission oil list ..................................... 6-7 7. Maintenance ............................................... 7-1 - 7-34 Precautions for maintenance ........................ 7-3 Maintenance table ........................................ 7-4 8 hours / daily service .................................. 7-5 40 hours / weekly service ............................. 7-13 250 hours service ......................................... 7-15 500 hours service ......................................... 7-20 1000 hours service ....................................... 7-23 2000 hours service ....................................... 7-28 Maintenance when required ......................... 7-31 8. Technical data ............................................ 8-1 - 8-14 Measurements .............................................. 8-3 Engine .......................................................... 8-4 Transmission ................................................ 8-4 Hydraulic system ......................................... 8-5 Air system .................................................... 8-5 Tyre inflation ............................................... 8-5 Electrical system .......................................... 8-6 Metering conversion table ........................... 8-7 Tool kit content ............................................ 8-7 Performance chart ........................................ 8-8 Exhaust brake capacity chart ....................... 8-9 Optional: Retarder brake capacity chart ...... 8-10 Torque limit tables ....................................... 8-11 Reference information (fill in tables) ........... 8-11 Periodic service (fill in tables) ..................... 8-12 1-3

Operating & Maintenance Manual

1. FOREWORD

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

1. Read this manual carefully before operating the machine.

2. Continue studying the manual until proper operating is completely converted into personal habit.

3. This manual describes the basic techniques. The operator skill will increase with correct knowledge of machine operation.

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

The manufacturer can not be held responsible for damage or injury caused through improper handling, operation and utilization of the dump truck in other ways than those described in this manual. Nor can the manufacturer be held responsible for unauthorized modifications or the neglect of local or national government regulations.

This Operating & Maintenance Manual may contain attachment and optional equipment that not are available in your area. Please consult your local MOXY dealer for those items you may require.

GENERAL DESCRIPTION. Moxy MT27 / MT30 are articulated, constant 6-wheel drive dump trucks suitable for earthmoving at sites, both on- and off-road condition as well as in-terrain travel. The wide range of optional equipment allows the dump truck to be applied in several different applications.

1.

2.

3.

4.

5.

Dump body Operator cab Fuel tank Engine bonnet Head, parking and direction light 6. Hydraulic tank 7. Air cleaner 8. Rear frame

Operating & Maintenance Manual

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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 optional equipment and attachments.

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2. SAFETY INSTRUCTIONS

CONTENTS 2. Safety instructions...................................... 2-1 - 2-14 1. General precautions ................................ 2-3 2. Operation precaution .............................. 2-3 3. Machine turning ..................................... 2-3 4. Machine knowledge ............................... 2-3 5. Emergency exit ....................................... 2-4 6. Emergency steering ................................ 2-4 7. Machine inclination ................................ 2-4 8. Operation of brakes ................................ 2-5 9. Wading ................................................... 2-5 10. Optional: Exhaust heated body .............. 2-5 11. Optional: Top tailgate ............................ 2-6 12. Engine bonnet......................................... 2-6 13. Body support .......................................... 2-7 14. Service position ...................................... 2-7 15. Brake blocks ........................................... 2-8 16. Articulation lock ..................................... 2-8 17. Lifting / hoisting ..................................... 2-8 18. Truck transportation ............................... 2-9 19. Welding .................................................. 2-9 20. High pressures ........................................ 2-9 21. Safety labels ........................................... 2-10

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Operating & Maintenance Manual

2. SAFETY INSTRUCTIONS

1. GENERAL PRECAUTIONS. See also Precautions for maintenance.

Observe all rules, precautions and instructions related to each job and work site. Use suitable clothing, and safety shoes, helmet, gloves, etc if necessary.

Use handrails and steps when entering and getting off the truck. Do not jump! Clean off grease, oil, snow and dirt to avoid slippery truck surfaces.

Be aware of and confirm the presence of safety devices such as fire extinguisher, first aid kit, warning triangle, etc. Learn how to use them.

Keep the cabin tidy and secure loose objects. Clean the windows, mirrors and lights and adjust mirrors to obtain best visibility.

Check the site and determine dangerous areas. Take every precaution for safe operation to avoid accidents and dangerous incidents.

Do not operate the truck if failures, damages or other discrepancies are detected.

2. OPERATION PRECAUTIONS. Further details in Operating instructions.

Before driving the dump truck, check that no persons or objects are in the area.

Fasten the seat belt and be seated during travel. Standing up is dangerous! Concentrate and evaluate surroundings. Stop the dump truck if you are uncertain of operation safety.

Slow driving is required to ensure that operation can be done without hazards, especially in curves, narrow roads, hills/cliffs, bumpy or slippy ground, or if the visibility is restricted.

Pay attention and keep a safe distance from other vehicles and nearby people. Be sure that no persons or objects are situated in the articulation area before turning or behind the truck before reversing or tipping.

3. 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 is possible.

It is possible that the operator will not receive warning signs of an overturn, therefore: 1. Avoid high speed turning and hard braking in curves.

2. Reduce speed, avoid sudden turning if travelling across slopes is necessary.

3. The rear chassis stability decreases when tipping. Be alert when body is raised.

Do not travel with raised body!

4. MACHINE KNOWLEDGE.

WARNING

Learn how to use the control devices, instruments and warning devices. Be sure you understand the meaning of the CAUTION signs and other warnings. Always know the dimension and performance limits of your machine.

Remember the check points and checking method of fluid levels.

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2. SAFETY INSTRUCTIONS

5. EMERGENCY EXIT. Your dump truck is fitted with an emergency exit. If the doors are blocked by any means, the frontscreen can be removed by pulling the handle under the window backwards. The rubber lining must be pulled completely off before pushing the front screen out.

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6. EMERGENCY STEERING. The emergency steering system will be activated if the main steering system fails or if the engine stops. It is possible to steer the truck when it is in motion, but the movement will be slower.

If the emergency steering light illuminates at truck speeds above approx. 5 km/h:

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Stop as soon as possible and park in a safe place! Continued driving may result in uncontrollable steering. Amend the failure before operating the truck again. If necessary, contact authorized dealer.

7. MACHINE INCLINATION. Max. allowed machine inclination during operation: 26o (49%) downhill driving.

30o (58%) uphill driving.

10o (17%) sideways.

The given angles are also valid for empty machine where limits are determined by ground conditions, gradients etc.

Always travel straight up or down on slopes. Consult your dealer for accurate information.

NOTE! Safe inclination angle depends on ground condition, friction, available traction and weight on the wheels!

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Operating & Maintenance Manual

2. SAFETY INSTRUCTIONS

8. OPERATION OF BRAKES. The main brakes must never be applied for a long period 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. See also Operating Instructions.

The max. downhill slope is 10o to keep a fully loaded machine at an even speed with the engine brake applied, depending upon slope (road) condition.

Optional: Retarder brake The max. downhill slope is 12,5o to keep a fully loaded machine at an even speed with the retarder brake applied, depending upon slope (road) condition.

9. 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 stream 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 discs are wet.

The maximum wading depth is: 0.8 meter (with 20.5R25 or 25/65R25 tyres) 0.9 meter (with 23.5R25 tyres). i.e. up to the front fenders or steering cylinders.

Under no circumstances let water flow through the grill!

10. OPTIONAL: EXHAUST HEATED BODY If the body is exhaust heated, explosives and inflammable materials like petrols, oils, etc. must not be transported.

To blind off the exhaust heating following must be done: Always allow dump truck to cool down before changing exhaust gas direction.

1. Remove the clamps.

2. Remove cover which gives heating of body.

3. Install the plate which blind off the exhaust to the body 4. Refit the clamps.

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2. SAFETY INSTRUCTIONS

11. OPTIONAL: TOP TAILGATE. For safe tipping: See Operating Instructions.

If a top hinged tailgate is fitted, particular attention should be paid to the material handled by such trucks 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 continous 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.

NOTE! The manufacturer cannot be held responsible for any damage that may occur through improper use of the top hinged tailgate.

Removal of the top tail gate: Raise the body and secure it with the tip support.

Attach wire or chain to the lifting point (arrow).

Remove screw on body bracket (both sides) and lift the tail gate ass'y up.Approx. weight: 300 kg.

12. ENGINE BONNET.

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

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

To close the bonnet: * Lift the bonnet catcher. * Push the bonnet down. * Apply the locks on both sides.

Operating & Maintenance Manual

2. SAFETY INSTRUCTIONS

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

1. Raise the body.

2. Lift the body support in top position.

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

4. Return the tip handle to neutral (hold) position.

5. Stop the engine and remove the ignition key.

Lift the body slightly for disengagement of the support device.

NOTE! It is hazardous to stay underneath the body without applying the body support device! Do not operate the truck when the body is raised and secured!

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

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

Block the wheels (see point 15).

- Apply the articulation lock (see point 16).

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

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

- Be aware of hot fluids and components.

- Drop the air system pressures (see point 20).

- Block up all lifted components to prevent them from falling during stay underneath.

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

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2. SAFETY INSTRUCTIONS

15. BRAKE BLOCKS. Always place wheel chocks under the wheels to avoid spontaneous rolling: - when parking on slopes, - during maintenance and other work - during transportation.

16. ARTICULATION LOCK. The lock prevent dump truck turning when applied.

- Take out the spring cotter, lift the pin and swing the linkage forward into the hinge ear.

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

- Unlock the opposite way.

The lock must always be applied:

Lock Open Linkage

* During maintenance, greasing and other work. * When lifting or hoisting the truck, see below. * During dump truck transportation, see below.

17. LIFTING / HOISTING. Apply the articulation lock.

Open the bonnet.

Fit suitable lifting wires or chains to the Hoisting Points at both sides of the body and engine.

The lifting wires / chain must be vertically positioned during lifting operation.

Machine net weight: approx. 18250 kgs.

NOTE! Never lift or hoist a loaded truck, the points are intended for empty body only!

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Operating & Maintenance Manual

2. SAFETY INSTRUCTIONS

18.TRUCK TRANSPORTATION. Apply the parking brake.

Apply the articulation lock.

Apply wheel blocks, if necessary.

Fit suitable wires or chains to the Tie Down Points as shown and tighten them up.

2 eyes in front

2 eyes on the frame

NOTE! Always transport the truck without load in the body!

19. WELDING.

Electronic control unit

The dump truck is equipped with an electronic control unit.

Before welding on the dump truck: 1. Disconnect batteries.

2. Unplug the connector on the electronic control unit. The unit is located in side right hand dashboard panel.

3. Earth point should be within 1 m from welding point.

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

20. HIGH PRESSURES. Be aware of high pressure in the hydraulic system (at running engine), air system, brake fluid system (at operated service brakes) and tyres. Do not strike or bend pressure hoses or tubes. Do not use bare hand for checking leaks, use bord or cartboard to avoid personal injury. Even a pin-holesize leak can penetrate body tissue. Always release pressure before maintenance or servicing: Hydraulic: Stop the engine. Be aware of possible hot oil.

Air: Stop the engine, drain all air tanks and air dryer unit, see Maintenance chapter.

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

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2. SAFETY INSTRUCTIONS

21. SAFETY LABELS. The following labels are related to safety and should always be present and easy readable: Cab certification.

The cab has been approved to current ROPS/FOPS standards. Structural damage, an overturn, modification, alteration or unpermitted repair can affect the cab strength and thereby voiding the certification.

Consult your Moxy dealer to determine this structure’s limitations without voiding it’s certification.

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6

13

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3

14

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Operating & Maintenance Manual

2. SAFETY INSTRUCTIONS

1.

ROPS/FOPS approved cab.

2.

Keep clear, pinch danger in articulation area.

3.

Keep clear, limited visibility.

4.

Keep clear, body support.

5.

Danger, use of top tailgate.

6.

Danger, system under pressure.

7.

Keep clear, engine running.

8.

Danger, body is exhaust heated.

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2. SAFETY INSTRUCTIONS

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9.

Danger, welding precaution.

10.

Danger, never travel in neutral.

11.

Danger, operate exhustbrake below 2400 rpm.

12.

Note, check oil specification.

13.

Note, sling point.

14.

Emergency exit.

15.

Note, proper use of machine, read Operating Manual

16.

Danger, battery acid and gases.

Operating & Maintenance Manual

2. SAFETY INSTRUCTIONS

17.

First aid kit

18.

Fire extinguisher

19.

Danger, hot water can spurt out.

20.

Diesel tank

21.

Hydraulic tank

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2. SAFETY INSTRUCTIONS

MEMO

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Operating & Maintenance Manual

3. OPERATING CONTROLS

OPERATING CONTROLS

Operating & Maintenance Manual

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3. OPERATING CONTROLS

CONTENTS 3. Operating controls ..................................... 3-3 - 3-20 Dashboard .................................................... 3-3 Instruments ................................................... 3-4 Warning / Indicator lights ............................. 3-7 Switches ....................................................... 3-9 Controls ........................................................ 3-12 Other cabin equipment ................................. 3-18

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Operating & Maintenance Manual

3. OPERATING CONTROLS

DASHBOARD

Normal optional equipment is also shown and described

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2

3

4

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6

7

8 10 9 11 12 29 13 14 15

27 26 25 24 23

17 22 21 20

19

18

16

Optional: Retarder brake handle

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Pos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Description Engine gauge Warning / indicator lights Warning / indicator lights Engine revolution gauge Optional: Speedometer Warning /indicator lights Warning /indicator lights Transmission / air gauges Optional: Tachograph Emergency exit handle Ignition Cigarette lighter Switches Parking brake lever Tip control lever Throttle pedal

Page 3-4 3-7 3-7 3-4 3-4 3-8 3-8 3-5 3-5 2-4 3-12 3-12 3-9 3-12 3-12 3-13

Pos Description Page 17 Transmission gear selector 3-13 Optional: Manual transm. gear selector 3-14 18 Brake pedal 3-14 19 Steering column 3-14 20 Engine stop handle 3-15 21 Column switch 3-15 22 Differential lock pedal 3-15 23 Optional switches 3-10 24 Switches 3-10 25 Switches 3-11 26 Switches 3-11 27 Cab ventilation controls 3-11 / 3-15/16 Fan switch 3-11 / 3-15/16 28 Gear display 3-6 29 Optional switches 3-9 30 Optional: Retarder brake handle 3-17

Operating & Maintenance Manual

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3. OPERATING CONTROLS

INSTRUMENTS. 1A. Fuel gauge.

The gauge indicates fuel tank level from empty to full.

Tank capacity: approx. 270 l. Top up with diesel when necessary, and at the end of the shift.

If driving out of fuel: Bleed the fuel system.

1B. Engine coolant temperature gauge.

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5

The gauge indicates the engine coolant temperature.

Normal range is 75-85 oC, max. operating temp. is 100 oC. Run engine at moderate speed and load until operating temp. is reached (warm-up period). If pointer exceeds 102 oC (warning light 3A), the engine load must be reduced. If temperature does not drop, stop the engine (possible fault).

1C. Not used.

1D. Engine oil pressure gauge.

The gauge indicates the engine oil pressure. Normal is 3-6 bar (above 800 rpm) at operating temperature. Minimum pressure at 800 rpm and warm oil is 0,7 bar. Pressure above 6 bar is normal at start of cold engine. At warning for low pressure (warning light 3D) the engine must be stopped immediately and fault remedied before restart.

4 4. Engine revolution gauge.

The gauge indicates the engine rpm.

Normal revolutions: Low idle: 700 rpm.

Max. torque and economic area: 1200-1800 rpm (in lock-up).

Max. output: 2200 rpm.

Max. allowed rpm: 2600 rpm.

During operation, avoid engine speeds below approx. 1200 rpm (lock-up clutch disconnection speed). Engine speed above max. is prohibited (it can damage the engine).

The hourmeter is electrical and indicates operated hours of the engine.

5. Optional: Speedometer.

The gauge indicates the dump truck travel speed in kilometer per hour (km/h) and miles per hour (mph). The counter indicates the travel distance in kilometer.

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3. OPERATING CONTROLS

8A. Transmission oil temperature gauge.

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8

The gauge indicates the oil temperature in the transmission.

Normal range is 80-110 oC, max. permitted: 120 oC. If temperature above maximum is reached during operation, stop immediately, select neutral gear, and run engine at mid-range speed for a while to cool down the oil. The reason for the high temperature could be use of a too high gear range or failure in the oil cooling system.

Optional: Retarder brake A temperatur of max. 150 oC is allowed during retarder operation. If warning light 6E lights up, stop immediately, select neutral gear, and run engine at mid-range speed for a while to cool down the oil. The reason for the high temperature could be use of a too high gear range or failure in the oil cooling system.

8B. Air pressure gauge (front axle brake).

The gauge indicates the air pressure in brake circuit 1.

Normal operating pressure is between 6.8 and 7.8 bar. Do not attempt to drive machine at air pressure below 5 bar.

Warning light 2A will light, and a warning buzzer will sound when the pressure is below 4.5 - 5 bar.

8C. Transmission oil pressure gauge.

The gauge indicates the oil pressure in the transmission clutches. Normal pressure is 16-18 bar in normal drive.

During gear shift, the pressure will drop for a moment. If the pressure stays lower than normal, the machine should be stopped immediately, and the failure corrected.

8D. Air pressure gauge (rear axle brake).

Same value as 8B for the brake circuit 2 (warning light 2B).

9. Optional: Tachograph

9

The gauge with incorporated clock indicates the dump truck travel speed in kilometer per hour (km/h) and the travel distance in kilometer. The replaceable card is situated inside the gauge. Opening and activating of the gauge with keys. Can indicate 3 different drivers by different keys.

Utilize the tachograph in accordance with the manufacturers instructions and national government regulations for such equipment.

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3. OPERATING CONTROLS 12345671234567 12345671234567 12345671234567 1234567 123456789 12345671234567 12345678 12345678912345678 12345678912345678 12345678912345678 12345678912345678 123456789 12345678 123456789 12345678912345678 12345678 123456789

28. Gear display

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28

1 Pos 1

2

3

4

Shows gear ranges: 1st gear 2nd gear 3rd gear D Automatic modus 1 - 6 Indicates Lock-up is engaged (replaces symbols for automatic/resp. fixed gears position as long as lock-up is engaged).

Pos 2

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

Pos 3

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

Pos 4

Starts flashing when an error has occured.

Error can be read when gear lever is switched to neutral position.

Following error codes can be read: Code 22 Incorrect gear selector input line combinations Code 23 Short-circuit of an output to ground Code 24 Faulty voltage supply Code 31 Fault in the data field Code 32 Fault in the program flow Code 33 Fault in the processor RAM Code 02 (42*) Failure of turbine speed sensor Code 10 (50*) Failure of output speed sensor Code 21 (61*) Cut-off/external power supply (+) to less critical outputs. * = Error code nos. 02, 10 & 21 will also indicate temporary failure even when eliminated. The value of actual failure under these circumstances is increased by +40 i.e to 42, 50 or 61.

Special features:

"NN" - means "waiting for gear selector neutral position" (Not Neutral) and will be indicated when ignition is switched on while selector is not in neutral position.

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

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3. OPERATING CONTROLS

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WARNING / INDICATOR LIGHTS 2A. Front axle brakes warning light (red).

Lights if air pressure in brake circuit 1 is below approx. 5 bar. (The buzzer will sound.)

2B. Rear axle brakes warning light (red).

Lights if air pressure in brake circuit 2 is below approx. 5 bar. (The buzzer will sound.)

2C. Parking brake circuit warning light (red).

Lights if air pressure in brake circuit 3 is below approx. 5 bar. (The buzzer will sound.)

2D. Parking brake indicator (red).

Lights when the parking brake (14) is engaged. The light will flash and a buzzer sound intermittently if the parking brake is on and a gear selected.

2E. Brake fluid warning light (red).

Lights if failure in a brake fluid circuit when brakes are operated (too long stroke in a master cylinder due to air in the system or leakage).

2F.

Emergency steering warning light (red).

Lights if failure in the steering circuit. Indicates low oil supply from main pump and that the emergency steering is activated. Will also light when machine is stationary and during slow driving.

3A. Engine temperature warning light (red).

Lights if engine coolant rises above 102 oC. 3B. Air filter warning light (red).

Lights if engine air filter is clogged and needs maintenance.

3C. Direction light indicator (green).

Flashes when direction light (21E/F) or hazard light (26C) is engaged. Will not flash if an external bulb is burnt out.

3D. Engine oil pressure warning light (red).

Lights if oil pressure is lower than 0.7 bar.

3E. Battery charge warning light (red).

Lights if battery charging is low (failure with alternator or fan belt).

3F.High beam indicator (blue).

Lights when head lights at high beam (switch 21).

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3. OPERATING CONTROLS

6 7

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6A. Engine brake indicator (green).

Lights when the engine brake is activated.

6B. Optional: Retarder brake indicator (green).

Lights when the retarder brake is activated.

6C. Transmission load indicator (green).

Lights when Kick down mode is activated.

6D. Lock-up indicator (green).

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

6E. Optional: Retarder brake indicator (red).

Lights if the transmission oil temperature after the cooler is above 120 oC. 6F.

Transmission load indicator (green).

Lights when Partial load mode is activated.

7A. Optional: Air condition indicator (green) Lights when the air condition compressor runs.

7B. Rotating beacon indicator (green).

Lights when the optional rotating beacon is engaged (switch 26B).

7C. Work light indicator (green).

Lights when work light at the roof (switch 25C) is engaged.

7D. Inter axle diff. lock indicator (green).

Lights when inter axle differential lock is meshed.

7E. Optional: Mirror heater indicator (green).

Lights when the electrical heated mirrors (switch 25A) is engaged.

7F.

Reversing light indicator (greeen).

Lights when a reverse gear is engaged.

C B

29A. Optional: Flame start system indicator light (green)

A

Lights when the flame start is activated.

29

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3. OPERATING CONTROLS

SWITCHES. 29A. Optional: Control light for flame start system See description under warning / indicator lights.

C

29B. Optional: Flame start system switch

B A

29

Push the switch and keep depressed to activate the flame start system. The switch must be kept depressed for 15 sec before the engine starts (pre-heating). Keep the switch depressed while the engine starts. When the engine have started the switch can be released and the time relay will automatically keep the system going for 5 minutes, as long as no interruption is done (see 29C).

Built-in light.

NOTE! The flame start system will only be activated if the switch is kept depressed while the engine starts and the gear selector is in neutral.

29C. Optional: Flame start system cancellation switch To interrupt the connection to the glow plug, the cancellation switch must be depressed to break the circuit to the time relay.

Interruption of the connection to the glow plug can also be done in two other ways: 1. Move the gear selector from neutral to foward or reverse gear.

2. Switch off the ignition after the engine has stopped.

13

13A. Spare space.

13B. Engine brake switch. (Not valid for U.S. market) Push to engage the engine brake. The brake will be applied when the throttle pedal is fully released, and the transmission is in lock-up.

An indicator light (6A) will light. Built-in indicator light.

NOTE! Do not operate the engine brake at speeds above 2400 rpm!

13C. Optional: Inter axle diff. lock switch Push to engage the inter axle diff. lock. The throttle pedal must be fully released to activate the lock. An indicator light (7D) will light when the lock is meshed. Built-in light.

Only to be engaged when truck is stationary, see 5. Operating Instructions.

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3. OPERATING CONTROLS

23A. Optional: Automatic central lubrication switch Push to engage the lubrication system for extra greasing of the connected points. Built-in light.

The lubrication system is electrically operated and an electronic timer is incorporated into the pump unit. It will automatically lubricate all connected grease points (nonrotating components) at preset intervals as long as ignition is ON. (See also Daily Maintenance) NOTE! All connected grease points will be greased at regular preset intervals automatically, even if the switch is not operated 23B. Optional: Air condition switch Push switch to engage air condition system. Built-in light.

See Cab ventilation controls.

23C. Spare space.

24A. Main light switch.

Two-stages: 1st. parking lights, 2nd. head lights.

When switch is set to 1st. position, the parking-/ marking-/ licence plate lights as well as instrument lights (if instrument light switch (24B) is engaged) will light.

When switch is set to 2nd. position the head lights (high or low beam according to position of column switch 21) also will light. Built-in light.

24B. Instrument light switch.

Push switch to light all instruments together with the main light switch (24A). Built-in light.

24C. Cab and engine compartment lights switch.

Push switch to light the cab and the engine compartment lights. Turn off the lights during operation. Built-in light.

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3. OPERATING CONTROLS

27

25A. Optional: Mirror heater switch.

Push switch to heat the external mirrors for ice and dew removal. The indicator light 7E will illuminate when engaged. Built-in light.

NOTE! Engage only when necessary!

25B. Optional: Roof fan switch.

Push to engage the one-speed fan in the roof. Built-in light.

25C. Work light switch.

Push switch to light the work light on the roof. An indicator light (7C) lights up when engaged. Built-in light.

26A. Test switch for brake warning light.

Push the switch and check that the warning light for brake fluid circuit failure (2E) lights up. Automatic return.

26B. Rotating beacon switch.

Push switch to engage the optional rotating beacon at the roof. An indicator light (7B) lights up when engaged.

Built-in light.

26C. Hazard light switch.

Push switch to engage the hazard light (all directional lights flash at the same time). An indicator light on the central panel (3C) will flash concurrently. Built-in indicator light.

27. Fan switch.

See Cab ventilation controls for utilization.

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3. OPERATING CONTROLS

CONTROLS. 11. Ignition.

The ignition is key operated, and has 4 positions: P= Park position (key removeable).

0 = Ignition off (key removeable).

I = Ignition on (drive position).

II = Engine starter connected (key returns to pos. I when released.)

To start engine, see: 5. Operating Instructions.

12. Cigarette lighter.

Push in to activate heating function. Automatic return when hot. Can also be utilized as a plug socket (max. 15 Amp).

14. Parking brake lever.

The parking brake is on (locked) when the lever is in right position (indicator light 2D). In left position the brake is released. The parking brake must not be applied when the machine is in motion unless in an emergency situation!

NOTE! Do not drive the dump truck if air pressure is below 5 bar (warning light 2C and buzzer), the parking brake will not be fully released!

15. Tip control lever.

15

Lock device

3-12

The lever controls the body lifting and lowering.

The lever has 3 positions: 1: Lift (body up).

2: Neutral (hold position).

3: Lower (body down), float position The lever is mechanically locked in neutral and lower position. Lift the lock device to release the lever in these positions. Always keep lever in lower position during loading and driving.

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3. OPERATING CONTROLS

16. Throttle pedal (accelerator).

The pedal controls the engine speed mechanically via cable.

17. Transmission gear selector.

For correct utilization, see 5. Operating Instructions.

The dump truck is equipped with an automatic transmission with 6 forward and 3 reverse speeds.

The selector has manual range in forward and reverse direction, covering 1st, 2nd, and 3rd speed. Up-shifting is not possible at engaged engine brake (or optional retarder brake)!

Pos 1, 2 and 3, reverse gear: The selected gear is engaged directly if the truck is stationary. The selector must be moved to change gear. When driving, the selected gear will be engaged when the speed is within gear range.

17

NOTE! Travel speed:

16

1R = 1F 2R = 3F 3R = 5F

Pos. N: Pos. D:

Neutral gear.

Drive position forwards, automatic gear shift between 1st-6th gear according to truck speed and engine revolutions.

Pos. 3, 2 and 1: The selected gear is engaged directly if the truck is stationary. The selector must be moved to change gear. When driving, the selected gear will be engaged when the speed is within the gear range.

The selector is tiltable for comfortable operation. Easy entry and exit through the right door is obtained by tilting it fully backwards. Confirm that the selector is adjusted and fastened before operating the truck. Do not adjust selector position while driving!

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3. OPERATING CONTROLS

17. Optional: Manual transmission gear selector.

Optional manual gear selector

17

For correct utilization, see 5. Operating Instructions.

The dump truck is equipped with an semi-automatic transmission with 6 forward and 3 reverse speeds.

Basically the gear selector must be moved in order to change gears. Up-shifting is not possible at engaged engine brake (or optional retarder brake)!

Pos 1, 2 and 3, reverse gear: The selected gear is engaged directly if the truck is stationary. The selector must be moved to change gear. When driving, the selected gear will be engaged when the speed is within gear range.

NOTE! Travel speed:

18

1R = 1F 2R = 3F 3R = 5F

Pos. N: Neutral gear.

Pos. 6 through 1: The selected gear is engaged directly if the truck is stationary. The selector must be moved to change gear. When driving, the selected gear will be engaged when the speed is within the gear range.

The selector is tiltable for comfortable operation. Easy entry and exit through the right door is obtained by tilting it fully backwards. Confirm that the selector is adjusted and fastened before operating the truck. Do not adjust selector position while driving!

18. Brake pedal.

The pedal controls the main brake (stop 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 unloaded machine. Do not use pedal for long period retardations, i.e loaded, downhill. This will overheat and damage the disc brakes as well as oil seals in the hub.

NOTE! If warning for brake fluid circuit failure lights up (light 2E), stop machine at once!

19

19. Steering column.

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

1: height adjustment (lift lever up to unlock), 2: tilt adjustment (push lever down to unlock).

To change lever angle (3): pull outwards and turn.

Confirm that steering column is adjusted and fastened before operating the truck.

Do not adjust position while driving!

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3. OPERATING CONTROLS

20. Engine stop handle.

The handle must be pushed completely in before starting the engine. Pull out the handle to stop a running engine.

Press in centre button to unlock before moving handle.

21. Column switch.

J

21

The column switch is a multi-function switch for main lights, horn, direction lights and windscreen wiper/washer.

Main lights (A, B, C): A. Low beam (when switch 24A in position 2).

B. High beam (when switch 24A in position 2).

Indicator 3F will light.

C. High beam flash. Automatic return.

D. Horn (centre button). Automatic return.

E. Right turn. All right directional lights flash.

Indicator 3C flashes correspondingly.

F. Left turn. All left directional lights flash.

Indicator 3C flashes correspondingly.

G. Wind screen wiper. Turn handle. Positions: = high speed _ low speed 0 OFF interval H. Wind screen washer. Push outer ring to activate the washer motor. At the same time the wiper wipes 6 times after releasing the ring.

20

22. Differential lock pedal.

22

27

Depress the pedal to engage the inter axle differential lock.

The throttle pedal must be fully released to activate the lock. An indicator light (7D) will light when the lock is meshed. Built-in light.

Only to be engaged when truck is stationary, see 5. Operating Instructions.

27. Cab ventilation controls.

A: Fan switch. Turn knob to operate the 3-speed fan.

B: Air flow regulator (blue).

Max.: Recirculation of internal air. Fan must be used to circulate the air.

Min.: Air from outside. Air intake is fully open.

C: Temperature regulator (red).

Adjust the nozzle air temperature with the handle. The air is heated by the engine coolant.

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3. OPERATING CONTROLS

Optional Roof mounted ventilation

The intake air is filtrated before it enters the cabin. All nozzles are adjustable, and air may be directed to desired direction. It is also possible to close the nozzles. All nozzles are used for both hot and cold air.

The regulator knobs on control panel are stepless adjustable. Turn knob clockwise for max. and counterclockwise for min. function. If the handle is set between it’s outer positions, the function will be mixed.

Periodically ventilate fresh air into the cabin when using full recirculation of the air. Proper ventilation system use is a training matter.

Ice and dew removal: Set fan to speed 3, knob C to max. (hot) and B to min. (recirc.). Close the floor nozzle and direct the other ones towards the windows. After the mission is completed, adjust regulator knobs and nozzles to positions which gives comfortable ventilation.

Optional: Air conditioner A compressor (engine mounted) and a cooling element cools the air when the engine is running and the Air condition switch (23B) is set on. To increase the efficiency, set knob 27B to max. (recirculation) (see previous page).

When the Air condition switch (23B) is set to off, the system function is equal to the standard heater control.

Engage the air condition system a few minutes every week (also in the cold season) to maintenance the system!

Cooling grade.

The air conditioner cooling grade can be adjusted to fit local ambient temperature. The adjusting knob situated in the ventilator unit behind the rubber plug is preset to max. cooling grade from factory. Turn knob clockwise for increased cooling (+) and counterclockwise for decreased cooling (-). Windows and doors must be closed to achieve max. effect! Be careful not to excessively cool the cabin air.

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3. OPERATING CONTROLS

Optional: Roof mounted ventilation A one-speed fan blows fresh air into the cab through 2 roof nozzles when the switch (25B) is engaged. Intake air is filtrated (filter is located under the outside sun shield).

Direct the nozzles to desired direction.

30 30. Optional: Retarder brake handle The handle controls the retarder brake effect. The effect is stepless adjustable between off and max. position. An indicator light 6B will light when engaged.

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3. OPERATING CONTROLS

OTHER CABIN EQUIPMENT. Driver seat.

The seat is air suspended and adjustable in height, inclination, lumbar support and lengthwise position. Adjust the seat to the desired position. Always use the safety belt when operating the machine.

Seat adjustment: 1. Seat cushion inclination.

Stepless adjustment of seat cushion.

Backward - clockwise, forward - anti clockwise.

2. Height adjustment.

Stepless seat height adjustment.

Elevation - clockwise. Lowering - anti clockwise.

Automatic weight adjustment.

3. 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.

4. Forward and backward adjustment.

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

5. Not fitted.

6. Electrical heating. (Not standard.)

7. Lumbar support adjustment.

Stepless adjustment of the support.

8. Neck rest. (Not standard.)

9. Arm rest.

Stepless height adjustment with hand wheel. Tiltable to fully upright position.

10. Backrest inclination adjustment.

Stepless adjustment of backrest inclination.

11. Fore and aft damping.

Handle forwards: damping, backwards: fixed.

If the damping is unsuitable, a spring in the seat base can be repositioned.

12. Suspension height limiter.

1. Lever to the right: Comfort position (max. suspension height, 150 mm).

2. Lever in middle position: Normal position, suspension height limited to 90 mm.

3. Lever to the left: Fixed position (no height suspension). Seat must be in correct position (75 mm above bottom position) when locking.

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3. OPERATING CONTROLS

Door openers/ -locks.

Right h.s.door is shown

Door opener Door lock Locked Open

The doors are fitted with lockable door openers.

Inside opener: Lift the handle to open the door.

Outside opener: Press in button on the handle grip.

The doors can be locked from both the inside and the outside. A locked door will be released when using the inside opener.

Outside lock: Use the door key in center of button.

Inside lock: Lift handle inside the door, see illus.

Door window.

Window lock

It is possible to open both door windows. There are 4 different opening stages by two locking mechanism at the upper edge of the top windows.

To open the window: Lift both lock arms upwards and push the window down.

Release the lock arms in a suitable position.

To close the window: Push window completely upward and check that the window locks are meshed.

Safety equipment.

The dump truck is originally equipped with following safety equipment, which should always be present and in order: A: Fire extinguisher (2 kg’s, ABE class II powder) installed on the driver seat bracket.

B: First aid kit fitted underneath right dashboard.

C: Warning triangle placed inside driver seat bracket.

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3. OPERATING CONTROLS

MEMO

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4. RUNNING IN PERIOD

RUNNING IN PERIOD

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4. RUNNING IN PERIOD

CONTENTS 4. Running in period ...................................... 4-3 - 4-6 Running in operation .................................... 4-3 Running in services ....................................... 4-4

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4. RUNNING IN PERIOD

RUNNING IN OPERATION. Each new dump truck has been carefully inspected, tested and adjusted before delivery ex-factory. A further check beyond 8 hours/daily service is not required before the initial operation.

However, the new dump truck requires careful operation the first 100 hours (refer to hourmeter) to break in (run in) all moving parts.

Follow below instructions in this period: 1. Start engine as described in "Operating Instructions". Run engine at low idle until air pressure in the various circuits are normal.

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

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

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 accelerations 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 trucks capacity during the running in period, may premature reduce the performance potential.

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4. RUNNING IN PERIOD

RUNNING IN SERVICES. Running in service is to be carried out after operating the machine the first 8, 100 and 500 hours. These services are most important for running in a new machine.

This is the owner’s responsibility.

First 8 hours: 1. Wheel nuts.

Check tightening of nuts.

Torque setting: 600 Nm. Spanner: 30 mm.

2. Lubricating.

Grease all lubricating points.

3. Carry on with the normal 8 hours service.

First 100 hours: 1.

2 3.

4.

5.

Change transmission oil (20).

See 1000 hours service.

Replace transmission filter (21).

See 1000 hours service.

Replace hydraulic filter (43).

See 500 hours service.

Retorque window wiper spindle nuts. Torque setting: 35 Nm (M10), 18 Nm (M8) Lubricating. Grease all lubricating points. See: 7. Maintenance.

First 500 hours: 1. Change oil in:

(30) Front differential.

See 1000 hours service.

(31) Rear differential.

See 1000 hours service.

(32) Tandem housings.

See 1000 hours service.

(33) Reduct. gears, front. See 1000 hours service.

2. Check/adjust: - Valve clearance. Procedure described in 2000 hours service.

- Hydraulic oil pressure. Contact your local Moxy dealer.

3. Carry on with the normal 500 hours service.

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

Numbers in brackets refer to position on Lubrication Schedule (chapter 6).

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4. RUNNING IN PERIOD

MEMO

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4. RUNNING IN PERIOD

MEMO

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5. OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS

Operating & Maintenance Manual

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5. OPERATING INSTRUCTIOINS

CONTENTS 5. Operating instructions ............................... 5-1 - 5-22 1. Starting the engine .................................. 5-3 2. Operating the machine ............................ 5-4 3. Stopping the engine ................................ 5-12 4. Parking the machine ............................... 5-12 5. Loading and tipping ................................ 5-13 6. Tyre handling .......................................... 5-14 7. Cold weather .......................................... 5-15 8. Long term storage .................................. 5-15 9. Battery power aid ................................... 5-16 10. Towing the machine ............................... 5-16 11. External air filling ................................... 5-17 12. Manual release of parking brake ............. 5-17 13. Tyre filling point ..................................... 5-17 14. Trouble shooting .................................... 5-18

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5. OPERATING INSTRUCTIONS

1. STARTING THE ENGINE Before starting the engine in the morning, perform the Daily Service. Remember to connect the battery main switch in the battery box (if disconnected) otherwise there will be no power supply.

1.1 Set gear selector in neutral position.

Optional manual gear selector

Standard

1.2 Confirm that parking brake is ON.

1.3 Push engine stop handle completely in.

1.4 Turn ignition ON (pos 1).

Check warning lights before starting: - engine oil pressure - battery charge - parking brake - emergency steering (switches off above 5 km/h)

1.5 Start the engine.

Revolution gauge

Press accelerator pedal down.

Turn the ignition key to the right (pos. II) to engage starter and hold until engine starts (max. 20 sec). Immediately after the engine starts, release the key and adjust engine speed to 1000 rpm. Check that warning lights for engine oil pressure and battery charge switches off.

1000 rpm

1 st minute 1.6 If engine does not start: Turn ignition OFF, and wait until engine has stopped completely before new starting attempt. (In cold weather: wait 30 sec before restart).

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5. OPERATING INSTRUCTIOINS

1.7 Starting in cold weather: If the engine does not start by normal starting procedure do following: - Pull out the engine stop handle.

- Turn ignition key to the right (pos II) and crank the engine for a few seconds (temp -10O C crank for 10 seconds, temp - 20 OC crank for 20 seconds).

- Push engine stop handle completely in.

2. OPERATING THE MACHINE 2.1 Driving off.

When the engine is running properly and the air pressures are within operating range: - Check that gauges and warning lights do not indicate any abnormalities.

- Confirm low idle speed.

- Depress the brake pedal.

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

- Select a suitable gear position at low idle (see 2.3 Gearshifting below).

- Increase the engine speed by pressing the accelerator pedal downwards.

2.2. Warming up period.

When driving off with a cold machine, operate the machine gently with reduced engine load rpm to warm up until all gauges indicate operating range. This is important to avoid reduction of the ma chine’s performance potential.

- Engine coolant temperature: min. 70°C - Transmission oil temperature: min. 60°C

2.3 Gear shifting.

The transmission has automatic gear shift to match the travel speed. The shifting is electronically controlled and an automatic lock-up clutch is fitted in the transmission to increase the efficiency in all gears. Connection/disconnection depends on the engine speed and shifting mode.

Gear positions 1, 2 and 3.

Manual selection of 1st, 2nd and 3rd gear. Select a manual gear position to avoid repeated up and down shifting when driving at heavy conditions (f.ex steep hills, slippery or soft ground), more details on next page.

Gear position D. The transmission shifts automatically between 1st-6th gear, depending on both engine as well as truck speed.

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 shifting will take place at high rpm (full load mode). With the throttle pedal fully depressed, the gear shifting 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 optional retarder brake) is engaged the down shifting will take place at high rpm.

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5. OPERATING INSTRUCTIONS

Operating hints.

Different types of terrain require different operating techniques. Use the position D for normal travel.

For advanced driving, select pos. 3 when driving off with unloaded truck in light conditions to avoid the shifting from 1st. to 3rd gear. Shift to pos. D for automatic gear shifting. When the intention is to stop the truck, pos. 3 can be selected to avoid the automatic down shifting from 3rd to 1st gear.

In terrain, before uphill/downhill driving, manually select a suitable position for the estimated speed in the area, avoid repeated up and down shifting and gear shifting in hills. * When selecting a gear from the neutral position and when switching between forward and reverse gears: - Stop the truck and release the throttle pedal completely.

- Select the desired gear and wait until the gear is connected before increasing the engine speed. * Always drive allowing the lock-up clutch to connect (indicator light)! * Neutral position must not be selected when driving.

Automatic gearshift.

Low idle

Part load mode

Full load mode

Kick down mode

Automatic gear shifting is carried out according to 3 different shifting modes. The mode is depended on the throttle pedal position.

Partial load, “rabbit” (mode P).

When operating in light condition with the throttle pedal light depressed, the transmission will shift gear at low rpm and an economical operation can be obtained.

Full load, (mode F).

When operating in heavy condition and the throttle pedal is heavy depressed, for instance loaded or in terrain where high engine power is necessary or gear shifting at high rpm is desired.

Kick-down, “bull”(mode KD).

When the throttle pedal fully depressed, the kick-down function will be activated, giving a higher rpm before shifting gear, regardless to load switch position. The higher engine speed can be used to obtain optimum acceleration and minimum deceleration before shifting gear.

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5. OPERATING INSTRUCTIOINS

Engine brake mode.

When the engine brake is engaged, the transmission will not shift to a higher gear if the speed increases at downhill driving. The lock-up clutch is always connected when the engine brake is engaged. The lock-up clutch and engine brake will disengage at gear shifting.

When reducing the speed and using the engine brake, down shifting happens at high rpm to obtain max. braking effect.

Optional: Retarder brake mode When the retarder brake is engaged, the transmission will not shift to a higher gear if the speed increases at downhill driving. The lock-up clutch is always connected when the retarder brake is engaged.

The lock-up clutch and retarder brake will disengage at gear shifting.

When reducing the speed and using the retarder brake, down shifting happens at high rpm to obtain max. braking effect.

Manual gear range on the standard gearselector.

Move the selector to the desired gear. The selected gear will be engaged when the registrated speed and load are within the gear range. If the dump truck is stationary, the selected gear will be engaged directly. When the selected gear is engaged the transmission operates then only in this gear until the selctor is moved to another position.

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5. OPERATING INSTRUCTIONS

2.3 Gear shifting. Optional: Manual gear change system Gear positions 6 through 1.

The transmission is semi-automatic, and operates in the gear selected by the operator. There are 6 speeds forward and 3 speeds reverse. Gear shift can be done with full load on the engine. The shift ing is depending on both engine and truck speed. This is to prevent overspeeding of the engine.

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

When the selected gear is engaged the transmission operates then only in this gear until the selector is moved to another position.

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

Select the correct gear before the parking brake is released (higher load means lower gear).

A lock-up system in the converter allows direct connection between the engine and transmission in all gears. This happens automatically when the engine speed reaches approx. 1400 rpm.

Disconnection happens automatically when the engine speed drops to approx 1200 rpm.

The lock up drive must be used as much as possible.

When using exhaust brake (or optional retarder brake), the lock-up clutch is always connected. The exhaust brake (or optional retarder brake) and the lock-up clutch will disengage at gear shifting.

When driving in soft terrain or inclines (heavy conditions), select a gear which make it possible to keep engine speed at 1800 - 2200 rpm (lock-up light on).

Avoid driving near stalling conditions (great speed difference on the input and output shafts in the converter). This will increase the transmission oil temperature quickly. Max. allowed temperature a short period is 120° C (150° C a short period if using optional retarder) . Stalling speed is approx.

1730 ± 30 rpm. * When selecting a gear from the neutral position and when switching between forward and reverse gears stop the truck and release the throttle pedal completely. * Always drive allowing the lock-up clutch to connect (green indicator light)! * Neutral position must not be selected when driving.

2.4 Reversing (back-up) operations.

G ON WR

Before reversing, make sure that no persons or obstacles are behind the truck or in the articulation area.

Stop the dump truck completly before selecting the reverse gear.

Move the selector to the desired gear. The selected gear will be engaged when the registrated speed and load are within the gear range. If the dump truck is stationary, the selected gear will be engaged directly. When the selected gear is engaged the transmission operates then only in this gear until the selctor is moved to another position.

NOTE! Be careful when reversing, the backwards visibility are limited!

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5. OPERATING INSTRUCTIOINS

2.5 Normal operation.

Always operate the machine with caution. Careful driving is recommended for safe and comfortable operation. Regulate machine speed in accordance with the ground conditions and surronding environments.

Always drive allowing the automatical lock-up clutch to connect (indicator light).

If abnormal noise, vibration or smell occurs during operation, check for possible faults and remedy.

Check at regular intervals that all gauges are indicating normal values (within green ranges), and that no warning lights are on.

Engine coolant temp.: 75-85°C, max 100°C. Engine oil pressure: 3-6 bar at normal engine temperatures.

Transm. oil temp.: 80-110°C, max 120°C short period (150°C when using optional retarder brake).

Transm. oil pressure: 16-18 bar.

Air pressures: 6,8 - 7,8 bar.

2.6 Brakes There are three different brake systems on the machine.

Check the brakes every day to ensure function (see 7.

Maintenance).

(A) Main brake.

Air over hydraulic operated single disc brake on each wheel. Front and rear axle has seperate circuits. Self adjusting system.

(B) Engine brake.

Air operated, speed depended brake which restrict exhaust flow. Efficient only at connected lock-up clutch.

NOTE! Do not operate the brake at engine speeds above 2400 rpm! An exhaust valve can hit the piston top and cause serious damage!

(B) Optional: Retarder brake Stepless adjustable, hydrodynamic, wear resistant and speed depended oil retarder fitted in front of transmission torgue converter.

(C) Parking brake.

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

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5. OPERATING INSTRUCTIONS

2.7 Braking/stopping the machine.

Learn to associate the braking requirements for loaded and unloaded machine. See also chapter 2. Safety Instructions.

A. Release the throttle pedal, if necessary shift to a lower gear position and apply the engine brake (or optional: retarder brake).

B. At the same time depress the brake pedal gradually, so that the deceleration is uniform.

C. When the machine is completely stopped, move the gear selector to neutral and apply the parking brake.

G ON WR

2.8 Emergency braking.

If use of the main brake is ineffective, the machine can be braked as follows: NOTE! Release throttle pedal and apply engine brake.

Set the parking brake to Locked posistion.

Move gear selector to pos. 1 as quickly as possible.

G RI

HT

When the machine has stopped, immediately put brake blocks under the wheels.

After an emergency stop, the parking brake MUST be checked as well as the reason for the main brake failure!

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5. OPERATING INSTRUCTIOINS

2.9 Steering The dump truck has 2 frames. The steering movement is created by articulation of the frames in proportion to each other. The steering is fully hydraulic 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 machine is equipped with an emergency steering system, which will deliver oil when the machine is in motion due to a ground driven pump. It will then be possible to steer the machine if the engine stops. The steering movement will then be more slowly and the warning light for emergency steering will light. Amend the failure before operating the machine again!

NOTE! Mechanical stops are fitted on the frame. Movement of the steering that will “hammer” these stops is to be avoided. Continuance of the steering actions against the stops causes maximum pressure in the system - this must be avoided!

2.10 Differentials The machine has constant 6-wheel drive with 3 differentials.

A: Front axle differential (limited slip).

Fitted to the transmission. transfers the power to left and right front wheels. See also below (limited slip).

B: Inter axle differential (lockable torque divider).

Integrated in the transmission. Transfers the power by 1/3 to the front and 2/3 to the rear axle. When the differential is locked a 50/50 distribution is obtained.

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

NOTE! Spinning more than 10 sec. can damage the limited slip discs.

The throttle pedal must be realased to allow the inter axle differential to be engaged.

The lock must not be engaged when driving on firm ground!

C: Rear axle differential (limited slip).

Fitted in the rear axle housing. Transfers the power to left and right tandem drive. See also next page (limited slip).

5-10

Operating & Maintenance Manual

5. OPERATING INSTRUCTIONS

Limited slip (front and rear differential): The differential will automatically provide highest torque to the wheel which have 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.

NOTE! Use the interaxle differential lock to avoid spinning. Spinning more than 10 sec. can damage the limited slip discs.

2.11 Up-, down- and crossgradient travel.

1. 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.

2. Before starting downhill, release the throttle pedal and slow down the machine to a safe speed for the downhill slope. Move the gear selector to a suitable posistion.

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

4. If use of engine brake (or optional retarder brake) is unsufficient to keep machine 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 optional retarder brake)applied.

5. Operate the machine senisibly and avoid crossgradient travel in excess of 15°. Select a low speed and negotiate the terrain without exaggerated steering movements and sudden braking.

6. Do not drive machine in a crossgradient with raised body.

7. Keep engine speed at the upper area (2000 - 2600 rpm) in heavy conditions and at hill travel. Select a manual gear position at steep hill travel.

8. Apply the parking brake and secure the machine from spontaneous rolling by adding brake blocks under the wheels when leaving the machine at slopes.

Operating & Maintenance Manual

5-11

5. OPERATING INSTRUCTIOINS

2.12 Important operating instructions.

1. Machine must not cost with gear selection in neutral position.

2. Engine speed must be reduced, and the dump truck must have come to a complete stop before changing between reverse and forward gears.

3. Do not keep steering at the mechanical end stop, or force it beyond this point when turning maximally.

4. There is no braking effect from transmission (even in gear) with engine stopped.

5. Select neutral gear and apply the parking brake when leaving the machine. Never leave the machine with a gear engaged!

6. Always operate the machine at engine speed within 1200 - 2600 rpm. Engine speed within 1400 2400 rpm with engaged lock-up is recommended during driving.

7. Do not continue to operate the machine if a warning lamp lights, a gauge shows red area, or if the warning buzzer sounds.

8. Always operate the machine within the rated limits and carry out maintenance according to the scheduled program. Overloading and lack of maintenance reduces the safety and lifetime of the machine drops.

9. In case of machine problem, stop and contact trained personnel to amend the fault.

3. STOPPING THE ENGINE. 3.1 Select neutral gear position.

3.2 Run the engine at low idle for a few minutes to allow it gradually to cool down if machine has been driven with a heavy load for a long period of time.

If engine is stopped abruptly before it cools down, engine life may be shortened. Never stop the engine abruptly except in case of emergency.

3.3 Stop the engine by pulling out the engine stop handle.

3.4 When the engine has stopped, turn ignition off.

4. PARKING THE MACHINE. 4.1 Avoid parking with loaded body.

4.2 Park on a safe ground, secured from freezing stuck, sinking down, etc. (A change of weather may influence the ground).

4.3 Lower the body completely.

4.4 Neutralize all operating controls.

4.5 Apply the parking brake.

4.6 Secure the machine from spontaneous rolling by putting brake blocks under the wheels before leaving the machine on slopes and grades.

4.7 Lock the windows and the cab doors.

4.8 Turn off and remove the main switch (located in the battery box).

4.9 Release the air pressure from the air tanks (to drain condensated water).

5-12

Operating & Maintenance Manual

5. OPERATING INSTRUCTIONS

5. LOADING AND TIPPING. Loading The body must be completely lowered before loading of materials. The tip lever shall stay in lower 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.

Before driving off, check that no danger occurs during the drive. Maintain an even load distribution, avoid unbalanced loads.

Never overload the machine. The operator safety will be considerably reduced and lifetime of the machine will drop.

Tipping Place the machine on a level ground. Check that the tipping can be done without danger.

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

5.2 Move the tip control lever to body lift position and increase the engine speed. The body will raise, and the tailgate opens automatically. The tipping speed is proportional with the engine speed.

5.3 Reduce the engine speed before the body reaches the top position. The last piston has a restriction for the oil flow which also will reduce the speed of the body.

5.4 To stop the tipping movement, release the control lever. It will then automatically return to neutral position.

5.5 Move the tip control lever to lower, and the body will go down. The tailgate will then automatically close when the body is completely down.

5.6 The tip control lever should stay in body lower position when not tipping.

CAUTION! * Reduce tipping speed when dumping large rocks! * Do not load material into the body when the body is raised! * Do not drive loaded truck while body is raised! * Do not raise body near electrical power lines! * Avoid tipping on crossgradients! * Utilization of top tailgate has safety restrictions! See Chapter 2. SAFETY INSTRUCTIONS!

Operating & Maintenance Manual

5-13

5. OPERATING INSTRUCTIOINS

6. TYRE HANDLING. General This is a general instruction for the standard tyres in the table below. Contact tyre supplier or local distributor for exact specification. 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.

If it is necessary to exchange wheel by puncture or in emergency cases, Moxy Trucks AS will allow up to 5 % difference in the tyre diameter on the same side of the bogie.

NOTE! The most ideal situation is to have the same tyre diameter on the same side of the bogie.

NOTE! Extremely low temperature (below -40°C) require special operation!

6.1 Correct tyre inflation.

The inflation pressures mainly depend on operation speed and load. Secondly, the road configuration, floatation/traction requirements, risk of cutting, hacking, shock damage and ambient temperatures, are factors to consider. Both too high and too low tyre inflation pressure may result in damage and shortened lifetime of the tyres. Tyre inflation checks and corrections must be done on cold tyres.

See Chapter 8 Technical Data for basic tyre pressure.

6.2 Specified loading.

Do not overload the truck. Maintain an even load distribution, avoid unbalanced loads. Protect tyres from falling stones during loading.

6.3 Prescribed speed.

Keep machine within a proper speed for the ground condition. Do not exceed max. average work day speed, see table below.

6.4 Proper maintenance.

Perform tyre inspections according to Maintenance shedule. Also roads and driving paths should be maintenanced to achieve max. tyre serviceability. Damaged, excessively worn or aged tyres should be replaced. Removal or repairing of tyres should be performed by a tyre specialist to avoid unsafe work ing conditions.

6.5 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 or 80 km (whichever comes first) and stop for 30 min. Drive another 2 hours or 80 km and stop for 1 hour. Repeat.

- Upper speed limit for this operation: 32 km/h. Must NOT be exceeded!

TYRE

5-14

up to 5 km

5 - 10 km

above 10 km

Bridgestone VMT / VKT

27 km/h

24 km/h

22 km/h

Michelin XADT / XADN

28 km/h

28 km/h

28 km/h

Michelin XRB**

35 km/h

30,5 km/h

30,5 km/h

Operating & Maintenance Manual

5. OPERATING INSTRUCTIONS

7. COLD WEATHER. Cold weather operation (below 0 °C) requires special care to avoid problems and to maintain high comfort and safety.

7.1 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.

7.2 The coolant must contain anti-freeze to avoid ice in the cooling system, see 1000 Hours Service.

7.3 As the temperature drops, the battery capacity drops accordingly. The batteries must be in good condition and fully charged when the machine is operated in low temperatures.

7.4 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 (iso-propanol) can be added to avoid condensation.

7.5 The washer fluid (reservoir on the hydraulic tank) should contain a mix of alcohol (iso-propanol) and water which at least is sufficient to avoid icing in the tubes.

7.6 The engine must be started according to the cold start procedure, see Starting the engine. After starting it is necessary to warm up the engine, transmission and hydraulic oil without load.

7.7 Extend the warm-up period to secure that component lubrication is obtained. The machine shall be operated with light load and reduced rpm during warming up.

7.8 Pay special attention to the ground surface. In case of snow and ice, use snow chains on the wheels to secure the wheel grip.

7.9 If the machine is equipped with exhaust heated body, this should be connected to avoid the material freezing to body before tipping.

7.10It is recommended to use engine heater or flame start system (optional equipment) at low tempera tures. The engine heater has an electrical element which heat the engine coolant. 2-4 hours connec tion is sufficient to ease engine starting and reduce engine wear.

The flame start system has a glow plug fitted in the intake manifold. Heating of intake air takes place by burning engine fuel. The heating is activated by pre-heating switch and will continue approx. 5 min. after the engine has started.

At very low temperatures (below - 10 oC) use of engine heater or flame start system can be necessary to avoid starting difficulties.

8. LONG TERM STORAGE. If the truck shall be stored for a longer period of time, special preparation must be carried out to avoid deterioration and damage. Store it preferably indoor in a dry and ventilated room or outdoor under shelter.

Before storage: -

Neutralize all operating controls and apply the parking brake.

Release the air pressure in all circuits.

Thoroughly wash and clean the machine.

Replace oil and filters with new and lubricate all nipples. Check viscosities to match the expected ambient temperature.

Fully charge the batteries and disconnect terminals. Preferably stored separately in a cold place (0-10oC).

Cover all cylinder piston rods with rust protecting fluid.

Inflate the tyres to correct pressure.

Lock the windows, doors, fender hatches and bonnet.

During storage: Operate the truck once a month by driving it f. ex. until engine tempearture reaches green range. 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.

Operating & Maintenance Manual

5-15

5. OPERATING INSTRUCTIOINS

9. BATTERY POWER AID.

÷ +

÷

In case of discharged batteries, starting can be done by connecting charged batteries (24 volts) with capacity approx. equal to the discharged batteries. Discharged batteries should be charged as soon as possible.

+

Connection: Batteri for Batteri for engine which was started running engine Body of the machine which was started

Turn off the main switch in the battery box.

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

8.2 .... to the +terminal on the aid battery.

8.3 Connect second cable from ÷ (negative) terminal on aid battery....

8.4 .... to the ground (chassis) on machine with dis charged batteries (fit the clamp far away from the batteries).

Turn on the main switch and start engine the normal way.

Disconnection: Disconnect cables the opposite way (8.4 - 8.3 - 8.2 - 8.1).

CAUTION ! - Use cables with 25 mm2 cross section.

- Connect in sequence described above.

- Good clamp contact is essential.

- Do not stand near a battery when connecting.

- Do not disconnect the original battery cables.

10. TOWING THE MACHINE. WRONG

Towing of the machine can be done by fitting wire/chain to the eye(s) in front/rear of the machine.

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 machine the normal way. If the engine is stopped, the steering movement will be heavier and more slowly than normal because there is no oil flow from the main hydraulic pump.

The maximum towing weight is: front, 5.000 kg/hook rear, 9.000 kg.

NOTE! - If air pressure is lost, the main brake will not function. The air system can be filled by external air, see next page.

- An engaged parking brake can be loosen even if there are no air in the system, see next page.

- It is not possible to start the engine by towing!

5-16

Operating & Maintenance Manual

5. OPERATING INSTRUCTIONS

11. EXTERNAL AIR FILLING.

Air connector point

Filling of the air system can be done with external air through the air connector fitted into right side front fender.

In the tool kit there is a hose for this purpose. The parking brake must be applied, or wheel chocks put under the wheels.

- Remove the protection cap.

- Connect the hose nipple to the connector.

- Start filling and check the pressure at the cabin gauges.

The machine can now be moved if the parking brake can be released.

NOTE! The pressure will gradually drop when braking.

Pay attention to the braking effect!

12. MANUAL RELEASE OF PARKING BRAKE. If the parking brake can not be disengaged by the parking brake lever (air pressure is lost), a manual releasing can be done: - Put brake blocks under the wheels.

- Screw the parking brake caliper adjusting screw inwards until the brake is released.

CAUTION ! All braking systems are now out of func tion. Extreme care must be taken to avoid spontaneous rolling.

13. TYRE FILLING POINT. The air filling connector (see item 11 above) can also be used for filling air into the tyres. Use the hose in the tool kit.

- Connect the hose to the connector and fill air.

- Check the air pressure with a separate gauge.

- For basic tyre inflation, see: chapt. 8. Technical Data.

CAUTION ! Be sure to use a self-locking nipple and do not stay in front of the tyre during filling!

Operating & Maintenance Manual

5-17

5. OPERATING INSTRUCTIOINS

14. TROUBLE SHOOTING. If below action not solves the problem or failure can not be found, contact Moxy dealer. *= Always contact Moxy dealer.

Phenomen

Cause

Action

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

Turn on Refill diesel, bleed system Recharge Check circuit Check connections, wires Repair* Replace*

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

Low output

Fuel system disturbance Condensated water in diesel Bad fuel quality 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

Check fuel lines, bleed system Drain tank Change fuel Replace filters Replace or clean Clean tank cover Adjust/replace/repair Adjust* Repair/replace* Repair/replace* Overhaul*

Overheated (warning light)

Low coolant level Fan belt problem Air in cooling system Dirt inside cooling system Radiator fins clogged/damaged Thermostat faulty Incorrect oil type Sensor/gauge defective Coolant pump worn

Add coolant, check for leakages Tighten/replace Bleed system Clean and replace coolant Clean Replace Change to correct oil type Replace Overhaul*

Low coolant temperature

Sensor/gauge defective Thermostat stuck open

Replace Replace

Low oil pressure

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

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

Blue smoke, oil consumed

Too high oil level Incorrect oil type Worn engine or internal damage

Adjust to specified level Change to correct oil type Overhaul*

Black or white smoke

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

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

Replace* Overhaul*

Knocking noise

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

Change fuel Adjust Adjust* Replace* Overhaul*

1. Engine: Will not start

5-18

Operating & Maintenance Manual

5. OPERATING INSTRUCTIONS Phenomen

Cause

Action

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*

Too low oil level Blown fuse Converter prop. shaft Electronic control unit registration system failure, neutral engaged Electronic control unit defective Flywheel damper separated Drive line failure Internal transmission failure

Add oil, check for leakage Check circuit Replace

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) Inter axle diff. lock incorrect adjusted Worn transm. or internal damage

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

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*

System leakage Governor problem Compressor failure

Check circuits Adjust setting/repair Overhaul*

No oil flow from main pump, or no oil flow from emerg. pump

Check and repair* Check and repair*

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

Low hydraulic oil level Clogged oil filter Air trapped in hydraulic system Contaminated oil Incorrect oil type Clogged tank strainer Steering cylinders internal leak Orbitrol or steering valve failure

Add oil, check for leakage Replace Bleed system Change oil and flush system Change to correct oil type Replace/clean 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 No oil flow from pump Tip valve failure

Add oil, check for leakage Replace Check charging Replace/clean Check/repair* Check/reapir* Overhaul*

2. Transmission: Too high temperature

No drive in any gear

3. Brakes: Poor braking effect or truck pull to one side when braking

4. Air system: Low air pressure (all circuits)

5. Hydraulic system: Emergency steering light on when driving

Operating & Maintenance Manual

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

5-19

5. OPERATING INSTRUCTIOINS Phenomen 6. Electrical: No electrical power

Charge warning light on

7. Chassis: Uncomfortable travel (jumping)

Vibrations

5-20

Cause

Action

Main switch disconnected Batteries discharged Battery terminals/wiring defective

Turn on Recharge Repair

Fan belt problem Defective/worn alternator Defective wiring

Tighten/replace Replace Check connections, wires

Defective shock absorber Defective rubber suspension Articulation turning ring worn

Replace Replace Overhaul*

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

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

Operating & Maintenance Manual

5. OPERATING INSTRUCTIONS

MEMO

Operating & Maintenance Manual

5-21

5. OPERATING INSTRUCTIOINS

MEMO

5-22

Operating & Maintenance Manual

6. LUBRICANTS

LUBRICANTS

Operating & Maintenance Manual

6-1

6. LUBRICANTS

CONTENTS 6. Lubricants ................................................... 6-1 - 6-10 Lubrication schedule .................................... 6-3 Oil specification sheet................................... 6-5 Filling capacities ........................................... 6-6 Transmission oil list ...................................... 6-7

6-2

Operating & Maintenance Manual

6. LUBRICANTS

LUBRICATION SCHEDULE

1 st time HOURS →

POS COMPONENT

100 500

SERVICE INTERVAL

8

Min. Lubricants once a filled from 40 250 500 1000 2000 year producer

ENGINE 1 2 3 4

Engine oil Centrifugal cleaner Turbo filter Fuel filter

V

Rimula TX SAE 15W-40

R C R R

5 Coolant / cooling system

V

V

40% Glycoshell

C

ENGINE RELATED 10 Air filter, outer element *-Inner element: Replace every 3. year* 11 Batteries (2) 12 Air system / air dryer 13 Fuel tank

C/R* V

V

VD

R*

R

D

TRANSMISSION 20 Transmission oil 21 Filter

R R

V

R1) R1)

R R

R R

R2) R2)

R R

R R

R

R

R

R

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

R2)

Rimula TX SAE 15W-40 Gear oil 90 LS ↑ Spirax HD SAE 80W/90 ↑

HYDRAULIC 40 41 42 43

Hydraulic oil Suction strainers in tank Breather element on tank Filter

V

R

D

R C R* R*

V

LUBRICATION POINTS · · · · · · ·

50 51 52 53 54 55 56 57 58 60 61 · 62 · 63

Articulation turning ring Tip hinges Tailgate hinges & joints Tandem bearings Articulation bearings Steering cyl. bearings Tip cylinder bearings Rear axle prop.shaft Articulation prop. shaft Front axle prop.shafts Doors and fender hatches Body safety bar Suspension legs

5 2 9 2 2 4 4 2 2 4 8 1 4

⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗

L L L L L L L L L L L L L

Donax TM

L L L L L L

SRS 2000 NLGI-1,5 ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ C.B.G.0 SRS 2000 ↑

BRAKES 70 R ⊗ · R1) R2)

Brake fluid V 2 containers =REPLACE V=CHECK C=CLEAN L=LUBRICATE D=DRAIN =Lubricators =Alternatively greased by automatical lubrication system (optional) =Replace when retarder (optional) is integrated in transmission =Replace at high speed, long haul

Operating & Maintenance Manual

R R Donax YB R*=REPLACE WHEN REQUIRED

6-3

6. LUBRICANTS

5

Complete instructions in: 7. Maintenance.

The numbers refer to the table on last page.

SYMBOL KEY Filling Level Drain Lubricator Filter Strainer

6-4

Operating & Maintenance Manual

6. LUBRICANTS

OIL SPECIFICATION SHEET This table presents guidelines for oil, coolant, fuel, lubricants and other fluids best suited for good performance and long life.

COMPONENT

KIND OF FLUID

AMBIENT TEMPERATURE 14 32 50 68 86 °F -10 0 10 20 30 °C

-4 -20

SAE 20WSAE 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

WIN T E R S UM M E R - D IE S E L

Water + antifreeze SAE 10W/10W-30/10W-40

Transmission

Engine oil

SAE 15W-40 SAE 20W-20 (ATF

Tandem housing, Planetary red. gear Front diff.

Rear diff.

Gear oil

SAE 80W-90 SAE 85W-140

Gear oil with LSadditives

SAE 90 O t he r ge a r o ils a s a bo v e *

Hydraulic oil

HV ISO VG 32 HM ISO VG 46 HV ISO VG 46

Lubricator Brake system

The engine oil must at least meet the requirements of: - Service CE or CF as per API - CMC-D5 - ACEA E3-96 If fuel contain more than 0.3% (weight) sulphur: reduce the oil change interval.

Make sure the oil can sustain all temperature variations until next oil change.

Ask your local MOXY dealer or oil supplier.

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

Sulphur contets: max. 0,3 %.

Max. 2 % isopropanol additive.

30-50 % Nitrite-free glycol anti freeze is recommended. See 1000 Hours Service .

API-classes: CD/CE/CF, SF/SG. Only oils in Transmission Oil List , page 6-7 - 6-8, can be used!

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

SAE 85W-90

HM ISO VG 32

Hydraulic tank

REMARKS

ATF

DEXRON II

Engine oil

SAE 10W

Universal grease Brake fluid

According to: API GL-5 or MIL-L-2105D (gear oil with EP-additives) *= max. 2% (weight) VI-Improver and Pour Point Depressant in the basic gear oil.

O nly m ine ra l ba s e d o ils .

Visco sity appro x. 20 cSt at no rmal o perating temperature. Range: 10-250 cSt, max. 850 cSt at co ld start.

Hydraulic o il: HM o r HV o ils (ISO 6743/4, CETOP RP 91H) o r H-LP o ils (DIN 51524).

Co ntact o il supplier when o perating in temp. belo w -25°.

Warm up in neutral after starting at temperatures near lo wer limitatio n o f the o il.

When using B io lo gic a l o il co ntact yo ur M o xy dealer befo re use.

Lithiumsaponfied with EP-additive.

Concistency NLGI-2.

According to: SAE J1703 (DOT4 or DOT3) or FMVSS 116 DOT 5

NOTE! Remember, ATF oil must not be mixed with engine or hydraulic oil!

Operating & Maintenance Manual

6-5

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.

Descriptions: Specified capacity: Refill amount: piping, etc.

Total tank/reservoir volume or total capacitiy from empty.

Refill volume after normal fluid draining. The difference are fluid left in the component,

COMPONENT / FLUID

SPECIFIED REFILL CAPACITY AMOUNT

Engine oil Engine coolant

25 35 (37)

24 33 (35)

Fuel tank Transmission oil *

270 25 (34)

250 14 (23)

Rear differential Front differential

20 9

19 8

Tandem housing, each Front reduction gear, each

32 2,5

24 2,5

Hydraulic system Brake fluid **

125 3,8

115 as req'd

Window washer tank

2,6

2,5

* = Check level when engine runs at low idle.

Do NOT run engine without oil in the transmission! ** = New pads.

Capacity in brackets ( ) = With optional oil retarder brake fitted.

6-6

Operating & Maintenance Manual

6. LUBRICANTS

TRANSMISSION OIL LIST Transmission to be filled with engine oil according to API class CD, CE, CF or SF, SG (MIL-L-2104 C/ -D/ -E or MIL-L-46152 C/ -D/ -E) in the SAE class 10W, 10W-30, 10W-40, 15W-40 or 20W-20.

Automatic Transmission Fluid (ATF), see next page.

ENGINE OILS Manufacturer

Trade name

Manufacturer

Operating & Maintenance Manual

Trade name

6-7

6. LUBRICANTS

TRANSMISSION OIL LIST Automatic Transmission Fluid (ATF) may only be used when ambient temperature is lower than -10 ºC (+14 ºF).

Should the temperature increase, it is necessary to change to engine oil.

AUTOMATIC TRANSMISSION FLUID (ATF) Manufacturer

6-8

Trade name

Manufacturer

Operating & Maintenance Manual

Trade name

6. LUBRICANTS

MEMO

Operating & Maintenance Manual

6-9

6. LUBRICANTS

MEMO

6-10

Operating & Maintenance Manual

7. MAINTENANCE

MAINTENANCE

Operating & Maintenance Manual

7-1

7. MAINTENANCE

CONTENTS 7. Maintenance ............................................... 7-1 - 7-34 Precautions for maintenance ........................ 7-3 Maintenance table ........................................ 7-4 8 hours / daily service .................................. 7-5 40 hours / weekly service ............................. 7-13 250 hours service ......................................... 7-15 500 hours service ......................................... 7-20 1000 hours service ....................................... 7-23 2000 hours service ....................................... 7-28 Maintenance when required ......................... 7-31

7-2

Operating & Maintenance Manual

7. MAINTENANCE

PRECAUTIONS FOR MAINTENANCE * Always prepare the truck before starting any maintenance, adjustements or other work on the machine, see Service Position in the Safety Instructions chapter. * Wear a well-fitting helmet, safety shoes and working clothes. When drilling, grinding or hammring, always wear protective goggles. * Place machine on firm, flat ground. Apply the Articulation Lock. * Unless you have special instructions to the contrary, maintenance should always be carried out with engine stopped. If maintenance is carried out with the engine running, there must be two persons present: One operating the engine, and the other one performing the maintenance. In such a case, never touch any moving parts. * When working with others; Choose a group leader and work according to his instructions. Do not perform any maintenance beyond the agreeed work. * Fuel and oil are dangerous substances. Never handle fuel, oil, grease or oily clothes in places where there is any fire or flame. As preparation in case of fire, always know the location and the use of fire extinguishers and other fire-fighting equipment. * Flames should never be used instead of lamps. Never use a naked flame to check leaks or level of oil, fuel, anti-freeze or electrolyte. * Always stop the engine when performing maintenance near the moving parts. * During maintenance; Do not allow any unauthorized person to stand near the machine. * Exhaust gas is dangerous. When working inside, be particulary careful to have good ventilation. * Thoroughly wash the engine. In particular, be careful to clean the filler caps, grease fittings and the area around the dipsticks. Be careful not to let any dirt or dust into the system. * Always use MOXY genuine parts for replacement. * Always use the grades of grease and oil recommended by the manufacturer. Choose the viscosity specified for the ambient temperature. * Always use pure oil or grease, and be sure to use clean containers. * When checking or changing the oil, do it in a place free of dust, and prevent any dirt from getting into the oil. * Before draining the oil, warm it up to a temperature of 30o to 40o C. Be aware of possible internal pressure when opening any drain, level or filling plug. Hot oil can spurt out and give personal injury. * Be particularly careful when removing the expansion tank cap. If this is done immediately after using the engine, there is a danger that boiling water and steam may spurt out. * After replacing oil, filter element or strainer, bleed the air from the circuit. * When the strainer is located in the oil filler, the strainer must not be removed while adding oil. * When adding oil or checking the oil level, check that the oil is at the correct level. * After greasing up, always wipe off the old grease which was forced out. * Before servicing the air system, remember always to remove the air pressure through drain valves. * When changing the oil or filter, check the drained oil and filter for any signs of excessive metal particles or other foreign materials. * When removing parts containing o-rings, gaskets or seals, clean the mounting surface and replace with new sealing parts. * When washing the machine, be careful not to wet electrical components or inside cabin. * When lubricating oil or cooling water has been drained, keep an eye on the instrument panel so that the machine not is operated without oil or cooling water. * In case of difficult maintenance, refer to your MOXY distributor.

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7. MAINTENANCE

MAINTENANCE TABLE 8 HOURS / DAILY SERVICE 1. General 2. Engine

3. Transmission 4. Hydraulic system

500 HOURS SERVICE

Walk around check check driver seat Check oil level general condition check check coolant level check air dryer drain air tanks Check oil level Check oil level check filter indicator Check fluid levels

5. Brake system 6. Lubrication: a) Artic. turning ring 5 lubricators b) Tip hinges 2 —“— c) Tailgate 9 —“— d) Tandem bearings 2 —“— e) Artic. bearings 2 —“— f) Steering cyl. bearings 4 — “ — g) Tip cyl. bearings 4 —“— 7. Tyres Check condition/inflation 8. Parking brake Check function 9. Main brakes Check function 10. Engine brake Check function 10. Optional: Ret. brake Check function 11. Steering Check function 12. Optional: Auto. central lubrication Check grease level Re-adjusting of Timer

7-5 7-5 7-5 7-6 7-6 7-6 7-7 7-7 7-7 7-7 7-8 7-8 7-8 7-8 7-9 7-9 7-9 7-9 7-10 7-10 7-10 7-10 7-10 7-11 7-11 7-12

1. Transmission General check If optional retarder brake is fitted: change oil/replace filter 2. Drive line General check 3. Fuel and hydr. tanks General check 4. Brake system Check linings 5. Hydraulic system Replace breather replace filter 6. Lubrication: a) Fr. axle prop. shafts 4 lubricators b) Doors and fenders 8 —“— c) Body safety bar 1 —“— d) Suspension legs 4—“—

1. Driver seat 2. Engine

3. Transmission 4.

5.

6.

7.

Front differential Rear differential Tandem housings Front reduction gears

3. Electrical system 4. Optional: Air cond.

250 HOURS SERVICE 1. Engine

2.

3.

4.

5.

Safety check replace fuel filter check coolant check batteries Change oil replace filter Change oil Change oil Change oil Change oil

7-23 7-23 7-24 7-25 7-25 7-25 7-26 7-26 7-27 7-27

2. Hydraulic system

3. Brake system

Check injectors check cooling system check valve clearance replace air dryer filter Change oil inspect hoses clean strainers Inspect lines change fluid

7-28 7-28 7-28 7-29 7-29 7-29 7-29 7-30 7-30

SERVICE WHEN REQUIRED Change oil clean centr. cleaner replace turbo filter check fan belts Drain cond. water Safety check Check filter Check oil level Check oil level Check oil level Check oil level Drain cond. water Check nuts torque

Fuel tank Exhaust system Cab ventilation a) Front differential b) Rear differential c) Tandem housings d) Front reduct. gears 6. Hydraulic tank 7. Wheels 8. Lubrication a) Rear axle prop. shaft 2 lubricators b) Artic. prop. shaft 2 —“—

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7-22 7-22 7-22 7-22

2000 HOURS SERVICE

40 HOURS / WEEKLY SERVICE Check function 7-13 Check/clean prefilter 7-13 check batteries 7-13 Check wiring 7-13 Operate for a few minutes 7-14

7-20/7-25 7-20 7-20 7-20 7-21 7-21

1000 HOURS SERVICE

1. Engine

1. Driver seat 2. Engine

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7-15 7-15 7-17 7-17 7-17 7-18 7-18 7-18 7-18 7-18 7-18 7-19 7-19

1. Engine

2. Tailgate 3. Parking brake 4. Bearings

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Operating & Maintenance Manual

Clean/replace air filter clean cooling system check air dryer Check function Check breather Check clearanse

7-31 7-32 7-32 7-32 7-32 7-33

7. MAINTENANCE - DAILY

8 HOURS / DAILY SERVICE To be performed every 8th hour of operation or once a day.

1. GENERAL. Walk around check (before start).

A) Check for leaks at the engine, transmission, differentials, reduction- /tandem housings and tanks.

B) General check for loose bolts at the driveline, specially on radiator, engine-/transmission brackets and at the prop. shaft flanges.

C) Check for damages, wear and other abnormalties on the visible parts of frames, body, tyres, cylinders, etc.

D) Check lights. Replace burnt out bulbs.

Check the driver seat (before start).

1. Foreign objects must not disturb function.

2. Check safety belt for damage and wear.

3. Check for air leakage if seat not remains in position.

2. ENGINE. (1) Check oil level (before start).

The level shall be between upper and lower mark on the dip stick (machine on level ground).

Refill oil (see Oil Specification Sheet) if level has dropped to the bottom marking. Check that level now is correct.

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7. MAINTENANCE - DAILY

General condition check.

- Check tightness of lubrication, coolant, fuel, air and exhaust systems when engine is running. * Tighten or change defective connections.

- 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.

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

This leakage normally stops after a time.

If there is a large amount of leakage - contact your local Moxy dealer.

- Check condition of the engine rubber mountings and tighten bolts if necessary.

(5) Check coolant level (before start).

Level

The expansion tank shall be approx. half filled when the machine is on level ground.

Refill with coolant of correct mixture if level is lower. If large quantities is required to correct the level, a leakage can be the assumed.

Check and remedy the cause in such a case.

NOTE! Never add larger amounts cold coolant when the engine is hot. The great temperature difference can cause cracks in the engine.

Be careful when removing the filler cap at hot engine. Hot water and steam can spurt out!

(12) Check air dryer (before operation).

With the engine running, air and moisture shall blow out of the bottom when the compressor is relieved. Air must not leak from the supply circuit or dryer during charging.

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7. MAINTENANCE - DAILY

(12) Drain air tanks (after operation).

Front chassis: Pull the handle in front of the truck outwards to release air pressures from all front chassis air tanks.

Rear chassis: Pull the drain chain on the underside of the tank sideways to release the air pressure. * If condensated water is present in the escaping air, release system pressure completely and replace the dryer filter, see 2000 Hours Service.

3. TRANSMISSION. (20) Check oil level (before operation).

- Run the engine at low idle speed.

- Turn the dip stick handle (right side under cab) a few turns to the left to release the seal pressure.

- Pull out the dip stick and wipe it with a clean cloth.

- Insert dip stick fully and remove it again.

- Check level: Cold oil (40 oC): at bottom mark.

Hot oil (80 oC): at upper mark.

- If necessary correct the level by adding oil through the filler to the left into the engine compartment.

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

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

4. HYDRAULIC SYSTEM. Oil level gauge

Level

(40) Check oil level (before start).

- Read the oil level in the tank eye. * Level shall be approx. at the middle of the eye.

NOTE! Machine must be horizontal and dump body completely lowered!

(43) Check filter indicator (before operation).

Sight cap Indicator

Check the visual clog indicator on the filter head when engine runs at 1500 rpm (normal oil temperature). * If red is shown in the sight cap, replace the filter cartridge, see 500 Hours Service.

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7. MAINTENANCE - DAILY

5. BRAKE SYSTEM. (70) Check brake fluid levels (before operation).

One container on left hand side in engine compartment and one container on rear chassis. * The containers shall be min. 2/3 filled (see marks). If level decreases, check the brake system for leaks.

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

(50) Articulation turning ring (5 lubricators).

Lubricators located on the distribution block.

Start with the lowermost points. Overflow valve on inner side of the ring’s upper edge.

(51) Tip hinges (2 lubricators).

One lubricator on each tip hinge.

(52) Tailgate (9 lubricators).

One lubricator on each tailgate hinge and 7 lubricators on the mechanism linkages.

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7. MAINTENANCE - DAILY

(53) Tandem bearings (2 lubricators).

One lubricator on rear end of each tandem housing.

(54) Articulation bearings (2 lubricators).

Turn the machine completely to the right for easy access to the lubricators on the bearing hinge.

(55) Steering cylinder bearings (4 lubricators).

2 lubricators on each cylinder (one at each end).

Check the complete lenght of cylinder rods for scratches and other damages.

(56) Tip cylinder bearings (4 lubricators).

2 lubricators on each cylinder (one at each end).

Raise the body to check all cylinder pistons for scratches and other damages.

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7. MAINTENANCE - DAILY

7. TYRES. Check general condition (before operation).

Replace or repair worn, aged or damaged tyres. Always deflate the tyre before removing foreign objects stuck in the tread.

Check inflation pressures (before operation).

Measure the pressure at cold tyres with a tyre pressure gauge and adjust if necessary. For correct pressure, see chapt. 8. Technical Data.

8. PARKING BRAKE. Check braking capacity (before operation).

- Pressurize brakes to system pressure and apply the parking brake (indicator light).

- With the gear selector in 3rd gear, increase engine speed slowly.

- The parking brake must be able to keep the machine stationary at engine speeds below 1500 rpm. If not, check parking brake system.

9. MAIN BRAKES. Check function (before operation).

-

Pressurize brakes to system pressure and stop the engine.

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

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

Drive machine slowly at a firm, level ground and depress the brake pedal firmly.

Check that the braking effect is good and equal.

10. ENGINE BRAKE. Check function (before operation).

- Drive machine forwards in 1st gear at 1500 rpm with lock-up engaged.

- Apply the engine brake and check that the exhaust sound changes and notify the braking effort when releasing the throttle.

- Check the indicator light to function.

10. OPTIONAL: RETARDER BRAKE Check function (before operation) - Drive machine forwards in 3 gear at 2000 rpm with lock-up engaged.

- Apply the retarder brake and release the throttle - Check the indicator light to function and notify the braking effort.

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7. MAINTENANCE - DAILY

11. STEERING. Check function (before operation).

- Drive slowly forwards (5-10 km/h) and check that the emergency steering light goes off - Turn the steering wheel at an even speed until end stop.

- Check that the movement is uniform.

Check the emergency steering.

- Drive forwards on a closed area in 3rd gear at 1500 rpm, stop the engine and allow the truck to roll.

- Check that the emergency steering light illuminates and turn the steering wheel.

- Check that it is possible to steer the truck (steering movement will be slower).

12. OPTIONAL: Magnet

Max.

AUTOMATIC CENTRAL LUBRICATION SYSTEM

Check grease level in the reservoir Refill when grease level approaches the MIN:-marking: 1.Turn ignition on.

2. Place magnet (1) onto embossed symbol (2) on top of the pump.

3. Pump grease into the reservoir through the filling nipple (3) to the MAX.-marking. * Do not overfill!

Use a grease gun or a special filling pump.

4. Remove magnet and check that the rotating paddle inside the pump stops within a few minutes.

Check pipes, hoses and nipples.

Min.

There must be no sharp bends on hoses or damage to any parts.

If one gresae point is blocked, all greasing points will be obstructed! * Replace damaged / worn items.

MANUAL LUBRICATION Examine your dump truck to determine which lubrication points are to be greased. Normally the following points must be greased by hand at normal intervals: -Rear axle prop. shaft -Articulation prop. shaft -Front axle prop. shaft -Doors and fender hatch hinges (details on the lubrication chart and in maintenance section) Techincal data of the automatic central lubrication: * Reservoir capacity: * Grease consistency: * Max. work pressure: * Temperatur range:

2,0 dm3 up to NLGI-2 300 bar - 30 to + 80 ºC

For re-adjusting the Timer Settings, see next page Operating & Maintenance Manual

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7. MAINTENANCE - DAILY

Re-adjusting the Timer Settings for Automatic central lubrication system.

The electronic timer is integrated into the cover of the pump reservoir. The pause time is factory set at 1 hour (position 1, blue switch) and the working time is factory set at 6 minutes (position 3, red switch).

Should it be necessary to either adjust the pause or working time of the pump unit the following instructions should be followed.

Schemate view of the timer board.

Black square indicates switch position

Pause time Switch numbers

Range

Working time Switch numbers

1. Switch 8 always to right hand side 2. Switch 8 always to left hand side

Hours

Minutes

To adjust the working or pause times, move the appropriate switch to the right hand side. All other switches must remain on the left hand side, except switch no. 8 (see above tables)

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Operating & Maintenance Manual

7. MAINTENANCE - 40 HRS

40 HOURS / WEEKLY SERVICE To be performed every 40th hour of operation or once a week.

1. DRIVER SEAT. Check function.

- Check all seat adjustments for easy operation.

- Check function of the air valve.

- Check safety belt for proper lock functions.

2. ENGINE. (10) Check / clean prefilter of the air filter.

Dust cap (evacuator)

- Loosen wing bolt (A).

- Remove prefilter (B) and clean with compressed air, if necessary.

- Reassemble air cleaner.

- Turn prefilter so that marking TOP (or arrow) faces up, dust cap shall show downwards (max. angle: 20o).

- Check air filter warning light at full engine load.

- Procedure for filter elements, see Service when Required. * Adjust the check interval if another requirement is experienced.

(11) Check batteries.

10 - 15 mm

The fluid level in each cell shall be approx. 10 - 15 mm above the plates. * Refill with distilled water if level is lower.

3. ELECTRICAL SYSTEM. Check wiring.

The wiring harness must not be damaged. Check that cables not are squeezed, has sharp bends or loose/bad connections.

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7. MAINTENANCE - 40 HRS

4. Optional: Air conditioner To avoid compressor damage, operate the air conditioner for 10 - 15 min.

See Operating Controls.

NOTE! This must also be done during cold weather operation.

5. Continue with all items in 8 hours / daily service.

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Operating & Maintenance Manual

7. MAINTENANCE - 250 HRS

250 HOURS SERVICE Maintenance to be performed every 250th hour of operation.

1. ENGINE. (1) Change engine oil.

- Remove the drain plug at the oil pan. Access through the drain hole in engine protection plate (belly plate).

- Clean magnet on plug.

- Reinstall it when all oil is drained. * Plug torque: 80 Nm. - Fill oil through filler. Do not overfill!

- Check oil level on dip stick.

(2) Clean centrifugal cleaner.

Unscrew nut and remove cover.

Lift out rotor assembly and loosen nut for rotor cover 3 turns.

If nut sticks: Clamp the nut (absolutely not the rotor) in a vice and turn the rotor 3 turns by hand or using a screwdriver.

Tap the nut with the hand or with a plastic mallet to separate the rotor from bottom plate.

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7. MAINTENANCE - 250 HRS

Loosen the nut and lift off the rotor cover.

Carefully pry the strainer loose from the bottom plate.

Scrape off the deposits inside of rotor cover. * Clean more frequently if deposits are thicker than 20 mm. Deposits elsewhere means that the cleaner must be repaired.

Clean all parts in diesel fuel.

Place the o-ring in the rotor cover. * The o-ring must not be damaged, change if necessary.

Assemble the rotor.

Tighten rotor nut firmly by hand.

Reinstall the rotor. * Check that it rotates easily.

Check that the o-ring in the cover is not damaged.

Hard or damaged o-ring must be replaced.

Tighten cover firmly by hand.

If nut is tightened too hard (for instance by using tools), the rotor shaft, cover or the nut may be damaged!

Change damaged parts!

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7. MAINTENANCE - 250 HRS

Function check.

The rotor rotates very fast, and will normally carry on rotating after the engine is stopped.

- Stop the engine when it is warm.

- Listen for spinning sound from rotor, or feel if cleaner housing vibrates.

- The rotor normally rotates 30-60 seconds after the engine has stopped.

- If not, dismantle and check the cleaner.

(3) Replace turbo filter.

- Remove the old filter and discard it according to enviromental requirements (wrench in tool kit).

- Oil the rubber gasket on the new filter.

- Fit the new filter.

- Tighten by hand as hard as possible.

- Start the engine and check for leaks.

NOTE! Never use tool to tighten the filter. It can be damaged and the circulation hampered! Use only genuine filter!

Check fan belts condition.

Change the multi-groove belt (1) if it is damaged or worn.

Also check that the automatic belt tensioner (2) functions and holds the belt sufficiantly tightened.

2. FUEL TANK. (13) Drain condensated water.

- Open right foot step hatch.

- Place a suitable container to catch spillage.

- Open the drainer cock and drain until water/ sediment free fuel comes out.

- Check for leakage.

NOTE! If larger amount of dirt and contamination is collected into the tank: - Drain all fuel.

- Remove the flange for the hoses (in the engine compartment) and clean inside of the tank.

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7. MAINTENANCE - 250 HRS

3. EXHAUST SYSTEM. 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.

NOTE! Be aware of hot parts when engine has been running!

4. CAB VENTILATION. Check filter element condition.

- Open 2 clamps (A) and remove inlet cover (B).

- Check if the element (C) is clogged/damaged. * Replace if necessary.

Adjust the check interval if another requirement is experienced.

5. DRIVE LINE. Check oil levels.

Measurements must be done when machine 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 machine (or tandem housing) is angeled, the reading can be incorrect.

NOTE! Be aware of possible internal pressure when the oil is hot!

(30) Front differential (key in tool kit). Unscrew the upper (filling/level) plug.

(31) Rear differential. Unscrew the filling/level plug at the rear of housing.

(32) Tandem housings. Unscrew the level plugs on the outside of the housings.

(33) Front reduction gears. Turn the housings until level indicator is horizontal. Unscrew the plugs. * Plug torque: 80 Nm.

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7. MAINTENANCE - 250 HRS

6. HYDRAULIC TANK. (40) Drain condensated water.

-

Open left foot step hatch.

Place a suitable container to catch spillage.

Remove the blanking plug from drainer.

Install draining hose with nipple (tool kit).

Open the drainer cock.

Drain until oil free water/sediment comes out.

Remove hose and reinstall the blanking plug.

Check for leakage.

Refill with clean oil to correct level if necessary.

NOTE! If larger amount of dirt and contamination is collected into the tank: - Drain all oil.

- Remove the hose flanges in engine compartment and thoroughly clean inside of the tank.

7. WHEELS. Check wheel nuts torque.

Torque setting 600 Nm. Wheel spanner in the tool box.

8. LUBRICATION. Grease the following lubrication points.

(57) Rear axle prop. shaft (2 lubricators).

Lift the body and apply the tip support.

Grease the universal joint lubricators at each end.

(58) Articulation prop. shaft (2 lubricators).

Turn the machine completely to the right.

Grease the universal joint lubricators at each end.

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7. MAINTENANCE - 500 HRS

500 HOURS SERVICE Maintenance to be performed every 500th hour of operation.

1. TRANSMISSION. General condition check.

- Check tightness of lubrication system when engine is running. * Tighten or change defective connections.

- Check transmission rubber mountings and replace if necessary. Inspect the mounting bolts.

If optional retarder brake is installed: Change oil (20) and replace filter element (21), see 1000 hours service item 3 for procedure.

2.

DRIVE LINE.

General condition check.

C B

C

A

D C

A

Check the general condition and mountings, joints, bearings, etc. for general deterioration, wear, damages and leakages. * Replace or recondition if necessary.

A) Rear axle and tandem housings.

B) Articulation hinge and turning ring.

C) Suspension: shock absorbers rubber dampers arms and rods D) All prop. shafts, universal joints included.

3. TANKS. General condition check.

Check the hydraulic and the diesel tank bolts/mountings.

4. BRAKE SYSTEM. Check lining thickness.

Std. lining thickness Main brakes: Parking brake:

22,0 mm 18,0 mm

Min. lining thickness (3,5 mm)

Main brake: Remove one wheel at the front and one front wheel at the rear axle and check thickness of linings. If wear limit is approaching, replace all linings on that axle.

Parking brake: Lift body and apply the tip support. Check thickness of linings through inspection hole on top of the caliper. Change when approaching limit. * After replacement perform initial adjustment,see below.

Min. thickness:Main brakes: 3.5 mm.

Parking brake: 3.5 mm.

NOTE! Rough operating conditions with much braking requires more often checking (every 250 hours).

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7. MAINTENANCE - 500 HRS

Initial parking brake adjustment.

To be performed after replacement of parking brake linings.

1. Secure machine with wheel chocks. Pressurize brakes to system pressure, and release the parking brake.

2. Turn the adjusting screw (see arrow) until a total clearance of 1.0-1.5 mm is obtained between outer lining and disk. (Measure at center of lining when sliding caliper max. outwards.)

3. Place a wrench on the adjusting screw, and apply the parking brake several times. When no further rotation on the adjusting screw is observed, the brake is correct adjusted.

4. Remove the wrench and check function and effect.

5. HYDRAULIC SYSTEM. (42) Replace breather element (at the same time as 43).

Spin off the old element on the hydraulic tank.

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

NOTE! Both breather and filter must be replaced (regardless to ordinary interval) if red is seen in the clog indicator on the filter head when running the engine at 1500 rpm.

Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering distrubances and reduce the safety.

(43) Replace hydraulic oil filter.

The right filter on left side of the machine

NOTE! Running in: perform after the first 100 hours.

- Clean well around the filter housing.

- Place a suitable receptacle beneath the filter to catch spillage.

- Unscrew filter housing (A), spanner comes with the machine.

- Check for wear particles in the oil.

- Change o-ring (B). Check backing ring (arrow) for damage.

- Replace the filter element (C) with a new one.

- Clean the housing and apply oil or grease to threads and o-rings.

- Fill housing half full with clean oil.

- Screw filter housing back into place. * Torque: 141 Nm. - Start engine and check for tightness.

- Check clog indicator at 1500 rpm, see Daily service.

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7. MAINTENANCE - 500 HRS

6. LUBRICATION. Grease lubrication points until pure grease is forced out of the components.

(60) Front axle prop. shafts (2+2 lubricators).

The lubricators are located in centre of the universal joint at each end of the shaft.

Turn prop. shaft and lubricator downwards to reach lubricator at the hub end. Lubricate from the underside of the shaft.

(61) Doors and fender hatches (8 lubricators).

There are 2 lubricators on each door and hatch (one per hinge)

(62) Body safety bar (1 lubricator).

The lubricator is located at the frame bearing.

(63) Suspension legs (4 lubricators).

The lubricators are located on the distribution block (fitted on rear, left side of the front frame).

8. Continue with all items in 250 Hours Service.

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7. MAINTENANCE - 1000 HRS

1000 HOURS SERVICE Maintenance to be performed every 1000th hour of operation.

1. DRIVER SEAT General safety check.

1. Check for play in seat gliders. Max. allowed in lenght or sideways: 1 mm. Grease the gliders.

2. Check shock absorbers for oil leakage 3. Check seat mounting to the machine.

4. Check safety belt and lock mechanism for wear and damage.

5. Check that no pins are loose / worn in the seat base. * Replace worn/damaged parts.

2. ENGINE (4) Replace the fuel filter.

- Wash the filter externally and undo it, wrench in tool kit.

- Tighten the new filter by hand. * Never use tools to tighten the filter! The cartridge may be damaged and the fuel flow hampered.

- Bleed the fuel system, procedure below.

- Start engine and check for leaks.

NOTE! Observe extreme cleanliness when working with the fuel system. Otherwise may operation disturbances easily occur and the injection equipment may be damaged.

Bleed fuel system: 1. Open the bleeder screw (1) on the fuel filter unit.

2. Screw out hand pump handle (2) and pull it out.

3. Pump with the hand pump (2) until bubble-free fuel flows from the bleeder screw.

4. Close the bleeder screw. Pump a few times using the handpump.

5. Restore the handle.

In case of starting difficulties after bleeding: - Slacken the injection pump overflow valve (3) one half turn and try staring again.

If the engine still does not start: - Loosen two or three of the delivery pipe union nuts a few turns. Pump with the hand pump and at the same time attempt to start.

- Tighten the union nuts with 20 Nm when engine has started.

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7. MAINTENANCE - 1000 HRS

(5) Check coolant.

COOLANT: Water + Anti-freeze or Water + anti-corrosive (see text) Freezing Antipoint °C freeze -18 30 % 10,5 ltr.

-24 35 % 12,5 ltr -30 40 % 14,0 ltr.

-38 45 % 16,0 ltr.

-40 50 % 17,5 ltr Total volume: 35 litres

Filler

A) Check that the coolant is clean and transparent.

Collect some coolant in a vessel and check the coolant. If it is cloudy or contaminated, consider a change of coolant. The water used in coolant must be soft drinking water (pH-value of 6-9) free from dirt, calcium and salts.

B) Check content of glycol in case of risk of freezing.

If there is risk of ambient temperature below 0 oC, the coolant should contain a mix of water and minimum 30% glycol. The amount of anti-freeze is determined acc. to lowest expected temperature. Make sure it is enough anti-freeze to avoid freezing, see table. An anti-freeze glycol with nitrite-free glycol anti-freeze with following supplier designations is recommended: - BASF G 48-24 - Dow 542/1993 (or equivalent).

C) Check content of anti-corrosive.

A sufficient content of anti-corrosive (inhibitor) is essencial to obtain sufficient protection for the parts in the cooling system and in the engine.

If the coolant do not contain anti-freeze, 5-7% by volume (1,75 - 2,45 litre) Scania anti-corrosive shall be added in the water.

The anti-corrosive content in a nitrate based glycol can be checked by a special analysing kit which can be obtained by a engine work shop.

Coolant replacement procedure:

Radiator drain cock

1. Remove filler cap from expansion tank.

2. Drain the coolant in two places: - drain cock on the engine, - drain cock on the radiator hose.

3. Close the cocks.

4. Fill with correct mixture, pre-blended coolant in the filler hole on the expansion tank.

NOTE! To ensure a good coolant performance with minimum corrosion and freezing problems, the system must be filled with PRE-BLENDED coolant in correct ratio of water / anti-freeze or water / anti-corrosive!

Never fill up with water only or anti-corrosive only!

Lost fluid should always be replaced with premixed coolant: water + 7% Scania anti-corrosive by volume

7-24

Operating & Maintenance Manual

7. MAINTENANCE - 1000 HRS

(11) Check batteries.

Use a hydrometer to check the density of the electrolyte.

The density of a fully charged battery should be: 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.

CAUTION! The electrolyte level must be correct when charging! During recharge a explosive gas is emissed. Open cell plugs and ventilate properly to avoid explosion!

Check batteries terminals for tightness and corrosion.

Clean if necessary, apply acid-free vaseline on the terminals and retighten the clamps.

3. TRANSMISSION. (20) Change oil (change at least once a year).

- Unscrew the dip stick (A).

- Remove drain hatch on transm. protection plate or lower the rear protection plate under transmission.

- Unscrew drain plug (B) under the transmission and drain the oil into a suitable container.

- Clean plug, replace seal if necessary and reinstall. * Tightening torque: 80 Nm.

L.h. side in engine comp.

(21) Replace filter element (at the same time as 20).

Left filter

NOTE! Running in: perform after the first 100 hours.

- Unscrew the filter element.

- Apply oil to the seal on the new element.

- Tighten the element firmly by hand.

Fill new oil through the filler (C) located on left hand side of the engine compartment, see Transmission Oil List and Oil Specification Sheet for approved oil.

Start the engine and check oil level at low idle. Both too low and too high level is harmful to the transmission!

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

NOTE! If the truck is equipped with a oil retarder brake, both oil and filter must be replaced every 500 hours.

Operating & Maintenance Manual

7-25

7. MAINTENANCE - 1000 HRS

4. FRONT DIFFERENTIAL. (30) Change oil (change at least once a year).

- Open level / filling plug (D), special spanner in tool kit.

NOTE! Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening a plug!

- Unscrew drain plug (E).

- Drain the oil into a suitable container.

- Clean the drain plug, replace seal if necessary and reinstall. * Tightening torque: 80 Nm. - Fill new oil through the level / filling plug, level shall be at lower edge of hole when machine is horizontal.

- Clean the plug, replace seal if necessary and reinstall. * Tightening torque: 80 Nm.

NOTE! Running in: perform after the first 500 hours.

5. REAR DIFFERENTIAL. (31) Change oil (change at least once a year).

-

Open level/filling plug (G).

NOTE! Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening a plug!

NOTE! Running in: perform after the first 500 hours.

7-26

- Unscrew drain plug (F) underneath the housing and drain the oil into a suitable container.

- Clean the drain plug, replace seal if necessary and reinstall. * Tightening torque: 80 Nm. - Fill new oil through the level/filling plug, level shall be at lower edge of hole when machine is horizontal.

- Clean the plug, replace seal if necessary and reinstall. * Tightening torque: 80 Nm.

Operating & Maintenance Manual

7. MAINTENANCE - 1000 HRS

6. TANDEM HOUSINGS. (32) Change oil (change at least once a year).

- Machine and tandem housings must be horizontal.

- Unscrew drain plugs (H) on the inside of the housing and drain the oil into a suitable container.

NOTE! Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening a plug!

NOTE! Running in: perform after the first 500 hours.

- Clean plugs, replace seal if necessary and reinstall. * Tightening torque: 80 Nm. - Fill new oil through the filler plug (I) to correct level.

- Clean plugs, replace seals if necessary and reinstall.

7. FRONT REDUCTION GEARS. (33) Change oil (change at least once a year).

- The machine must be horizontal.

- Turn the housing, so that the plug shows downwards.

- Unscrew the plug and drain the oil into a suitable container.

NOTE! Running in: perform after the first 500 hours.

NOTE! Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening a plug!

- Turn the housing 90o, so that the level indicator is horizontal.

- Fill new oil to correct level through level/filling plug.

- Clean plug, replace seal if necessary and reinstall. * Tightening torque: 80 Nm. - Recheck oil level after test driving.

11. Continue with all items in 500 hours service.

Operating & Maintenance Manual

7-27

7. MAINTENANCE - 2000 HRS

2000 HOURS SERVICE Maintenance to be performed every 2000th hour of operation.

1. ENGINE. Check fuel injectors (check at least once a year).

Contact Moxy-dealer for checking of the fuel injectors.

(5) Cooling system.

- Clean externally the radiator fins and hoses.

- Check the fins, rubber hoses, clamps and pipes for corrosion, damages and leakages.

NOTE! Running in: perform after the first 500 hours.

Check valve clearance.

Adjust if necessary. Inlet: 0.45 mm, exhaust: 0.80 mm, see instruction sign on one of the rocker covers.

Valve clearances shall be checked/adjusted on cold engine, at the earliest 30 min after it has been stopped.

Procedure:

FLYWHEEL Cylinder numbering TDC cyl. no. 6

TDC cyl. no. 1

Alternative 1: - Turn cyl. no. 1 to TDC by turning engine in its direction of rotation, until both valves are closed.

- Adjust following valves: 1 in, 1 ex, 2 in, 3 ex, 4 in and 5 ex.

- Turn cyl. no. 6 to TDC by turning engine in its direction of rotation.

- Adjust following valves: 2 ex, 3 in, 4 ex, 5 in, 6 in and 6 ex.

Alternative 2: - Turn cyl. no. 1 to TDC by turning engine in its direction of rotation, until both valves are closed.

- Adjust both valves for cyl. no. 1 for correct clearance.

- Proceed in the same way with the remaining cyl. in the order 5-3-6-2-4 (firing sequence) by turning the engine 1/3 turn in its direction of rotation between each adjustment.

NOTE! Make sure that the engine will not be started when working with the engine.

If engine starts out of control, there is a SERIOUS RISK OF INJURY!

FLYWHEEL Intake valve

TDC= Top Dead Centre

Exhaust valve

7-28

Operating & Maintenance Manual

7. MAINTENANCE

(12) Replace dryer filter (replace at least once a year).

1. Release air pressure in dryer through air filling point.

2. Unscrew bolt D and remove cover C. Discard cartridge (1).

3. Clean all parts, included aluminium filter F and bottom plate E in a proprietary fluid and dry.

4. Reassemble parts with new cartridge and lightly grease the new seals (2-5).

5. Tighten bolt D to 20-25 Nm. 6. Start engine end check for air leaks.

2. HYDRAULIC SYSTEM. (40) Change oil.

- Open the left foot step hatch and unscrew the blanking plug of the drainer underneath the tank.

- Fit the draining hose (tool kit) to the drainer. Open the cock and drain the main reservoir oil into a container.

- Disconnect the hose from the tank to the emergency steering pump to drain emerg. steering reservoir.

Lower the transmission protection plate if necessary.

Collect the oil in a container.

- Clean inside of the tank.

NOTE! Remember, ATF oil must not be mixed with engine or hydraulic oil!

Inspect the hydraulic hoses.

Replace hoses which are deteriorated, leaking or otherwise damaged.

(41) Clean suction strainers.

Open the bolts and remove the 2 suction flanges on the inner side of the tank. Clean the strainers thoroughly.

Check gaskets and o-rings before mounting.

Refill the tank with new, clean oil, see Oil Specification Sheet.

Start up and check for leaks.

NOTE! Pay special attention to cleanliness when working with the hydraulic system!

Operating & Maintenance Manual

7-29

7. MAINTENANCE - 2000 HRS

3. BRAKE SYSTEM. Inspect brake lines.

Replace pipes, hoses and fittings which are corroded (deep seated rust), deteriorated (aged), leaking or otherwise damaged.

NOTE! Check more often when operating in salty conditions or equal environment that may affect the brake system!

(70) Change brake fluid (change at least once a year).

Contact Moxy-dealer or authorized work shop for performing the fluid replacement. Always follow the valid governmental regulations for work on the brake system.

Master cylinder bleeder plug

Brake fluid container

1. Drain the fluid from all circuits, pipes included.

2. Refill with new brake fluid acc. to Oil Specificaion Sheet.

3. Bleed the brake circuits (one at the time): a. First bleed the master cylinder and then the calipers. Fit a transparent hose to the bleeder and collect the spillage fluid in a container. b.Depress the brake pedal and open bleeder plug (*).

Close bleeder before fluid flow stops. c. Refill brake fluid during the bleeding process. d. Bleed until brake fluid free of air cease to appear. e. Bleeder torque: 2,9 Nm. 4. Fill up to correct container level.

5. Perform brake function test and check for leakage.

5. Continue with all items in 1000 hours service.

7-30

Operating & Maintenance Manual

7. MAINTENANCE - WHEN REQUIRED

MAINTENANCE WHEN REQUIRED Maintenance to be performed when necessary.

1. ENGINE. (10) Air filter.

V-clamp Outer element Inner element Retainers Prefilter

Outer element: Clean element when the air filter warning light illuminates at full load on the engine.

Replace it after 6 times of cleaning, or at least once a year.

1. Loosen v-clamp and retainer, remove outer element.

Do not remove inner element when cleaning outer element!

2. Clean retainer and inside of filter housing.

3. Direct dry compressed air (less than 7 bar) to the element from inside along its folds, then direct it from the outside along its folds, and then from inside again.

4. Check that the element is clean and undamaged, and install it again. Marking TOP or arrow must show up.

5. Clean the prefilter, see 40 Hours Service.

Inner element: Replace element every 3rd replacement of the outer element, or at least every 3rd year.

1. Remove outer element. Then remove inner element.

2. Cover the air inlet port.

3. Clean inside of filter housing, and remove inlet cover.

4. Fit a new inner element and the inner element retainer into the housing, and tighten the nut.

5. Install a new or cleaned outer element and outer element retainer, and tighten wing nut.

6. Install cover.

7. Clean the prefilter, see 40 Hours Service.

CAUTION! * Do not attempt to reinstall a cleaned inner element. * Do not clean or replace the element when the engine is running. * Replace the element if small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning. * Do not use an element which folds, gasket or seal are damaged. * When cleaning element, do not hit or beat it. * Do not dismantle the inner element unnecessarily. * Punch a mark in the edge of the inner element each time the outer element is replaced.

Operating & Maintenance Manual

7-31

7. MAINTENANCE - WHEN REQUIRED

(5) Clean cooling system.

WARNING! When handling the cleansing agent: Study the warning tabs!

Follow the instructions!

Clean the cooling system internally. Use original engine cleansing agent and follow the instructions closely. Study the warning tabs.

- Drain 5 liters of coolant.

- Top up with 5 litres cleansing agent.

- Use the engine normally for 250 hours.

- Drain cooling system by removing a low hose or pipe. NOTE! Do not use the drain cocks, the loosened deposits can clog them.

- Refill system with hot, clean water.

- Run engine to operating temperature (opening of thermostats).

- Drain all water the normal way, and refill with coolant, see 1000 Hours Service.

(12) Check air dryer (in the cold season).

Check the air dryer thermostat by chilling dryer bottom to below 1oC. Feel with hand that bottom becomes warm within a minute.

2. TAILGATE. Check function.

- Rise and lower the body and check the tailgate for proper function.

- Check the linkages and joints for wear and damages.

- Check the gas cylinder (A) for tension. * If the gas cylinder has lost tension, contact your local Moxy dealer for repair.

- If necessary (the tailgate not is pressed towards the body), the linkage can be adjusted by shims at B. CAUTION! Pay special attention to the operation of the tailgate if a top tailgate (optional) is fitted.

3. PARKING BRAKE. Check breather.

Loosen the circlip (A), remove cover plate (B) and take out the breather element (C).

- Check if the element is clogged or damaged. Clean with solvent or cleaning fluid. Dry with compressed air.

- Check the rubber bellow for wear and damages. * Replace parts if necessary.

Adjust the check interval according to the surroundings (dusty/muddy conditions, etc.)

7-32

Operating & Maintenance Manual

7. MAINTENANCE - WHEN REQUIRED

4. BEARINGS Check clearance Contact your local dealer for checking of the bearing clearance (every 3000 - 4000 hours is recommended: A. Tandem bearings B. Tip bearings C. Turning ring and articulation bearings D. Wheel bearings

Operating & Maintenance Manual

7-33

7. MAINTENANCE

MEMO

7-34

Operating & Maintenance Manual

8. TECHNICAL DATA

TECHNICAL DATA

Operating & Maintenance Manual

8-1

8. TECHNICAL DATA

CONTENTS 8. Technical data ............................................ 8-1 - 8-14 Measurements .............................................. 8-3 Engine .......................................................... 8-4 Transmission ................................................ 8-4 Hydraulic system .......................................... 8-5 Air system .................................................... 8-5 Tyre inflation ................................................ 8-5 Electrical system ........................................... 8-6 Metering conversion table ............................ 8-7 Tool kit content ............................................ 8-7 Performance chart ........................................ 8-8 Exhaust brake capacity chart ........................ 8-9 Optional: Retarder brake capacity chart ....... 8-10 Torque limit tables ....................................... 8-11 Reference information (fill in tables) ............ 8-11 Periodic service (fill in tables) ...................... 8-12

8-2

Operating & Maintenance Manual

8. TECHNICAL DATA

MEASUREMENTS Machine dimensions (mm):

MT 27

MT 30R

MT 30S

Total length 9300 Total width 2525 Total height 3375 Total height, loaded 3305 Overhang, front 2490 Overhang, rear 1176 Wheelbase 3982/1652 Body upper height (rear edge) 2820 Body floor height (rear edge) 1700 Total height, raised body 6110 Ground clearance at tailgate, raised body 640 Min. ground clearance (f) 505 loaded (f) 440 Turning radius (ISO 7457) 8550 Body tipping angle 67° Steering angle, both sides 45° Standard tyre dimension 20,5R25 Tyre load/speed index 177B (**)

< < < < < < < < < < < < < < < < < <

< 2718 3440 3365 < < < 3055 1755 6240 700 (f) 570 (f) 500 8600 < < 23,5R25 185B (**)

17250 44550 27300

< < <

18250 45550 <

8750 8500 15200 32000

< < < <

9050 9200 < <

11.7 (12.4*) 14.1 (15.3*)

< <

13.6 (14.7*) 16.1 (17.9*)

Machine weights (kg): Empty weight Gross weight Maximum payload Weight distribution (kg): Front axle, empty Rear axle, empty Max. adm. axl load, front Max. adm. axle load, rear Body capacity (m3): Struck Heaped, SAE 2:1 Machine speed (km/h): Forward speeds Reverse speed

5.5-8-13-20-28-43 5.5-13-28

< 6-9-14-21-30-46 < 6-14-30

Towing load on hooks (kg): Front Rear

5000 9000

5000 9000

5000 9000

The measurements are valid for a standard, unloaded machine if nothing else is given. *= with top tail gate fitted Interior sound level (ISO 6394): Sound pressure level (ISO 6393)

82 dB(A) 111 dB(A)

Ambient operating temperature (° C): Min. (-) Max. (+)

- 20 + 40 Operating & Maintenance Manual

8-3

8. TECHNICAL DATA

ENGINE Water cooled, 4-stroke, direct injected diesel engine with turbo charger, intercooler and engine brake.

Type Scania DSC9 Cylinder volume 8.97 litres Bore x stroke 115 x 144 mm No. of cylinders 6 (in line) Power rating (ISO 3046) at 2200 rpm 263 hp (194 kW) Power rating (ISO 9249) at 2200 rpm 249 hp (183 kW) Engine speed, low idle 700 ±50 rpm Engine speed, high idle 2400 +25 rpm Max. allowed engine speed 2600 rpm Oil capacity (min./max.)

Oil pressure, warm engine at 2200 rpm Oil pressure, warm engine at 800 rpm Specific oil consumption

20/25 litres 3.0-6.0 bar min. 0.7 bar 0.3 g/kWh

Coolant volume Normal temperature Thermostat Max. system pressure

35 litres (approx.)

75-85 oC, max. 102 oC 79 oC 0.5 bar

Compression ratio Firing order Engine rotation, seen from rear Valve clearance (cold engine)

17:1 1-5-3-6-2-4 Counterclockwise 0.45 mm, inlet valves 0.80 mm, exhaust valves 16o before TDC 300 bar

Pump timing (see rocker cover sign) Opening pressure, injectors

TRANSMISSION Automatic transmission. Integrated in the gearbox: torque converter, automatic lock-up clutch and lockable inter axle differential. An oil retarder brake is optional.

Type ZF 6WG 200 Converter torque increase 1.545 No. of forward gears 6 No. of reverse gears 3 Oil capacity Oil pressure, clutches Normal temperature Max. permitted temperature If optional oil retarder brake is fitted:

25 litres (approx.)

16 (+2) bar 80-110 oC 120 oC (short period only) 150 oC (short period only)

Stall speed Lock-up clutch Lock-up in/out

1730 ± 30 rpm in all gears acc. to engaged mode

DRIVE LINE Inter axle differential Front axle differential: Rear axle differential Final drives

8-4

ZF (integrated in transmission) longitudinal torque divider 1/3 to front axle, 2/3 to rear axle, locked: 50/50 ZF APG-8/HK (i = 3,1), 45% limited slip ZF LK (i = 4,63), 45% limited slip Front: ZF RP9 (i = 6,353), planetary reduction gears Rear: Moxy (i = 4,31), spur gear tandem housing

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 117 litres (approx.)

Normal oil temperature 40-90 oC (at tank) Filter Full flow pressure filter w/ indicator Main pump Pump delivery

Gear pump, engine speed dependent 175 l/min at 2400 rpm

Emergency steering pump Pump delivery

Piston pump, machine speed dependent Max. 50 l/min

Pressure setting- safety valves:

Tipping circuit Steering circuit

Tipping cylinders Tipping time

2x single acting w/ 6 telescopic pistons 16 sec.

Steering cylinders Steering wheel turns

2x double acting w/ 1 piston Max. 4

160 +20 bar at 900 rpm 175 ±5 bar at 1900 rpm

AIR SYSTEM Applied for brakes, tip control, differential lock and driver seat. The air dryer is fitted with heater, thermostat and silencer.

System pressure 6.8-7.8 bar Safety valve (max. pressure allowed) 19.0 bar Safety valve, supply circuit 9.3 bar Low pressure indication (buzzer) Below 4.8 bar Air tanks Air compressor Air compressor capacity

4 (3x 20 l and 1x 3 l) Piston, 2 cylinders, single acting 275 l/min at 1100 rpm

Heater element, air dryer Thermostat range, air dryer

100 W 2-33 oC

TYRE INFLATIONS Basic inflations for cold tyres in bar (psi): Michelin XADN / XADT 20.5 R 25 Bridgestone VMT 20.5 R 25 Michelin XADN / XADT 23.5 R 25 Bridgestone VKT / VMT / VLT 23.5 R 25 Michelin XRB** 25/65 R 25 Bridgestone VKT 25/65 R 25

front MT 27: 3.50 (51) 3.75 (54) 2.50 (36) 2.75 (40) 3.0 (44) 3.25 (47)

- rear

Michelin XADN / XADT 23.5 R 25 Bridgestone VKT / VMT /VLT 23.5 R 25

MT 30S: 2.75 (40) - 3.50 (51) 3.0 (44) - 3.50 (51)

- 4.50 (65) - 4.50 (65) - 3.0 (44) - 3,25 (47) - 3.75 (54) - 3.50 (51)

front MT 30R: 3.75 (54) 4.0 (58) 2.75 (40) 3.0 (44) 3.25 (47) 3.25 (47)

- rear - 4.50 (65) - 4.50 (65) - 3.50 (51) - 3.50 (51) - 4.25 (62) - 3.75 (54)

Regarding tyre inflation: Contact your dealer or tyre supplier for further information.

Operating & Maintenance Manual

8-5

8. TECHNICAL DATA

ELECTRICAL SYSTEM System voltage Battery Grounding Alternator Starting motor

24 V 2x 12 V, 135 Ah Negative earthcable 28 V, 65 A 5.4 hp (4.0 kW)

Fuses: 16 15 14

13 12 11

The fuses are located in the fuse boxes inside left side dashboard. Be sure to use fuses of correct size. Never install larger fuses than specified! If a certain fuse blows several times, the circuit must be checked and failure corrected.

Separate fuses: Radio/cassetteplayer, factory fitted (5 amp) on the radio power supply, if installed.

RELAYS

10 9 8 7 6 5 4 3 2 1

123456 123456 123456 123456

D C B A

FUSES

Pos Size Circuit lights A1 15 A Parking Autom. head lights beam flash A2 15 A High Hazard light Supply 3 (relay 12) Lighter A3 15 A Air dryer Heated mirrors* Heated seat* Supply 1 (relay 7) Work light A4 15 A Wiper/washer Horn Rotating beacon* Supply 2 (relay 6) fan A5 15 A Ventilator Roof ventilator* Air conditioner* light supply A6 15 A Head Relay 6 and 7

Pos Size Circuit B1 10 A Starter Cab light B2 10 A Engine comp. light Brake light Reverse light/alarm B3 5 A Radio* B4 Spare Park. brake alarm B5 10 A Control light Instruments Buzzer brake B6 10 A Engine Gear shift Speedometer*

Pos Size Circuit C1 10 A High beam, right High beam, left C2 10 A w/indicator C3 10 A Low beam, right C4 10 A Low beam, left C5 10 A Direction lights Switch lights C6 10 A Differential lock

Pos Size Circuit Park light, left front D1 5 A Mark. light, left Park light, r. front D2 5 A Mark. light, right D3 5 A Park light, left rear light, r. rear D4 5 A Park Licence plate lights lubr. system* D5 5 A Aut. Tachograph* D6 5 A Tachograph*

*= Optional- / market depended equipment.

Relays: The relays are located inside left side dashboard.

The relays (except relay no. 14,15 and 16) are interchangeable. A broken relay can be replaced by a less important relay as a temporary solution.

Pos Circuit

Operated by

Pos Circuit

Operated by

1

Reverse lights*

6 Supply 2

Ignition

2

Park. brake alarm

7 Supply 1

Ignition

3

Reverse light

8 Inter axle diff. lock

4

Aut. head lights*

5

Aut. head lights*

Charge warn. lamp

Pos Circuit 11 Working light (roof) 12 Supply 3

9 10 Starter

Park. light

13

Engine brake / Retarder*

14 Direction lights

*= Optional- / market depended equipment.

15 Park. brake alarm 16 Wiper/washer

8-6

Operating & Maintenance Manual

Operated by

Charge warn. lamp

8. TECHNICAL DATA

Bulbs: Light Head lights (H4) Parking lights in head light Direction lights Stop lights Marking lights Licence plate lights Work light on roof Back-up light Rotating beacon (H1) Rear lights Engine compartment light Cabin light Instrument lights Warning/indicator lights Switch lights

Watts 75/70 4 21 21 5 5 70 70 70 5 18 5 1.2 1.2 1.2

Socket P 45t BA 9s BA 15s BA 15s S 8,5 S 8,5 Pk 22s Pk 22s P 14,5s BA 15s S 8,5 S 8,5 W2x4,6d W2x4,6d

METERING CONVERSION TABLE Length: Volume:

Weight: Power: Torque: Pressure: Temp.: Speed:

1 m= 1.094 yd= 3.281 ft= 39.37 in 1 km= 1000 m= 0.621 mile 1 dm3= 1 litre= 0.264 gal (US)= 0.220 gal (UK) 1 dm3= 0.0353 ft3= 61.02 in3 1 m3= 35.32 ft3 1 kg= 2.20 lb= 35.27 oz 1000 kg= 1 tonnes (metric)= 0.984 ton (UK)= 0.902 ton (US) 1 hp= 0.746 kW= 1.015 hk.

10 Nm= 1.02 kpm= 7.38 lbf ft (pound-force foot) 1 bar= 1.02 kp/cm2= 14.5 p.s.i.= 100 kPa o C= 5/9 x (oF- 32) o F= (9/5 x oC)+32 1 km/h= 0.62 mph

TOOL KIT CONTENT Spanner 8 mm Spanner 10 mm Spanner 12 mm Spanner 13 mm Spanner 14 mm Spanner 16 mm Spanner 17 mm Spanner 18 mm Spanner 19 mm Spanner 21 mm Spanner 22 mm Spanner 46 mm

Socket 10 mm Socket 12 mm Socket 13 mm Socket 14 mm Socket 16 mm Socket 17 mm Socket 18 mm Socket 19 mm Socket 21 mm Socket 22 mm Socket 24 mm

Ratchet lever Socket extention Socket conv. 3/8"-1/2" Hex. socket 12 mm Hex. socket 19 mm Hex. screw driver Screw driver, comb.

Plier, universal Hex. bit front hub Filter-wrench Hammer

Fire extinguisher Hose for tire filling Warning triangle First aid kit Tool bag Grease gun Paint 0,3l Extention arm Spanner front diff.

Arm, wheel-spanner Wheel-spanner

Operating & Maintenance Manual

Parts catalogue Operation manual Driver instruction

8-7

8. TECHNICAL DATA

PERFORMANCE CHART Below diagrams gives guidelines for calculation of the dump truck gradeability performance related to rolling + grade resistance. The traction capabilities depend on the ground conditions and surroundings, i.e. available wheel grip (friction), tyre pattern, weight on the wheels, etc.

How to find gradeability perfomance: 1. Read from actual dump truck weight up to the percentage grade.

2. Then read horizontally to the curve with highest gear range.

3. From this point, read vertically down to maximum speed.

MT27:

Empty

40%

Loaded

35% 20,00 30%

25%

Rimpull (ton)

15,00

20% 10,00 15%

10% 5,00 5% 3% 2% 0,00 0

10

20

30

40

50

60

Travel Speed (km/h) , Weight (ton)

MT30:

50% Loaded 45%

Empty

20,00

40%

35%

30%

25%

Rimpull (ton)

15,00

20%

10,00 15%

10% 5,00

5% 3% 2% 0,00 0

10

20

30

Travel Speed (km/h) , Weight (ton)

8-8

Operating & Maintenance Manual

40

50

60

8. TECHNICAL DATA

ENGINE BRAKE CAPACITY CHART Below diagrams gives guidelines for calculation of the dump truck engine 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 grade.

2. Then read horizontally to the curve with highest gear range.

3. From this point, read vertically down to maximum speed.

File: mo-br-27.xlc 25. May

MT27:

50%

40%

45%

30

35%

25%

12 11 F1

20%

10 9

Brake capacity [ton]

8 15%

7 F2

6 10%

5 F3

4 3

F4 5%

F5

2

3%

F6

2%

1 0 0

5

10

15

20

25

30

35

40

45

50

Travel speed [km/h], Gross w eight [ton]

MT30: File: mo-br-30.xlc 25. May 50%

45%

40%

35%

25%

30

20%

10 F1

9

8 15%

Brake capacity [ton]

7 F2

6

10%

5 F3

4

3 F4

5%

2

F5 3%

F6

1

2%

0 0

5

10

15

20

25

30

35

40

45

50

Travel speed [km/h] , Gross weight [ton]

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8. TECHNICAL DATA

OPTIONAL: RETARDER BRAKE CAPACITY CHART Below diagrams gives guidelines for calculation of the dump truck 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 grade.

2. Then read horizontally to the curve with highest gear range.

3. From this point, read vertically down to maximum speed.

MT27:

50%

35%

40

45

16

F1

30%

14 25% Brake capacity (kg x 1000)

12

20%

F2

10

8

15

B

F3

C

6

10%

F4

4

F5

5%

F6

2

0 0

D10

5

15

20

25

30

A

35

3% 2%

40

45

50

Weight (kg x 1000), Travel speed (km /h)

MT30:

50% 14

45

40

35%

30%

F1 25%

Brake capacity (kg x 1000)

12

20%

10

F2 8 15

C

6

B

F3

10% 4

F4 F5

5%

2

F6

0 0

5

D 10

15

20

25

30

35

Weight (kg x 1000), Travel speed (km /h)

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Operating & Maintenance Manual

A

40

3% 2% 45

50

8. TECHNICAL DATA

TORQUE LIMITS FOR BOLTS This tables indicates standard torque limits in Nm for the various screw and bolt qualities and dimensions.

Fine Metric Threads

Metric Threads Dim. / Class

8.8

10.9

12.9

Dim. / Class

8.8

10.9

12.9

M8 M10 M12

24 47 81

33 65 114

40 79 136

M8 x 1 M10 x 1,25 M10 x 1 M12 x 1,5

25 48 49 83

35 68 70 117

42 81 84 140

M14 M16 M18

128 197 275

181 277 386

217 333 463

M12 x 1,25 M14 x 1,5 M16 x 1,5

85 135 204

120 190 287

144 288 344

M20 M22 M24

385 518 665

541 728 935

649 874 1120

M18 x 1,5 M20 x 1,5 M22 x 1,5

294 408 546

413 574 768

496 688 921

M27 M30 M33 M36

961 1310 1770 2280

1350 1840 2480 3210

1620 2210 2980 3850

M24 x 2 M27 x 2 M30 x 2 M33 x 2 M36 x 2

696 1000 1390 1860 2350

979 1410 1950 2610 3310

1170 1690 2340 3130 3970

REFERENCE INFORMATION Machine model: _______________ Serial no.: _____________________ (right hand side) Prod. year: ___________________ In operation: ___________________ Engine s/no.: __________________ Transm. s/no.: __________________ Dealer: ____________________________________________________ _________________________________________________________

Consumeable parts Part no.

Q'ty

Description

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8. TECHNICAL DATA

PERIODIC SERVICE DELIVERY Hrs: ________ Date: _____________ Stamp / Sign.:

Fill in the boxes according to the maintenance performed on the dump truck serial no.: _________________

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

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8. TECHNICAL DATA

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

SERVICE Hrs: ________ Date: _____________ Stamp / Sign.:

Operating & Maintenance Manual

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8. TECHNICAL DATA

MEMO

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Operating & Maintenance Manual