Daewoo Doosan MT41 Operation and Maintenance Manual MX511847 - PDF DOWNLOAD

MT41 Operation and Maintenance Manual MX511847 Serial Number 810001 and UP May 2004

Doosan reserves the right to improve its products continuously, delivering the best possible product to the marketplace. These improvements can be implemented at any time with no obligation to change materials previously sold. It is recommended that consumers periodically contact their distributors for most recent documentation on purchased equipment.

This documentation may include attachments and optional equipment not available in your machine's package. Please call your distributor for additional items that you may require.

Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item.

MX511847 Operation and Maintenance Manual

Copyright 2009 Doosan

1. Foreword

E

OPERATING & MAINTENANCE MANUAL

MT41 Serial no.

810001

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

Manufacturer:

Dealer:

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

Operating & Maintenance Manual

Part no.: 511847 Edition: May 1 2004

1. Foreword

2

Operating & Maintenance Manual

Table of contents

1. Foreword

1. Foreword ................................................................. 5 - 8 Foreword ....................................................................... 5 Safety information ......................................................... 6 Introduction ................................................................... 7

Reference information (fill in tables) ....................... 194 Consumeable parts .................................................. 194 Product signs ............................................................ 195 Periodic service (fill in tables) .................................. 196

2. Safety instructions .............................................. 9 - 40

9. Alphabetical Index ......................................... 199 - 204

3. Operating controls ............................................. 41 - 78 Overview of the instruments and controls ................. 43 Instruments ................................................................ 44 Warning / indicator lights ........................................... 49 Switches ..................................................................... 55 Controls ...................................................................... 61 Cab ventilation ............................................................ 69 Other cabin equipment .............................................. 73 4. Running-in period ............................................... 79 - 84 Running-in operation ................................................. 81 Running-in services ................................................... 82 5. Operating instructions ...................................... 85 -116 Some simple rules to be observed prior to operation 87 Starting the engine ..................................................... 88 Operating the dump truck .......................................... 90 Parking the dump truck ............................................ 102 Stopping the engine ................................................. 102 Checks after stopping the engine ........................... 103 Loading and tipping ................................................. 103 Tyre handling ............................................................ 105 Cold weather ............................................................ 107 Long term storage .................................................... 108 Battery power assistance ........................................ 109 Towing the dump truck ............................................. 110 Manual release of parking brake ............................. 110 Manual release of the tip valve ................................ 111 Troubleshooting ....................................................... 112 6. Lubricants ....................................................... 117 - 124 Lubrication schedule ................................................ 119 Oil specification sheet .............................................. 121 Filling capacities ....................................................... 122 Transmission oil list .................................................. 123 7. Maintenance ................................................... 125 - 184 Maintenance precautions ........................................ 127 Maintenance table .................................................... 129 8 Hours / Daily service ............................................. 131 40 Hours / Weekly service ........................................ 143 500 Hours Service .................................................... 145 1000 Hours Service ................................................. 161 2000 Hours Service ................................................. 173 4000 Hours Service ................................................. 181 Yearly recommended maintenance ........................ 183 8. Technical data ................................................ 185 - 198 Measurements .......................................................... 187 Engine ....................................................................... 188 Transmission ............................................................ 188 Hydraulic system ...................................................... 189 Tyre pressures .......................................................... 189 Electrical system ....................................................... 190 Metering conversion table ........................................ 191 Tool kit content .......................................................... 191 Performance chart .................................................... 192 Engine and retarder brake chart .............................. 193 Torque limit tables .................................................... 194

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1. Foreword

4

Operating & Maintenance Manual

1. Foreword

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

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

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

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

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

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

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

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

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

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

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

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

WARNING • This dump truck complies with EC directives 98/37/EC with amendments and 89/336/EC with amendments.

Dump trucks complying with the directives display the CE mark.

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

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

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

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

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

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

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

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1. Foreword

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

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

NOTE

-

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

CAUTION

-

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

WARNING

-

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

DANGER

-

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

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

YELLOW & BLACK -

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

GREEN & WHITE

These colours are used on information labels.

-

Know the capacity and limits of your dump truck!

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Operating & Maintenance Manual

1. Foreword

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

General description Moxy MT41 is an articulated, 6-wheel drive dump truck. The free-swinging rear tandem housing, and the special Moxy articulation system, provide excellent performance in soft and difficult terrain. The special body design ensures that a low centre of gravity is maintained and an even load distribution to front and rear wheels, for stability on uneven ground and for fast easy tipping. The Moxy dump truck is designed and manufactured to work under difficult conditions.

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

Operators cab Dump body Engine bonnet

Hydraulic tank

Head and side light

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1. Foreword

8

Operating & Maintenance Manual

2. Safety Instructions

Safety Instructions

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

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

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2. Safety Instructions

Content

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

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Operating & Maintenance Manual

2. Safety Instructions

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

Remember the check points and checking method of fluid levels.

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

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

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

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

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

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

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2. Safety Instructions

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

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

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

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

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

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

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

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Operating & Maintenance Manual

2. Safety Instructions

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

• Stop the engine and do not smoke when refuelling.

• Tighten all fuel and oil caps securely.

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

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

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

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

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

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

3. Slowly loosen cap to relieve pressure before removing.

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

3. Slowly loosen cap to relieve pressure before removing.

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2. Safety Instructions

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

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

Location: Left hand side in the cab.

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

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

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

Location: Toolbox in the right hand side fender.

• See also Safety equipment in chapter 3.

• Know what to do in case of fire.

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

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

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

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

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Operating & Maintenance Manual

2. Safety Instructions

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

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

• This cab meets the requirements for roll-over protection.

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

DO NOT ATTEMPT TO JUMP CLEAR! • The approval sign for ROPS/FOPS is located on the fire wall underneath the bonnet.

• Structural damage, an overturn, modification, alteration or unpermitted repair can affect the cab strength and there by void the certification • Consult Moxy Engineering AS or your Moxy Dealer to determine this structure’s limitations without voiding its certification.

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

• Left door and front sidewindow on right hand side.

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

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

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2. Safety Instructions

3. PRECAUTIONS before starting the engine

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

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

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

THEY COULD CAUSE FIRE!.

• Marshland, when dry, is highly flammable. Marshland can selfignite even in low temperatures.

Always keep the engine and engine compartment clean!

• Check fuel, lubrication and hydraulic system for leaks.

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

The fire extinguisher shall be located on left hand side in the cab.

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Operating & Maintenance Manual

2. Safety Instructions

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

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

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

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

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2. Safety Instructions

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

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

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

Check also that they light up properly.

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

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

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

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

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

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

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

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

Do not raise the body near high-voltage cables.

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

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

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

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

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

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2. Safety Instructions

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

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

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

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

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

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

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

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

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

2. Disconnect the battery cable between the batteries.

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

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

• Tighten the battery caps securely.

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

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

Loosened terminals can generate sparks and lead to an explosion.

1

3 2

Battery main switch (OFF)

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2. Safety Instructions

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

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

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

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

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

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

Do not smoke when servicing the air conditioning system!

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

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

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

Contact a doctor.

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

Contact a doctor.

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

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2. Safety Instructions

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

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

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

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

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

• Never use fuel for washing any parts.

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

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

3. Always refill using pre-mixed coolant. (see chapter 7, maintenance)

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

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

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

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

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2. Safety Instructions

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

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

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

• Correct the fault before operating the dump truck again.

If necessary, contact your Moxy Dealer.

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

• Always check ground conditions before travelling on slopes.

• Always travel straight up or down on slopes.

• Do not turn on slopes or travel across slopes.

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

• Keep travel speed very low.

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

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

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

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2. Safety Instructions

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

If the engine speed exceeds 2600 rpm, the retarder brake (emergency retarder) will automatically engage, to avoid overspeed of the engine. This will happen regardless to the throttle pedal and switch position.

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

Be aware of reduced braking effect when brakes are wet.

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

The maximum wading depth is: 1,25 metres, i.e. up to the front fenders.

NOTE Under no circumstances let water flow through the grill!

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2. Safety Instructions

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

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

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

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

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

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

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

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2. Safety Instructions

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

2. Unplug the connectors on the electronic control units for the engine and the transmission. The units are located behind the cover on the backwall (behind the instructor seat back rest, if that is fitted).

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

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

OFF

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2. Safety Instructions

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

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

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

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

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

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

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

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

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

The tailgate shall be disassembled in three parts, tailgate arms (left and right) and the rear tailgate plate. Be sure that wire or chain are attached to all three tailgate parts before disassembling.

2. Remove all screws (see arrows) on the tailgate (both sides) and lift off the tailgate parts. Approx. weight: 1500 kg.

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2. Safety Instructions

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

The bonnet is fitted with lockable bonnet opener on left hand side.

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

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

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

2. Lift the bonnet catcher.

3. Push up the bonnet.

4. Check that the bonnet catcher engages.

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

2. Lift the bonnet catcher.

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

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

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

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

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

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

To tilt the cab, see next page

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2. Safety Instructions

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

2. Stop the engine.

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

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

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

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

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

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

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

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

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

The safety support is to be found in the toolbox. a

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

b

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

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

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

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

5. Close the bonnet.

6. Lower the body.

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

DANGER c

28

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

Do not enter the cab while it is tilted!

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

Operating & Maintenance Manual

2. Safety Instructions

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

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

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

3. Lift the body support in top position.

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

5. Return the tip control lever to hold position.

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

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

2. Lift the body slightly.

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

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

5. Lower the body support.

6. Lower the body.

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

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

Operating & Maintenance Manual

29

2. Safety Instructions

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

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

2. Apply the articulation lock (see item 24).

Block the wheels (see item 23).

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

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

5. Be aware of hot fluids and components.

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

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

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

30

Operating & Maintenance Manual

2. Safety Instructions

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

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

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

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

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

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

• When lifting or hoisting the truck, see item 25.

• During dump truck transportation, see item 26.

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

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

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

Machine net weight:

approx. 31080 kg incl. tailgate

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

Operating & Maintenance Manual

31

2. Safety Instructions

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

2. Apply the articulation lock.

3. Apply wheel chocks.

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

CAUTION Always transport the truck without load in the body!

27. High pressure Be aware of high pressure in the hydraulic system (with running engine and operated service brakes) and tyres. Do not strike or bend pressure hoses or tubes. Do not use bare hands for checking leaks, use shield as protection to avoid personal injury. Even a pin-hole size leak can penetrate the skin. Always release pressure before maintenance or servicing: Hydraulic: Accumulators contain oil under high pressure!

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

Procedure: • Stop the engine.

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

Accumulators can also be emptied through the accumulator test connectors.

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

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

32

Operating & Maintenance Manual

2. Safety Instructions

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

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

Warning - use of top tailgate • Top tailgate is fitted on this dump truck.

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

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

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

Warning - dangerous loads Warning - never coast in neutral • Never coast with the gear selector in the neutral position.

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

Operating & Maintenance Manual

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

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

33

2. Safety Instructions

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

Emergency exit • The emergency exit can be opened by pulling the handle under the window backwards.

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

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

34

Operating & Maintenance Manual

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

• Always keep the manual in the cab.

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

2. Safety Instructions

Fire extinguisher WARNING! Accumulators contain oil under high pressure!

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

• Procedure: Stop the engine Operate the brake pedal repeatedly until the accumulators are empty.

Accumulators can also be emptied through the accumulator test connectors.

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

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

Be aware of that the accumulators will be recharged with oil when the engine is restarted.

See also Operating and Maintainance Manual.

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

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

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

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

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

Operating & Maintenance Manual

35

2. Safety Instructions

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

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

36

Operating & Maintenance Manual

2. Safety Instructions

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

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

• Sound horn to alert people nearby.

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

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

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

• Do not touch hot surfaces!

Fingers or hands can be burnt.

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

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

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

• Sound horn to alert people nearby.

• Always use the articulation lock when servicing!

• Read the operating manual (safety instructions, item 24).

Operating & Maintenance Manual

37

2. Safety Instructions

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

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

• Empty body before body support is used.

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

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

WARNING! Accumulators contain oil under high pressure!

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

• Procedure: Stop the engine Operate the brake pedal repeatedly until the accumulators are empty.

Accumulators can also be emptied through the accumulator test connectors.

Be aware of that the accumulators will be recharged with oil when the engine is restarted.

See also Operating and Maintainance Manual.

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

MT25/MT26/MT31/MT36/MT41

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

38

Operating & Maintenance Manual

• Read the operating manual (safety instructions, item 2.9).

2. Safety Instructions

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

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

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

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

Operating & Maintenance Manual

39

2. Safety Instructions

(Behind the hydr. tank)

(Behind the cab)

Note - transmission

Note - fuel tank

Note - hydraulic tank

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

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

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

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

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

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

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

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

40

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

Operating & Maintenance Manual

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

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

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

3. Operating controls

Operating Controls

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

41

3. Operating Controls

Contents

3. Operating controls ................................................... 41-78 Overview of the instruments and controls ................ 43 Instruments ............................................................... 44 Warning / indicator lights .......................................... 49 Switches .................................................................... 55 Controls ..................................................................... 61 Cab ventilation ........................................................... 69 Other cab equipment ................................................. 73

* Numbers refer to positions on the electrical circuit diagram 42

Operating & Maintenance Manual

3. Operating controls

Overview of the instrument panels and controls

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

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

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

• To be able to check the function of instruments and controls, the battery main switch must be connected and the starting switch key must be in position 1. See item 87.

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

43

3. Operating Controls

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

2

1

Pos 1 2 3 4 5

3

4

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

5

Remarks

* Numbers refer to positions on the electrical circuit diagram 44

Operating & Maintenance Manual

3. Operating controls

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

Tank capacity: approx. 490 litres Fill up with diesel when necessary, and at the end of the shift.

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

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

1500 - 1900 rpm

• High idle:

2430 rpm ± 50

• Max. allowed rpm:

2600 rpm

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

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

continued overleaf

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

45

3. Operating Controls

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

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

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

D. Starts flashing if error has been detected.

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

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

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

3. Check and note the error codes on the display, which will be shown at pos B and C when the gear selector is in neutral position. If more than one error has been detected, each error code will be shown for about 1 second.

4. Contact your Moxy Dealer (a short explanation of the codes is listed under troubleshooting, chapter 5).

NOTE • •

•

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

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

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

continued overleaf

* Numbers refer to positions on the electrical circuit diagram 46

Operating & Maintenance Manual

3. Operating controls

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

Special features: "NN" -

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

"EE" -

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

"

will be shown on the display if the oil temperature is below -12°C. The transmission controller will not release any gear before the oil has been warmed up. Keep the engine rpm above 1200 rpm and the gear selector in neutral position during the warm-up period.

"-

"BA" -

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

See 1000 hours serivce for procedure.

"WS"-

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

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

"WR"-

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

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

"WT"-

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

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

"WE"-

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

WE starts flashing if the engine rpm reaches 2600 rpm. The main warning light (30) will also illuminate, and the emergency retarder will automatically engage.

The engine speed must be reduced immediately!

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

47

3. Operating Controls

Instruments

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

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

• The partial travel distance in kilometres.

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

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

Normal range is 50 - 105°C, max.permitted for a short period 120°C. Normal operation temperature during retarder brake operation is up to 140°C, max. permitted for a short period 150°C. If the oil temperature in the transmission is too high during operation, the following warnings will show up: the main warning light (30), the wrench on the gear display (3) will flash and the display will show the letters WS, WR or WT (see explanation under item 3, gear display). Stop the dump truck immediately, select neutral gear, and run engine at mid-range speed for a while to cool down the oil.

One reason for the high temperature could be use of a too high gear range.

* Numbers refer to positions on the electrical circuit diagram 48

Operating & Maintenance Manual

3. Operating controls

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

21

22

30 31

13 14 15 23 24

25

33 34 35 43 44 45

12 20 10 11

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

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

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

32 40 41 42

Description Page Main warning light, transmission failure 52 Engine coolant level warning light 52 Tipping system warning light 52 Hydraulic filter warning light 52 Seat belt on driver's seat warning light 52 Lock-up indicator 52 High beam indicator 53 Engine brake indicator 53 Inter axle differential lock indicator 53 Direction light indicator 53 Retarder brake indicator 53 Automatic central lubrication indicator 53

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

49

3. Operating Controls

Warning / indicator lights

10

11

12

10. Spare space

11. Spare space

12. Spare space

13

14

15

13. Brake system warning light, red 6-A2* Lights if the fluid pressure in front or/and rear brake circuit is below approx. 150 bar. Do not attempt to drive the dump truck at fluid pressure below 150 bar.

Can also light when the starter switch is turned on, switches off when the fluid pressure is above 150 bar. If the light does not switch off, check for leakage.

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

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

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

15. Parking brake indicator, red 6-C2* Lights when the parking brake (77) is engaged.

The light will flash and a buzzer will sound if a gear is selected while the parking brake is on.

* Numbers refer to positions on the electrical circuit diagram 50

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights

20

21

22

20. Engine coolant temperature warning light, red 7-A1* Lights if the engine coolant rises above 103 °C. Additional the main warning lights (22 and 25) will start flashing.

Stop the engine (possible fault) immediately and contact your Moxy Dealer.

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

23

24

25

Lights if oil pressure is lower than 1.0 bar. Additional the main warning lights (22 and 25) will start flashing.

Stop the engine (possible fault) immediately and contact your Moxy Dealer.

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

Stop the engine (possible fault) immediately and contact your Moxy Dealer.

23. Battery charge warning light, red 7-A2* Lights if the battery charging voltage is too low (less than 24 volts). Check alternator, multi-groove belt and regulator.

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

See 1000 hours service for procedure.

25. Warning light, engine failure, co-ordinator, red 7- C2* Lights and flashes if there is an engine /engine controller failure.

Stop the engine (possible fault) immediately and contact your Moxy Dealer.

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

51

3. Operating Controls

Warning / indicator lights

30

31

32

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

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

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

31. Engine coolant level warning light, red 8-B1* Lights if the level in the expansion tank has dropped to minimum.

33

34

35

Refill with coolant of correct mixture. See 8 hours service and 1000 hours service for procedures.

32. Tipping system warning light, orange 8-C1* Lights when the body is raised.

Switches off when the body is lowered and resting on the frame rubber pads.

33. Hydraulic filter warning light, red 8-A2* Lights if the hydraulic filter is clogged and needs maintenance.

See 1000 hours service for procedure.

34. Seat belt on driver's seat warning light, red 8-B2* Lights if the seat belt is not fastened.

Fasten the seat belt!

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

* Numbers refer to positions on the electrical circuit diagram 52

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights

40

41

42

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

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

43

44

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

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

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

44. Retarder brake indicator, orange 9-B2* Lights when the retarder brake is engaged (switch 62)

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

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

The system performs all operation automatically. After the starter switch is turned on or is in operation the pump will at 10 minutes interval supply measured quantities of grease to all the lubrication points.

NOTE If there is a failure in the system, it is only possible to run the dump truck in 2. gear until the failure is corrected. continued overleaf * Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

53

3. Operating Controls

Warning / indicator lights

Blink codes for the automatic central lubrication indicator: Blink codes

Cause/Meaning

The light flashes 4 times once (0.5s on/0.5s off) The automatic central lubrication is activated. as soon as the starter switch has been turned on: The light does not flash when the starter switch 1. The system is not powered. Check fuses and is turned on: connection to earth and replace if necessary.

The light flashing for 2 minutes (0.5s on/0.5s off) at the beginning of each cycle:

2. Lamp or wiring to lamp could be defective.

Check lamp and wiring and replace if necessary.

Minimum grease level in the reservoir has been reached. Refill the reservoir as soon as possible, see 500 hours service.

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

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

System out of order! Immediate action is required.

Possible causes: • Insufficient grease pressure during 10 consecutive cycles (or 10 consecutive times in the same main pipe channel). Check cause and reset by depress-ing the test button (on the reservoir) for at least one second while the hi • Reservoiri empty; refilld the reservoir and after that depress the test button (on the reservoir) for at least one second while the starter switch is turned on.

The light flashing during one complete cycle (2.0s on/2.0s off):

Single test run being executed (see "test")

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

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

Located under the cover

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

1. Starter switch turned on.

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

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

Test button

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

1. Starter switch turned on.

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

The system will perform a continuous lubrication cycle run.

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

* Numbers refer to positions on the electrical circuit diagram 54

Operating & Maintenance Manual

3. Operating controls

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

50

51

52

53

54

55

63

60

76

64

61

77 65

62 70

71

72

Pos 50 51 52 53 54 55 60 61 62 63 64 65 70 71 72 73 74 75 76 77

73

74

75

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

Page 56 56 56 56 56 56 57 57 57 57 57 57 58 58 58 58 58 58 59 59

Remarks

Optional Optional Optional

Optional Optional

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

55

3. Operating Controls

Switches

50

51

50. Main light switch 90*

52

1st position, Side lights.

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

2nd position, Headlights.

When the switch is set to 2nd position the headlights (high or low beam according to position of column switch (80)) will also illuminate. Built-in light.

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

Turn off during operation. Built-in light.

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

Built-in light.

53

I

54

53. Working lights and extra high beam 20*

55

I

0

0

II

II

Push the switch to activate the lights.

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

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

0. Neutral, the lights are switched off.

II. The working lights will light.

54. Spare space

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

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

Built-in light.

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

0. Neutral, the lights are switched off.

II. The working lights will light.

* Numbers refer to positions on the electrical circuit diagram 56

Operating & Maintenance Manual

3. Operating controls

Switches

60

61

62

60. Spare space

61. Spare space

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

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

This will happen regardless to the switch position.

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

Push the switch to engage the retarder brake.

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

Built-in light.

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

63

64

65

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

64. Spare space

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

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

57

3. Operating Controls

Switches

70

71

72

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

Engage only when necessary!

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

Built-in light.

72. Spare space

73

74

75

73. Spare space

74. Spare space

75. Engine controller switch for code reading Push the switch to read the codes for the engine controller (22) and the co-ordinator (25).

* Numbers refer to positions on the electrical circuit diagram 58

Operating & Maintenance Manual

3. Operating controls

Switches

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

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

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

Built in light.

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

• when necessary!

77. Parking brake switch

77

0

The parking brake is on (locked) when the switch is in the backward position. An indicator light (15) will light when the parking brake is on. Push the lock device to release the parking brake. In the forward position the parking brake is off (released).

The parking brake must not be applied when the dump truck is in motion unless in an emergency situation.

Indicator light (15) and a buzzer will sound if a gear is selected while the parking brake is on (locked).

Lock device

I

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

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

59

3. Operating Controls

* Numbers refer to positions on the electrical circuit diagram 60

Operating & Maintenance Manual

3. Operating controls

Controls

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

80

82

81

86

85

89 90

88 87 83

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

84

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

Page 62 64 65 65 66 67 67 67 68 69

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

61

3. Operating Controls

Controls 80. Column switch 16* The column switch is a multi-function switch for main lights, horn, direction indicators and windscreen wiper/washer.

Main lights (A, B, C):

B

A. Low beam (when switch 50 is in position 2)

C

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

C. High beam flash. Automatic return.

A

D. Horn, centre button automatic return.

D

E. Right turn, all right direction indicators flash.

Indicator light 43 flashes correspondingly.

E

F. Left turn. All left direction indicators flash.

Indicator light 43 flashes correspondingly.

F

* Numbers refer to position on the electrical circuit diagram 62

Operating & Maintenance Manual

3. Operating controls

Controls

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

G

J interval I

low speed

II high speed

H

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

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

63

3. Operating Controls

Controls 82. Steering column The steering wheel is fitted on an adjustable column for comfortable reach and easy operation.

• Height adjustment - lift lever up to unlock.

• Tilt adjustment - push lever down to unlock.

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

WARNING Do not adjust position while driving!

* Numbers refer to position on the electrical circuit diagram 64

Operating & Maintenance Manual

3. Operating controls

Controls 83. Brake pedal The pedal controls the main brake (service brake). When depressing the pedal, the rear stop light will light. Braking effect depends on pedal position. Depress pedal gradually, and learn to associate braking requirements for loaded and unladen dump truck.

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

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

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

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

65

3. Operating Controls

Controls

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

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

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

Pos V: Forward drive position.

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

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

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

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

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

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

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

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

See also chapter 5, Operating Instructions

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

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

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

* Numbers refer to position on the electrical circuit diagram 66

Operating & Maintenance Manual

3. Operating controls

Controls 86. Tip control lever 1

The lever controls the body lifting and lowering.

The lever has 3 positions:

2

1. Lower (body down/power down).

2. Hold (hold and floating position).

3. Lift (body up).

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

Always keep the lever in hold position during loading and driving.

Check that the body is resting on the frame rubber pad during loading and driving.

A warning light (32) will light when the body is lifted (i.e. when the body is not resting on the frame rubber pads).

87. Starter switch 50* The starter switch is key operated, and has 4 positions.

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

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

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

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

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

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

67

3. Operating Controls

Controls

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

• Left door and front sidewindow on right hand side.

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

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

* Numbers refer to position on the electrical circuit diagram 68

Operating & Maintenance Manual

3. Operating controls

Cab ventilation

90. Cab ventilation 1

2

3

4

1. Ventilation fan switch 55* Turn switch to operate the 3-speed cab fan.

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

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

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

Turning clockwise to increase the air flow towards the windows.

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

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

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

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

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

• Always open the nozzles when operating the dump truck.

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

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

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

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

69

3. Operating Controls

Cab ventilation Setting heat and ventilation Without air conditioning How to get...... ......maximum heat: • • • •

All nozzles fully open.

Heater regulator (90.3) on max., i.e right position Fan switch (90.1) on max, i.e. speed 3.

Air flow regulator (90.2) to driver's feet i.e. left position.

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

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

• Heater regulator (90.3) on max., i.e. right position • When the correct temperature has been obtained, turn heater regulator (90.3) (left) until you maintain the desired temperature.

• Air flow regulator (90.2) turned to the position which feels most comfortable.

• Fan switch (90.1) set to speed 1 or 2.

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

• Heater regulator (90.3) on min., i.e. left position • Air flow regulator (90.2) on max. air flow towards the driver's feet, i.e. left position.

• Fan switch (90.1) on max, i.e. speed 3.

* Numbers refer to position on the electrical circuit diagram 70

Operating & Maintenance Manual

3. Operating controls

Cab ventilation Setting heat and ventilation Without air conditioning How to get...... ......rid of condensation and ice on all windows: • Nozzles towards the windows fully open.

• Heater regulator (90.3) on max., i.e. right position • Air flow regulator (90.2) on max. air flow towards the windows, i.e. right position.

• Fan switch (90.1) on max, i.e. speed 3.

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

CAUTION Ensure good ventilation!

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

Poor ventilation can cause drowsiness (lack of oxygen).

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

71

3. Operating Controls

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

• Heater regulator (90.3) on min., i.e. left position • Air flow regulator (90.2) on max. air flow towards the driver's feet, i.e. left position.

• Fan switch (90.1) on max, i.e. speed 3.

• Switch (90.4) pressed down, i.e. air conditioner engaged.

When the temperature has been lowered to the level you want: • Turn the fan switch (90.1) to the position which maintains the desired temperature.

• Turn the air flow regulator (90.2) to the position which feels most comfortable.

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

...... rid of air humidity in the cab: • All nozzles fully open.

• Heater regulator (90.3) on max., i.e right position • Air flow regulator (90.2) on max. air flow towards the windows, i.e. right position.

• Fan switch (90.1) on max., i.e speed 3.

• Switch (90.4) pressed down, i.e air conditioner engaged.

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

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

* Numbers refer to position on the electrical circuit diagram 72

Operating & Maintenance Manual

3. Operating controls

Other cab equipment

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

1

2

Seat adjustment.

3 5

4

1.

Lumbar support adjustment.

Stepless adjustment of the support.

2.

Backrest inclination adjustment.

3.

Seat cushion inclination.

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

4.

Forward and backward adjustment.

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

5.

Height adjustment.

Stepless seat height adjustment.

Elevation - Push the button. Lowering - Pull out the button.

Automatic weight adjustment.

7.

Headrest.

8.

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

9.

Adjustment screw Stepless inclination adjustment.

10.

Backrest.

11.

Suspension height limiter.

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

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

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

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

71.

Electrically heated seat.

7 8

9 8

10

11

70

71

72

The seat can be heated by pushing the switch.

Refer to item 71 in this chapter.

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

73

3. Operating Controls

Other cab equipment

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

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

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

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

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

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

* Numbers refer to position on the electrical circuit diagram 74

Operating & Maintenance Manual

3. Operating controls

Other cab equipment

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

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

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

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

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

(Distributor / Dealer fitted)

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

75

3. Operating Controls

Other cab equipment

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

Ashtray

Retractable roller sunblind on front windscreen

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

* Numbers refer to position on the electrical circuit diagram 76

Operating & Maintenance Manual

3. Operating controls

Other cab equipment

Radio/Cassette player 201,212* The radio has following security features: Detachable panel, switchable warning light, security warning sticker and identification number.

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

1.

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

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

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

2.

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

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

3.

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

4.

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

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

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

5.

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

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

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

77

3. Operating Controls

* Numbers refer to position on the electrical circuit diagram 78

Operating & Maintenance Manual

4. Running-in period

Running-in period

Operating & Maintenance Manual

79

4. Running-in period

Content

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

80

Operating & Maintenance Manual

4. Running-in period

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

Follow instructions below during this period: 1. Start engine as described in "Operating Instructions"(chapter 5) . Run engine at low idle speed until pressure in the various circuits is normal (i.e. brake system warning light switched off, also see chapter 3).

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

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

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

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

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

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

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

Operating & Maintenance Manual

81

4. Running-in period

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

This is the owner’s responsibility.

2.1

First 8 hours: 1. Wheel nuts.

• Torque setting:

Check tightening of nuts.

450 Nm. Spanner: 32 mm

2. Lubricating.

Grease all lubricating points.

3. Battery:

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

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

4. Multi-groove belt:

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

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

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

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

• Walk around check .............................................. item 1.1.

• Check driver's seat .............................................. item 1.2.

• General condition check - look for leakages, ..... item 2.1.

• Drain water separating fuel filter ......................... item 2.2 • Check oil level, engine ........................................ item 2.3.

• Check coolant level ............................................. item 2.4.

Coolant should be filled up when the engine is stopped after first stop.

It is recommended to fill up with the same mixture as filled from the producer - 40% glycol / 60% water, see also 2000 hours service, item 1.4 check the coolant.

• Check fuel level ................................................... item 2.5.

• Function check of the centrifugal cleaner, .......... after first operation ............................................... item 2.6.

• Check oil level, transmission .............................. item 3.1.

• Check oil level, hydraulic system ........................ item 4.1.

• Check parking brake capacity, ........................... item 6.1.

• Check main brake capacity ................................. item 7.1.

• Check main brakes function, ............................... item 7.2.

• Check steering function ....................................... item 8.1.

• Check engine brake function .............................. item 9.1.

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

2.2

First 100 hours: 1. Change transmission oil.

20*

See 1000 hours service, item 3.1.

2. Replace transmission filter. 21*

See 1000 hours service, item 3.1.

3. Clean strainer.

22*

See 1000 hours service, item 3.1.

4. Replace hydraulic filter.

43*

See 1000 hours service, item 4.2.

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

6. Expander bolts:

Checking torque setting on expander bolts on tip- and steering cylinders, see 500 hours service, item 6.1

7. Retorque window wiper spindle nuts.

• Torque setting: 35 Nm (M10), 18 Nm (M8) 8. Lubricating. Grease all lubricating points.

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

Operating & Maintenance Manual

4. Running-in period

2.3

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

• Rear differential.

• Tandem housings.

• Reduct. gears, front.

30* 31* 32* 33*

See 1000 hours service, item 5.1.

See 1000 hours service, item 6.1.

See 2000 hours service, item 4.1.

See 1000 hours service, item 7.1.

2. Check/adjust: • PDE injector rocker arms See 2000 jours service, item 1.1 • Valve clearance See 2000 hours service, item 1.2.

• Hydraulic oil pressure. Contact your local Moxy dealer.

3. Lubricating. Grease all lubricating points.

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

• Change oil, engine ............................................... item 1.1.

• Clean centrifugal cleaner ..................................... item 1.2.

• Replace oil filter ................................................... item 1.3.

• Check batteries .................................................... item 1.4.

• Check battery terminals ...................................... item 1.5.

• Run the AEB-Tester ............................................. item 2.1 • Check brake lining thickness ............................. item 4.1.

• Check wheel nuts torque .................................... item 5.1.

• Check expander bolts, tip- and steering cyl. ...... item 6.1.

• Air conditioner system, test operation ................ item 7.1.

• Check cab ventilation filter element .................... item 7.2.

• Refill the reservoir for autom. central lubrication item 8.1 • Check the automatic central lubrication system item 8.2

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

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

83

4. Running-in period

84

Operating & Maintenance Manual

5. Operating Instructions

Operating Instructions

Operating & Maintenance Manual

85

5. Operating Instructions

Content

5. Operating instructions ............................................. 85 - 116 Some simple rules to be observed prior to operation 87 1. Starting the engine .............................................. 88 2. Operating the dump truck .................................... 90 3. Parking the dump truck ........................................ 102 4. Stopping the engine ............................................ 102 5. Checks after stopping the engine ....................... 103 6. Loading and tipping ............................................ 103 7. Tyre handling ....................................................... 105 8. Cold weather ........................................................ 107 9. Long term storage ............................................... 108 10. Battery power assistance .................................... 109 11. Towing the dump truck ........................................ 110 12. Manual release of parking brake ........................ 110 13. Manual release of the tip valve ........................... 111 14. Troubleshooting ................................................... 112

86

Operating & Maintenance Manual

5. Operating Instructions

Some simple rules to be observed prior to operation.

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

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

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

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

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

• Check that the steering column is adjusted for comfortable operation, and confirm that it is fixed before operation. DO NOT ADJUST POSITION OF THE STEERING WHEEL WHILE DRIVING!

• Use helmet to increase protection of your head.

• Always use the seat belt during driving!

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

• When you climb up or down from the dump truck, always climb with your face towards the dump truck and use steps and handles. Always use two hands and one foot, or one hand and two feet.

DO NOT JUMP!

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

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

• Check that the brake system warning light is not lighted before driving.

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

• The cab has two exits, one door and the front sidewindow on the right hand side as emergency exit. The front sidewindow is opened by pulling the handle under the window backwards. The rubber seal must be pulled completely off before pushing the front sidewindow out.

Operating & Maintenance Manual

87

5. Operating Instructions

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

Remember to connect the battery main switch on the left hand side of the front fender (if disconnected) otherwise there will be no power supply.

1.1. Confirm that parking brake is ON

ON

1.2. Confirm that gear selector is in neutral position

1.3. Turn the starter switch ON, pos 1 Check warning lights before starting: • engine oil pressure • charging light • parking brake • brake system - could light up if the fluid pressure is too low. If the light does not switch off, check for possible fault.

• emergency steering warning light - switches off above 5 km/h.

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

• seat belt - fasten the seat belt.

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

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

88

Operating & Maintenance Manual

5. Operating Instructions

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

2. Hold until engine starts (max. 30 sec).

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

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

2. In cold weather, wait 2 minutes before restart.

2 min.

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

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

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

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

Operating & Maintenance Manual

89

5. Operating Instructions

2. Operating the dump truck 2.1. Before operation When the engine is running properly and the fluid pressures are within operating range:

1. Clean/defrost the windows before driving.

6. Sound the horn as alert.

2. Fasten the seatbelt before driving.

7. Depress the brake pedal.

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

90

OFF

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

4. Confirm low idle speed.

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

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

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

Operating & Maintenance Manual

5. Operating Instructions

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

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

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

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

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

Gear position V: Forward drive position.

Automatic gear shift

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

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

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

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

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

continued overleaf

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5. Operating Instructions

Preselection of gears.

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

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

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

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

Manual gear shifting Manual gear shift

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

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

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

Preselection of gears is also possible in manual gear shift.

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

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

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

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

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

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Operating hints Different types of terrain require different operating techniques.

Automatic gear shift

• Use automatic gear shift, for normal travel.

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

• Shifting directly between forward and reverse direction.

Manual gear shift

• Changing between automatic and manual gear shift.

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

• When selecting a gear from the neutral position and when shifting between forward and reverse gears:

N

OFF

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

• Stop the truck and release the throttle pedal completely.

• Neutral position must not be selected during driving.

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

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

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

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

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5. Operating Instructions

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

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

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

The transmission will always select 1st reverse.

4. Increase the engine speed.

The reverse drive position has only manual gear shift between 1st, 2nd and 3th gear. The selector must be pushed in order to change gear. When a gear is engaged, the transmission will only operate in this gear until the selector is pushed to another position.

WARNING •

Be careful when reversing, the rear visibility is limited!

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

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

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

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

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

• Transm. oil temp.:

50 - 105°C, max 120°C a short period

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

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

Check the brakes every day to ensure function.

Service brake (main brake) All hydraulic operated dry single disc brake on each wheel. There are two separate circuits. If a fault occurs in one of the circuits, the dump truck can still brake with the intact circuit. Self adjusting system.

Engine brake Hydraulic operated, speed dependent brake which restricts exhaust flow.

Efficient only when lock-up clutch is connected.

Retarder brake Infinitely variable, hydrodynamic, wear resistant and speed dependent oil retarder fitted before transmission torque converter. The braking effect of the retarder brake depends on the engine rpm. High engine rpm gives high retarder braking effect.

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

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

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

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

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

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

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

NOTE

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•

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

•

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

•

To avoid overspeed of the engine, the retarder brake will automatically engage if the engine speed exceeds 2600 rpm. This will happen ragardless to the throttle pedal an switch position.

Reduce the engine speed immediately!

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

See also chapter 2. Safety Instructions 1. Release the throttle pedal.

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

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

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

5. Apply the parking brake.

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

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

2. Apply the engine and retarder brake.

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

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

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

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

Consult your Moxy Dealer.

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

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

NOTE Mechanical endstops are fitted in the steering cylinders.

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

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

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

1

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

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

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

3

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

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

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

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

3. Rear differential, automatic diff. brake (limited slip type) Fitted in the rear axle housing. Transfers the power to left and right tandem drive.

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

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5. Operating Instructions

2.12. Up, down and crossgradient travel

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

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

• Before starting downhill, release the throttle pedal and slow down the dump truck to a safe speed for the downhill slope. Move the gear selector to a suitable position (1st, 2nd or 3rd).

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

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

• Always use the engine brake or the engine and retarder brake for constant retardation.

Long time engagement and unnecessary use of the service brakes can cause excessive wear and a possibility of loss of braking effect due to over-heated brake discs.

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

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

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

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

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

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

This is to avoid overspeed of the engine.

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2.13. Important operating instructions

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

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

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

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

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

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

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

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

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

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

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

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5. Operating Instructions

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

2. Do not park on grades or slopes.

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

4. Move the gear selector to neutral position.

5. Apply the parking brake.

6. Lower the body completely.

7. Neutralize all operating controls.

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

4. Stopping the engine 1. Stop the dump truck.

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

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

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

3. Before stopping the engine, check that the main warning lights for engine failure is not on or flashing.

See chapter 3, Operating Controls for procedure if the warning lights are on or flashing.

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

5. Remove the key from starter switch.

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

2. Turn off the battery main switch.

3. Check for leakage of oil or water.

4. Fill up the fuel tank.

Make sure that the filler cap and the area around the filler opening is clean to avoid contamination of the fuel 5. Remove any waste paper or other flammable material which may cause fire in the engine compartment.

6. Remove any mud stuck to the chassis.

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

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

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

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

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

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5. Operating Instructions

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

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

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

4. Reduce the engine speed before the body reaches the top position (check that the top tailgate, if fitted, opens).

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

It will then automatically return to hold position.

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

The tipping cylinders are double acting. The lowering speed is proportional with the engine speed.

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

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

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

WARNING • • • • • •

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Reduce tipping speed when dumping large rocks!

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

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

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

Utilisation of top tailgate has safety restrictions!

See Chapter 2. SAFETY INSTRUCTIONS!

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7. Tyre handling General This is a general instruction for the standard tyres in the table under item 7.2. Contact tyre supplier or your local Moxy Dealer for exact specifications.

Off-road tyres produce more heat during operation than tyres for ordinary cars. Therefore, the tyres must be used correctly to obtain long lifetime and safe operation.

Please note that the following can cause overheating of tyres: • Too low tyre pressure • Overloading • Driving long distances non-stop • Travelling at high speed

CAUTION Extremely low temperature (below -40°C) requires special operation!

7.1. Difference in tyre diameter If it is necessary to change a wheel as a result of puncture or in emergencies, Moxy Engineering AS allows up to 5% difference in the tyre diameter on the same side of the tandem. But the most ideal situation in all cases is to have the same tyre diameter on the same side of the tandem. This is strongly recommended.

7.2. Correct tyre pressures Tyre pressures mainly depend on operation speed and load.

Road configuration, flotation/traction requirements, risk of cutting, hacking, shock damage and ambient temperatures, are also factors to consider.

Both too high and too low tyre pressure may result in damage and shortened lifetime of the tyres.

Tyre pressure checks and corrections must be carry out on cold tyres.

Basic pressure for cold tyres (based on max. load and max. speed): Type GoodYear RL2+ ** Michelin XADN Bridgestone VLT **

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Front bar (psi) 2.9 (42) 2.9 (42) 3.35 (48.5)

Rear bar (psi) 3.6 (52) 3.6 (52) 4.2 (61)

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5. Operating Instructions

7.3. Specified loading Do not overload the dump truck. Maintain an even load distribution, avoid unbalanced loads.

Protect tyres from falling stones during loading.

7.4. Proper maintenance Perform tyre inspections according to Maintenance schedule.

Also roads and driving paths should be maintenanced to achieve max. tyre serviceability.

Damaged, excessively worn or aged tyres should be replaced.

Remove foreign objects from the threads, these will sooner or later penetrate into the tyre.

Removal or repairing of tyres should be performed by a tyre specialist to avoid unsafe working conditions.

WARNING Always let the air out of the tyre before removing foreign objects and before demounting or repairing!

See also chapter 2, Safety Instructions (High pressure)

7.5. Transit, long distance drive-away on road This special type of driving requires special operation: • Check and adjust the tyre pressure on cold tyres before starting. Do not reduce pressure during driving.

• Drive only without load.

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

• Upper speed limit for this operation: 32 km/h.

Must not be exceeded!

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

• The viscosity of oils in engine, transmission, differentials, and hydraulic system should be of a suitable viscosity for the lowest expected ambient temperature, see Oil Specification Sheet.

• The coolant must contain anti-freeze to avoid ice in the cooling system and to protect against corrosion, see chapter 7, maintenance, 2000 Hours Service.

• As the temperature drops, the battery capacity drops accordingly.

The batteries must be in good condition and fully charged when the dump truck is operated in low temperatures.

• Fuel must be of a low pour point, and the fuel tank must be filled up at the end of the shift. 0.5 - 2 % alcohol (isopropanol) can be added to avoid condensation.

• The washer fluid should contain a mix of alcohol (isopropanol) and water which at least is sufficient to avoid icing in the tubes.

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

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

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

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

• If the dump truck is equipped with exhaust-heated body, this should be connected to avoid material freezing to the body.

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9. Long term storage If the dump truck shall be stored for a longer period of time, special preparation must be carried out to avoid deterioration and damage.

Store it preferably indoors in a dry and ventilated room or outdoors under shelter.

9.1. Before storage: 1. Neutralise all operating controls, place the gear selector in neutral position, the retarder brake switch must be turned OFF and apply the parking brake.

2. Thoroughly wash and clean the dump truck.

3. Completely fill the fuel tank.

4. Replace oil and filters with new and lubricate all nipples.

Check viscosities to match the expected ambient temperature.

5. If the ambient temperature is expected to drop below 0oC, always add antifreeze to the cooling water.

6. Fully charge the batteries and disconnect terminals.

Preferably stored separately in a cold place (0-10oC).

7. Cover all cylinder piston rods with rust protecting fluid.

8. Inflate the tyres to correct pressure. (see chapter 8) 9. Lock the sliding windows, door, fender hatches and bonnet.

9.2. During storage: Operate the truck once a month by driving it i.e. until engine temperature reaches normal operating temperatures. This will lubricate all moving parts. At the same time check for leakages and recharge the batteries. Grease the nipples.

NOTE Check oil and fluid levels before starting the engine!

Drive slowly and with care the first 5 minutes or 1 km.

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10. Battery power assistance In case of discharged batteries, the dump truck can be started by connecting charged batteries, 24 volts with capacity approx. equal to the discharged batteries.

• If the batteries have been discharged, check the reason why (are the batteries defect?, is there a short circuit somewhere on the dump truck? etc.)

• Discharged batteries should be charged as soon as possible.

• Check the electrolyte level and density after charging the batteries.

Connection: A

1. Turn off the battery main switch on the left hand side fender.

3

4

2

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

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

Good batteries

B

Low batteries

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

5

Chassis of vehicle with low battery

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

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

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

CAUTION • • • • •

Use cables with min. 25 mm2 cross section.

Connect in sequence described above.

Good clamp contact is essential.

Do not stand near a battery when connecting the cable to the chassis.

Do not disconnect the original battery cables.

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11. Towing the dump truck.

• The dump truck can be towed by fitting a wire/chain to the eye(s) in front/rear of the dump truck.

• Check that the wire/chain is capable of towing the load.

• The towing distance must not exceed 10 km, and the maximum allowed speed is 10 km/h!

• The engine must run at low idle to steer the dump truck in the normal way. If the engine is stopped, the steering movement will be heavier and slower than normal because there is no oil flow from the main hydraulic pump.

• The maximum towing force is: • Front,100 kN (each) • Rear, 200 kN

CAUTION • • •

If fluid pressure is lost, the service brake will not function and the parking brake will be engaged.

An engaged parking brake can be loosened even if there is no fluid pressure in the system, see item 12.

It is not possible to start the engine by towing!

12. Manual release of parking brake Cylinder mounting nuts

If the parking brake must be disengaged when hydraulic pressure is not available, the following procedure should be followed:

Clevis pin Clevis Cylinder

1. Secure the dump truck with wheel chocks so that it will not move as the parking brake is disengaged.

2. Raise the body and secure it eith the body support (see chapter 2 - safety instructions).

3. Loosen the jam nut that locks the clevis to the cylinder pull-rod.

Jam nut Cylinder Pull rod

4. Turn the cylinder pull-rod to expose additional clevis threads.

This will reduce spring pressure on the brake.

Continue turning the pull-rod until there is clearance between the linings and disc.

At this point the parking brake will no longer function and the dump truck can be moved to a repair facility.

5. Repair the dump truck so that hydraulic pressure is available to the parking brake.

6. Remove the cylinder from the brake and screw the clevis into the cylinder pull-rod until the center of the clevis pin is 70-73 mm from the mounting face of the cylinder (no pressure).

7. Torque the jam nut to 13.6-20.3 Nm to lock the clevis to the cylinder pull-rod.

8. Reinstall the cylinder onto the brake. Torque the cylinder mounting nuts to 40.5-54.5 Nm. 9. Reinstall the clevis pin and check for proper brake adjustment.

DANGER All braking systems are out of function when the parking brake is manual released. Extreme care must be taken to avoid spontaneous rolling.

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

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

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

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

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

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

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

*= Always contact your Moxy Dealer.

Symptom

Cause

Action

Engine: • • • • • • • •

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

• • • • • • • • • • • • •

Fuel system disturbance Condensated water in diesel Bad fuel quality Low fuel level Fuel filters clogged Air filter clogged Fuel tank breather clogged Throttle system disturbance Wrong injection timing Injector defective Turbo charger defective Worn engine or internal damage Electronic controller or sensors defective

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

Overheated (warning light)

• • • • • • • •

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

Add coolant, check for leakages Tighten/replace Bleed system Clean and replace coolant Clean Replace Replace Overhaul*

Low coolant temperature

• Sensor/gauge defective • Thermostat stuck open

Replace Replace

Low oil pressure

• • • • •

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

Will not start

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

Low output

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

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

5. Operating Instructions

Symptom

Cause

Action

Blue smoke, oil consumed

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

Adjust to specified level Change to correct oil type Overhaul*

Black or white smoke

• • • •

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

Oil in coolant or coolant in oil

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

Replace* Overhaul* Replace*

Knocking noise

• • • • •

Change fuel Adjust Adjust* Replace* Overhaul*

Main warning light illuminates

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

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

• Engine / engine controller failure

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Stop the dump truck at a safe place and check the error codes. Contact your Moxy Dealer

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Symptom

Cause

Action

Transmission:

Too high temperature

• • • • •

Too low oil level Incorrect oil type Cooling circuit failure Lock-up fault Worn oil pump

Add oil, check for leakage Change to correct oil type Check/repair Overhaul* Overhaul*

• Too low oil level • Blown fuse • Converter prop. shaft • Electronic controller detect failure, neutral engaged

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

• • • • •

Electronic controller or sensors defective Flywheel damper separated Drive line failure Internal transmission failure Automatic central lubrication failure

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

Low oil pressure

• • • • • •

Too low oil level Incorrect oil type Sensor/gauge defective Pressure control valve failure Worn oil pump Internal transmission failure

Add oil, check for leakage Change to correct oil type Replace Check/repair* Overhaul* Overhaul/replace*

Noise

• Too high oil level • Incorrect oil type in differential(s) • Worn transm. or internal damage

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

• Transmission / transmission controller failure Main warning light illuminates

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

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Operating & Maintenance Manual

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

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

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

5. Operating Instructions

Symptom

Cause

Action

Brakes:

Poor braking effect or truck pull to one side when braking

• • • •

Low hydraulic oil level Uneven worn brake pads Insufficient fluid pressure A brake caliper is stuck

Add oil, check for leakage Replace pads Check charging and system Repair*

Hydraulic system:

Emergency steering light on when driving

• No oil flow from main pump, or no oil flow from emergency pump • Oil flow switch defective

Check and repair* Check and repair* Replace*

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

• • • • • •

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

Add oil, check for leakage.

Bleed system Change oil and flush system Change to correct oil type Overhaul* Check and repair*

Not possible to tip or slow tipping

• • • • • • •

Low hydraulic oil level Clogged oil filter Insufficient air pressure Clogged tank strainer or breather Low oil pressure Worn oil pump Tip valve failure

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

Electrical system:

No electrical power

• Main switch disconnected • Batteries discharged • Battery terminals/wiring defective

Turn on Recharge Repair

Charge warning light on

• Fan belt problem • Defective/worn alternator • Defective wiring

Tighten/replace Replace Check connections, wires

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115

5. Operating Instructions

Symptom

Cause

Action

Chassis:

Uncomfortable travel (jumping)

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

Replace Replace Overhaul*

Vibrations

• • • • •

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

116

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

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6. Lubricants

Lubricants

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117

6. Lubricants

Content

6. Lubricants ................................................................. 117 - 124 Lubrication schedule ................................................. 119 Oil specification sheet ............................................... 121 Filling capacities ........................................................ 122 Transmission oil list ................................................... 123

118

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6. Lubricants

Lubrication schedule

1st time

POS COMPONENT ENGINE 1 2 3 4 5

HOURS-->

100 500

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

SERVICE INTERVAL 8

40

V V

500 1000 2000 4000

Min. once a year

Shell Rimula Super 15W - 40

R C R

D V

Lubricants filled from producer

R C/V/R* C/R

10 Air filter, outer element -Inner element: replace every 2th

C/V/R*

C/R*

C/R*

V

V

R R C

R R C

R R

R R

40% Glycoshell

year 11 Batteries (2) 13 Fuel tank

V V

TRANSMISSION 20 Transmission oil 21 Filter (2) 22 Strainer

R R C

V

DRIVE LINE 30 Front differential oil 31 Rear differential oil

R R

V V

32 Tandem housing oil (2)

R

V

33 Front reduction gear oil (2)

R

V

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

R R

Shell Rimula X 10W/30

R

HYDRAULIC 40 Hydraulic oil 42 Breather element on tank 43 Filter

V

R

R

LUBRICATION POINTS 50 51 52 53 54 55 56 57 58 59

Articulation turning ring Tip hinges Tandem bearings Articulation bearings Steering cyl. bearings Tip cylinder bearings Tailgate arm hinge (optional) Door and fender hatches Cab rear hinges Suspension legs

1 lubric.

2 lubric.

2 lubric.

2 lubric.

4 lubric.

4 lubric.

2 lubric.

8 lubric 2 lubric.

2 lubric.

Shell Tellus T 46

R R Shell SRS 4000 NLGI - 2

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

MISCELLANEOUS 70 Cab ventilation filter 80 Hydr. pump, tiltable cab

C/R* V/R* Shell Tellus T15

R= Replace V= Check C= Clean L= Lubricate D= Drain *= or when required L-X = The number after the L means number of pump stroke per lubricator (1 stroke = 1-1 1/2 cm 3) = Alternatively greased by automatic central lubrication system (optional)

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119

6. Lubricants

The numbers refer to table on previous page.

4

5

11

1 3

21

2

1 10 4

33

30

22

33

42

13

40

58

43

20

59 59

54

50

54 54 54 55 53

55

53 56

55

31

32

32

51 120

52 51

Operating & Maintenance Manual

6. Lubricants

Oil specification sheet This table presents guidelines for oil, coolant, fuel, lubricants and other fluids best suited for good performance and long life.

COMPONENT

KIND OF FLUID

-4 -20

AMBIENT TEMPERATURE 14 32 50 68 86 °F -10 0 10 20 30 °C SAE 20W-30 SAE 30 SAE 40

Engine oil pan

Engine oil

SAE 50 SAE 5W-30 SAE 10W-30 SAE 15W-40

Fuel tank Cooling system

Diesel fuel

SUM M E R - D IE S E L

Dexron -IID/ -III / Mercon -M SAE 10W

Engine oil

SAE 10W-30/10W-40 SAE 15W-40 SAE 20W-20

Tandem housing, Planetary red. gear Front diff.

Rear diff.

If fuel contains more than 0.3% (weight) sulphur: reduce the oil change interval.

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

Ask your local Moxy Dealer or oil supplier Acc. to: ASTM and ISO standards Cetane number: min. 49.

Sulphure contents: max. 0.3 %.

Max. 2 % isopropanol additive.

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

Only oils in the Transmission oil list can be used!

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

SAE 85W-90 Gear oil

SAE 80W-90

According to: API GL-5 or MIL-L-2105D (gear oil with EP-additives)

SAE 85W-140 Gear oil with LSadditives

*= max. 2% (weight) VI-Improver and Pour Point Depressant in the basic gear oil.

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

HM ISO VG 32

Hydraulic tank

The engine oil should at least meet the requirements for one of the following oil classifications: - ACEA E3, E4 or E5 - API CG-4 - Global DHD-1 - The Total Base Number (TBN) should be minimum 12-13 (ASTM 2896).

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

Water + antifreeze ATF

ZF Transmission

WIN T E R

REMARKS

HV ISO VG

Hydraulic oil

HM ISO VG 46 HV ISO VG

ATF

DEXRON IID SAE 10W

Engine oil Lubricator

Universal grease

Optional: Automatic

Universal grease

Centr. lubr. system Hydr. pump, Hydraulic oil tiltable cab

Only mineral based oils.

Viscosity approx. 20 cSt at normal operating temperature.

Range: 10-250 cSt, max. 850 cSt at cold start.

Hydraulic oil: HM or HV oils (ISO 6743/4, CETOP RP 91H) or H-LP oils (DIN 51524).

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

• Warm up in neutral after starting at temperatures near lower limitation of the oil.

• If using Biological oil contact your Moxy Dealer before use. The oil must be approved by Moxy Engineering AS.

Lithiumsaponfied with EP-additive.

Consistency NLGI-1 / 1,5 / 2.

Grease should not contain graphite or PTFE. Consistency NLGI-2 or synthetic 2, NLGI 0/1 or synthetic 0/1

NLGI 2 NLGI 0/1 ISO VG 15 See remarks

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

CAUTION Remember, Automatic Transmission Fluid must not be mixed with engine or hydraulic oil.

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121

6. Lubricants

Filling capacities All capacities are measured in litres (dm3), and are approximate values. To achieve correct level: check at dip stick, level eye, level plug etc.

Description: Specified capacity: Total tank/reservoir volume or total capacity from empty.

Refil amount:

Refill volume after normal fluid draining. The differences are fluid left in components, piping etc.

Component/Fluid Engine oil Engine coolant

Refill amount

34

34

50

42

490

as req'd

Transmission oil*

55

38

Rear differential

56

53

Fuel tank

Front differential

10

10

Tandem housing, each

2 x 150

2 x 135

Front reduction gear, each

2 x 7.5

2 x 7.5

Hydraulic system

232

209

Windscreen washer tank

4.5

4.5

*=

122

Specified capacity

Check level when engine runs at low idle.

Do not run engine without oil in the transmission.

Operating & Maintenance Manual

6. Lubricants

Transmission oil list Engine oil

Lubricant class 03A Mineral oil-based engine oil in accordance with Group standard ZFN 13030 (API CD/CE/CF-4/CF/CG-4/CH-4/CI-4//SF/SG/SH/SJ/SL or ACEA, categories A, B, E) Viscosity class: SAE 20W-20 / 30 / 10W-30 / 10W-40 / 15W-30 / 15W-40 / 20W-40 Note: All mineral oil-based trade products which satisfy the above specifications may be used.

Lubricant class 03B Engine oil in accordance with Group standard ZFN 13030 (API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/SF/SG/SH/SJ/SL or ACEA, categories A, B, E) Viscosity class: SAE 10W / 5W-30 / 5W-40 Manufacturer

Trade name

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

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

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123

6. Lubricants

Transmission oil list Automatic Transmission Fluid (ATF) Lubricant class 03D Automatic Transmission Fluids (ATF) in accordance with Group standard ZFN 13030 Manufacturer

Trade name

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

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

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7. Maintenance

Maintenance

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

125

7. Maintenance

Contents

7. Maintenance ............................................................. 125 - 184 Maintenance precaustions ........................................ 127 Maintenance table ..................................................... 129 8 Hours / Daily Service .............................................. 131 40 Hours / Weekly Service ........................................ 143 500 Hours Service ..................................................... 145 1000 Hours Service .................................................. 161 2000 Hours Service .................................................. 173 4000 Hours Service .................................................. 181 Yearly recommended maintenance ......................... 183

* Numbers refer to positions on the lubrication schedule, chapter 6 126

Operating & Maintenance Manual

7. Maintenance

Maintenance precautions • Always prepare the dump truck before starting any maintenance, adjustments or other work on the dump truck, see Service Position in the Safety Instructions chapter (Chapter 2).

• Fuel and oil are dangerous substances. Never handle fuel, oil, grease or oily clothes in places where there is any fire or flame.

As preparation in case of fire, always know the location and the use of fire extinguishers and other firefighting equipment.

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

• Flames should never be used instead of lamps. Never use a naked flame to check leaks or level of oil, fuel, anti-freeze or electrolyte.

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

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

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

• Thoroughly wash the engine. In particular, be careful to clean the filler caps, grease fittings and the area around the dipsticks. Be careful not to let any dirt or dust into the system.

• Always stop the engine when performing maintenance near moving parts.

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

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

• Always use Moxy genuine parts for replacement.

• Unless you have special instructions to the contrary, maintenance should always be carried out with engine stopped. If maintenance is carried out with the engine running, there must be two persons present: One operating the engine, and the other one performing the maintenance. In such a case, never touch any moving parts.

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

See chapter 6.

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

127

7. Maintenance

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

Un de rp rep ara tio n

• Before servicing/working on or opening the hydraulic system, remember always to release the pressure in the accumulators.

Empty the accumulators through the accumulator test connectors, or by operating the brake pedal repeatedly while the engine is stopped.

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

• Before draining the oil, warm it up to a temperature of 30o to 40o C. Be aware of possible internal pressure when opening any drain, level or filling plug. Hot oil can spurt out and inflict personal injury.

• Be particularly careful when removing the expansion tank cap. If this is done immediately after using the engine, there is a danger that boiling water and steam may spurt out.

• When lubricating oil or cooling water has been drained, keep an eye on the instrument panel so that the dump truck is not operated without oil or cooling water.

• Always use pure oil or grease, and be sure to use clean containers.

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

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

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

• 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.

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

* Numbers refer to positions on the lubrication schedule, chapter 6 128

Operating & Maintenance Manual

7. Maintenance

Maintenance table 8 Hours / Daily Service 1. General 2. Engine

3. Transmission 4. Hydraulic system 5. Lubrication: • Artic. turning ring • Suspension legs • Artic. bearings • Steering cyl. bearings • Tip cyl. bearings • Tailgate arm hinges • Tip hinges • Tandem bearings • Door and fenders • Cab rear hinges 6. Brake system

Walk around check .........................................................

Check driver's seat .........................................................

General condition check ................................................

Drain water separating fuel filter ....................................

Check oil level ................................................................

Check coolant level ........................................................

Check fuel level ..............................................................

Check centrifugal cleaner ..............................................

Check oil level ................................................................

Check oil level ................................................................

131 131 132 132 133 133 134 134 135 136

1 lubricator ...................................................................... 137 2 lubricators ................................................................... 137 2 — “ — ........................................................................... 137 4 — “ — .......................................................................... 137 4 — “ — .......................................................................... 137 2 — “ — ........................................................................... 138 2 — “ — .......................................................................... 138 2 — “ — .......................................................................... 139 8 — “ — .......................................................................... 139 2 — “ — .......................................................................... 140 Parking brake, check braking capacity .......................... 140 Service brake, check braking capacity ........................... 140 Service brake, check function ........................................ 141 Accumulators, check oil pressure .................................. 141 7. Steering Check function ................................................................ 142 8. Engine brake Check function ................................................................ 142 9. Engine and retarder brake Check function ................................................................ 142

40 Hours / Weekly Service 1. Cab ventilation 2. Tyres

Clean prefilter ................................................................. 143 Air conditioner ................................................................ 143 Check tyre pressure ....................................................... 144

500 Hours Service 1. Engine

2.

3.

4.

5.

6.

7.

Transmission Drive line Brake system Wheels Tip- and steering cyl.

Cab ventilation

8. Automatic central lubr.

Change oil ...................................................................... 145 Clean centrifugal cleaner ............................................... 146 Replace oil filter .............................................................. 149 Check batteries ............................................................... 150 Check battery terminals .................................................. 150 Run the AEB-Tester ........................................................ 150 Check oil levels .............................................................. 152 Check linings .................................................................. 154 Check wheel nuts torque ................................................ 156 Check expander bolts .................................................... 156 Test of air conditioner ..................................................... 157 Check cab ventilation filter ............................................. 158 Refill reservoir ................................................................ 159 Check the system ........................................................... 159

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

129

7. Maintenance

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

3. Transmission

4. Hydraulic system 5.

6.

7.

8.

Front differential Rear differential Front reduction gears Electrical system

Safety check ................................................................... 161 Replace fuel filter and water separating fuel filter ......... 161 Bleed the fuel system ..................................................... 162 Check batteries ............................................................... 162 Check multi-groove belt ................................................. 163 Clean/replace air filter .................................................... 163 Change oil ...................................................................... 166 Replace filter elements ................................................... 166 Clean strainer ................................................................. 167 Replace breather element ............................................. 168 Replace hydr. return filter ............................................... 169 Change oil ...................................................................... 170 Change oil ...................................................................... 171 Change oil ...................................................................... 172 Check wiring ................................................................... 172

2000 Hours Service 1. Engine

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

Check/adjust PDE injector rocker arms ......................... 173 Check/adjust valve clearance ........................................ 173 External cleaning, radiator ............................................. 174 Check coolant ................................................................. 175 Change oil ...................................................................... 178 Inspect brake lines ......................................................... 178 Change oil ...................................................................... 179

4000 Hours Service 1. Cooling system

Internal cleaning ............................................................. 181 Changing coolant ........................................................... 182

Yearly recommended maintenance 1.

2.

3.

4.

5.

6.

Transmission Drive line Tanks Hydraulic system Exhaust system Bearings

General condition check ................................................ 183 General condition check ................................................ 183 General condition check ................................................ 183 Inspect the hydr. hoses ................................................... 184 Safety check ................................................................... 184 Check clearance ............................................................ 184

* Numbers refer to positions on the lubrication schedule, chapter 6 130

Operating & Maintenance Manual

7. Maintenance

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

1. General 1.1. Walk around check, before start • Check for leaks at the engine (see also item 2.1), transmission, differentials, reduction/tandem housings, tanks, hydraulic hoses and lubrication system.

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

• Check for damage, wear and other abnormalities on the visible parts of frames, body, tyres, cylinders, etc.

• Check lights. Replace burnt out bulbs.

If leakages, loose bolts, damages or other abnormalities are observed, remedy if necessary (before operation).

If necessary contact your local Moxy Dealer.

1.2. Check driver's seat, before start • Check function.

• Check all seat adjustments for easy operation.

• Check function of the air valve.

• Check safety belt for proper lock functions.

See chapter 3, seat adjustment, for more detailed information.

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

131

7. Maintenance

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

2. Engine 2.1. General condition check - look for leakages Remedy as necessary 1. Start the engine.

2. Look for leakage of oil, coolant, fuel, air and exhaust.

3. Tighten or change leaking connections. Check the overflow holes (1) which show whether the O-rings between the cylinder liner and crankcase are leaking, see figure. a. If coolant is leaking out, the O-rings are leaking. b. If oil is leaking out, the liner shelf is leaking.

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

This leakage normally stops after a time.

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

2.2

Drain the water separating fuel filter 4* The water separating fuel filter is located on the left hand side of the engine.

Drain the filter by unscrewing the tap in the bottom of the filter.

Draining tap

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

Operating & Maintenance Manual

7. Maintenance

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

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

2

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

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

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

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

• Check level correctness.

1

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

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

• If large quantities are required to correct the level, check and remedy the cause in such a case.

CAUTION Be careful when removing the filler cap of a hot engine.

Hot coolant and steam can spurt out!

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

Always top up with pre-mixed coolant.

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

133

7. Maintenance

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

2.5. Check fuel level, before start 13*

1

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

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

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

NEVER run out of fuel.

2

2.6. Function check of the centrifugal cleaner, after operation 2* The rotor rotates very fast, and will normally carry on rotating after the engine is stopped.

1. Stop the engine when it is hot.

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

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

4. If not, dismantle and check the cleaner, see 500 hours service.

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

Operating & Maintenance Manual

7. Maintenance

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

3. Transmission 3.1. Check oil level, before operation 20* 1. The dump truck must be standing on level ground.

2. The gear selector shall be in neutral and confirm that the parking brake is ON. 3. Run the engine at low idle.

4. Turn the dip stick handle (behind the cab, right hand side) a few turns to the left to release the seal pressure.

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

6. Insert dip stick fully and remove it again (at least 2x) 7. Check level:

Cold oil, 40 °C: Hot oil, 80 °C:

lower mark upper mark

8. If necessary correct the level by adding oil according to the transmission oil list (chapter 6) through the dip stick tube.

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

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

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

135

7. Maintenance

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

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

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

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

Oil filler located on the top of the hydraulic filter.

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

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

Operating & Maintenance Manual

7. Maintenance

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

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

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

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

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

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

5.3.

59 59

54

50

54

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

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

54 54 55

5.4.

53

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

53

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

55

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

5.5.

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

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

Upper tip cylinder bearings

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

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

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

137

7. Maintenance

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

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

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

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

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

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

Operating & Maintenance Manual

7. Maintenance

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

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

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

52

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

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

139

7. Maintenance

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

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

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

6. Brake system 6.1. Parking brake Check braking (holding) capacity, before operation 1. Apply the parking brake (indicator light).

2. Set the gear selector in 1st gear.

3. Increase the engine speed slowly.

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

6.2. Service brake (main brake) Check braking (holding) capacity, before operation 1. Apply the parking brake (indicator light).

2. Depress the brake pedal.

3. Release the parking brake.

4. Set the gear selector in 1st gear.

5. Increase the engine speed slowly.

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

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

Operating & Maintenance Manual

7. Maintenance

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

6.3. Service brake (main brake) Check function, before operation 1. Apply the parking brake (indicator light).

2. Stop the engine.

3. Check for hydraulic oil leakage at accumulators, pipes, hoses and calipers.

4. Start the engine and release the parking brake.

5. Check that the brake system warning light (chapter 3) does not illuminate.

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

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

6.4. Accumulators Check the oil pressure, before operation 1. The dump truck must be parked on a horizontal ground.

2. Apply the parking brake.

3. Start the engine and let it run at low idle until the accumulators are fully charged (warning light off).

4. Stop the engine.

5. Release the parking brake, wait 5 sec. Apply the parking brake, wait 10 sec. Release the parking brake again, wait 5 sec. Apply the parking brake again, wait 10 sec.

Countinue until the brake warning light comes on.

• Count how many times the parking brake can be applied until the brake system warning light comes on 6. The parking brake should be applied at least 6 times before the warning light comes on. If not, check the brake system and contact your Moxy Dealer.

7. Recharge the accumulators by starting the engine and let it run at low idle until the accumulators are fully charged (warning light off).

WARNING Accumulators contain oil under high pressure!

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

• Procedure: • Stop the engine • Operate the brake pedal repeatedly until the accumulators are empty.

Accumulators can also be emptied through the accumulator test connectors.

Be aware of that the accumulators will be recharged with oil when the engine is restarted.

8. Stop the engine 9. With the parking brake applied, check the service brake as follows: 10.Apply the service brake pedal, hold for 10 sec. Release the brake pedal and wait 5 sec. Apply the brake pedal again and hold for 10 sec. Then release the brake pedal again and wait 5 sec.

Countinue until the brake warning light comes on.

• Count how many times the service brake pedal can be applied until the brake system warning light comes on 11.The service brake pedal should be applied at least 5 times before the warning light comes on. If not, check the brake system and contact your Moxy Dealer.

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

141

7. Maintenance

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

7. Steering 7.1. Check function, before operation 1. Drive slowly forwards (5-10 km/h) and check that the emergency steering light goes off.

2. Turn the steering wheel at an even speed until end stop, both sides.

3. Check that the movement is uniform.

8. Engine brake 8.1. Check function, before operation 1. Drive the dump truck forwards at approx 10-15 km/h with lock-up engaged.

2. Apply the engine brake by releasing the throttle pedal.

3. Check that the exhaust sound changes.

4. Check the indicator light for function and note the braking power.

5. Depress the throttle pedal again and note that the engine brake goes off (i.e no braking power, exhaust sound changes and the indicator light switches off).

9. Engine and retarder brake 9.1. Check function, before operation 1. Drive the dump truck forwards at approx 10-15 km/h with lock-up engaged.

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

3. Check that the exhaust sound changes.

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

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

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

Operating & Maintenance Manual

7. Maintenance

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

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

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

• Replace if necessary 3. Reassamble the opposite way.

2 1

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

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

1.2. Air conditioner system • The equipment must be used for at least five minutes every week, to distribute oil in the system, this prevent leaks and ensure that the seals are lubricated • See operating controls, chapter 3, cab ventilation, about how to use the air conditioner.

• This must also be done during cold weather operation.

NOTE At ambient temperatures below + 4° C the air conditioner will not engage. Warm up the cab before operating the air conditioner for 10 minutes.

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

143

7. Maintenance

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

2. Tyres 2.1. Check tyre pressures, before operation When the pressure shall be measured, the dump truck must be unloaded.

Measure the pressure for cold tyres with a tyre pressure gauge and adjust if necessary.

For tyre pressure recommendation, see chapter 8 - Technical data, and chapter 5 - Operating instructions.

WARNING Stand behind the tread when checking the inflation pressure.

Pressures inside tyres are substantial and an explosion can cause damage and serious personal injury.

3. Continue with all items in 8 Hours / Daily Service.

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

Operating & Maintenance Manual

7. Maintenance

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

1. Engine 1.1. Change oil 1*

If the dump truck is used for particulary demanding operation, especially in a dusty environment or if the deposits in the centrifugal cleaner are thicker than 20 mm: Change oil more often.

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

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

1

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

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

5. Fill oil through filler (2). Do not overfill!

6. Check oil level on dip stick (3).

CAUTION The oil may be hot! Wear protective gloves and eye protection.

3

2

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

145

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1.2. Clean centrifugal cleaner 2* (at the same time as oil change, item 1.1)

1. Clean the cover. Unscrew the nut and remove cover.

CAUTION Open the cover with care. The oil and inner parts may be hot!

2. Lift out the rotor assembly and loosen the nut for the rotor cover three turns.

* Numbers refer to positions on the lubrication schedule, chapter 6 146

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

3. If the nut sticks: Secure the nut, absolutely not the rotor, in a vice and turn the rotor three turns by hand or using a screwdriver.

4. Gently tap the nut with the hand or with a plastic hammer to separate the rotor from bottom plate.

5. Undo the nut and remove the rotor cover.

6. Carefully prise the strainer loose from the bottom plate.

7. Scrape off the deposits from the inside of rotor cover.

• If there are no deposits, this shows that the cleaner is not working.

• Clean more frequently if deposits are thicker than 20 mm.

8. Clean all parts in diesel fuel.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

147

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

9. Place the O-ring in position in the rotor cover.

• The O-ring must not be damaged.

Change if necessary.

10. Assemble the rotor.

11. Tighten rotor nut firmly by hand.

12. Reinstall the rotor.

• Check that it rotates easily.

* Numbers refer to positions on the lubrication schedule, chapter 6 148

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

13. Check that the O-ring in the cover is not damaged.

Hard or damaged O-ring must be replaced.

14. Tighten cover firmly by hand.

15. If the nut is tightened too hard (for instance by using tools), the cover, nut or rotor shaft may be damaged!

16. Replace damaged parts!

17. Function check The rotor rotates very fast, and will normally carry on rotating after the engine is stopped. a. Stop the engine when it is warm. b. Listen for spinning sound from rotor, or feel if cleaner housing vibrates. c. The rotor normally rotates 30 - 60 seconds after the engine has stopped. d. If not, dismantle and check the cleaner.

1.3. Replace oil filter 3* (at the same time as oil change, item 1.1) 1. The filter is located on the right hand side of the engine.

2. Remove the old filter and discard it according to enviromental requirements.

3. Oil the rubber gasket on the new genuine filter.

4. Fit the new genuine filter.

5. Tighten the filter by hand as tight as possible.

6. Start the engine and check for leaks.

m e

If the deposits in the centrifugal cleaner exceed 20 mm, the oil filter must be changed more often, at the same time as cleaning the centrifugal filter and changing the oil.

NOTE • •

Never use tools to tighten the filter. It can be damaged and the circulation obstructed!

Use only genuine filter!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

149

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1.4. Check batteries 11* 10 - 15 mm

• Checking of batteries shall also be carried out after the first 8 hours of operation.

1. Open left hand side fender cover (open the bonnet first and then the fender cover) 2. Undo the plugs and check electrolyte level in all cells.

3. The fluid level in each cell shall be between 10-15 mm above the plates.

4. Refill with distilled water if level is lower.

NOTE Only distilled or chemically cleaned water must be used.

1.5. Check battery terminals for tightness and corrosion Clean if necessary, apply acid-free vaseline on the terminals and retighten the clamps.

2. Transmission 2.1. Run the AEB-Tester AEB = Automatic Filling Parameter Adjustment To optimize the transmission, run the AEB-Tester.

1. Remove the cover on the backwall (remove the instructor's seat back rest, if that is fitted).

2. Follow the procedure described in the table on next page.

The gear display will show the AEB's actions. ("Display message" in the table on the next page).

TCU = Transmission Control Unit

* Numbers refer to positions on the lubrication schedule, chapter 6 150

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

Run the AEB-Tester continued..............

Moxy part no.

8453

AEB = Automatic Filling Parameter Adjustment TCU = Transmission Control Unit

How to run the AEB-Tester

1 Warm up the transmission oil,

Display message Normal operating messages

Remarks

the oil must have a temperature at O

70 - 80 C

2 - Move the gear selector to

-

Neutral position.

- Engage the parking brake

3 Turn OFF the starter switch

-

4 Plug the AEB-Tester into the

-

diagnostic contact no. 607

5 Start the engine

"PL"

6 Set engine speed to low idle rpm

"PL" if starts condidtions are OK

7 Press button on the AEB Tester

"ST" if starts conditions are OK

The button must not be released before TCU has started the AEB or quit with an error code.

8 Keep the button depressed until

"K1" ……

(Information about the AEB state)

TCU has started the AEB and goes to adjusting K1, K2, …, KR. (Button may be released).

the AEB has started

9 Wait until AEB is finished 10 Turn OFF the starter switch and

TCU must recognize "PL" for at least 2 sec. before you can press the button.

"OK" (AEB has been successful) -

unplug the AEB-Tester

11 Remount the cover on the

-

backwall

NOTE • • •

If the oil temperature is too low or too high, following message will apear on the gear display: T or T . Adjust the oil temperature and try again.

If there is a malfunction, turn the starter switch off and start the engine again.

The AEB will not start if any error codes are shown on the gear display, except error code "F6"

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

151

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

3. Drive line 3.1. Check oil levels • Measurements must be carried out when dump truck is parked on a horizontal ground.

• Check that oil level is near the bottom edge of the plugs.

• Refill with oil if level is too low.

• If the dump truck tandem housing is angled, the reading will be incorrect.

CAUTION Be aware of possible internal pressure when the oil is hot!

1. Front differential 30* Use a hexagonal key to unscrew the upper filling/ level plug.

• Plug torque: 80 Nm

2. Rear differential 31* Use a hexagonal key to unscrew the filling/level plug at the rear of housing.

• Plug torque: 80 Nm.

* Numbers refer to positions on the lubrication schedule, chapter 6 152

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

3. Tandem housings 32* Use a hexagonal key to unscrew the level plugs on the inside of the housings.

• Plug torque: 80 Nm.

4. Front reduction gears 33* Turn the hubs until level indicator is horizontal. Use a hexagonal key to unscrew the plugs.

• Plug torque: 80 Nm.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

153

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

Service brake

4. Brake system 4.1. Check lining thickness

• Checking of brake lining thickness shall also be carried out after the first 500 hours of operation.

1. Service brakes: Check brake linings. Brake linings should be changed before the thickness of the linings on the most worn areas reaches 3,5 mm.

• How often the brake linings have to be checked/replaced depends on how much the brakes are used and/or applications.

After checking the brake linings for the first 500 hours, consider whether or not the brake linings should be checked more often, based on lining wear.

2. Parking brake: Lift body and apply the body support.

Remove the protection on the top of the parking brake and check thickness of linings. Change when approaching limit.

• In connection with replacement perform adjustment, see next page.

Standard lining thickness: Service brakes: Parking brake:

22.0 mm 20.0 mm

Min. thickness:

3.5 mm.

5.1 mm.

Service brakes: Parking brake:

CAUTION Parking brake

This applies to normal driving. For rough operating conditions with much braking and/or driving in water, the brake linings should be checked more often!

* Numbers refer to positions on the lubrication schedule, chapter 6 154

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

4.2. How to adjust the parking brake.

To be performed in connection with replacement of parking brake linings.

• Before removing the parking brake linings, do as follows:

1

1. Apply the parking brake.

2. Lift the body.

3. Apply the body support (1) (see also safety instructions, chapter 2).

4. Stop the engine.

5. Secure the dump truck with wheel chocks (see also safety instructions, chapter 2) 6. Release the parking brake by the parking brake switch.

7. Remove the adjuster plug and washer from the cylinder bracket.

Washer-adjuster plug

8. Use a 6 mm allen wrench to de-adjust the brake (turning the allen wrench in clockwise direction). Stop turning the allen wrench when you feel resistance, which indicates that the adjuster pistons are fully retracted.

• When you de-adjust the brake (increase disc clearance) you will hear a "clicking" sound and feel a "pulsing" sensation during the adjustment.

• To ensure that the automatic adjustment will occur: Adjust the brake an additional 1/4 turn after you reach the resistance point.

• Do not use an air gun to adjust or de-adjust the parking brake! Components could be damaged.

Adjuster plug

Allen wrench

9. The parking brake linings can now be replaced.

• After installation of new parking brake linings, do as follows: 1. Adjust the caliper by reducing the caliper-to-disc clearance to ZERO (turning the allen wrench in counter clockwise direction).

2. Check that the load plate fully contacts the lining backing plate.

3. To increase the disc clearance, turn the allen wrench SEVEN CLICKS in clockwise direction, which sets the initial clearance.

4. Install the adjuster plug and washer.

• Tightening torque: 11-17 Nm 5. Apply and release the parking brake 15-20 times to allow the adjuster to set the final caliper clearance.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

155

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

5. Wheels 5.1

Check wheel nuts torque.

Torque setting 450 Nm.

6. Tip- and steering cylinders 6.1

Check expander bolts.

• Checking of the expander bolts torque setting shall also be carried out after the first 100 hours of operation.

Torque setting: • Tip cylinder bolt: • Steering cylinder bolt:

250 Nm 380 Nm

• The torque must be checked on on both sides of the bolts.

• Be aware of the lubrication nipples on the bolts when checking the torque.

* Numbers refer to positions on the lubrication schedule, chapter 6 156

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

7. Cab ventilation 7.1. Air conditioner system, test operation 1. Start the engine.

2

2. Press down the air conditioner switch, set the fan switch to position 3 (see also chapter 3) and open all nozzles.

1

3. Check that the temperature in the cab decreases.

• If the temperature does not decrease: • Check whether the fuse is burnt out, if yes, replace the fuse.

• If the fuse is not burnt out, there can be a failure or too little refrigerant in the system: CONTACT YOUR LOCAL MOXY DEALER

WARNING •

If the air conditioning system does not work properly, contact your Moxy Dealer.

•

Always use safety glasses or goggles, gloves, boiler suit and protective footwear when inspecting, servicing and repairing the air conditioning system.

•

Refrigerant R134a has a property that can cause frostbite if it comes into contact with bare skin or eyes.

•

Always work on the air conditioning system in well ventilated places.

•

The system contains refrigerant R134a under pressure. Repair and refilling of the refrigerant circuit must only be done by accredited personnel.

•

Dispose of waste oil/fluids in an enviromentally friendly manner!

•

High concentration of the refrigerant in gaseous form can cause drowsiness, headache, dizziness and at worst unconciousness. Very high concentration of the gas can even cause cardiac insufficiency.

Do not smoke when servicing the air conditioning system!

•

Be careful with all hoses connected to the air conditioning system. There is always a certain overpressure in the system. Therefore, never undo hoses or the filler opening on the compressor except during repairs to the system.

•

If there is any suspicion of leakage, the system must not be filled up - leave the leakage site and contact your Moxy Dealer for repairs.

•

Get your Moxy Dealer to check the air conditioning system yearly and refill refrigerant, if necessary.

•

See also chapter 2, Safety Instructions * Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

157

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

7.2. Check cab ventilation filter element condition 70* 1. Remove the rear panel on the right hand side inside the cab (behind the driver's seat).

2. Open the cover (1) with a screw driver.

3. There is two filter elements (2).

4. Check if the filter elements are clogged or damaged.

• Replace if necessary.

5. Reassamble the opposite way.

1

6. Adjust the check interval if another requirement is experienced.

2

* Numbers refer to positions on the lubrication schedule, chapter 6 158

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

Located under the cover

8. Automatic central lubrication 8.1. Refill the reservoir, the reservoir must be refilled if the indicator light flashes for 2 minutes (0.5s on/0.5s off) at the beginning of each cycle.

1. Remove the dust cap from the filler coupling.

2. Carefully clean the filler coupling and the coupling on the filler hose.

3. Fit the filler hose on the filler coupling.

4. Fill the reservoir up to the maximum level indicated on the reservoir.

5. Remove the filler hose and fit the dust cap.

Filler coupling

8.2. Check the system • Check the pump for damage and leakage.

• Check the grease lines for damage and leakage.

• Check, if possible, the condition of the grease points the system serves. Sufficient fresh grease should be present.

• Check the operation of the system. Perform a cycle test (see chapter 3 for how to perform a cycle test).

Note that every time you perform a cycle test, grease is supplied to the grease points.

• Clean the pump-unit and its surroundings.

NOTE •

If you use a high-pressure air or water gun to clean the dump truck, do not spray directly onto the pump unit. Water or dirt might enter the pump-unit through the de-aerating openings.

•

Even if the automatic central lubrication is installed, do not forget that there are still some greasing points that must be greased by hand, these are the door, fender hatches and the cab rear hinges.

9. Continue with all items in 40 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

159

7. Maintenance

* Numbers refer to positions on the lubrication schedule, chapter 6 160

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

1. Driver's seat 1.1. General safety check • Check for play in seat gliders. Max. allowed in length or sideways: 1 mm. Grease the gliders.

• Check shock absorbers for oil leakages.

• Check seat mounting to the dump truck.

• Check safety belt and lock mechanism for wear and damage.

• Check that no pins are loose / worn in the seat base.

• Replace worn/damaged parts.

2. Engine 2.1

Replace fuel filter 4* Replace water separating fuel filter 4* The filters consist of one filter unit each.

The filters are located on the left hand side of the engine.

The fuel filter in the front of the engine and the water separating fuel filter on the rear of the engine, see ill.

1. Wash the filters externally and unscrew it.

Discard the filters according to environmental requirements.

2. Fit the new genuine filters and tighten it by hand.

• Never use tools to tighten the filters! The filters may be damaged and the fuel flow hampered.

Fuel filter Water separating fuel filter

3. Bleed the fuel system, procedure on next page, item 2.2.

4. Start engine and check for leaks.

CAUTION Observe extreme cleanliness when working with the fuel system. Otherwise may operational interruption easily occur and the injection equipment may be damaged.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

161

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.2

3

1

Bleed the fuel system: 1. Attach a clear plastic hose to the bleeder nipple (1) to channel fuel into a container.

The bleeder nipple is located at the end of the fuel manifold at the front of the engine.

2

2. Open the bleeder nipple (1).

3. Pump with the hand pump (2) until bubble-free fuel flows out of the opened bleeder nipple.

• If the system is completely empty, it will take approx. 250 strokes.

• After changing the fuel filters, it will take approx. 170 strokes.

• Approx. 150 strokes are required to bleed the fuel manifold.

4. Close the bleeder nipple and remove the hose.

5. Undo the banjo screw for overflow valve (3) slightly.

Pump the hand pump (2) additional 20 strokes until the overflow valve opens.

If the engine fails to start after bleeding: • Open the bleeder nipple again and pump the hand pump until bubble-free fuel flows out.

• Tighten the bleeder nipple. Start the enigne and check for leaks.

WARNING The engine may be hot! Use gloves when pumping with the hand pump to avoid burning your hands.

2.3. Check batteries, at least once a year 11*

• Checking battery charge shall also be carried out after the first 8 hours of operation.

Use a hydrometer to check the density of the electrolyte. The density of a fully charged battery should be: 1.240 at higher than +20 oC 1.280 at +20 oC, 1.294 at 0 oC, 1.308 at -20 oC. Recharge the battery if the density is lower than 1.20.

A discharged battery freezes at -5 oC.

WARNING The electrolyte level must be correct when charging!

During recharge a explosive gas is emitted. Open cell plugs and ventilate properly to avoid explosion!

* Numbers refer to positions on the lubrication schedule, chapter 6 162

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.4. Check multi-groove belt condition, at least once a year

• Checking of multi-groove belt condition shall also be carried out after the first 8 and 100 hours of operation.

• Stop the engine to inspect the multi-groove belt (1).

• Change the belt (1) if damaged or worn.

• Check that the automatic belt tensioner (2) is in proper working order and keeps the multi-groove belt sufficiantly tightened.

2.5. Air filter 10* The air filter is located on the top of the engine, under the bonnet.

• Always stop the engine before servicing the air filter.

• Open the bonnet and apply the bonnet catcher.

• Cleaning and replacement of outer and inner element, see next page.

continue overleaf

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

163

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Outer element: Clean element every 1000 hours of operation or if the air filter warning light illuminates at full load on the engine.

• Replace the outer element after 5 times of cleaning, or at the latest after 2 years.

1. Loosen all clamps and remove the cover (fig. 1).

Dust cap

Fig. 1

2. Remove outer element with a light turning movement (fig. 2).

Do not remove inner element when cleaning outer element!

3. To blow out the filter element, use tube with a bent end which is attached to a compressed air gun; the end of the tube must be bent by approx. 90°. It must be of sufficient length to reach down to the bottom of the filter element.

Blow out the filter element using dry compressed air (max. 5 bar) by moving the tube up and down inside the filter element until there is no more dust coming out (fig. 3).

Fig. 2

• Never wash out or brush out the outer element. When blowing out make sure that no dust is allowed to enter the inside area of the outer element.

4. Punch a mark in the edge of the inner element each time the outer element is cleaned.

5. Check the cleaned element for damage of the paper element and of the rubber seals.

• Cracks and holes in the paper element can be discovered by shining through light from an electric bulb (fig. 4).

6. Never carry on using a damaged outer element. In case of doubt, always fit a new outer element.

Fig. 3

7. Reinstall the outer element, the cover, and fasten all the clamps. Turn the cover so that the dust cap is pointed downwards (max angle: 15°).

See also precautions on next page

Fig. 4

Servicing the dust cap The dust cap require very little maintenance.

Possible dust packs to be removed by squeezing the cap (fig. 5).

Fig. 5

* Numbers refer to positions on the lubrication schedule, chapter 6 164

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Inner element: • Replace element every 5th cleaning of the outer element, or at the latest after 2 year.

• Do not clean the inner element and do not reuse it after it has been taken out. Only open the seal in order to replace the inner element.

1. Loosen all clamps and remove the cover.

2. Remove outer element.

Fig. 6

3. Remove the inner element; Use a suitable tool (e.g. screw driver) to push through the seal of the inner element from the inside to the outside and pull both the straps upwards (fig. 6).

4. Use both straps to take hold of the inner element and then pull out with a light turning movement (fig. 7).

5. Install a new inner element into the housing.

6. Install a new or cleaned outer element.

7. Reinstall the cover, and fasten all the clamps.

Turn the cover so that the dust cap is pointed downwards (max angle: 15°).

Fig. 7

CAUTION • • •

• • • •

Do not attempt to reinstall a cleaned inner element.

Do not clean or replace the elements when the engine is running.

Replace the outer element if small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning.

Do not use an element in which folds, gasket or seal are damaged.

When cleaning the element, do not hit or hammer it.

Do not dismantle the inner element unnecessarily.

Punch a mark in the edge of the inner element each time the outer element is cleaned.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

165

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

3. Transmission 3.1. Change oil 20* Replace filter element 21* Clean strainer 22* , at least once a year

• Changing transmission oil, replacement of transmission filter and cleaning of the strainer shall also be carried out after the first 100 hours of operation.

Drain oil: 1. The dump truck must be standing on level ground.

2. The oil must be at operating temperature.

3. Unscrew the dip stick (located behind the cab).

4. Access to the drain plug through transmission bottom guard (rear cover).

5. Unscrew drain plug, at the bottom of the transmission and drain the oil into a suitable container.

6. Clean the drain plug with magnetic insert, replace seal if necessary and reinstall the plug.

• Tightening torque: 80 Nm.

Rear cover

Drain plug

Replace filter elements (located on the left hand side): Access to the filters through the engine bottom guard 7. Remove the engine bottom guard (front cover) 8. Clean well around the filters.

9. Place a suitable container beneath the filters to catch spillage.

10. Unscrew the filter elements.

11. Check for wear particles in the oil.

12. Apply oil to the seals on the new elements.

13. Screw the filter elements in until contact with the sealing surface is obtained. Tighten the elements firmly by hand.

continued overleaf

* Numbers refer to positions on the lubrication schedule, chapter 6 166

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Clean stranier: Access to remove the strainer

14. The strainer is located on the left hand side of the drain plug.

15. Unscrew the three nuts (1) and washers (2).

16. Remove the cover (3).

17. Replace the O-ring on the cover, if necessary.

18. Remove the strainer (4) and clean it.

Rear cover

19. Reassemble and torque nuts to 23 Nm. 20. Remount the all bottom guards and covers.

1

2

3

4

Fill new oil: 21. Fill new oil, according to the transmission oil list and oil specification sheet (chapter 6), through the dip stick tube.

22. Insert the dip stick again and turn handle clockwise to tighten the sealing.

Check: 23. Start the engine and check oil level (see daily maintenance, for procedure) at low idle. Both too low and too high level can cause serious internal damage!

24. Warm up the oil and check for leaks. Recheck level and adjust if necessary.

NOTE • •

Do not overfill! Both too high and too low level can cause serious internal damage!

For rough operation conditions the oil and the filter element must be changed more often (every 500 hours) and the strainer must be cleaned as well.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

167

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

4. Hydraulic system 4.1. Replace breather element 42* • Accumulators contain oil under high pressure!

Empty the accumulators, before unscrewing the element.

Procedure is described in chapter 2, item 27.

• Unscrew the old element on the hydraulic tank (under the cover).

• Check the o-ring for deterioration, apply oil and screw on a new element.

CAUTION Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

* Numbers refer to positions on the lubrication schedule, chapter 6 168

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

4.2. Replace hydraulic return filter element 43*.

•

Replacement of hydraulic return filter element shall also be carried out after the first 100 hours of operation.

1. Accumulators contain oil under high pressure!

Empty the accumulators, before unscrewing the filter.

Procedure is described in chapter 2, item 27.

2. The filter is located on the back of the hydraulic tank.

Remove the cover to get into the filter.

3. Clean well around the filter housing.

4. Place a suitable container beneath the draining hose to catch spillage.

5. Use a filter key to unscrew the old filter (counterclockwise). Remove also the old O-ring.

The old filter contains 4 litres oil. Discard the filter element, and oil according to environmental requirements.

6. Check for wear particles in the oil.

7. Clean the O-ring groove, apply oil to the new O-ring and install it.

8. Apply oil or grease to the threads and install a new filter element by turning it clockwise until seals make contact. Then tighten by hand 1/4 to 1/3 turn more.

9. Fill 4 litres hydraulic oil, as specified in chapter 6, lubricants, through the oil filler on the top of the filter unit (under the cover on the top of the hydraulic tank).

10. Screw the oil plug back into place and clean off any oil spill.

11. Start engine and check for leaks.

The accumulators will be recharged with oil when the engine is re-started.

CAUTION Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

Fill 4 litres hydraulic oil throguh the oil filler.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

169

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

5. Front differential 5.1

Change oil, at least once a year 30*

• Change front diff. oil shall also be carried out after the first 500 hours of operation.

1. Access to the drain plug through transmission bottom guard.

2. Open level / filling plug (1), special spanner in tool kit.

3. Unscrew drain plug (2).

4. Drain the oil into a suitable container.

5. Clean the drain plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 6. Fill new oil, according to the oil specification sheet (chapter 6), through the level / filling plug, level shall be at lower edge of hole when dump truck is horizontal.

1

7. Clean the plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

CAUTION Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening the drain plug.

2

* Numbers refer to positions on the lubrication schedule, chapter 6 170

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

6. Rear differential 6.1. Change oil, at least once a year 31*

• Change rear diff. oil shall also be carried out after the first 500 hours of operation.

1. Open level/filling plug (1).

2. Unscrew drain plug (2) underneath the housing.

3. Drain the oil into a suitable container.

4. Clean the drain plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 5. Fill new oil, according to the oil specification sheet (chapter 6), through the level/filling plug, level shall be at lower edge of hole when dump truck is horizontal.

1

6. Clean the plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

CAUTION

2

Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening the drain plug.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

171

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

7. Front reduction gears 7.1. Change oil, at least once a year 33*

• Change front reduct. gear oil shall also be carried out after the first 500 hours of operation.

1. The dump truck must be horizontal.

2. Turn the hub, so that the plug is pointed downwards.

1

3. Unscrew the plug (1).

4. Drain the oil into a suitable container.

5. Turn the hub 90o, so that the level indicator is horizontal (2).

6. Fill new oil, according to the oil specification sheet (chapter 6), through level/filling plug, level shall be at lower edge of hole when dump truck is horizontal.

7. Clean plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

2

8. Recheck oil level after test driving.

CAUTION Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening the drain plug.

8. Electrical system 8.1. Check wiring The wiring harness must not be damaged. Check that the cables on the articulation hinge and on the rear frame/body are not squeezed, have sharp bends or loose/bad connections.

9. Continue with all items in 500 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 172

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

1. Engine 1.1. Check/adjust PDE injector rocker arms

• Checking/adjusting PDE injector rocker arms shall also be carried out after the first 500 hours of operation.

• Contact Moxy Dealer for checking/adjusting of the PDE injector rocker arms • The checking/adjusting of the PDE injector rocker arms must only be carried out by qualified personnel.

1.2. Check/adjust valve clearance

• Checking/adjusting valve clearance shall also be carried out after the first 500 hours of operation.

• Contact Moxy Dealer for checking/adjusting of the valve clearance • The checking/adjusting of the valve clearance must only be carried out by qualified personnel.

FLYWHEEL Cylinder numbering TDC position No. 6 cylinder

TDC position No. 1 cylinder

• The air filter and air filter bracket has to be removed before adjustment takes place.

Adjust if necessary: • Inlet: 0,45 mm • Exhaust: 0,70 mm see instruction sign on one of the rocker covers.

Valves should be adjusted when the engine is cold, at least 30 minutes after operation.

Rocker cover gaskets must be changed if necessary.

• Tightening torque: 26 Nm 1. Set no. 1 cylinder to TDC (Top Dead Centre) by turning the engine in its direction of rotation until all four valves are closed.

2. Adjust the following valves: Cylinder

FLYWHEEL Intake valve Exhaust valve

1 2 3 4 5

Inlet and exhaust Inlet Exhaust Inlet Exhaust

3. Set no. 6 cylinder to TDC (Top Dead Centre) by turning the engine one revolution in its direction of rotation.

4. Adjust the following valves:

The readings can only be taken from underneath

Cylinder

2 3 4 5 6

Exhaust Inlet Exhaust Inlet Inlet and exhaust

WARNING Covers for reading on flywheel casing

Block the starter device when working on the engine!

If the engine starts out of control, there is a SERIOUS RISK OF INJURY!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

173

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

1.3. External cleaning of the radiator, at least once a year 5* If necessary, the cooling system should be cleaned more often.

1. Clean externally the radiator fins and hoses by using a brush.

The radiator can also be washed with water from the backside.

2. Check that the radiator is not blocked on the air side and that the fins are not damaged.

3. Carefully scrape the deposit away from the radiator fins.

If necessary, a paraffin-based engine cleaner may be used.

4. Check the fins, rubber hoses, clamps and pipes for corrosion, damage and leakages.

5. Bent fins can be carefully straightened, e.g. using a steel wire brush.

CAUTION The cooling system must not be cleaned using caustic soda. It can damage aluminium parts.

* Numbers refer to positions on the lubrication schedule, chapter 6 174

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

1.4. Check the coolant, at least once a year 5*

Coolant: Water + Anti-freeze or Water + Anti-corrosive (see text)

NOTE Coolant composition: If there is a danger of freezing: • at least 30% glycol by volume (15 litres by total volume) • max. 60% glycol by volume (30 litres by total volume) If there is no danger for freezing: • 10% anti-corrosive by volume (5 litres by total volume)

1.4.1 Check the appearance of the coolant, at least once a year • Take a little coolant in a vessel and check that it is clean and clear.

• If the coolant is contaminated or cloudy: Consider changing the coolant.

• The water for the coolant should be free of dirt.

• Use drinking water with a pH of 6 - 9.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

175

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

Freezing O

point ( C)

Antifreeze

- 16

30 % 15 L

- 22

35 % 18 L

- 27

40 % 20 L

- 36

45 % 23 L

- 46

50 % 25 L

1.4.2 Coolant with glycol only: Check glycol content, at least once a year If there is risk of ambient temperature below 0 °C, use only glycol as protection against corrosion in the coolant.

• Cooling system with glycol must contain at least 30% glycol by volume (15 litres by total volume) to offer sufficient protection against corrosion.

• 30% glycol by volume (15 litres by total volume) provides anti-freeze protection down to -16 °C. If more protection is required, see the table for calculating the necessary amount of glycol. The amount of glycol (anti-freeze) is determined acc. to lowest expected temperature.

Always be sure that it is enough glycol (anti-freeze) mixed with the water in the cooling system to avoid freezing, see table.

Total volume: 50 litres

We recommend only nitrite-free anti-freeze glycols with the following supplier designation: • BASF Glysantin G48

• Always fill up the anti-freeze if the glycol content drops below 30% by volume (15 litres by total volume). A glycol content above 60% by volume (30 litres by total volume) will not improve the protection against corrosion.

WARNING • •

Ethylene glycol is highly dangerous if consumed and can prove fatal.

Avoid contact with the skin.

NOTE •

•

•

The coolant should be mixed before it is filled into the cooling system. Never top up with only water or only glycol.

The recommended glycols must not be mixed with glycol which has nitrite-based anti-corrosive nor with other anti-corrosive. This could cause sludging and reduced cooling capacity.

The coolant should be changed when the cooling system is cleaned. Every 4000 hours or at least every 4th year.

* Numbers refer to positions on the lubrication schedule, chapter 6 176

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

1.4.3 Coolant with only anti-corrosive: Check protection against corrosion, at least once a year There must always be sufficient anti-corrosive (inhibitor) in the coolant to protect the cooling system against corrosion.

• If there is no danger of freezing use only Anti-corrosive.

• The inhibitor in the Anti-corrosive must be nitrite-free with the following supplier designation: • BASF Glysacorr G93.

• The correct level of Anti-corrosive is 10% by volume (5 litres by total volume).

• Fill with Anti-corrosive as indicated on the packaging.

• Filling up with 1% by volume (0.5 litres by total volume) of Anti-corrosive should be done after every 2000 operating hours.

• Never fill up with water only or Anti-corrosive only. Lost fluid should always be replaced by pre-mixed coolant: water + 10% Anti-corrosive by volume.

• Anti-corrosive content must not be lower than 5% by volume or exceed 30% by volume.

NOTE • • • •

Anti-corrosive must not be mixed with glycol.

Mixing or over concentration can cause sludging and reduced cooling capacity.

Any coolant filter must not contain inhibitor.

The coolant should be changed when the cooling system is cleaned. Every 4000 hours or at least every 4th year.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

177

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

2. Hydraulic system 2.1. Change oil 40*

.

1. Accumulators contain oil under high pressure!

Empty the accumulators, before draining the hydraulic oil.

Procedure is described in chapter 2, item 27.

2. The drain plugs both for the main reservoir and the emergency steering reservoir are to be found on the right hand side of the hydraulic tank (on the bottom).

Remove the cover to get into the drain plugs.

3. Place a suitable container to catch spillage.

4. Remove the cap from both drain plugs.

5. Install the draining hose with nipple to the first drain plug and drain the oil into the container.

6. Install the draining hose to the second drain plug and drain the oil into the container.

7. Remove the draining hose and reinstall both caps.

8. The oil filler is located on the top of the hydraulic filter unit under the cover on the top of the hydraulic tank.

9. Fill new oil through the oil filler, according to the oil specification sheet, chapter 6.

• The accumulators will be recharged with oil when the engine is re-started.

Oil filler

Drain plug

3. Brake system 3.1. Inspect brake lines, at least once a year.

Replace pipes, hoses and fittings which are corroded (deep seated rust), deteriorated (aged), leaking or otherwise damaged.

CAUTION Check more often when operating in salty condtions or similar environment that may affect the brake system! * Numbers refer to positions on the lubrication schedule, chapter 6 178

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

4. Tandem housings 4.1. Change oil 32*

• Change of tandem housing oil shall also be carried out after the first 500 hours of operation.

1. The dump truck and tandem housings must be horizontal.

2. Unscrew drain plugs (1) on the inside of the housings.

3. Drain the oil into a suitable container.

4. Clean plugs, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 5. Fill new oil, according to the oil specification sheet (chapter 6), through the filler plugs (2) to correct level.

6. Clean plugs, replace seals if necessary and reinstall.

• Tightening torque: 80 Nm. 7. After test driving, check that level is at lower edge of the level plug.

2

1

CAUTION Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

5. Continue with all items in 1000 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

179

7. Maintenance

* Numbers refer to positions on the lubrication schedule, chapter 6 180

Operating & Maintenance Manual

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation.

1. Cooling system 1.1

Internal cleaning, at least every 4th year 5* Removing deposits, oil and grease

For internal cleaning use liquid dishwasher detergent designed for household use. Alternative BASF Glycacorr G93 or Texaco Havoline XLI can be used.

Important: The cleaning agent must not foam.

1. If possible, run the engine until it is warm and then drain the cooling system, see changing coolant, item 1.4 2. Remove the thermostat housing (1) and replace it with a hose. Plug the by-pass.

3. Fill the system with clean, hot water mixed with liquid dishwasher designed for household use.

Concentration 1% (0.1 L by 10 L water).

Alternative BASF Glycacorr G93 or Texaco Havoline XLI can be used.

1

4. Run the engine for about 20-30 minutes.

NOTE! Do not forget the cab heater system.

5. Drain the cooling system.

6 Fill the system again with hot water and run the engine for about 20 -30 minutes.

7. Drain the water from the cooling system.

8. Refit the thermostat housing and the connections.

9. Fill the system with coolant as described in the specifications in item 1.4 at 2000 hours service.

WARNING Handling cleaning agents for the cooling system: Read the warning label on the container

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

181

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation.

1.2

Change coolant, at least every 4th year 5* 1. Remove the filler cap from the expansion tank.

2. Drain the coolant in two places: • the "lowest point" on the engine block, see ill.

• the "lowest point" of the cooling system (1), under the oil cooler on left hand side. Access through the engine bottom guard.

3. Close the cocks.

4. Fill with correct mixture, pre-mixed coolant through the expansion tank filler hole (2). See item 1.4 at 2000 hours service.

2 1

2. Continue with all items in 2000 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 182

Operating & Maintenance Manual

7. Maintenance

Yearly recommended maintenance Maintenance recommended to be performed yearly.

1. Transmission 1.1. General condition check 1. Check tightness of lubrication system when engine is running.

• Tighten or change defective connections.

2. Check transmission rubber mountings and replace if necessary.

Inspect the mounting bolts.

2. Drive line 2.1. General condition check Check the general condition and mountings, joints, bearings, etc. for general deterioration, wear, damages and leakages.

• Replace or recondition if necessary.

1. Rear axle and tandem housings.

2. Articulation hinge and turning ring.

3. Suspension:

• shock absorbers • rubber dampers • arms and rods

4. All prop. shafts, universal joints included.

3. Tanks 3.1. General condition check Check the hydraulic and the diesel tank bolts/mountings.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

183

7. Maintenance

Yearly recommended maintenance Maintenance recommended to be performed yearly.

4. Hydraulic system 4.1. Inspect the hydraulic hoses Replace hoses which are deteriorated, leaking or otherwise damaged.

5. Exhaust system 5.1. Safety check • Check fastening brackets, muffler, pipes and joints for leaks, damages and insecurity.

• If body is exhaust heated, check also that the channels in the body not are clogged by any means.

CAUTION Be aware of hot parts when engine has been running!

6. Bearings 6.1. Check clearance Contact your local Moxy Dealer for checking of the bearing clearance: • Tandem bearing • Tip bearings • Turning ring and articulation bearings • Wheel bearings

* Numbers refer to positions on the lubrication schedule, chapter 6 184

Operating & Maintenance Manual

8. Technical Data

Technical Data

Operating & Maintenance Manual

185

8. Technical Data

Contents

8. Technical data .......................................................... 185 - 198 Measurements ........................................................... 187 Engine ........................................................................ 188 Transmission ............................................................. 188 Hydraulic system ....................................................... 189 Tyre pressures ........................................................... 189 Electrical system ........................................................ 190 Metering conversion table ......................................... 191 Tool kit content ........................................................... 191 Performance chart ..................................................... 192 Engine and retarder brake chart ............................... 193 Torque limit tables ..................................................... 194 Reference information (fill in table) .......................... 194 Consumable parts ..................................................... 194 Product signs ............................................................. 195 Periodic service (fill in table) ..................................... 196

186

Operating & Maintenance Manual

8. Technical Data

Measurements Machine dimensions (mm): ..................................... MT41 Total length ................................................................ 10445 Total width w/ standard tyres (29,5R25) ................... 3475 Total width w/ optional tyres (875/65 R29) ............... 3550 Total height ................................................................ 3800 Total height, loaded .................................................. 3738 Overhang, front .......................................................... 2835 Overhang, rear ........................................................... 1270 Wheelbase ................................................................. 4380/1960 Body upper height (rear edge) ................................. 3255 Body floor height (rear edge) .................................... 2315 Total height, raised body ........................................... 6480 Ground clearance, raised body ................................ 615 Min. ground clearance .............................................. 652 (front) Min. ground clearance, loaded ................................. 588 Turning radius (ISO 7457) ......................................... 8420 Body tipping angle .................................................... 70° Steering angle, both sides ........................................ 45° Standard tyre dimension ........................................... 29.5R25 Tyre load/speed index ............................................... 194B (2-stars) Machine weights (kg): Empty weight ............................................................. 29500 Gross weight .............................................................. 66700 Maximum payload ..................................................... 37200 Weight distribution (kg): Front axle, empty ....................................................... 13720 Rear axle, empty ........................................................ 15780 Body capacity (m³): Struck ......................................................................... 17.9 (18.6) Heaped, SAE 2:1 ....................................................... 22.7 (24.1) (with top tailgate in brackets) Machine speed (km/h): Forward speeds 6 ...................................................... 6 - 9 - 15 - 23 - 34 - 53 Reverse speed 3 ...................................................... 6 - 15 - 34 Towing load on hooks (kN): Front ........................................................................... 100 (each) Rear ........................................................................... 200

Ambient operating temperature (°C): Min. (-) ........................................................................ 20 Max. (+) ...................................................................... 40

The measurements are valid for a standard, unloaded machine if nothing else is given.

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8. Technical Data

Engine Water cooled, unit injected diesel engine with turbo charger and air to air intercooler

1 kW = hp 1,36

Type ........................................................................... Scania DC 12 Cylinder volume ........................................................ 11.7 litres Bore x stroke .............................................................. 127 x 154 mm No. of cylinders .......................................................... 6 (in line) Power rating (ISO 3046) ............................................ 330 kW (448 hp) Power rating (ISO 9249) ............................................ 316 kW (429 hp) Max. torque ................................................................ 1854 Nm Engine speed, low idle .............................................. 600 rpm ± 50 Engine speed, high idle ............................................ 2430 rpm ± 50 Max. allowed engine speed ...................................... 2600 rpm Oil capacity ................................................................ 34 litres Oil pressure, warm engine at 2200 rpm ................... 3.0-6.0 bar Oil pressure, warm engine at 1000 rpm ................... min. 1.0 bar Specific oil consumption ........................................... 0.3 g/kWh Coolant volume ......................................................... 50 litres (approx.)

Normal temperature .................................................. 70-93 oC Thermostat ................................................................. 75 oC Max. system pressure ............................................... 0.5 bar Compression ratio ..................................................... 17 : 1 Firing order ................................................................ 1-5-3-6-2-4 Engine rotation, seen from rear ................................ Counterclockwise Valve clearance (cold engine) .................................. 0.45 mm, inlet valves .............................................................................. 0.70 mm, exh. valves Pump timing (see rocker cover sign) ........................ 13o before TDC Opening pressure, injectors ...................................... 300 bar

Transmission Automatic transmission. Integrated in the gearbox: torque converter, automatic lock-up clutch, retarder brake and lockable inter axle differential.

Type ........................................................................... ZF 6WG310 No. of forward gears .................................................. 6 No. of reverse gears .................................................. 3 Oil capacity ................................................................ 55 litres (approx.)

Normal temperature ................................................... 50-105 oC Max. permitted temp. when using retarder brake ...... 150 oC (short period only) Lock-up clutch ............................................................ in all gears Lock-up in/out ............................................................ acc. to engaged mode Inter axle diff. distribution .......................................... 1/3 to front axle, 2/3 to rear axle, lockable

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8. Technical Data

Hydraulic system Applied for brakes, steering, cooling fan and work equipment. The system have two variable displacement piston pumps. One pump for the steering and the work equipment, where the steering circuit has priority above the work circuit.

One pump for the brakes and cooling fan, where the brake circuit has priority above the cooling circuit.

The main- and emergency steering pumps are fitted on the transmission.

Tank capacity ............................................................. 209 litres (approx.)

Normal oil temperature ............................................. 40-90 oC (at tank) Filter ........................................................................... Full flow return filter without indicator Pumps ........................................................................ 2 variable displacement piston pumps Capacity per pump: ...................................................

Steering/tipping ......................................................... 320 l/min at 2200 rpm Brakes/cooling fan etc. .............................................. 60 l/min at 2200 rpm Emergency steering pump ........................................ Piston pump, ground driven, speed dependent Pump delivery ............................................................ Max. 40 l/min Pressure settings- main safety valves: Tipping circuit - up (pump setting) ............................ 280 Tipping circuit - down (pump setting) ....................... 280 Shock valves in the tip circuit .................................... 330 Steering circuit ........................................................... 210

bar bar bar (up), 80 bar (down) bar

Tipping cylinders ........................................................ single stage, double acting Tipping time ............................................................... 12 sec.

Steering cylinders ...................................................... 2 x double acting w/ 1 piston Steering wheel turns ................................................. Approx. 5 Accumulators ............................................................. 5 units, pre-charged with Nitrogen to pressure 112,5 bar

Tyre pressures Basic pressure for cold tyres (based on max. load and max. speed): Type GoodYear RL2+ ** Michelin XADN Bridgestone VLT **

Front bar (psi) 2.9 (42) 2.9 (42) 3.35 (48.5)

Rear bar (psi) 3.6 (52) 3.6 (52) 4.2 (61)

Regarding tyre pressure: Contact your Moxy Dealer or tyre supplier to get further information.

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8. Technical Data

Electrical system System voltage .......................................................... 24 V Battery ........................................................................ 2x 12 V, 230 Ah Grounding .................................................................. Negative earth cable Alternator .................................................................... 28 V, 65 A Starter motor .............................................................. 6.7 kW (9.1 hp) Fuses and relays: The fuses and relays are located behind the cover on the backwall.

Be sure to use fuses of correct size. Never install larger fuses than specified! If a certain fuse blows several times, the circuit must be checked and failure corrected.

Relays: 98

98 B

2 28

252

2 53

254

• Directio n light • Direction light • P arking brake • Transmission • Supply wiper, • Hazard light alarm contro ller washer, horn

105

10 6

• High beam

• Reverse light

107

10 8

• Heated seat

• Heater unit

85

87

• Wo rking light, • Wiper/washer • Engine rear contro ller

109

118

• P arking brake • Heated alarm mirro rs

119

99 •

Charging activated

12 0

• Engine coo ler • Co ntrol, retarder

100 • Start lock

121

10 2

104

• Working light • High beam

• Lo w beam

129

• P arking brake • B rake light alarm

Fuses: Fusebox A (Natural) 1/ 15A • Ignition

2 / 15A • Low beam

3 / 15A • High beam

4 / 15A

Fusebox B (Green) 5/ 15A

• Supply, wiper

6 / 15A • Heater unit

1/ 10 A

2 / 10 A

• Engine cont roller

• Transm. cont roller

3 / 10 A • Reverse light • Reverse alarm

4 / 10 A • Heated mirrors • Heated seat

Fusebox C (Yellow) 5/ 10 A

• Parking light • Rotat ing beacon

6 / 10 A • Hazard light

Fusebox D (Black) 1/ 10 A

2 / 10 A

• Inst rument • Radio light • Swit ch light

3 / 10 A • Cont rol light

4 / 10 A • Engine cooler

2 / 10 A

• Radio memory

• Parking brake • Seat comp.

3 / 10 A • Brake light

4 / 10 A • Lighter • Cab light

Fusebox E (Red) 5/ 10 A • Transm.

• Parking brake alarm

6 / 10 A • Parking brake alarm • Prop. valve controller

1/ 10 A

Light ........................................................................... Watts Head lights (H3/H7) .................................................. 75/70 Side lights in head light ............................................ 4 Direction indicators ................................................... 21 Stop lights .................................................................. 21 Licence plate lights ................................................... 5 Work light ................................................................... 70 Reverse light .............................................................. 70 Rotating beacon (H1) ................................................ 70 Rear lights ................................................................. 5 Cab light .................................................................... 10 Instrument lights ....................................................... 2 Warning/indicator lights ............................................ 1.2 Switch lights .............................................................. 1.2

2 / 10 A

3/20A

• Autom.

• Head light • Starter central lubricat ion • Body switch

Bulbs:

190

1/ 10 A

Socket P 43t/38 BA 9s BA 15s BA 15s S 8,5 Pk 22s Pk 22s P 14,5s BA 15s BA 15s W2x4,6d W2x4,6d

Operating & Maintenance Manual

4 / 5A

5/ 5A

• Parking • Parking light, r.h.s. light l.h.s.

6 / 10 A • Direction light

5/ 10 A

6 / 10 A

• Ext ra • Working high beam light, rear • Working light

8. Technical Data

Metering conversion table Length:

1m 1 km

= =

1.094 yd 1000 m

= =

3.281 ft 0.621 mile

=

39.37 in

Volume:

1 dm3 1 dm3 1 m3

= = =

1 litre 0.0353 ft3 35.32 ft3

= =

0.264 gal (US) 61.02 in3

=

0.220 gal (UK)

Weight:

1 kg = 1000 kg =

2.20 lb 1 ton (metric)

= =

35.27 oz 0.984 ton (UK) =

0.902 ton (US)

Power:

1 kW

1.34 hp (British) 1.36 hk (Metric)

Torque:

10 Nm =

=

7.38 lbf ft (pound-force foot)

=

14.5 p.s.i.

Pressure:

1 bar

Temperature:

o

C F

o

Speed:

= =

= = =

1 km/h =

1.02 kpm 1.02 kp/cm

2

=

100 kPa

o

5/9 x ( F- 32) (9/5 x oC)+32 0.62 mph

Tool kit content (standard)

Operation manual Driver instruction Parts catalogue

Arm, hydraulic pump (tiltable cab) - only High Line Safety support (tiltable cab) Draining hose

Tool kit content (optional) Hex. socket 12 mm Hex. bit front hub Diagonal wrench

Wheel-spanner Grease gun Arm, wheel-spanner

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8. Technical Data

Performance chart Below diagram gives guidelines for calculation of the dump truck gradeability performance related to rolling + grade resistance. The traction capabilities depend on the ground conditions and surroundings, i.e. available wheel grip (friction), tyre pattern, weight on the wheels, etc.

How to find downhill gradeability performance: 1. Read from actual dump truck weight (A) up to the percentage gradient (B).

(Rolling resistance is not included in the percentage grade).

2. From this point, read horizontally to the curve with highest speed range (C).

3. Then down to maximum speed (D).

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8. Technical Data

Engine and retarder brake capacity chart Below diagram gives guidelines for calculation of the dump truck engine and retarder brake performance related to rolling + grade. The traction capabilities depend on the ground conditions and surroundings, i.e. available wheel grip (friction), tyre pattern, weight on the wheels, etc. If the driving conditions (f.ex curves) requires hard decellerating by using the main brake, driving in a lower gear is advised.

How to find downhill gradeability capacity: 1. Read from actual dump truck weight up to the percentage gradient (Rolling resistance is not included in the percentage grade).

2. From this point, read horizontally to the curve with highest speed range.

3. Then down to maximum speed.

Under preparation

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8. Technical Data

Torque limits for bolts This tables indicates standard torque limits in Nm for the various screw and bolt qualities and dimensions.

The torques are valid for screws on the outside of the components.

Metric Threads

Dim./Class

8.8

Fine Metric Threads

10.9

12.9

Dim./Class

8.8

24 47 81

33 65 114

40 79 136

M8 x 1 M10 x 1.25 M10 x 1

25 48 49

35 68 70

42 81 84

M14 M16 M18

128 197 275

181 277 386

217 333 463

M12 x 1.5 M12 x 1.25 M14 x 1.5 M16 x 1.5

83 85 135 204

117 120 190 287

140 144 228 344

M20 M22 M24

385 518 665

541 728 935

649 874 1120

M27 M30 M33 M36

961 1310 1770 2280

1350 1840 2480 3210

1620 2210 2980 3850

M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2

294 408 546 696

413 574 768 979

496 688 921 1170

1000 1390 1860 2350

1410 1950 2610 3310

1690 2340 3130 3970

M27 x 2 M30 x 2 M33 x 2 M36 x 3

Machine model:

Serial no.:

Prod. year:

In operation:

Engine s/no.:

Transm. s/no.:

Dealer:

Consumeable parts

194

12.9

M8 M10 M12

Reference information

Part no.

10.9

Q'ty

Description

Operating & Maintenance Manual

8. Technical Data

Product signs

DI 12

DI 12

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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.:

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8. Technical Data

198

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9. Index

Index

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9. Index

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9. Index

Index 1000 Hours Service ........................................................ 161 2000 Hours Service ........................................................ 173 40 Hours Service ............................................................ 143 4000 Hours Service ........................................................ 181 500 Hours Service .......................................................... 145 8 Hours Service .............................................................. 131 Accumulators ........................................................... 32, 141 AEB-Tester ...................................................................... 150 Air conditioner system .................................. 143, 157, 159 Air conditioning system hazard prevention ...................... 20 Air filter ............................................................................ 163 Air filter warning light ........................................................ 51 Articulation lock ................................................................ 31 Ashtray .............................................................................. 76 Automatic central lubrication .......................................... 159 Automatic central lubrication indicator ............................. 53 Automatic Transmission Fluid (ATF) ............................... 124 Batteries ................................................................. 150, 162 Battery charge warning light ............................................ 51 Battery hazard prevention ................................................ 19 Battery power assistance ............................................... 109 Bearings ......................................................................... 184 Before operation ............................................................... 90 Bleed fuel system ........................................................... 162 Body capacity ................................................................. 187 Body support .................................................................... 29 Brake lines ...................................................................... 178 Brake pedal ...................................................................... 65 Brake system ................................................ 140, 154, 178 Brake system warning light .............................................. 50 Brakes ........................................................................ 22, 95 Braking/stopping the dump truck ...................................... 97 Breather element ............................................................ 168 Bulbs ............................................................................... 190 Cab and engine compartment light .................................. 56 Cab certification ................................................................ 33 Cab light ........................................................................... 76 Cab ventilation ............................................... 69, 143, 157 Central lubrication .......................................................... 159 Centrifugal cleaner ......................................................... 146 Change coolant .............................................................. 182 Change oil, engine ......................................................... 145 Change oil, front differential ........................................... 170 Change oil, front reduction gears ................................... 172 Change oil, hydraulic system ......................................... 178 Change oil, rear differential ............................................ 171 Change oil, tandem housings ........................................ 179 Change oil, transmission ................................................ 166 Check batteries ...................................................... 150, 162 Check battery terminals .................................................. 150 Check braking (holding) capacity .................................. 140 Check cab ventilation filter element ............................... 158 Check clearance of bearings ......................................... 184 Check coolant level ........................................................ 133 Check driver's seat ......................................................... 131 Check fuel injectors ........................................................ 173 Check fuel level .............................................................. 134

Check function, engine and retarder brake ................... 142 Check function, engine brake ........................................ 142 Check function, main brake ............................................ 141 Check function, steering ................................................. 142 Check glycol content in the coolant ............................... 176 Check lining thickness ................................................... 154 Check multi-groove belt ................................................. 163 Check of the centrifugal cleaner .................................... 134 Check oil level, drive line ...................................... 150, 152 Check oil level, engine ................................................... 133 Check oil level, front differential ..................................... 152 Check oil level, front reduction gears ............................. 153 Check oil level, hydraulic system ................................... 136 Check oil level, rear differential ...................................... 152 Check oil level, tandem housings .................................. 153 Check oil level, transmission .......................................... 135 Check protection against corrosion in the coolant ......... 177 Check the appearance of the coolant ............................ 175 Check the coolant ........................................................... 175 Check tyre pressures ...................................................... 144 Check wheel nuts torque ................................................ 156 Check wiring ................................................................... 172 Check/adjust valve clearance ........................................ 173 Checks after stopping the engine .................................. 103 Cigarette lighter ................................................................ 67 Clean centrifugal cleaner ............................................... 146 Clean prefilter, cab ventilation ........................................ 143 Clean strainer ................................................................. 166 Clothing and personal protection items ........................... 12 Cold weather .................................................................. 107 Column switch .................................................................. 62 Consumeable parts ........................................................ 194 Controls ............................................................................ 61 Coolant .................................................................. 175, 182 Cooling system ............................................................... 181 Correct tyre pressures .................................................... 105 Daily Service .................................................................. 131 Dangerous loads .............................................................. 24 Difference in tyre diameter ............................................. 105 Differentials ....................................................................... 99 Direction light indicator ..................................................... 53 Do not go close to high-voltage cables ............................ 18 Drive line ...................................................... 150, 152, 183 Driver's seat ............................................................. 73, 161 Dump truck knowledge ..................................................... 11 Dump truck transportation ................................................ 32 Electrical system .................................................... 172, 190 Electrically heated driver's seat switch ............................. 58 Emergency braking .......................................................... 97 Emergency exit .......................................................... 15, 68 Emergency retarder .......................................................... 23 Emergency steering ......................................................... 22 Emergency steering warning light ................................... 50 Engine ........................................ 132, 145, 161, 173, 188 Engine and retarder brake ............................................. 142 Engine and retarder brake capacity chart ...................... 193 Engine and retarder brake mode ..................................... 92 Engine and retarder brake operation ............................... 96

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9. Index

Engine bonnet .................................................................. 27 Engine brake ........................................................... 95, 142 Engine brake indicator ..................................................... 53 Engine controller switch for code reading ....................... 58 Engine coolant level warning light ................................... 52 Engine coolant temperature warning light ....................... 51 Engine, general condition check .................................... 132 Engine oil pressure warning light .................................... 51 Engine overspeed ............................................................ 23 Engine revolution counter and hour meter ...................... 45 Exhaust heating ................................................................ 24 Exhaust system ............................................................... 184 Expansion tank coolant level ........................................... 21 External cleaning of the radiator .................................... 174 External door opener/lock ................................................ 74 Filling capacities ............................................................. 122 Filling fuel or oil ................................................................ 21 Fire extinguisher ............................................................... 14 Fire prevention ................................................................. 16 Fire prevention for fuel and oil ......................................... 13 First 100 hours .................................................................. 82 First 500 hours .................................................................. 83 First 8 hours ...................................................................... 82 First aid kit ......................................................................... 14 FOPS ................................................................................ 15 Foreword ............................................................................ 5 Forward drive position ...................................................... 91 Front differential ....................................................... 99, 170 Front reduction gears ...................................................... 172 Fuel filter ................................................................ 132, 161 Fuel gauge ....................................................................... 45 Fuel injectors .................................................................. 173 Fuses .............................................................................. 190 Gear display ..................................................................... 45 Gear position N ................................................................. 91 Gear position V ................................................................. 91 Gear selector .................................................................... 66 Gear shift program ............................................................ 91 Gear shifting ..................................................................... 91 General condition check, drive line ................................ 183 General condition check, engine ................................... 132 General condition check, tanks ...................................... 183 General condition check, transmission .......................... 183 General description ............................................................ 7 General precautions ......................................................... 11 General safety check, driver's seat ................................. 161 Getting on and off the dump truck .................................... 12

Inspect the hydraulic hoses ........................................... 184 Inspect brake lines ......................................................... 178 Instructor seat ................................................................... 74 Instruments ....................................................................... 44 Intended use ....................................................................... 7 Inter axle differential ......................................................... 99 Inter-axle differential lock ................................................. 59 Inter-axle differential lock indicator .................................. 53 Internal cleaning, cooling system ................................... 181 Internal door opener ......................................................... 74 Introduction ......................................................................... 7 Labels ............................................................................... 33 Lifting ................................................................................ 31 Loading ........................................................................... 103 Lock-up indicator .............................................................. 52 Long term storage .......................................................... 108 Lubricants ....................................................................... 117 Lubrication ...................................................................... 137 Lubrication, articulation bearings ................................... 137 Lubrication, articulation turning ring .............................. 137 Lubrication, cab rear hinges .......................................... 140 Lubrication, door and fender hatches ............................ 139 Lubrication schedule ...................................................... 119 Lubrication, steering cylinder bearings .......................... 137 Lubrication, tailgate arm hinge ....................................... 138 Lubrication, tandem bearings ........................................ 139 Lubrication, tip cylinder bearings ................................... 137 Lubrication, tip hinges .................................................... 138 Lubrication,suspension legs .......................................... 137 Machine dimensions ...................................................... 187 Machine speed ............................................................... 187 Machine turning ................................................................ 21 Machine weights ............................................................ 187 Main light switch ............................................................... 56 Main warning light, engine failure .................................... 51 Main warning light, transmission failure .......................... 52 Maintenance ................................................................... 125 Maintenance precautions ............................................... 127 Maintenance table ................................................. 129, 130 Manual gear shifting ......................................................... 92 Manual release of the tip valve ..................................... 111 Manual release of parking brake .......................... 110, 111 Measurements ................................................................ 187 Metering conversion table .............................................. 191 Mirror heating switch ........................................................ 58 Neutral gear position ........................................................ 91 Normal operation .............................................................. 94

Hazard light switch ........................................................... 57 High beam indicator ......................................................... 53 High pressure ................................................................... 32 High temperatures ............................................................ 13 High-voltage cables ......................................................... 18 Hoisting ............................................................................. 31 How to adjust the parking brake .................................... 155 Hydraulic filter warning light ............................................. 52 Hydraulic return filter element ........................................ 169 Hydraulic system ........................ 136, 168, 178, 184, 189

Oil specification sheet .................................................... 121 Operating Controls ........................................................... 41 Operating hints ................................................................. 93 Operating Instructions ...................................................... 85 Operating the dump truck ................................................. 90 Operation of brakes .......................................................... 22 Operator's cab .................................................................. 17 Optional accessories ........................................................ 14 Other cab equipment ........................................................ 73

Important operating instructions ..................................... 101 Indicator lights .................................................................. 49

Parking brake ................................................. 95, 140, 155 Parking brake indicator .................................................... 50

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9. Index

Parking brake switch ........................................................ 59 Parking the dump truck ................................................... 102 Performance chart .......................................................... 192 Periodic service .............................................................. 196 Precautions before starting the engine ............................ 16 Precautions for mirrors, windows and lights .................... 18 Precautions for optional accessories ............................... 14 Precautions when handling at high temperatures ........... 13 Preselection of gears ........................................................ 92 Product signs .................................................................. 195 Proper maintenance ....................................................... 106 Protection against falling objects ..................................... 15 Radiator .......................................................................... 174 Radio/Cassette player ...................................................... 77 Rear differential ....................................................... 99, 171 Reference information .................................................... 194 Refrigerant ........................................................................ 20 Relays ............................................................................. 190 Replace breather element ............................................. 168 Replace fuel filter ................................................... 132, 161 Replace hydraulic return filter element .......................... 169 Replace transmission filter element ............................... 166 Replace turbo filter ......................................................... 149 Retarder brake ........................................................ 95, 142 Retarder brake capacity chart ........................................ 193 Retarder brake indicator .................................................. 53 Retarder brake mode ....................................................... 92 Retarder brake switch ...................................................... 57 Retractable roller sunblind on front window .................... 76 Reversing (back-up) operations ...................................... 94 Roll-over protection .......................................................... 15 ROPS ................................................................................ 15 Rotating beacon switch .................................................... 56 Rules to follow when filling fuel or oil ............................... 21 Run the AEB-Tester ........................................................ 150 Running-in operation ....................................................... 81 Running-in period ............................................................ 79 Running-in services ......................................................... 82 Safety at the worksite ........................................................ 16 Safety check, exhaust system ........................................ 184 Safety equipment .............................................................. 75 Safety information ............................................................... 6 Safety Instructions .............................................................. 9 Safety labels ..................................................................... 33 Safety rules ....................................................................... 11 Seat belt on driver's seat warning light ............................ 52 Service brake ........................................................... 95, 140 Service position ................................................................ 30 Side window ..................................................................... 75 Specified loading ............................................................ 106 Speedometer .................................................................... 48 Starter switch .................................................................... 67 Starting in cold weather .................................................... 89 Starting the engine ........................................................... 88 Steering ................................................................... 98, 142 Steering column ............................................................... 64 Stopping the engine ....................................................... 102 Switches ........................................................................... 55

Technical Data ................................................................ 185 Test switch for brake warning light ................................... 57 Throttle pedal .................................................................... 65 Tiltable cab ....................................................................... 27 Tip control lever ................................................................ 67 Tip- and steering cylinders ............................................. 156 Tipping ............................................................................ 104 Tipping system warning light ............................................ 52 Tool kit content ................................................................ 191 Top tailgate ....................................................................... 26 Torque limits for bolts ...................................................... 194 Towing the dump truck ................................................... 110 Transit, long distance drive-away on road ..................... 106 Transmission .............................. 135, 150, 166, 183, 188 Transmission oil list ........................................................ 124 Transmission oil temperature gauge ................................ 48 Transportation ................................................................... 32 Travelling on slopes ......................................................... 22 Troubleshooting .............................................................. 112 Turbo filter ....................................................................... 149 Tyre handling .................................................................. 105 Tyre pressures ....................................................... 105, 189 Tyres ............................................................................... 144 Unauthorised modification ............................................... 12 Up, down and crossgradient travel ................................ 100 Valve clearance .............................................................. 173 Ventilation for enclosed areas .......................................... 17 Wading ............................................................................. 23 Walk around check ......................................................... 131 Warming up period ........................................................... 91 Warning / indicator lights .................................................. 49 Warning light, engine failure, co-ordinator ....................... 51 Warning triangle ............................................................... 14 Weekly Service ............................................................... 143 Weight distribution .......................................................... 187 Welding ............................................................................. 25 Wheel chocks ................................................................... 30 Wheels ............................................................................ 156 When starting the engine ................................................. 18 Worker protection rules, refrigerant .................................. 20 Working and back-up lights .............................................. 56 Working lights and extra high beam ................................ 56 Yearly recommended maintenance ............................... 183

Tandem housings ........................................................... 179 Tanks .............................................................................. 183

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9. Index

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