OHE897 cover - Terexconstructionsupport.terex.com/_library/technical... · and articulation pivot joint between the tractor and trailer units. Articulation is achieved by frame steering

TEREX Equipment Limited Operator Handbook

Ope

rato

r Han

dboo

k

TA27

/30/

RS

15504613OHE889/897/908 Original Operating Instructions

The page is Intentionally Left Blank

TEREX Equipment Limited Operator Handbook Re-order

Ope

rato

r Han

dboo

k

TA27

/30/

RS

Issued by;Customer Support Department

Terex Equipment LimitedNewhouse Industrial Estate

Motherwell, ML1 5RYScotland

Tel; +44 (0) 1698 732121Fax; +44 (0) 1698 503210

www.terex.co.uk

OHE889/892/894/897/908/920

Re-order Part Number15504613

This controlled document is the original instructions and should remain with the vehicle at all times.

Revision: April 2010

15504613OHE889/897/908

Dealer:


TEREX Equipment Limited Operator Handbook - Introduction

Ope

rato

r Han

dboo

k

TA27

/30

For further information on the subject matter detailed within this operator handbook,please refer to Terex Equipment Limited Maintenance Manuals and Product Parts Books.

Alternatively, please contact;

Customer Support DepartmentTerex Equipment Limited

Newhouse Industrial EstateMotherwell, ML1 5RY

Tel; +44 (0) 1698 732121Fax; +44 (0) 1698 503210

The illustrations, technical information, data and descriptive text in this manual, to the best of our knowledge, were correct at the time of print. The right to change specifications, equipment and maintenance instructions at any time without notice, is reserved as part of the Terex Equipment Limited policy of continuous development and improvement of the product.

No part of this publication may be reproduced, transmitted in any form - electronic,mechanical, photocopying, recording, translating or by any other means without priorpermission of Customer Support Department - Terex Equipment Limited.

Please refer to TEREX Specification Sheets or consult Factory Representatives to ensure that information is current.


ONLY TRAINED COMPETENT PERSONNELSHOULD BE ALLOWED TO OPERATE THIS

VEHICLE

The operator is responsible and must befamiliar with the contents of the Operator's

Handbook and any Local / Nationalregulations prior to operating this vehicle.

This Page Intentionally Left Blank

CALIFORNIAProposition 65 Warnings

WARNING: Diesel engine exhaust andsome of its constituents are known to theState of California to cause cancer, birthdefects, and other reproductive harm.

WARNING: Battery posts, terminalsand related accessories contain leadand lead compounds, chemicals known tothe State of California to cause cancer andreproductive harm.Wash hands afterhandling.

SPARE PARTS STATEMENT

When carrying out repairs, alterations or fitting attachments, it is important that only genuinespare parts are used to ensure the operating safety of the machine is not impaired.

It is only by using genuine parts that the technical requirements stipulated by the manufacturercan be maintained.

If a General Operating Approval is issued for this machine, it may be considered null and voidif non-genuine parts are used.

EC DECLARATION OF CONFORMITY

MANUFACTURERS NAME AND FULL ADDRESS:

Terex Equipment Limited, Newhouse Industrial Estate, Motherwell, Scotland. ML1 5RY

DESCRIPTION OF MACHINERY:

MAKE: TEREX

2000/14/EC

2004/108/EC

2006/42/EC

Name:Address:

Alan Clark, Newhouse Industrial Estate, Motherwell, Scotland. ML1 5RY

PERSON AUTHORISED TO COMPILE TECHNICAL FILE DIRECTIVES COMPLIED WITH:

MODEL/DESIGNATION:

UNIT SERIAL NUMBER:

INSPECTOR:

WE DECLARE THAT THE ABOVE MACHINERY FULFILS ALL THE RELEVANT PROVISIONS OF THE ABOVE DIRECTIVES

FULL QUALITY ASSURANCE (Annex X):

L.R.Q.A. Ltd., Hiramford, Middlemarch Office Village, Siskin Drive, Coventry. CV3 4FJ. England

NAME: Alan Clark

Head of Engineering

Motherwell, Scotland

POSITION:

PLACE:

CERTIFICATE NUMBER:

LRQ 0925301/A

FOR AND ON BEHALF OF THE MANUFACTURER:

DATE OF MANUFACTURE:

SIGNATURE:

DATE:

TA27/30 Articulated Truck






EC DECLARATION OF CONFORMITY

MANUFACTURERS NAME AND FULL ADDRESS:

Terex Equipment Limited, Newhouse Industrial Estate, Motherwell, Scotland. ML1 5RY

DESCRIPTION OF MACHINERY:

MAKE: TEREX

2000/14/EC

2004/108/EC

2006/42/EC

Name:Address:

Alan Clark, Newhouse Industrial Estate, Motherwell, Scotland. ML1 5RY

PERSON AUTHORISED TO COMPILE TECHNICAL FILE DIRECTIVES COMPLIED WITH:

MODEL/DESIGNATION:

UNIT SERIAL NUMBER:

INSPECTOR:

WE DECLARE THAT THE ABOVE MACHINERY FULFILS ALL THE RELEVANT PROVISIONS OF THE ABOVE DIRECTIVES

FULL QUALITY ASSURANCE (Annex X):

L.R.Q.A. Ltd., Hiramford, Middlemarch Office Village, Siskin Drive, Coventry. CV3 4FJ. England

NAME: Alan Clark

Head of Engineering

Motherwell, Scotland

POSITION:

PLACE:

CERTIFICATE NUMBER:

LRQ 0925301/A

FOR AND ON BEHALF OF THE MANUFACTURER:

DATE OF MANUFACTURE:

SIGNATURE:

DATE:







1-1

CONTENTS

1. INTRODUCTIONIntroduction 1-5Safety Alert Symbol 1-5Hazard Classification 1-5Intended Use of the Machine 1-6Product Identification No. 1-7Spare Parts Statement 1-7Theft Deterrent Practices 1-8

2. SAFETYGeneral 2-4Articulation and Oscillation Locks 2-5Vehicle Lifting Precautions 2-5Vehicle Tie Down Precautions 2-5Preventing Fire Hazards 2-6Mounting and Dismounting 2-7Pre-Starting 2-8Starting 2-8Operating 2-8Roading 2-10Lubrication and Servicing 2-10Scrapping the Machine 2-11Mirror and CCTV 2-12 Wheels and Tyres 2-14Avoid Tyre Explosion Hazard 2-15Emergency Exit from Cab 2-16Decals and Instruction Plates 2-17

3. CONTROLS AND OPERATINGControls and Instruments 3-3Fuse / Relay Box 3-4Basic Data 3-5Warning Lights 3-5Instruments 3-7Switches 3-9Controls 3-12Heater 3-13Air Conditioner 3-13Operator's Seat -Air Suspension 3-14Operator's Seat - Operation 3-15Seat Belt 3-17Machine Controls 3-18Braking 3-18Transmission Retarder 3-19Engine Brake 3-20Engine 3-21Electronic Foot Pedal 3-21Quantum Fuel System 3-21Description 3-22Operation 3-23

1-2


1-3

3. CONTROLS AND OPERATING (cont.)EST-37 Automatic Shift Transmission 3-29VTS-3 Shift Controller 3-30Differential Lock 3-35Hydraulic Controls 3-36Steering 3-37Body Control 3-38Tilting Cab 3-39

4. OPERATING THE TRUCKPre-Starting Inspection 4-3Component Checks 4-3Engine Operation 4-6Starting the Engine 4-7Starting the Engine with Jumper Cables 4-9Pre-Operating Checks 4-10Brake Function Checks 4-11Driving and Stopping 4-12Stopping the Engine 4-14Parking 4-15

5. WORKING THE TRUCKWorking the Truck 5-3Loading 5-3Hauling 5-5Dumping 5-6Empty Return 5-7

6. ROADINGRoading 6-3General 6-3Preparation Prior to Roading 6-3In Case Of Trouble 6-4

7. MOVING DISABLED TRUCKMoving Disabled Truck 7-3

8. LUBRICATION AND SERVICINGSafety 8-3Lubrication and Servicing 8-4Lubrication and Service Chart 8-5Miscellaneous Servicing Information 8-7Recommended Lubricants 8-8

9. TECHNICAL DATATA27 9-3TA30 9-10

10. SYMBOL IDENTIFICATION

1-4


1-5

Introduction

INTRODUCTION

Introduction

The Terex TA27/30 articulated haulers are 3 axle types with an oscillationand articulation pivot joint between the tractor and trailer units. Articulationis achieved by frame steering. The machine has part time or full time 6wheel drive controlled by operator. The machine range capacities varyfrom 25 US ton - 42 US ton or 17.7 yd3 - 30.3 yd3.

This Handbook is provided as a guide to familiarize the operator andserviceman with the controls, recommended inspections, start-up,operating, shutdown and parking procedures for TA27/TA30/TA30RSand TA30IS Articulated Trucks. It is essential that operators read andunderstand the manual before operating the machine

Safety Alert SymbolThe Safety Alert System identifies important safety messages in thismanual. When you see this symbol, BE ALERT!. Your safety is involved.Carefully read the message that fillows and inform other operators.

Hazard ClassificationMulti-tier hazard classification system is used to communicate potentialpersonal injury hazards. The following signal words used with the safetyalert symbol indicate a specific level of severity of the potential hazard.Signal words used without the safety alert symbol relate to propertydamage and protection only. All are used as attention getting devicesthroughout this handbook as well as on decals and labels fixed to themachinery to assist in potential hazard recognition and prevention.

Safety alert symbol

2184

GENERATION

1-6

Introduction

Intended Use of MachineThis product and its approved attachments are designed to perform the followingfunctions.

1. Loading2. Hauling3. Dumping

CAUTION used without the safety alert symbol indicates apotentially hazardous situation which, if not avoided, may result inproperty damage.

CAUTION

CAUTION

DANGER indicates an imminently hazardous situation which, if notavoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if notavoided, could result in death or serious injury.

DANGER

WARNING

CAUTION indicates a potentially hazardous situation which,if not avoided, may result in minor or moderate injury.

USE OTHER THAN INTENDED

Any use other than that stated in “Intended use” shall be consideredimpermissible.The manufacturer shall not be held liable for any resulting damage.The risk is borne by the user alone.

1-7

Introduction

Product Identification Number - Plate Location

Information regarding the machine model, code and chassis serial numberis found on the unit serial number plate on the rear right of the front frame.The machine model and serial number should always be referenced in anycorrespondence with your dealer or factory.

While reading this handbook you will notice references to controls andequipment which may not be found on all machines. It isimportant that you know your machine and its equipment and how tooperate it properly.

There is a dealer serving every part of the world where theseproducts are sold. Your dealer is ready to provide you with anyadditional information needed and should be consulted for additionalpublications for this machine.

SPARE PARTS

When carrying out repairs, alterations or fitting attachments, it isimportant that only genuine spare parts are used to ensure theoperating safety of the machine is not impaired.

It is only by using genuine parts that the technical requirementsstipulated by the manufacturer can be maintained.

If a General Operating Approval is issued for this machine, it may beconsidered null and void if non-genuine parts are used.

WARNING

Serial Plate Location CE Identification

2182

1-8

Theft Deterrent Practices

GeneralThe owner/operator should take the following precautions todiscourage theft, to aid in the recovery in the event that the machine isstolen, or to reduce vandalism.

Actions to Discourage Theft and VandalismRemove all keys any time the machine is left unattended.

At night lock all doors and attach, secure or lock all anti-vandalism and anti-theft devices on the machine.

Immobilize the machine by removing a critical electrical or starting systemdevice, for example Fuse 31 or 32.

Upon receipt of a machine, record the machine serial number and theserial numbers of all major components and attachments. Keep this list upto date and filed in a safe location for fast retrieval.Place a decal or notice on the machine that all serial numbers arerecorded.

Discourage the thief! Inspect the gates and fences of the machinerystorage yard or construction site. Keep machines in well-lit areas and askthe local law enforcement authorities to make frequent checks around thestorage yard or work site.

Establish liaison with neighbours and ask them to watch equipment left atjob sites and to report any suspicious activities to the local law enforcementauthorities.

Make frequent inventories of machines to promptly detect losses orvandalism.

Actions to Aid in Recovery of Stolen MachinesIn the event of theft, immediately notify the law enforcement authoritieshaving jurisdiction. Provide the investigating officer with name, type ofequipment, chassis and serial numbers of major attachments andcomponents. It is helpful to show the investigating officer an Operator’sHandbook, photographs, and advertising, to familiarize him with theappearance of the machine.

Report the theft to the insurance company. Provide the model and all serialnumbers.

Report the model and serial numbers of the stolen machine to a dealerhandling the respective line of equipment. Request that the dealer forwardthis same information to the equipment manufacturer.

2-1

Safety

2 - Safety

2-2

Safety


2-3

Safety

SafetyThe machine should be properly operated and maintained to keep it insafe, efficient operating condition. Be sure that all controls are free of mud,grease, or other matter that might cause slips hazardous to the operator,serviceman, or other personnel or equipment. Report all malfunctions tothose responsible for maintenance, and, do not operate the equipmentuntil corrected. Normal service or maintenance performed as requiredcan prevent unexpected and unnecessary downtime.

This Handbook describes general inspections, servicing andoperation with the normal safety precautions required for normalservicing and operating conditions. It is not a guide however, for other thannormal conditions or situations, and therefore, servicemen andoperators must be safety conscious and alert to recognize potentialservicing or operating safety hazards at all times, and take necessaryprecautions to assure safe servicing and operation of the machine.

These machines are equipped with cylinders containingcompressed nitrogen gas. Transportation of these machinesby any method may require a special permit from theappropriate authority of the country involved. Consult yourdealer for details.

All information, illustrations and specifications contained in this publicationare based on the latest product information available at the time ofpublication. The right is reserved to make changes at any time withoutnotice.

Continuing improvement and advancement of the design may causechanges to your machine which may not be included in this publication.Each publication is reviewed and revised, as required, to update andinclude these changes in later editions.

This Handbook contains lubrication and routine servicing instructions,most of which can be performed in the field. Maintenance manualscontaining repair/rebuild procedures can be obtained from your dealer.

2-4

Safety

SAFETYGeneral* Read this Operator’s Handbook and learn the operating

characteristics and limitations of the vehicle. Know whatoperating clearances the vehicle requires.

• Read and understand all the safety signs prior to operation.

• If the safety signs are obstructed by dirt or debris, clean themusing mild soap and water prior to operation.

• If the safety signs are damaged or illegible, replace themimmediately, prior to operation.

* Read the AEM Safety Manual and follow the recommendedsafety precautions.

* Know clearances of all side and overhead obstructions such aswires, bridges, etc., for operating safely.

* Be especially aware of overhead power lines.

* Always know all traffic rules, signs, flags and hand signals usedon the job and know who has the responsibility for signalling.

* Be aware of operating hazards that weather changes can createon the job. Know proper procedures to follow when a severe rainor electrical storm strikes.

* Never attempt to operate or work on a vehicle when not feelingphysically fit.

* Know what safety equipment is required and use it. Suchequipment may be: Hard hat, safety glasses, reflector type vests,respirators,Safety shoes and ear plugs.

* Never wear loose clothing, rings, watches etc., that might catchlevers and controls and cause loss of control.

* Keep hands and controls free from water, grease and mud toassure nonslip control.

* Handle fuels and lubricants carefully and clean up spills to avoidfire and slipping hazards.

* Clean any mud, grease or oil from controls, handrails, laddersand decks. Lash necessary tools securely and remove all looseitems before operating the vehicle. Never rush. Walk, do not run.

* Never carry more than one passenger and only in the passengerseat. 1782

1768

SAFETY

MANUAL

1767

1769

2-5

Safety

The protection offered by the roll over and falling objectprotective structure may be impaired if it has beensubjected to any modification or damage. Unauthorizedmodification will void certification.

Articulation and Oscillation Lock* Always connect the steering and oscillation lock bar before

working in the articulation area, before lifting the vehicle andduring transportation of this vehicle by trailer/vessel.

* Always disconnect the steering and oscillation lock bar andsecure in the 'Stowed' position before operating the vehicle. Thevehicle would not be free to steer otherwise.

Articulation and OscillationLock - 'Locked' Position505

Articulation and OscillationLock - 'Stowed' Position506

Vehicle Lifting Precautions* Prior to lifting, the vehicle should be parked on a level surface,

wheels blocked, steering and oscillation lock bars connected.

* The vehicle should be lifted using a spreader bar if possible. Liftusing FOUR slings from the lifting points provided at the bumperend of the front chassis and at the rear of the body.

Note: Be aware that this vehicle is free to oscillate if not liftedcorrectly. If in any doubt contact your dealer for furtherinformation.

Vehicle Tie Down Precautions* The vehicle should be secured at the tie down points located at

the bumper end of the front chassis, the front face of the trailerchassis and the tow pin at the rear of the trailer chassis.

919

Vehicle Tie Down Instructions1493

Vehicle Lifting Instructions

2-6

Safety

Preventing Fire HazardsGeneral Fire Precautions* Make sure the vehicle has a fire extinguisher and that it is

accessible and fully charged. (Not furnished with the vehicle).

* Never use an open flame as a light anywhere on, or around, thevehicle.

* Clean all dirt, oil, grease and other fluids from systems andcomponents to minimize fire hazards and aid in spotting looseor leaking lines, fittings etc..

* Check the engine compartment for rubbish, oily rags or otherdebris that could cause fires before starting the engine.

* Don’t let greasy, oily rags or similar hazards accumulate in thecab.

* If the vehicle has been operated with an under inflated tyre,make sure that the tyre has cooled sufficiently before parkingand leaving the vehicle unattended.

Flammable Fluid Precautions* Don’t use diesel fuel or other flammable fluids for cleaning

purposes. Use approved, nonflammable solvents.

* Make sure all fluid system caps, drain cocks, valves, fittings,lines, etc., are secure and leak free.

* Never use an open flame (match, lighter etc.) when checkingfuel, lubricant, coolant and battery fluid levels, or when checkingfor fluid leaks. Use a flashlight or other safe lighting only.

* Shut off engine and use extra caution if engine is hot whenrefuelling. Ground the hose spout to prevent sparks when spoutis touched to fuel tank filler tube.

* Never smoke while checking or adding fuel or other fluids orhandling fluid containers and lines.

* Use care and do not stand downwind when adding fuel or otherflammable fluids to tanks and reservoirs to avoid fluids beingblown or splashed onto clothing.

* Close fuel tank shut-off valves, if used, before servicing fuelsystem.

* When preparing vehicles or components for storage, seal andtape all openings and close containers tightly to seal in allvolatile inhibitor fluids and compounds used.

FUEL

1770

1789

2-7

Safety

* Follow manufacturer’s recommendations when handling andusing engine-starting fluids and disposing of spent containers.Do not puncture or burn empty containers. These fluids areexplosive and highly flammable.

Electrical Hazard Precautions* Never smoke or allow open flames or sparks near batteries.

* Leave battery box open when charging batteries in the vehiclefor adequate ventilation of explosive gas (hydrogen) produced.

* Always disconnect batteries before repairing electrical systemto avoid danger of fire-causing sparks. Disconnect batteryground cable first and reconnect last.

* Always disconnect batteries, alternator leads, engine ECM,hydraulic system ECU, body control lever, transmission ECU,instrument panel ECU and all harness connections at front ofcab before carrying out any welding on the vehicle.

* Never check battery charge by placing metal objects acrossbattery posts to avoid sparks at battery posts.

* Use jumper cables only as recommended. Improper use canresult in battery explosion or unexpected vehicle motion.

* Never operate engine starter for more than 30 seconds andallow two minutes between long cranking periods for cooling. Anoverheated starter could cause a fire.

* If electric coolant or lubricant heaters are used, be sure to followheater manufacturer’s recommendations for use to avoidelectrical and/or fire hazards.

Mounting and Dismounting* Always face the access system and maintain at least three

points of support to mount or dismount the vehicle (two handsand one foot, or two feet and one hand).

* Always face the access system and maintain at least threepoints of support to mount or dismount the vehicle.

* Ensure walkways, stairways, platforms, handrails and handholdsare free of frost, ice, oil, water or anything else that could causeslip, trip or falls.

* Never mount or dismount a moving vehicle. Never jump off thevehicle.

1771

1772

2-8

Safety

Pre-Starting* If engine is to be started and run indoors, ensure proper

ventilation to remove deadly exhaust gases.

* Always perform 'Pre-Starting Inspection' instructions describedon page 4-3 to ensure the vehicle is ready for operation.

* Always walk around the vehicle to make sure no-one is working on,underneath or close to the vehicle before starting the engine oroperating the vehicle.

* Adjust, secure and latch the seat and fasten the seat belt beforestarting the vehicle.

* Sound horn before starting the engine or beginning to move thevehicle; two blasts for forward and three blasts for reverse.

Starting* Do not start the engine or operate any control if there is a 'DO

NOT OPERATE' or similar warning sign attached to any control.

* Use jumper cables only as recommended. Improper use canresult in battery explosion or unexpected vehicle motion.

* Always obey 'Starting the Engine' instructions described onpage 4-7.

* Do not bypass the vehicle’s neutral-start system. The neutral-start system must be repaired if it malfunctions.

* Start and operate the vehicle only from the operator’s seat.

Operating* Ensure all cab glass, mirrors and light lenses are clean during

vehicle operation for maximum visibility. Ensure mirrors areproperly set / positioned.

* Always keep cab floor clear of anything that could restrict fulloperation of pedals.

* Always make sure all gauges, warning/indicator lights andcontrols are working properly before operating the vehicle.

* Always perform 'Pre-Operating Checks' described on page 4-10to ensure the vehicle is ready for operating.

* Always wear seat belts when operating the vehicle.

* Do not operate if exposed personnel enter the immediate workarea.

* Sound horn before starting engine or beginning to move thevehicle; two blasts for forward and three blasts for reverse.

1773

P

STOP

1

2

10

10

20

30

40 50

60

70

80

km/h

2030

40

mph

50

30

0

0

5

r / min x100

10

20

25

15

40

70

100

150

105

210250

120

60

140

275 320390

135 165200

˚C

˚F

˚C

˚FL

H

1776

DO NOT

OPERATE

1775

1790

2-9

Safety

* Watch for ground crew and other personnel on foot. Sound hornas a warning before setting the vehicle in motion and whenapproaching ground crew.

* Be sure the body is fully down before moving the vehicle.

* Always try to face or look in the direction the vehicle istravelling.

* Use extreme caution and turn on lights at night or when fog,dust or similar hazards limit visibility. Do not overdrive yourheadlights.

* Observe instruments frequently. Report any defects or unusualnoises in the vehicle during operation.

* Stay in gear when driving downhill. Do not coast withtransmission in neutral. Select the proper gear and maintainsafe speed with the service brakes or/and retarder. Alwaysmaintain safe speeds for haul road operating conditions formaximum control. Reduce speed before turning.

* In the event of a loss of electric power to the gear shift control,the transmission will automatically lock in a gear range. If thisoccurs, stop the vehicle using the service brakes.ApplyParking / Emergency brake.Do not operate until the fault iscorrected.

* Always operate straight up or down slopes whenever possible,side-hill operation can cause sideslip and possible roll-over.

* Slow down when moving in congested areas. Do not race withother vehicles. Stop in authorized areas only, except inemergency.

* Brake firmly in one application. Do not FAN the pedal. Neveroperate the vehicle if a warning light or parkbrake service alarmis on. It indicates a fault in the braking system.

* Always give loaded vehicles the right-of-way when your vehicleis empty.

* Always watch for holes, soft edges or other hazards whenbacking to dump over a spoil bank.

* Always stay in cab when being loaded.

* Always lower the body and shut down the vehicle according tothe procedure under 'Stopping The Engine' described on page4-14 before leaving the vehicle unattended. If on a grade wheelsshould be blocked.

1779

1778

1774

2-10

Safety

Roading* Match speed to road conditions.

* Yield the right of way when required. Obey the rules of the road.

* Stay as close to the side of the road as possible. Pass otherequipment only when the road is clear, there is sufficient spaceto pass, and reserve power is available.

* Stop at appropriate intervals to inspect the vehicle and allow thetyres to cool. Tyre air pressure will rise during operation. Do notreduce tyre pressure. Excess speed will cause tyres to heat up.Reduce your travel speed, not tyre pressure.

* Use accessory lights and devices at night or in poor visibility.Carry a flare kit. Do not overdrive your headlights.

Lubrication and Servicing* Do not allow unauthorized personnel to service or maintain this

vehicle. Study this Operator’s Handbook and the MaintenanceManual before starting, operating or servicing this vehicle.Always follow procedures and safety precautions detailedthroughout the Maintenance Manual.

* Always attach a 'DO NOT OPERATE' or similar warning sign tothe ignition switch or a prominent control before cleaning,lubricating or servicing the vehicle.

* Never allow anyone to work on the vehicle while it is moving.Make sure there is no one on the vehicle before working on it.

* Do not work under or near an unblocked or unsupported body.Always use the body safety prop. The body safety prop mustonly be used when the body is empty.

* Do not work under or near any unblocked or unsupportedlinkage, part or vehicle.

* Always install the steering lock bar before making adjustmentsor servicing the vehicle with the engine running. Refer to'General' safety section.

* Always shut down the vehicle according to the procedure under'Stopping The Engine', described on page 4-14, and turn off themaster switch before cleaning, lubricating or servicing thevehicle except as called for in this Operator’s Handbook or theMaintenance Manual.

1777

Body Safety Prop171

1780

2-11

Safety

* Always relieve pressure before servicing any pressurisedsystem. Follow the procedures and safety precautions detailedin the relevant Maintenance Manual section.

* When changing oil in the engine, transmission and hydraulicsystems, or removing hydraulic lines, remember that the oil maybe hot and can cause burns to unprotected skin.

* When working on or around exhaust components, rememberthat the components may be hot and can cause burns tounprotected skin.

* Always deflate the tyre before attempting to remove anyembedded objects or removing the tyre and rim assembly fromthe vehicle.

* Always use a self-attaching chuck with a long airline, and, standto one side while the tyre is inflating. Refer to Section 160-0050,WHEEL RIM AND TYRE in the Maintenance Manual.

* Do not work under or near an unblocked or unsupported raisedoperator’s cab. Always use the operator’s cab safety prop withthe locking pin.

Scrapping the Machine

At the end of its life, the machine should be disassembled by acompetent person using safe working practices, wearing theappropriate Personal Protective Equipment and working in accordancewith local regulations.

The appropriate lifting equipment, chocks and stands must be usedto maintain a stable machine as components are removed and themachines centre of mass changes. Fluids must be drained off intosuitable containers and if possible recycled or otherwise disposed ofan environmentally friendly in accordance with local regulations.

Care must be taken when dealing with flammable liquids and themachine parts that contained those liquids. Any process that couldignite flammable materials must not be used on components thathave contained flammable liquids in them or have residual flammableliquids on them.

Fire extinguishers must be readily available if cutting/weldingequipment is to be used.

When possible recyclable materials should be separated out andprocessed in accordance with local regulations using an authorisedagent.

Operators Cab Safety Prop1727

1993

Operators Cab Safety Prop & Locking PinWith Cab Raised

2-12

Safety

Mirrors and CCTV

The operator must survey their surroundings before entering the machine, andcheck their field of vision prior to and during operation of the machine. All mirrorsmust be adjusted when installed, and prior to operating the machine, to achieveoptimum visibility and thus minimize the risk of injury to themself and others.Site management should utilize appropriate jobsite organization to minimizehazards due to restricted visibility. Modifications made to the machine mayrestrict the visibility and compromise compliance with safety standards(ISO 5006:2006).

Make sure that all mirrors are installed and adjusted to optimize operator visibility. The mirrors,illustrated below, are all capable of adjustment. Make sure that the brackets which support thesemirrors are folded out from the cab to form an angle of 90O . These brackets may be folded parallelto the cab for transportation of the vehicle. Set the mirrors in the defined position shown in theillustration.

2113

2110

A B C D

500

150

490

140

2-13

Safety

When all the mirrors have been fitted, the machine has a total of four mirrors,designated A to D respectively, and positioned generally as illustrated. Thearea surrounding the machine is to be considered as two distinct fields ofview, ilustrated below as areas 1 to 9 in the immediate vicinity, and areas 10to 15 at a radius of 12 m from the operator when seated. The operator MUSTadjust the mirrors, and set the CCTV camera, to achieve visibility asidentified below:

* Areas 2, 8 and 10 can be directly viewed from the operator’sseating position without the need for mirrors.

* Adjust mirror A to facilitate the view of Areas 1, 2, 3, 14 and 15.* Adjust mirror B such that Areas 4 and 14 are fully visible.* Adjust mirror C such that Areas 6 and 12 are fully visible.* Adjust mirror D to facilitate the view of Areas 7, 8, 9, 11

and 12.* Set the CCTV to facilitate vision of Areas 5 and 13.

2112

2111

1

48

7 5

2 3

6

1500mm

1000

mm

1000

mm

1000mm

R 1

2 m

14

13

109

12

11

2-14

Safety

Wheels and TyresIf tyres on the vehicle were inflated at the factory with dry nitrogengas, the tyre walls will be marked 'N' and the following factoryinstalled decal will be found mounted on the fenders.

NOTICE

TYRES ON THIS VEHICLE ARE FACTORY INFLATED WITH DRYNITROGEN. IT IS RECOMMENDED THAT DRY NITROGEN BEUSED EXCLUSIVELY FOR ALL TYRE PRESSUREADJUSTMENTS AS WELL AS INFLATION OF REPLACEMENTTYRES.

Nitrogen gas improves tyre pressure retention, increases tyre life byreducing carcass oxidation from within, minimizes rim rust, and hasno known detrimental effect on the tyre. It also reduces the potential ofa tyre explosion because it is an inert gas and will not supportcombustion inside the tyre. The same tyre inflation pressure used forair inflation should be used for nitrogen inflation. Refer to Section160-0050, Wheel, Rim and Tyre of the vehicle Maintenance Manualfor recommended procedures for inflating and pressure adjustingtyres with dry nitrogen gas. Only proper nitrogen charging equipmentoperated by personnel trained in its use should be used.

Never mix components of one manufacturer’s rims with thoseof another. Using the rim base of one manufacturer with thelock ring of another or vice versa is dangerous. The lock ringof one may not fully engage with the lock ring groove of theother. Always consult the rim manufacturers for propermatching, assembly and safety instructions. Also, use andservicing of damaged, worn out or improperly assembled rimassemblies is a very dangerous practice. Failure to complywith the above warnings could result in an explosion fromtyre pressure causing serious property damage and seriouspersonnel injury or death.

2-15

Safety

Avoid Tyre Explosion Hazard

Whenever a vehicle’s tyre(s) is (are)exposed to excessive heat such as avehicle fire or extremely hot brakes, thehazard of a subsequent violent tyreexplosion must be recognized. All nearbypersons must avoid approaching thevehicle so as not to be physicallyendangered in the event of an explosion ofthe tyre and rim parts. The vehicle shouldbe moved to a remote area, but only whenthis can be done with complete safety ofthe operator operating or towing thevehicle. All other persons should stay clearof the vehicle. The fire or overheatedbrakes, wheel etc., should be extinguishedor cooled from a safe distance. Do notattempt to extinguish the fire or cool thevehicle by use of hand-held fireextinguishers. If it is absolutely necessaryto approach a vehicle with a suspect tyre,approach only from the front or the back.Stay at least 15 m (50 ft) from the treadarea. Keep observers out of the area and atleast 460 m (1500 ft) from the tyre sidewall.Refer to the accompanying sketch. Thetyre(s) should be allowed at least eight (8)hours cooling time after the vehicle is shutdown or the fire extinguished beforeapproaching closer.

AT LEAST15m (50ft)

AT LEAST460m (1 500ft)

172

2-16

Safety

Emergency Exit from CabNormal access to, and egress from, the cab isfacilitated via the door on the left-hand side .However, in an emergency, an alternative exit canbe gained via the side windows. A hammer isprovided to break the left-hand or right-hand sidewindow glass to facilitate safe egress.

The hammer is mounted on a bracket on the rearwall of the cab, and can be easily lifted off in anemergency.

2082

Do not attempt to break the windscreenwith the Emergency hammer. It is ONLYprovided to allow access through theleft-hand and right-hand windows.

Exercise extreme care when breakingthe window glass to protect your faceand body from airborne glass particles.

Be careful when passing through thewindow aperture to avoid contact withshards of glass that may remainattached to the frame, or loose within oroutside of the cab.

2-17

Safety

2185

GENERATION

14

1

35 22

20

7334

21

INSIDE BATTERY BOX

HEADER TANK

14

3137

8

181930839 6 24291034 1814

27,401935

25

812 12

PSTOP

1

2

10

10

20

3040

50

60

70

80

km/h

20 30

40mph

50 300 0

5r / min x100

10 20

25

15

4070 100

150105

210250

120 60

140

275 320390

135 165

200

˚C

˚F

˚C

˚F

L H

8 28 14

39

2614

230

25

ONWINDOW

36

15

13

1741

38

23

32

16

5

11

2186

Decals and Instruction PlatesDecals and instruction plates fitted tovehicles may vary from country tocountry to suit local needs. Thesepages contain a brief description andthe location of the decals andinstruction plates that may appear onyour vehicle.1. ROPS and FOPS Certification

Plate2. Serial Plate3. Tank Steps Warning4. Accumulator Warning5. Power Lines Danger6. Battery Danger7. Accumulator Warning8. Vehicle Tie-down Hook9. Battery Negative Earth10.Jump Start11.Steering Column Adjustment12.Backalarm13.Decline14.Hot Surface Warning15.Park/Emergency Brake Control16.Park/Emergency Brake Warning17.Body Control Lever18.Tyre Inflation - Nitrogen Fill19.Crush Hazard warning20.Diagnostic Manifold Plate21.Cab Jacking Instructions22.Engine Filters23.Sound Power 109 db24.Hood Cable Location25.Hood Raise Warning26.Hydraulic Oil Recommendations27.Transmission Filters28.CE Certification29.ECU Welding Precautions30.Articulation Area31.Radiator Fill32.Emergency Exit (Inside and

Outside)33.Accumulator Notice34.Vehicle Lift Instruction35.Cab Tilting Warning36.Fuse Identification37.Anti-Freeze Caution38.Power Down Caution39.Service Plate

2-18

Safety

Pictorial Decal Set

9271069

Hook Point (1797)

9361787

Battery Earth (1798) CE Marking (1799)

15314811

Body Control (1800)

15318464

Steering ColumnAdjustment (1801) 1

5321634

Emergency Exit (1804)

15321636

1

2

Hood Catch (1837)

15321641

P

P

Park Brake (1805)

Transmission Filter (2189)

15331997

WA

Sound Power (1976)

15331998

WA

Sound Power (1977)

15332624

WA

Sound Power (1809)

15332852

Hood Raise Lower(1806)

15314033

WA

Sound Power (1975)

TA25 / 27 / 30TA25 / 27 / 30

TEREX : 15273572ZF : O750 131 061

TEREX : 15271723ZF : O750 131 063

15336110

F

R

P

TA27/30 Diagnostic Point (2190)

15356709

15356570

Fall Hazard (2221)Safety Harness (2222)

2-19

Safety

Pictorial Decal Set

TA350/400 Fuse Relay Box (2224)

15354606

P

NN

NN

K23

AUX SUPPLIES

HYDECU

HYDECU

R

R

TV

K17 K50 K32

K23 K14 K23 K52

K34 K71 K27 K64

K15

K48

K68

K69

K25 K63 K4 K23

F12

(7.5A)

F24

(10A)

F36

(15A)

F11

(10A)

F23

(3A)

F35

(5A)

F10

(15A)

F22

(3A)

F34

(15A)

F9

(7.5A)

F21

(3A)

F33

(10A)

F8

(10A)

F20

(15A)

F32

(30A)

F7

(10A)

F19

(3A)

F31

(10A)

F6

(10A)

F18

(15A)

F30

(5A)

F5

(10A)

F17

(7.5A)

F29

(15A)

F4

(10A)

F16

(3A)

F28

(15A)

F3

(7.5A)

F15

(5A)

F27

(10A)

F2

(15A)

F14

(5A)

F26

(15A)

F1

(20A)

F13

(30A)

F25

(30A)

H

L

H

L

H

L

12V

24V

24V

F'L'

(15A)

F'J'

(5A)

24V

F'K'

(20A)

F'M'

(10A)

K66

K67

H

L

P

AUTO

r/min

H

L

K72

P


15354737

P

NN

NN

K23

AUX SUPPLIES

HYDECU

HYDECU

R

R

TV

K17 K50 K32

K23 K14 K23

K33

K52

K34 K27

K15

K58

K57 K4 K23

F12

(7.5A)

F24

(10A)

F36

(15A)

F11

(10A)

F23

(3A)

F35

(5A)

F10

(15A)

F22

(3A)

F34

(3A)

F9

(7.5A)

F21

(3A)

F33

(10A)

F8

(10A)

F20

(15A)

F32

(30A)

F7

(10A)

F19

(3A)

F31

(5A)

F6

(10A)

F18

(15A)

F30

(5A)

F5

(10A)

F17

(7.5A)

F29

(15A)

F4

(10A)

F16

(3A)

F28

(15A)

F3

(7.5A)

F15

(5A)

F27

(10A)

F2

(15A)

F14

(5A)

F26

(15A)

F1

(20A)

F13

(30A)

F25

(30A)

12V

24V

12V

24V

F'L'

(10A)

F'K'

(20A)

F'A'

(5A)

F'M'

(15A)

1/R

K71

P

15333633

P

NN

NN

K23

AUX SUPPLIES

HYDECU

HYDECU

R

R

TV

K17 K50 K32

K23 K14 K23 K52

K34 K27K5

K15

K58

K57 K4 K23

F12

(7.5A)

F24

(10A)

F36

(15A)

F11

(10A)

F23

(3A)

F35

(5A)

F10

(15A)

F22

(3A)

F34

(3A)

F9

(7.5A)

F21

(3A)

F33

(10A)

F8

(10A)

F20

(15A)

F32

(30A)

F7

(10A)

F19

(3A)

F31

(10A)

F6

(10A)

F18

(15A)

F30

(5A)

F5

(10A)

F17

(7.5A)

F29

(15A)

F4

(10A)

F16

(3A)

F28

(15A)

F3

(7.5A)

F15

(5A)

F27

(10A)

F2

(15A)

F14

(5A)

F26

(15A)

F1

(20A)

F13

(30A)

F25

(30A)

H

L

12V

24V

12V

24V

F'L'

(15A)

F'K'

(20A)

F'M'

(10A)

1/R


15333012

P

NN

NN

K23

AUX SUPPLIES

HYDECU

HYDECU

R

R

TV

K17 K50 K32

K23 K14 K23 K52

K34 K65 K27 K64

K15

K48

K25 K63 K4 K23

F12

(7.5A)

F24

(10A)

F36

(15A)

F11

(10A)

F23

(3A)

F35

(5A)

F10

(15A)

F22

(3A)

F34

(15A)

F9

(7.5A)

F21

(3A)

F33

(10A)

F8

(10A)

F20

(15A)

F32

(30A)

F7

(10A)

F19

(3A)

F31

(10A)

F6

(10A)

F18

(15A)

F30

(5A)

F5

(10A)

F17

(7.5A)

F29

(15A)

F4

(10A)

F16

(3A)

F28

(15A)

F3

(7.5A)

F15

(5A)

F27

(10A)

F2

(15A)

F14

(5A)

F26

(15A)

F1

(20A)

F13

(30A)

F25

(30A)

H

L

H

L

H

L

H

L

12V

24V

24V

24V

F'M'

(15A)

F'K'

(20A)

F'L'

(10A)

K66


2-20

Safety

Pictorial Decal Set

MIL-L-2104 ECF, CD, SF

MILA. P. I.

MIL-L-46152 B / C

15334899

TA400 Brake Cooling Oil (1982)

Serial Plate

15316595

TEREX EQUIPMENT LIMITEDNEWHOUSE INDUSTRIAL ESTATEMOTHERWELL, SCOTLAND. ML1 5RY.

MODEL NO.

PRODUCT IDENTIFICATION NO.

MAX. RATED PAYLOAD

MASS UNLADEN

STRUCK CAPACITY

ENGINE POWER

lb /kg

lb /kg

yd³ /m³

hp /kW

YEAR OF MANUFACTURE

MODEL YEAR

Serial Plate (1808)

15333286

1800 PSI55 bar

2800 PSI55 bar

31500 PSI103 bar

TA400 AccumulatorNitrogen Precharge

(1831)

15333287

11500 PSI103 bar

21500 PSI103 bar

31500 PSI103 bar

TA350 AccumulatorNitrogen Precharge

(1832)

15334426

11500 PSI103 bar

31500 PSI103 bar

21500 PSI103 bar

TA27/30 AccumulatorNitrogen Precharge

(1979)

MIN.

MAX.

-54°C (-65°F) 54°C (130°F)

-29°C (-20°F) 74°C (165°F)

-18°C (-0°F) 82°C (180°F)

0°C (32°F) 99°C (210°F)

7°C (45°F) 99°C (210°F)

DEXRON®

10W

20W-20

30W

MIL-H-5606A

MILA.P.I.S.A.E.

MIL-L-210B / C

MIL-L-210B / C

MIL-L-210B / C

CC/CD

CC/CD

CC/CD

AUTO.

15334778

TA350/400 Hydraulic Oil (1980)

15334887

1

2

3

4

5

6

TA350/400Transmission Retarder

(1981)

15353607

I . D kg

TA350

TA400

29279 kg ( 64549 lb )

30820 kg ( 67946 lb )

15333031

I . D kg

TA25

TA27

TA30

TA35

TA40

20870 kg ( 46010 lb )

21900 kg ( 48280 lb )

22420 kg ( 49430 lb )

29279 kg ( 64549 lb )

30820 kg ( 67946 lb )

Lift Instruction (1807)

Lift Instruction TA350/400(2169)

2-21

Safety

Safety Decals Set ISO Standard

TA27/30 Gradeability Chart (1867)15334645

% KPH MPH % KPH MPH

0 6 50 31 0 6 50 31

5 5 27 17 5 6 48 30

10 4 15 9 10 5 28 17

15 3 9 6 15 5 22 14

20 2 8 5 20 4 16 10

25 2 6 4 25 3 12 7

30 1 5 3 30 3 11 7

15334756

Crush Hazard Warning, Use safetyprop (1874)

15334759

N2

PSI / BAR

0

Accumulator Warning, Maintain nitrogenprecharge for proper operation (1875)

N

15334761

P1. 2.

Crush Hazard Warning, Apply parkbrake, Shift to neutral (1876)

15334765

Entanglement Warning, Stopengine before servicing (1879)

15334764

Read And Understand OperatorHandbook (1878)

15334766

Hot Surface Warning, Allow to coolbefore servicing (1880)

15334754

1 .

2 .

Crush From Articulation Warning, Usesafety lock (1873)

15334762

Skin Injection Warning, Relieve pressure beforeservice, Use card to search for leaks (1877)

15334646

L

H

% %KPH MPH KPH MPH

0 6 39 24 0 6 39 24

0 6 60 37 0 6 60 37

5 4 28 17 5 6 60 37

5 5 28 17 5 6 39 24

20 2 7 4 20 3 15 9

25 2 6 4 25 3 12 7

15 2 9 6 15 4 21 13

10 3 14 9 10 5 32 20

30 1 5 3 30 2 9 6

15 2 9 6 15 3 21 13

25 1 6 4 25 2 12 7

20 1 7 4 20 2 15 9

30 1 5 3 30 2 9 6

10 2 14 9 10 4 32 20

Gradeability Chart (1866)

2-22

Safety

15334767

Burn Hazard, allow to cool beforeopening (1881)

15334768

Anti-freeze Notice, See handbookfor correct concentration (1882)

15334770

Filters Notice, See handbook forreplacement intervals (1884)

15334771

Jump Start Notice, Jump start usingidentical battery pack (1885)

15334772

N

Nitrogen Filled Tyres, Use nitrogenonly to fill (1886)

15334774

Welding Notice, See handbook forwelding procedures (1888)

15334777

Cab Jack Notice (1889)


15334769

1.

2.

Cab Tilt Notice, Raise hood beforetilting cab (1883)

15335080

Fall Hazard Warning, Use accesssystem provided (1894)

15334780

Reverse Warning, Keep clear oftruck when it is reversing (1890)

15356710

Fall Hazard Warning, Use SafetyHarness provided (2219)

2-23

Safety


Batteries Warning, Explosive, keepall flames and sparks away (1891)

15335077

Hydraulic Tank Pressurization Warning (2022)15343325

PSI / BAR

0

15334773

Power Down Notice, Power downtruck when not in use (1887)

Power Lines Warning, Maintain requiredclearance (2171)

15353574

kV

0 - 50 kV

50 - 200 kV

200 - 350 kV

350 - 500 kV

500 - 750 kV

750 - 1000 kV

d

d

10 ft (3m)

15 ft (4.6m)

20 ft (6.1m)

25 ft (7.6m)

35 ft (10.7m)

45 ft (13.7m)

15335079

PSI / BAR

0

Pressurised Accumulator Warning, Donot not weld, keep away from flames.Relieve all pressure before servicing

(1893)

4

2

2

2

2

42

24

2

H O2

72

4

15335663

1000h - 4000h

10h

50h

250h

500h

36

22

6

TA27/30 Service Lubrication Chart, See Operator Handbook section 8 for detail (1973)

2-24

Safety


4

2

2

2

2

4

2

2

TA40

2

H

L

H O2

H

L

138

4

H

L

6

15335665

1000h - 6000h

10h

50h

250h

500h

3

TA35/40 Service Lubrication Chart, See Operator Handbook Section 8 for detail (1974)

F R PTP1

TP3

H

L

F R

321

15336028

TA350/400 Service Lubrication Chart, See Operator Handbook Section 8 for detail (2179)

4

2

2

2

2

4

2

2

2

H

L

H O2

H

L

138

4

H

L

6

15353115

1000h - 6000h

10h

50h

250h

500h

3

TA350/400 Diagnostic Point (2181)

2-25

Safety

N

15333272

Crush Hazard.

Sudden and unwanted

machine movement can

result in serious

injury or death.

Always ensure when

starting / stopping

engine to :

1. Apply park brake.

2. Shift transmission

into neutral.

P1.

2.

WARNING

Park Brake Warning (1817)

15333273

Injection Hazard.Escaping fluid under pressurecan penetrate skin, resultingin serious injury.

Relieve pressure beforedisconnecting hydraulic lines.Keep away from leaks and pinholes. Use a piece of cardboard or paper to searchfor leaks. Do not use hand.

Fluid injected into skin must besurgically removed within a fewhours by a doctor familiar with this type of injury or gangrenewill result.

WARNING

Skin Injection Warning (1818)

15333277

Burn Hazard.Contact with hotsurfaces can result in burns.

Do not touch.Allow surfaces to cool beforeservicing.

WARNING

Hot Surface Warning (1822)

15333278

Burn Hazard.Hot fluid under pressure can scald.

Allow to cool beforeopening.

WARNING

Hot Radiator Steam Warning (1823)

Safety Decals Set ANSI Standard

15333265

WARNING

Crush HazardDeath or serious injury may result.

Install supportbefore servicing.

Crush Hazard (1812)

WARNING

15333268

% KPH MPH % KPH MPH

0 6 50 31 0 6 50 31

5 5 27 17 5 6 48 30

10 4 15 9 10 5 28 17

15 3 9 6 15 5 22 14

20 2 8 5 20 4 16 10

25 2 6 4 25 3 12 7

30 1 5 3 30 3 11 7

Operating the truck outside the stated limitson the chartcould result indeath or seriousinjury.

Do not operatetruck outsidethe limits statedon the chart.

Select the correctgear for thegradient you are on.

TA25/27/30 Gradeability Chart (1859)

WARNING

15333267

L

H

% %KPH MPH KPH MPH

TA35/40G7

0 6 39 24 0 6 39 24

0 6 60 37 0 6 60 37

5 4 28 17 5 6 60 37

5 5 28 17 5 6 39 24

20 2 7 4 20 3 15 9

25 2 6 4 25 3 12 7

15 2 9 6 15 4 21 13

10 3 14 9 10 5 32 20

30 1 5 3 30 2 9 6

15 2 9 6 15 3 21 13

25 1 6 4 25 2 12 7

20 1 7 4 20 2 15 9

30 1 5 3 30 2 9 6

Operating the

truck outside

the stated limits

on the chart

could result in

death or serious

injury.

Do not operate

truck outside

the limits stated

on the chart.

Select the correct

gear for the

gradient you are on.

10 2 14 9 10 4 32 20

TA35/40 G7 Gradeability Chart (1858)

WARNING

15354036

L

H

% %KPH MPH KPH MPH

TA350/400

0 6 39 24 0 6 39 24

0 6 60 37 0 6 60 37

5 4 28 17 5 6 60 37

5 5 28 17 5 6 39 24

20 2 7 4 20 3 15 9

25 2 6 4 25 3 12 7

15 2 9 6 15 4 21 13

10 3 14 9 10 5 32 20

30 1 5 3 30 2 9 6

15 2 9 6 15 3 21 13

25 1 6 4 25 2 12 7

20 1 7 4 20 2 15 9

30 1 5 3 30 2 9 6

Operating the

truck outside

the stated limits

on the chart

could result in

death or serious

injury.

Do not operate

truck outside

the limits stated

on the chart.

Select the correct

gear for the

gradient you are on.

10 2 14 9 10 4 32 20

TA350/400 Gradeability Chart (2168)

Fall Hazard

Falling can result in death

or serious injury.

Do not work on this machine

without safety harness

and lanyard.

15356708

WARNING

Fall Hazard Warning (2220)

2-26

Safety


15333275

Improper operation ormaintenance can resultin serious injury ordeath.

Read and understandoperator's manual and allsafety signs before using or maintaining machine.If you do not understandthe information in the manuals, consult yoursupervisor, the owner or the manufacturer.

WARNING

Read Operator Handbook Warning(1820)

Moving Parts Warning (1821)

Anti-freeze Notice (1824)

Cab Tilt Notice (1825)Filters Notice (1826)

15333454

Truck can crushwhen reversing.Death or seriousinjury may result.

Keep clear of truck when it isreversing.

WARNING

Reverse Warning (1835)

15334867

Explosion/Burn Hazard

Will cause death, burns or

blindness due to ignition of

explosive gases or contact

with corrosive acid.

Keep all open flames and sparks away. Wear

personal protective equipment, including

face shield, gloves and long sleeve shirt.

READ MANUALS

Read all manuals prior to operation.

DO NOT OPERATE equipment if you do not

understand the information in the manuals.

Consult your supervisor, the owner or the

manufacturer.

DANGER

Danger Batteries (1983) Danger Power Lines (2172)

15333276

Entanglement Hazard.Rotating parts canresult in personal injury.

Keep away from fan and belt when engine is running. Stop engine before servicing.

WARNING

15333279

Using incorrectconcentration ofanti-freeze mayresult in damage.

See hand bookfor correctconcentration ofanti-freeze.

NOTICE

15333280

NOTICE

When tilting cab,damage to hoodmay result.

Raise hood beforetilting cab.

15333281

NOTICE

Using filters pasttheir replacementintervals may result in damage.

See maintenancemanual for replacementintervals.

15353582

Maintain required clearanceElectrocution HazardDeath or serious injury canresult from contactingelectric power lines.

Always contact the electricpower line owner. The electricpower shall be disconnectedor the power lines moved orinsulated before machineoperations begin.

0 - 50 kV

50 - 200 kV

200 - 350 kV

350 - 500 kV

500 - 750 kV

750 - 1000 kV

10 ft (3m)

15 ft (4.6m)

20 ft (6.1m)

25 ft (7.6m)

35 ft (10.7m)

45 ft (13.7m)

Linevoltage

Requiredclearance

DANGER

NOTICE

15333288

Cab Jack Notice (1833)

2-27

Safety


Jump Start Notice (1827)

Nitrogen Filled Tyres Notice

(1828)

Power Down Notice (1829)15333282

NOTICE

Jump starting withwelding equipment willresult in damage to the electrial system.

Jump start usingidentical batterypack.

NOTICE

15333283

Use nitrogen onlyto inflate tyres.

AIR N

15333284

NOTICE

Power down truckwhen not in useor damage mayoccur.

NOTES ON LUBRICATION AND SERVICE CHART

NOTE 1 - CAPACITIES GIVEN ARE APPROXIMATE - WORK TO DIPSTICK, SIGHT GAUGES OR LEVEL PLUGS.

NOTE 2 - CAPACITY OF FRONT AND REAR DIFFERENTIALS IS 21 LTR (5.5 US GAL)

CAPACITY OF CENTRE DIFFERENTIAL IS 23 LTR (6 US GAL)

NOTE 3 - LUBRICATE SLOWLY UNTIL EXCESS LUBE IS SEEN.

NOTE 4 - REMOVE PLUG FROM PORT ON UNDERSIDE OF OSCILLATION HUB. PLUG IS REMOVED TO DRAIN THE CAVITY OF ANY OIL THAT

ENTERS THE CAVITY WHEN FILLING. REMOVE THE COVER PLATE AND LEVEL PLUG ON SIDE OF OSCILLATION HUB. ADD OIL

IF REQUIRED. REFIT ALL PLUGS.

NOTE 5 - CLEAN RADIATOR AND COOLER FINS MORE OFTEN WHEN OPERATING UNDER EXTREMELY DUSTY CONDITIONS.

NOTE 6 - CHANGE SAFETY ELEMENT AFTER EVERY THIRD PRIMARY ELEMENT SERVICE.

NOTE 7 - INDEPENDENT FRONT SUSPENSION (IFS) GREASE POINTS (2). REMOVE EXCESS GREASE FROM THE GREASE HOLES IN THE PIVOT BLOCKS (8 PER SIDE) AND AT THE DAMPER PINS (2 PER SIDE).

LUBRICATE THE LEFT-HAND IFS GREASE MANIFOLD UNTIL EXCESS IS OBSERVED EXITING THROUGH THE GREASE HOLES IN THE PIVOT BLOCKS (8) AND AT THE DAMPER PINS (2).

LUBRICATE THE RIGHT-HAND IFS GREASE MANIFOLD UNTIL EXCESS IS OBSERVED EXITING THROUGH THE GREASE HOLES IN THE PIVOT BLOCKS (8) AND AT THE DAMPER PINS (2).

NOTE 8 - THIS SERVICE INTERVAL IS DEPENDANT ON FUEL QUALITY. IF A LESSER GRADE OF FUEL IS USED THAN THAT SPECIFIED WITHIN THE RECOMMENDED LUBRICANTS, THE SERVICE INTERVAL

SHOULD BE REDUCED ACCORDINGLY.

NOTE 9 - CHECK THE AIR CLEANER RESTRICTION GAUGE AND OPERATE THE VACUATORVALVE. RENEW THE ELEMENT IF THE INDICATOR DENOTES A BLOCKAGE.

EO - ENGINE OIL. REFER TO "RECOMMENDED LUBRICANTS" AND "ENGINE OIL DRAIN INTERVALS".

HO - HYDRUALIC TRANSMISSION OIL. REFER TO "RECOMMENDED LURICANTS".

EPL - EXTREME PRESSURE GEAR LUBRICANT. REFER TO "RECOMENDED LUBRICANTS".

EP,NLGI - EXTREME PRESSURE LITHIUM No. 2 GREASE (WITHOUT "MOLYBDENUM").

PAG OIL - POLYALKLENE GLYCOL (PAG) COMPRESSOR LUBRICATING OIL - LOW VISCOSITY (ISO46)

LUBRICATION AND SERVICE CHART

INTERVAL

HOURS

NO.

PTS

REF

PTSSERVICE INSTRUCTIONS SERVICE QUANTITIES

LUBRICANT

OR COOLERIDENTIFICATION

10

DAILY

50

WEEKLY

250

MONTHLY

1

2

3

4

6

7

18

1

3

24

1

1

1

1

1

1

2

1

1

6

EO

EO

HO

ETHYLENE

GLYCOL

-

-

-

-

-

-

EP, NLGI

EP, NLGI

EP, NLGI

EP, NLGI

EP, NLGI

-

-

EP, NLGI

-

AS REQUIRED

AS REQUIRED

AS REQUIRED

-

-

MAINTENANCE MANUAL,

SEC 160-0050

ENGINE

TRANSMISSION

HYDRAULIC TANK

RADIATOR EXPANSION TANK

FUEL FILTER / WATER SEPARATOR

ENGINE AIR CLEANER

DRIVE BELTS

ENGINE CRANKCASE BREATHER

HYD. FILTER RESTRICTION GAUGE

TYRES

CHECK OIL LEVEL. ADD OIL IF LOW



CHECK COOLANT LEVEL. ADD IF LOW

DRAIN

CHECK. RENEW ELEMENT IF REQ'D

VISUAL INSPECTION FOR DAMAGE

INSPECT AND CLEAN IF REQUIRED

CHECK. RENEW ELEMENT IF REQ'D

CHECK CONDITION & PRESSURE

19

20

21

25

27

18

35

6

3

1

2

2

2

1

EPL

EPL

-

EP, NLGI

-

-

EP,NLGI

AS REQUIRED

AS REQUIRED

-

SEE NOTE 3

-

-

SEE NOTE 3

WHEEL PLANETARIES

DIFFERENTIALS

OSCILLATION PIVOT

ARTICULATION BEARINGS

PARKING BRAKE PADS

DRIVE BELTS

FRONT AXLE (IFS)

CHECK OIL LEVEL. ADD IF LOW


CHECK END FLOAT. ADJUST IF REQ'D

LUBRICATE

CHECK WEAR. RENEW IF REQ'D

CHECK TENSION. TIGHTEN IF REQ'D

LUBRICATE

9

12

10

11

13

15

30

14

8

2

2

4

4

2

72

1

4

2

SEE NOTE 3

SEE NOTE 3

SEE NOTE 3

SEE NOTE 3

SEE NOTE 3

600 Nm (442 lbf ft)

SEE NOTE 3

AS REQUIRED

OSCILLATION BUSHES

SUSPENSION BEAM BUSHINGS

STEERING CYLINDER PINS

BODY CYLINDER PINS

BODY HINGE /TAILGATE PINS

WHEEL RIM NUTS

CAB FRESH AIR FILTER

PANHARD ROD BEARINGS

BATTERY ELECTROLYTE

LUBRICATE

LUBRICATE

LUBRICATE

LUBRICATE

LUBRICATE

CHECK TORQUE

INSPECT & CLEAN IF REQUIRED

LUBRICATE

CHECK LEVEL. ADD ELECTRO IF LOW

15347627

500

3 MONTHLY

1

16

1

1

EO

-

-

-

ENGINE

ENGINE OIL FILTER

DRAIN OIL & REFILL WITH NEW OIL

RENEW

40005

33

-

1

-

PAG OIL

-

-

COOLING SYSTEM

AIR CON. COMPRESSOR

DRAIN, FLUSH & REFILL WITH NEW

COOLANT

DRAIN, FLUSH & REFILL WITH NEW

REFRIGERANT OIL

1000

6 MONTHLY

2000

ANNUALLY

2

2

3

6

17

2

28

29

22

30

32

1

1

1

1

1

1

2

1

1

1

1

EO

-

-

-

-

-

-

-

EPL

-

-

-

-

REF. SERVICE MANUAL

-

-

-

-

-

SEE NOTE 4

-

-

TRANSMISSION

TRANSMISSION

HYDRAULIC TANK BREATHER

FUEL FILTER / WATER SEPARATOR

DCA4 COOLANT FILTER

TRANSMISSION BREATHER

TRANSMISSION OIL FILTERS

TRANSMISSION INTERNAL

STRAINER

DRIVESHAFT BEARINGS


FUEL TANK


RUN AEB STARTER

RENEW

RENEW

RENEW

CLEAN IF REQUIRED

RENEW

CLEAN


RENEW

RENEW CAP FILTER / CATRIDGE

3

19

19

20

25

31

3

23

1

2

1

1

34

1

6

6

3

1

1

1

5

4

3

4

1

24

HO

-

EPL

EPL

-

-

-

-

-

-

-

-

-

-

REF. SERVICE MANUAL

-

SEE NOTE 2

1425 Nm (1050 lbf ft)

-

-

-

298 Nm (220 lbf ft)

920 Nm (679 lbf ft)

65 Nm (50 lbf ft)

-

671 Nm (495 lbf ft)

HYDRAULIC TANK

BRAKE PACKS

WHEEL PLANETARIES

DIFFERENTIALS

ARTICULATION PIVOT NUT

HYDRAULIC OIL FILTER

HYDRAULIC TANK STRAINER

DRIVELINES

ENGINE MOUNTING BOLTS

TRANSMISSION MOUNTING BOLTS

TURBOCHARGER MOUNTING

BOLTS

ENGINE WATER PUMP

AXLE MOUNTING BOLTS


CHECK BRAKE WEAR



CHECK TORQUE

RENEW

CLEAN

CHECK FOR LEAKS & DAMAGE

CHECK TORQUE

CHECK TORQUE

CHECK TORQUE

INSPECT DRAIN HOLE.

CLEAN IF REQUIRED

CHECK TORQUE

5

18

1

32

4

30

3 31

25

22

27

20

13

24

14

34

26

15

12

23

19

21

9

11

35

10

28

2

29

7

16

6

8

33

17

TA25/27/30 Service Lubrication Chart (2191_Decal)

2-28

Safety


15334870

WARNING

Fall HazardDeath or seriousinjury can resultfrom falling.

Use the accesssystem providedwhen servicingthe machine.

Fall Hazard Warning (1986)

TA350/400 Service Lubrication Chart (1795_Decal)

Welding Notice (1830)

WARNING

PSI / BAR

0

Explosion HazardDeath or seriousinjury can resultfrom release ofpressurised liquids.

Do not weld or drillinto accumulator.Keep away from flames.Relieve all pressure before performingservice on accumulator.

15334869

Accumulator Warning (1985)15333285

NOTICE

Welding truck can seriouslydamage ECUs andcomponents.

Disconnect the following,in order, before welding:1. Turn off master switch.2. Battery earth cable.3. Battery supply cable.4. Alternator earth cable.5. Alternator supply cable.6. Body control lever.7. Engine ECM.8. Transmission ECU.9. Hydraulic ECU.10. Instrument panel ECU.11. Cab bulkhead connectors

Crush From Articulation Warning (1810)

Crush HazardDeath or serious injuryfrom crushing can occurin articulating areawhen machine turns.

Before servicing:1. Turn key switch off and remove key.2. Install articulation lock arm.

15333263

WARNING

Hydraulic Tank Pressurization Warning (2021)

15343324

WARNING

Pressurisedhydraulic tank.

Before working on thetank, open the ball valveto remove pressure.Close valve afterpressure has relieved.

PSI / BAR

0

AIR

OIL

Accumulators.Incorrectly maintainedaccumulators can resultin brake failure, whichcan result in death or serious injury.

Maintain nitrogen precharge in accumulatorsfor proper operation ofbrake system.Read manual for brakesystem imformation.

15333270

N2

PSI / BAR

0WARNING

Accumulator Warning (1922)

NOTES ON LUBRICATION AND SERVICE CHART

NOTE 1 - CAPACITIES GIVEN ARE APPROXIMATE - WORK TO DIPSTICK, SIGHT GAUGES OR LEVEL PLUGS.

NOTE 2 - CHECK WITH THE ENGINE IDLING AND THE TRANSMISSION AT ITS NORMAL OPERATING TEMPERATURE.

NOTE 3 - LUBRICATE SLOWLY UNTIL EXCESS LUBE IS SEEN.

NOTE 4 - REMOVE PLUGS AND FIT LUBE FITTINGS. LUBRICATE SLOWLY UNTIL EXCESS LUBE IS SEEN. REMOVE FITTINGS AND REFIT PLUGS.

NOTE 5 - CAPACITY OF FRONT AND REAR DIFFERENTIALS 33 LITRE (8.7 USGAL). CAPACITY OF CENTRE DIFFERENTIAL 34 LITRE (9 USGAL)

PLUS 1 LITRE (2 PINTS) FOR PRIMING THE 3RD DIFFERENTIAL UNIT. (36 LITRE EPL + 2 LITRE LZ 6178).

NOTE 6 - REMOVE PLUG FROM PORT ON UNDERSIDE OF OSCILLATION HUB. PLUG IS REMOVED TO DRAIN THE CAVITY OF ANY OIL THAT ENTERS

THE CAVITY WHEN FILLING. REMOVE GROMMET AND LEVEL PLUG ON SIDE OF OSCILLATION HUB. ADD OIL IF REQUIRED. REFIT ALL PLUGS.

NOTE 7 - CHECK DROPBOX LEVEL COLD WITH ENGINE RUNNING.

EO - ENGINE OIL. REFER TO "RECOMMENDED LUBRICANTS".

* - REFER TO CHART UNDER "RECOMMENDED LUBRICANTS".

HO - HYDRUALIC OIL. REFER TO "RECOMMENDED LURICANTS".

EPL - EXTREME PRESSURE LUBRICANT SPEC. MIL-L21058.

EP,NLGI - EXTREME PRESSURE LITHIUM No. 2 GREASE (WITHOUT "MOLYBDENUM"). REF. EEMS 19014

EP,LI COMP - EXTREME PRESSURE LITHIUM COMPLEX GREASE. REF. EEMS 19057.

LZ - LUBRIZOL 6178

PAG OIL - POLYALKLENE GLYCOL (PAG) COMPRESSOR LUBRICATING OIL - LOW VISCOSITY (ISO46).


INTER

-VAL

HOURS

NO.

OF

PTS

REF

NO.

SERVICE

INSTRUCTIONS

SERVICE

QUANTITIES

LUBRICANT

OR COOLANTIDENTIFICATION

10

DAILY

1

1

2

3

4

5

14

32

11

6

27

1

1

1

1

1

1

1

1

1

6

EO

TRANSYND

HO

ETHYLENE

GLYCOL

EO

TEXTRAN TDH

PREMIUM

AS REQUIRED

SEE NOTE 2

AS REQUIRED

AS REQUIRED

SEE NOTE 7.

AS REQUIRED

ENGINE

ENGINE CRANKCASE BREATHER

TRANSMISSION

HYDRAULIC TANK

RADIATOR EXPANSION TANK

PRIMARY FUEL FILTER/WATER SEP

DROPBOX

OCDB TANK

ENGINE AIR CLEANER

DRIVE BELT

TYRES





CHECK COOLANT LEVEL. ADD IF LOW

CHECK. DRAIN AS REQUIRED



CHECK. REPLACE ELEMENT IF REQUIRED

VISUAL INSPECTION FOR DAMAGE

CHECK CONDITION & PRESSURE

2

5

15

16

17

18

19

25

6

1

1

1

3

6

2

1

2

1

EPL & LZ

EPL

EP LI COMP

AS REQUIRED

AS REQUIRED

SEE NOTE 3 & 4

TRANSMISSION BREATHER

PRIMARY FUEL FILTER/WATER SEP

SECONDARY FUEL FILTER

DIFFERENTIALS

WHEEL PLANETARIES

ARTICULATION BEARINGS

OSCILLATION PIVOT

PARKING BRAKE PADS

DRIVE BELT

CLEAN IF RQUIRED

RENEW

RENEW



LUBE

CHECK END FLOAT. ADJUST IF REQUIRED

CHECK WEAR. REPLACE IF REQUIRED

CHECK TENSION. TIGHTEN IF REQUIRED

1

13

14

14

1

2

1

1

EO

EO

32 LITRES / 8.4 US GAL


ENGINE

ENGINE OIL FILTERS

DROPBOX

DROPBOX OIL FILTER

DRAIN OIL AND REFILL WITH NEW OIL

RENEW


RENEW

50

WEEKLY

250

MONTHLY

11

28

9

29

30

31

26

1

1

1

1

1 EPL SEE NOTE 6


SEE NOTE 5

9 LITRE / 2.4 US GAL

ENGINE AIR CLEANER

COOLANT ADDITIVE


FUEL TANK BREATHER

HYDRAULIC TANK BREATHER

OCDB TANK BREATHER

DRIVESHAFT BEARINGS

RENEW ELEMENT

RENEW

RENEW

RENEW

RENEW

RENEW


1000

6 MONTH

3

3

6

24

34

2

1

1

1

1

1

1

1

2

2

2

HO

ETHYLENE

GLYCOL

298 LITRE / 79 US GAL

67 LITRES / 18 US GAL

1425 Nm / 1050 lbf ft

921 Nm / 680 lbf ft

921 Nm / 680 lbf ft

330 Nm / 239 lbf ft

HYDRAULIC TANK

HYDRAULIC OIL FILTER

DRIVE BELT

COOLING SYSTEM

ARTICULATION PIVOT NUT

TRANSMISSION MTG. BOLTS

TURBOCHARGER MTG. NUTS

ENGINE MOUNTING BOLTS


RENEW

RENEW BELT

CHECK CONCENTRATION. ADD BOOSTER

CHECK TORQUE (TORQUE SEAL)




2000

ANNUALLY

500

3 MONTH

32

16

17

33

33

1

3

6

1

1

TEXTRAN TDH

PREMIUM

EPL & LZ

EPL

OCDB TANK

DIFFERENTIALS

WHEEL PLANETARIES

OCDB FILTER

OCDB STRAINER




RENEW

CLEAN

1500

9 MONTH

12 2TRANSMISSION OIL FILTERS RENEW3000

2 1TRANSMISSION DRAIN OIL AND REFILL WITH NEW OIL6000

0.125 LITRES PAG OIL35 1

61 LITRES / 16 US GALTRANSYND1

AIR CONDITIONING COMPRESSOR DRAIN FLUSH AND REFILL WITH NEW OIL4000

7

8

9

10

19

20

21

22

23

2

114

1

4

2

2

4

4

2

EP. NLGI

EP, NLGI

EP, NLGI

EP, NLGI

EP, NLGI

EP, NLGI

AS REQUIRED

600 Nm / 442 lbf ft

SEE NOTE 3

SEE NOTE 3

SEE NOTE 3

SEE NOTE 3

SEE NOTE 3

SEE NOTE 3

BATTERY ELECTROLITE

WHEEL RIM NUTS


PANHARD ROD BEARINGS

OSCILLATION BUSH

SUSPENSION BEAM BUSHINGS

STEERING CYLINDER PINS

BODY CYLINDER PINS

BODY HINGE/TAILGATE PINS

CHECK LEVEL. ADD ELECTROLITE IF LOW

CHECK TORQUE


LUBE

LUBE

LUBE

LUBE

LUBE

LUBE

15353114

28

35

24

6

1

31

5

7

16 1017251918129112913

3332 4 3 30 15 2 12 21 14 34 22 26 17 20 8 27 23

3-1

Controls and Operating

3 - Controls and Operating

3-2



3-3


2183

1. Side Window Demister

2. Storage Pocket

3. Retarder Request Switch

4. Engine Brake Request Switch

5. Engine Diagnostic Switch

6. Engine Diagnostic Scroll Switch

7. Engine Brake - Low / High Switch

8. Transmission Diff-lock Request Switch.

9. Visual Display Unit (VDU)

10. N/A

11. Hazard Warning Lights

12. Main Lights

13. Front Working Lights

14. Rear Wash / Wipe

15. N/A

16. Heated Mirrors

17. Rear Working Lights

18. Flashing / Rotating Beacon

19. Rear Fog Lamp

20. Park / Emergency Brake Control

21. Heater Vent

22. Transmission Gear Shift Control

23. Body Control Lever

24. Cup Holder

25. Body Lower Emergency Switch

26. Fuse Box

27. Accelerator Control

28. Radio Facia

29. Service Brake Control

30. Ignition and Starter Key Switch

31. Steering Wheel

32. Steering Wheel Adjustment Lock

33. 12V / 24V Jack points

34. Headlight Dipper, Direction Indicator,Windscreen Wiper/Wash, Horn Control

35. Heater/Air Conditioner & Radio Controls

36. Battery Master Switch

37. ZF VDU

38. Cross Axle Diff-lock Request Switch

39. Rear View Camera

CONTROLS AND INSTRUMENTS

PSTOP

1

2

10

10

20

3040

50

60

70

80

km/h

20 30

40mph

50 300 0

5r / min x100

10 20

25

15

4070 100

150105

210250

120 60

140

275 320390

135 165

200

˚C

˚F

˚C

˚F

MENU SELECT DN UP + -

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

16171819

2021

2237

23

26

2729

303132

38

33

34

35 28

36

2124

25

39

3-4


FUSE / RELAY BOX

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

FM

FL

FK

FJ

FH

FG

FF

FE

FD

FC

FB

FA

12

131

3624

25

1788

1. Ignition sensed equipment 20A FL. Engine ECU battery 10A2. Keyswitch 15A FM. Instrument Panel / CPU Battery3. Hazard warning lights 7.5A supply 15A4. Rear wash/wipe 10A FK. Auxiliary 12V supply 20A5. Horn front wash/wipe 10A6. Air seat compressor 10A7. Dipped beam lights 10A A. Not used8. Main beam lights 10A B. Not used9. Front wiper motor park 7.5A C. Sound Power (Body raise) K5810. Transmission TCU battery 7.5A D. Sound Power (1st/Reverse Range)K5711. Transmission TCU ignition 10A E. A/C / Heater / Hyd.ECU Ignition K2312. Reverse alarm/lights 7.5A F. Wiper / ignition K2313. IFM controller ignition 30A G. Horns K3414. Cab interior light 5A H. Headlights K1515. Direction indicators 5A I. Reverse alarm / lights K1716. Emergency/park brake 3A J. Neutral start K1417. Instrument cluster/CPU ign. 7.5A K. N/A18. Heated mirrors. 15A L. N/A19. Ignition sensed relays 3A M. Brake lights K5020. 24V work socket battery 15A N. Engine ECU ignition K2321. Neutral start 3A O. Engine cooling fan K3322. Front washer pump 3A P. Indicator flasher unit K423. Rear washer pump 3A Q. Engine brake K3224. Horns 10A R. Body proximity switch K5225. Ignition sensed equipment 30A S. Differential lock K2726. Air conditioner/heater 15A T. Radio K2327. Reverse camera/monitor 10A28. Front working lights 15A29. Rear working lights 15A30. Rotating/flashing beacon 5A31. Engine ECU ignition 5A32. Engine ECU battery 10A33. Proximity switch 10A34. Sound Power Relay Supply 3A35. Brake pedal controls 5A36. 12V work socket battery 15A

3-5


BASIC DATA

PSTOP

1

2

1 102 93 84 75 6

1694 Instrument Panel - 'Warning Lights'

Warning Lights1. Front Brakes Accumulator Pressure (Red) - Illuminates to warn oflow pressure in the front brake system accumulator. A buzzer alsosounds. If light illuminates, stop machine and investigate the cause.

2. Rear Brakes Accumulator Pressure (Red) - Illuminates to warnof low pressure in the rear brake system accumulator. A buzzer alsosounds. If light illuminates, stop machine and investigate the cause.

3. Main Beam (Blue) - Illuminates when headlights are switched onand dip control is not engaged.

4. Direction Indicators (Green) - Flashes when the indicator lightsare operating.

5. Engine Stop Light (Red) - When the 'Stop Engine' light comes on,the computer has detected a major malfunction in the engine thatrequires immediate attention. It is the operator’s responsibility to shutdown the engine to avoid serious damage. This lamp is also used toflash out active fault codes in diagnostic mode.

6. Engine Check Light (Amber) - When the 'Check Engine' lightcomes on, the computer has detected a fault in the engine. The faultshould be diagnosed and corrected at the earliest opportunity.In diagnostic mode, the 'Check Engine' light will flash out inactivefault codes.

7. Parking Brake (Green) - Illuminates when the parking brake isapplied.

8. Transmission Check Light (Amber) - Illuminates when thecomputer has detected a fault in the transmission. The fault should bediagnosed and corrected at the earliest opportunity.

9. Emergency Steering (Red) - Illuminates to warn of a fault in thesteering system supply pressure. Illuminates when the ignition isturned on and should go out when the engine starts. If the lightilluminates, stop the machine and investigate the cause.

10. Differential Locks (Amber) - Illuminates when the transmissiondifferential lock is applied.

3-6


VDU - 'Warning Screen'1844

Warning Symbols.Note: Contained on the Warning screen of the VDU, this displays allpossible symbols as shown.

1. Low Fuel - Indicates that the level of fuel in the system should bemonitored and action to rectify this is imminent

2. Transmission oil temperature high - Indicates that thetemperature of the oil in the transmission is at a critical level, beyondthe prescribed operating range for the system and should beinvestigated.

3. Alternator charging - Indicates that the system batteries are in astate of overcharging, undercharging or battery voltage low.

4. Body Up - Indicates that the body has been raised and it is off thechassis bed. Transmission upshift is restricted while the light isilluminated.

5. Engine maintenance monitor - Notifies the operator that it is timeto change the engine oil.

6. Wait to start - Illuminates to indicate to the operator NOT to startthe engine until this light goes out.

7. Transmission retarder - Indicates that the retarder has beenrequested and is active. Will remain till the retarder is deactivated.

8. Engine brake- Indicates that the engine Jake brake has beenrequested and is active. Will remain till the brake is deactivated.(NOT USED AT PRESENT)

1 2 3

4

65

87

Note: On trucks using Ergotraction software, this lamp will illuminatebriefly when accelerating quickly from rest and when the engine brakeis activated. In both cases this identifies that the differential lock isengaging due to the level of torque/brake torque, and is normal.Ergotraction software, where fitted, monitors the torque/speed output tofront and rear drives, and if the difference exceeds design parametersthe TCU sends a signal to apply the differential lock automatically,locking the front and rear outputs and resulting in 1:1 drive.

3-7


Instruments

1843 Instrument Panel

1. Engine Water Temp. gauge - This gauge should read in thegreen zone after the engine has warmed. If the gauge reads in thered zone, stop engine and investigate the cause.

2. Speedometer - The speedometer indicates travel speed inkilometres per hour (displayed grey) and miles per hour, displayed(white). A digital odometer is centred at the base of the speedometer,consiting of a two line LCD. The upper line displays seven digits,which show the total miles travelled. The lower line displays a fourdigit reading which displays the trip mileage. The trip mileage can bereset by pressing the reset button for approximately one second. Thereadings can be used for operating and service records.

3. Tachometer - Driven from the engine ECU, the tachometerindicates the number of engine crankshaft revolutions per minute.The needle shows the variations in engine operating speed. Neveraccelerate the engine to speeds indicated by the red zone on the dialface.

4. Transmission Sump Oil Temperature Gauge - Indicatestransmission sump oil operating temperature. Gauge should read inthe green zone during normal operation. If the gauge reads in the redzone, stop vehicle and investigate the cause.

5. Visual Display Unit (VDU) - Monochrome LCD display. Centredin the instrument panel, this unit is the primary monitor within theinstrument panel. The VDU has a number of multi-level screenswhich can be accessed via the reset button(8). These screen levelshold and display critical systems information based on the inputswhich are received from the various vehicle sensors and monitors.

6. Dimming button - To dim or increase the illumination for theinstruments on the VDU.

7. Not used - (Buttons blanked-off)

PSTOP

1

2

10

10

20

3040

50

60

70

80

km/h

20 30

40mph

50 300 0

5r / min x100

10 20

25

15

4070 100

150105

210250

120 60

140

275 320390

135 165

200

˚C

˚F

˚C

˚F

00000000000

1 48 7 6 5

2 3

3-8


8. Reset Button - Trip counter reset button. When depressed forapprox. one second, this button will initiate a reset of the trip.

'Start-Up' Screen1692a

'Warning' Sceen1844

'Main' Screen1845

The following illustrations show the multi-level display in its threepossible conditions. On initial starting of the vehicle, the VDU willdisplay the screens and scroll through them in the order in which theyare displayed here, assuming the system is in correct working order.

Screen 1- Displays the TEREX logo.

Screen 2- Displays the Warning screen, consisting of warningsymbol graphics which have been pre-programmed into the system.(These are described in the BASIC DATA, warning lights / symbolsection prior to this.)

Screen 3 - Main Screen, this is the default screen which will remainactive at all times, unless another screen has been activated via awarning or is triggered by the operator requesting a screen changeusing the request button. If an active warning is present the VDU willtoggle between Screen 3 and Screen 2. The screens will togglebetween 'Warning' and 'Main' Screen until the Warning lightdisappears.The Main Screen contains information/monitoring of thefollowing vehicle functions-

1. Fuel level - Bargraph monitors fuel level within the tank. Shouldthe fuel level drop below 25% a Warning light (1) on the instrumentdisplay will light. Fill the tank overnight to minimize condensation inthe tank. Avoid a dry tank condition which requires bleeding the fuelsystem.

2. System Voltage - Monitors the potential voltage on the system.Should the level drop to a critical level, indicating a dischargedbattery/fault, a Warning light (3) on the instrument display will light.

3. Transmission Convertor Oil Temperature- Monitors thetransmission convertor oil temperature. The gauge should readbetween 80°C and 120°C during normal operation and may reach140°C when using the retarder or in converter mode. If the gaugereads above this, stop the vehicle and investigate.

4. Retarder - Indicates that the transmission retarder has beenrequested and is active.

1 2 3

4

65

87

Fuel Level

Voltmeter

00000

0

8 12 16 20 24 28 32

25 50 75

50 75 100 125 150

100

Trans Converter Temp

N

1

2

3

756 4

3-9


1846

1845

5. Engine Brake - Indicates that the engine Jake brake has beenrequested and is active. (NOT USED AT PRESENT)

6. Engine Hours Counter - Records the number of hours on theengine.

7. Transmission Gear Selected - Displays the current transmissiongear selected

'Main' Screen

Switches1. Retarder Request Switch - Press the bottom of the switch torequest and engage the transmission retarder, provided thetransmission is in 'lock up'. To disengage the retarder press theswitch to the off position. The retarder symbol will illuminate on theVDU when the retarder is engaged.

Note: When the transmission retarder is requested the engine brakeis deactivated.

2. Engine Brake Request Switch - Press the bottom of the switch torequest and engage the engine brake 'Low'. The engine brakesymbol will illuminate on the VDU when the engine Jake brake isengaged.

3. Engine Diagnostic Switch - To check for active fault codes:a. - turn the ignition key switch to the OFF (0) position.b. - press the diagnostic switch to the 'ON' position.c. - turn the ignition key switch to position ‘1’.

If no active codes are recorded the ‘STOP’ and ‘CHECK’ willilluminate and stay on. If active codes are recorded the ‘STOP’ and‘CHECK’ lights will illuminate momentarily. The amber ‘CHECK’ andred ‘STOP’ lights will begin to flash the code of the recorded fault.Refer to pages 3-26 to 3-27 for details of the fault codes.

Note: If the switch is pressed ‘ON’ during normal operation, the‘STOP’ light will ilumniate. However, this does not indicate an enginemalfunction, and the light will extinguish when the switch is pressed‘OFF’.

4. Engine Diagnostic Scroll Switch - When the engine is indiagnostic mode, this switch is used to search through a list of faultcodes, as follows:

Pressing the top of the switch momentarily will advance to the nextfault code, pressing the bottom of the switch will go back to theprevious code.

5. Engine Brake - Low/High request Switch - Different levels ofengine braking can be attained by using this switch when the enginebrake request switch has been engaged. Pressing the bottom of the

Left of instrument panel

1

2

34

5

6

LO

HI

Fuel Level

Voltmeter

00000

0

8 12 16 20 24 28 32

25 50 75

50 75 100 125 150

100


N

1

2

3

756 4

3-10


1501

switch will engage 'high' braking, pressing the top of the switch willreturn it to the ‘low’ braking setting. The engine brake request switch(2) must be activated, otherwise switch (5) will be inactive.

6. Transmission Differential Lock Request Switch - Press thebottom of the switch to engage the transmission differential lock. Thedifferential lock Warning lamp on the instrument panel will illuminate.Pressing the switch to the Off position will disengage the differentiallock.

7. Hazard Warning Lights - Press the bottom of the switch to makethe indicators flash simultaneously as hazard warning lights. Thedirection indicator Warning lamp on the instrument panel will flash.To switch the hazard lights off; press the top of the switch.

8. Main Lights - Press the bottom of the switch to the first postion tooperate the side, tail and panel lights. The lights in the other switcheswill illuminate. Press the switch to the second position to operate theheadlights. To switch the lights off; press the top of the switch.

9. Front Working Lights - Press the bottom of the switch to operatethe front work lights. To switch off, press the top of the switch.

10. Rear Wash/Wipe - Press the bottom of the switch to operate therear screen wiper. Press the switch again for wash. To switch off;press top of switch.

11. Heated Mirrors - Press the bottom of the switch to activate theheated mirrors. To switch off; press the top of the switch.

12. Rear Working Lights - Press the bottom of the switch to operatethe rear working lights. To switch off; press the top of the switch.

13. Flashing/Rotating Beacon - Press the bottom of the switch tooperate the flashing/rotating beacon. To switch off; press the top ofthe switch.

14. Rear Fog Lamp - Press the bottom of the switch to operate therear fog lamp. To switch off; press the top of the switch.

15. Body Lower Emergency Switch - Press to this switch to lowerthe body in the event of an engine, hydraulic or hydraulic ECU failure.

Note: If an electrical fault occurs which results in the body hoist valvedefaulting to the ‘Hold’ position whilst the body raised, the body canbe lowered under its own weight using the body lower emergencyswitch.

1847

1848Right Bank

Right of instrument panel

15

11 12 13 14

7

89

10

3-11


407 17

191513

1765 18

16. Cross Axle Differential Lock Request Switch - Pressing thefoot switch will activate the cross axle differential lock.

Note: The cross axle differential lock switch is only active when thetransmission differential lock switch is ON.

17. Ignition and Starter Key Switch - The combined switch operatesthe ignition and starter motor.

'0' - Ignition switched off. All electrical systems are inoperative. Thisposition also cuts off fuel to shut down the engine.

'1' - Ignition switched on, instruments, gauges and warning lightsregister as appropriate. All electrical systems are operative. The keymust remain in this position whilst operating the machine.

'2' - Starter motor operates. The key when released will return toposition '1'.

The key can only be withdrawn from position '0'.

1840 16

18. Diagnostic Test Point - (Located at the right hand side of thepassenger seat). This comprises a plug-in connector for engine,transmission and instrument panel/VDU diagnostic equipment.

19. Battery Master Switch - (Located at the left hand side of the truckin the battery box.) Turn the key clockwise to connect the batteries tothe electrical circuits. Switch the key off and remove it when leavingthe machine unattended.

01

2

3-12


Controls

Headlight Dipper, Direction Indicator, Windscreen Wiper/Washerand Horn

1. Headlight Dipper and Flasher:Neutral Position = Dipped BeamControl Rearwards = Headlight FlashControl Rearwardswith main lights on = Main beam

1710 1

1711 2

1712 3

1713 44444

3. Windscreen Wiper/Washer:Position 0 = Neutral PositionPosition 1 = Intermittent SweepPosition 2 = Wiper Slow SpeedPosition 3 = Wiper Fast SpeedSlide grip inward = Windscreen Wash

4. Horn:Button pushed in = Horn Sounds

2. Direction Indicator:Control Downwards = Left IndicatorsControl Upwards = Right Indicators

3-13


HeaterThe blower control (3) is rotated to select one of three blower speeds.Air direction can be adjusted by turning the direction controls (4 and 5).

The temperature control (1) is rotated to vary the heater outputtemperature. Heater output air is unheated with the control turned fullyanticlockwise and heated by turning clockwise.

Heater/air conditioner outlets (6) may be adjusted to control the airflow output by opening and closing the control flaps. Air direction canbe adjusted by rotating the complete outlet.

Air ConditionerKeep all windows and vents closed.

Blower control (3) is rotated to select one of three blower speeds. Theair conditioning will not operate if the blower control is not switchedon. Air direction can be adjusted by turning the direction controls (4 and5).

Turning control (2) to the right switches on the air conditioning. Theair conditioner output temperature can be contolled using thetemperature control (1).

The heater/air conditioner outlets (6) may be adjusted to control theair flow output by opening and closing the control flaps. Air directioncan be adjusted by rotating complete outlet.

Note: When the air conditioning is switched on, the engine coolingfan automatically engages.

1731

12 3

321

17304

5

1856

6 6 6 6

Air Condition Commissioning ProcedureIf the machine has been idle overnight or for an extended period of time, the refrigerant in the airconditioning unit converts from a gas to a liquid. This puts the compressor unit under a great deal ofstrain trying to compress a liquid instead of a gas, and could cause a failure of the air conditioning unit.The following commissioning procedure allows the air conditioning unit to achieve normal operatingparameters.

1. Start the machine and allow it to run until the engine is at a normal operating temperature of 80°C(176°F)2. Turn the blower control to setting 1.3. Turn on the air conditioning unit on for 5 seconds then off for 5 seconds.4. Repeatedly switch the air conditioning on and off for at least 1 minute. This should be at least 12repetitions.5. Commissioning the air conditioning unit is complete and ready for use.

NOTICEFollow the instructions given above, otherwise themachine may be damaged.

3-14


Operator's Seat - Air SuspensionThe air seat only reacts when the driver sits on the seat.When unoccupied, the seat sinks to the lowest positionto allow easier access.

The following is the list of controls to adjust the seat:

1. Height and weight adjustment.

2. Horizontal adjustment (sliderails).

3. Adjustable damper.

4. Seat belt.

5. Backrest angle adjustment.

6. Headrest height adjustment.

7. Fore/Aft isolator (forward position - unlocked,rearmost position - locked).

8. Seat cushion fore/aft adjustment.

9. Seat cushion angle adjustment.

10. Lumber support adjustment.

11. Arm rest adjustment (x2).

Do not attempt to adjust seat or seat belt whilemachine is moving. Loss of control may result.Stop machine; apply brakes; then adjust.

2081

6

9

10

(behind)

115

3

2

41

87

3-15


Operator's Seat - OperationTo achieve the most comfortable driving position, adjust the seat asfollows;

1. Sit in the seat.

2. Pull up and immediately release the height andweight adjustment (1) handle - this will set the seatto cater for the operator’s weight. Sit completely stillwhile carrying out the adjustment . The seat positionis now adjusted correctly to cater for the operator’sweight. Further lifting or pressing down on this leverwill raise or respectively lower the seat, if the heightrequires adjustment.

NOTICEDo not operate the height and weightadjustment lever for a period longer than oneminute, otherwise the inbuilt compressor maybe damaged.

3. Angular adjustment of the base cushion (seatpan) about the horizontal axis is achieved by liftinglever 8 and exerting pressure on front or rear of theseat pan to tilt it to the desired horizontal attitude.Release the handle when the required position isachieved.

4. Pull up the depth adjustment handle (7) tofacilitate movement of the seat forwards orbackwards. Release the handle when the requiredposition is achieved.

5. If adjustment of the armrest angles is desired, thiscan be achieved turning the rotary adjusters (10). Ifthe armrests are not required, they can be folded upout of the way. This is achieved by removing thecaps (11) on each side of the frame, undoing thehexagon nuts thus exposed, and hinging thearmrest upwards. Tighten the nuts and refit the caps(11) on completion.

6. Pull up (or push down) the headrest (6) to therequired height. This can be achieved, byincrements, up to its end stop. The angle of theheadrest (6) can also be adjusted, by pushing orpulling it in the desired direction, and completelyremoved by lifting it off over the end stop.

The cab is for protection of the operatorand adheres to the mandatory standard forRoll Over Protection Structure (ROPS).

A prerequisite for protection is that theoperator remain in the cab, with the seatbelt securely fastened. Should the vehiclebegin to roll, hold on to the steering wheel.

2081

6

9

10

(behind)

115

3

2

41

87

3-16


7. The height and curvature of the backrest cushion can be adjustedbyrotation of the lumber support (9) at the rear of the cushion.

8. Pull up the handle (5) and adjust the backrest to the required angle,release the handle when the required position is achieved.

9. Set the fore/aft isolator (3) position to suit the driving conditions.When active, shock impacts in the driving direction can be morereadily absorbed by the driver’s seat. (Forward position - off, rearmostposition - on.)

10. If necessary carry out fore/aft seat adjustments by first lifting thelever (2), moving the driver to the required position, then lowering thelever again until it locks. It should not be possible to move the driver’sseat in the forward/rearward plane with the lever in its locked position.

11. Engage the seat belt (4).

3-17


Seat BeltRetractable seat belts (1)are installed on both the operator’s seat andthe jump seat. The seat belts require no external adjustment and allowfreedom of movement for proper manipulation of all controls.

Note: To extract the jump seat belt, the button on the housing must bepressed.

Always wear seat belt when operating the machine.

Always check condition of seat belts and mounting hardwarebefore operating the machine.

Any signs of looseness or wear should be reported to yourService Department or Dealer for repair or replacementimmediately.

Replace the seat belt at least once every three years,regardless of appearance.

Stop the machine; apply park brakes; then carry outadjustments.

1

495 Typical Retractable Seat Belt

Trainer / Instructor Seat1656

Trainer / Instructor SeatThe trainer/instructor seat has only to be used when operator trainingor instruction is being performed, or for service personnel performingservice diagnostics.

To access the compartment below the instructor seat, lift the seat (1)and use the strap to hold the seat in position (2). The seat backrest canbe folded down when not in use. Pull the seat release catch, located onthe side of the seat, to unlock the backrest (3). The backrest can nowbe folded down (4).

1 4321972

NOTICEThe Trainer/instructorseat is NOT forcontinuous passenger

NOTICEThe backrest must beunlocked using the releasecatch before attempting tofold it down. Failure to dothis will damage the seat.

3-18


MACHINE CONTROLS

BrakingThe dual circuit brake system is applied during normal operation byusing the Service Brake Pedal or, in an emergency, by using the Park/Emergency Brake Control.

'Front Brake System' warning light and 'Rear Brake System' warninglight are located on the instrument panel. A buzzer will also sound if thebrake pressure is low. If any of these lights illuminate and/or the buzzersounds, stop the machine, apply parking brake and do not operate untilthe fault is corrected.

Service BrakeThis is a cab wall mounted pedal operated by the right foot. Depressthe pedal as required by speed, load and road conditions, to slow orstop the machine. Release the pedal as the machine slows until, whenstopped, the pedal is depressed just enough to hold it stationary. Donot 'FAN' the pedal.

Note: Pedal movement will be experienced when applying or releasingthe Park/Emergency Brake Control when the engine is running.

1716

1715

Park/ Emergency BrakePushing the control in will apply the spring operated driveline mountedparking brake and the service brakes at all wheels. The parking brakewarning light on the instrument panel will illuminate when the control ispushed in. To release the brakes; Turn the control clockwise and putthe transsmission in gear.

Always apply theparking brake beforeleaving the operator'sseat.

NOTICEThe automatic application of the park brake is released when aforward or reverse transmission gear is requested by theoperator. However, the park brake switch overrides the releaseof the automatic park brake control.

3-19


LO

HI

Transmission RetarderThis switch is used to request the transmission retarder. The retarder willengage when the bottom of the switch is pressed, and provided that thetransmission 'Stop' warning light is 'OUT', the transmission is in 'lockup',accelerator pedal is released (off gas) and the transmission oiltemperature is within operating range. To disengage the retarder; pressthe top of the switch or re-apply the accelerator pedal.

The retarder is used to apply a continuous braking force to hold the truckto a safe steady speed when descending gradients, to reduce the needfor service brake applications, thus reducing service brake wear andpreventing overheating. The retarder may be used any time to slow down.If additional braking is required, apply the service brakes. The retarder isnot intended for bringing the machine to a halt, or for sudden deceleration- the service brakes should be employed for this purpose.

Retarder OperationBefore the machine starts down the gradient, request the retarder andrelease the accelerator (off gas). For maximum retardation, oil circulationand cooling, the machine downgrade speed (retarder applied) it isrecommended that the gear should be preselected manually. Themanually pre-selected gear should be high enough to keep the engineoperating at governed speed. Generally the gear used to ascend agrade, fully laden, is also correct for its descent. Please refer to thegradeability decal for recommended gear selection per gradespecification. If the rate of descent is too slow, the transmission should beupshifted to the next highest gear. If the rate of descent is too fast, theservice brakes should be applied and the transmission shifted into alower gear which will allow a safe descent and efficient retarderoperation.

Frequent use of the retarder will result in higher transmission oiltemperatures. Therefore, the converter oil temperature gauge should bechecked frequently. During normal operation the gauge should readbetween 80 oC and 110 oC. However, during converter modetemperatures may reach 120 oC, and during retarder operation the oiltemperature can reach 140 oC.

NOTICEThe transmission 'CHECK' warning light and transmissiontemperature warning symbol on the VDU screen willilluminate when the transmission oil temperature reaches140 °C. The retarder will automatically disengage when theoil temperature reaches 150 °C. The speed must be reducedby using the service brakes so that the oil is cooled down.Reduce downgrade travel speed to avoid the oil overheatingand possible damage to the transmission.

If the vehicle is approaching an overspeed condition, the transmissionupshifts automatically through the gears (to 6th) to decrease the enginespeed, whether in manual or automatic mode.With the accelerator released (off gas) the retarder will then automaticallyapply when the vehicle speed reaches 2150 rev/min and will disengageat 1650rev/min. The service brakes can be applied to reduce travelspeed further.

1849

3-20


LO

HI

12

1850

Engine BrakeThe engine brake is activated by pressing the engine brake requestswitch (1). This will engage ‘low’ engine brake. Should an increasedlevel of braking be desired, pressing the bottom of the engine brakelow/high switch (2) will engage ‘high’ braking effort. Only when theengine brake request switch (1) is pressed and active will the switch(2) for a greater level of braking be operative. Otherwise switch (2)will be inactive. The engine brake applies a continuous braking forceto hold the truck to a safe steady speed when descending gradients,with foot off accelerator pedal (off gas), to reduce the need for servicebrake applications, thus reducing service brake wear and preventingoverheating. The engine brake may be used any time to slow down.To slow the machine even further, apply the service brakes. Theengine brake is not meant for bringing the machine to a halt, or forsudden deceleration - the service brakes should be employed for thispurpose.

OperationBefore the machine starts down the gradient fully laden, it isrecommended that the descent gear be preselected manually (Referto page 3-29). The manually pre-selected gear should be highenough to keep the engine operating at governed speed. Generallythe gear used to ascend a grade, fully laden, is also correct for itsdescent. Please refer to the gradeability decal for recommended gearselection per grade specification. The engine brake can now beselected and the accelerator released (off gas). If the rate ofdescent is too slow, the transmission should be upshifted to the nexthighest gear. If the rate of descent is too fast, the service brakesshould be applied and the transmission shifted into a lower gearwhich will allow a safe descent and efficient engine braking. If furtherbraking is required, apply the service brakes.

1507

WARNING

15333268

% KPH MPH % KPH MPH

0 6 50 31 0 6 50 31

5 5 27 17 5 6 48 30

10 4 15 9 10 5 28 17

15 3 9 6 15 5 22 14

20 2 8 5 20 4 16 10

25 2 6 4 25 3 12 7

30 1 5 3 30 3 11 7





Transmission Retarder (Continued)When the retarder temperature reaches 150 °C the retarder isdisengaged and a fault code will be displayed and recorded by theECU.

A larger scale Gradeability Chart is illustrated overleaf.

If descending a steep gradient in a laden truck in automatic gearshift mode, the transmission E.C.U. may automatically upshift toprevent a vehicle (engine) overspeed condition. Also, if theaccelerator is re-applied when engine brake is actuated and thetruck is in automatic gear shift mode, a rapid acceleration(increase in ground speed) and gear upshift could be incurred

3-21


Engine

Electronic Foot PedalThe electronic foot pedal provides an electrical signal to theengine's fuel control system in proportion to the degree ofpedal actuation.

Note: The engine MUST be started with the foot 'OFF' theelectronic foot pedal.

Do not place the engine under full load at full speedimmediately after starting. Always allow the engine to fullycirculate lubricant and warm up gradually before operating atfull speed and full load. Operate engine at top rated speedwhen maximum power is needed for the load.

QUANTUM Electronic Fuel SystemThis machine is equipped with the Quantum Electronic FuelSystem, an electronic engine control system, whichcontinually monitors the engine and warns the operator whena problem develops. The system also takes action to preventdamage to the engine and, provides the serviceman withdiagnostic capabilities so that problems can be correctedquickly and easily.

1720

NOTICEBefore any welding is done on a machine equipped with theQuantum System, disconnect the following in this order:Battery earth cable, battery supply cable, alternator earth cables,alternator supply cables and electrical connections at the engineECM, transmission ECU, body control lever, hydraulics ECUand cab bulkhead to avoid damage to electrical components.Turn off the battery master switch to isolate the batteries beforedisconnecting any components.

After welding, connect all of the above in the reverse order.

WARNING

15333268

% KPH MPH % KPH MPH

0 6 50 31 0 6 50 31

5 5 27 17 5 6 48 30

10 4 15 9 10 5 28 17

15 3 9 6 15 5 22 14

20 2 8 5 20 4 16 10

25 2 6 4 25 3 12 7

30 1 5 3 30 3 11 7





3-22


QUANTUM Electronic Fuel System - Description

1. Electronic Control Module (ECM) - Receives electronic inputsfrom the driver as well as from sensors that provide informationelectronically, such as oil pressure and temperature and intakemanifold pressure. This information is used to control both thequantity of fuel injected and the injection timing.

2. Programmable Read Only Memory (PROM) - Located in theECM and encoded with the operating software. Additionalinformation is programmed into the EEPROM. This informationcontrols the horsepower rating, torque curve, maximum enginespeed and engine protection devices. The ECM processes thisinformation and sends electronic signals to the Electronic FuelSystem Injectors where the precise amount of fuel is injected into theengine.

3. Electronic Fuel System Injectors - The injector is a lightweight,compact unit that injects diesel fuel directly into the combustionchamber. The amount of fuel injected and the beginning of injectiontiming is determined by the ECM. The ECM sends a command pulsewhich activates the injector solenoid.

1851

1 - Electronic Control Module (ECM)2 - Programmable Read Only Memory (PROM)3 - Quantum Fuel System Injectors

4 - Electronic Foot Pedal5 - 'Stop' Light6 - 'Check' Light

7 - Diagnostic Switches8 - Diagnostic Test Point9 - ‘Maintenance’ Light

LO

HI

PSTOP

1

2

4

3

1,2

8

7

5 6

9

3-23


The injector performs four functions:

a - Creates the high fuel pressure required for efficient injection.b - Meters and injects the exact amount of fuel required to handle theload.c - Atomizes the fuel for mixing with the air in the combustionchamber.d - Permits continuous fuel flow for component cooling.

Electronic fuel system injectors are self compensating and virtuallyeliminate engine tune-ups.

QUANTUM Electronic Fuel System - Operation

NOTICE

When the 'Stop' light on the dash panel illuminates, thecomputer has detected a major malfunction in the engine thatrequires immediate attention. It is the operators responsibilityto shut down the engine to avoid serious damage.

The machine is equipped with an engine protection derate system,which records fault codes and illuminates appropriate warning lightswhen an out-of-range condition associated with any of the followingsensors is found:

• Coolant temperature• Coolant level• Intake manifold temperature• Oil pressure• Oil temperature

The engine power and speed will be gradually reduced depending onthe level of severity of the out-of-range condition. The operator MUSTshut down the engine to avoid serious damage.

The engine should not be restarted after it has been shut down afteractivation of the engine protection derate system unless the problemhas been diagnosed and corrected.

Whenever the 'Stop' or 'Check' light comes on, the Electronic FuelSystem computer will determine where the problem is and will storethis information in its memory. If the malfunction is intermittent, thelights will come on and go off as the computer senses the changingengine condition.

Never apply 12 or 24 volts directly toterminals on the injector or enginesensors as they will burn out. Beforeremoving injectors, the fuel passagesmust be blown out to prevent fuel flowfrom entering the cylinder head.

NOTICE

3-24


The operator of aQuantum-equippedvehicle must notattempt to use or read aDDR of any kind whilethe vehicle is operating.Doing so can result inloss of control, whichmay cause vehicledamage and may resultin personal injury.

When engine orelectronics systemdiagnosis is required ona Quantum-equippedvehicle, this must bedone by a person otherthan the operator. Theoperator must maintaincontrol of the movingvehicle while theassistant performs thediagnosis.

The operator can check for active faults by turning the ignition keyswitch to the 'OFF' position, switching the diagnostic switch 'ON' andthen turning the ignition key switch to position '1'. If no active faultcodes are recorded, both ('Stop' and 'Check') lights will come on andstay on. If active codes are recorded, both lights will come onmomentarily. The amber ('Check') and red ('Stop') lights will begin toflash the code of the recorded fault. The fault codes flash in thefollowing sequence: the amber light flashes once, then there is apause where both lights are off. Then the numbers of the recordedfault code flash in red. There is a pause between each number.When the code is flashed, the amber light flashes again, for examplethe amber flashes once - pause - red flashes twice - pause - redflashes three times - pause - red flashes five times - pause - amberflashes once, indicates fault code 235. The number will repeat in thesame sequence until the system is advanced to the next active faultcode or the diagnostic switch is switched to the 'OFF' position. To goto the next fault code, press top of diagnostic engine scroll switch. Tostep back to the previous code, press bottom of diagnostic enginescroll switch. If only one code is active, the system will continouslydisplay the same fault code. Refer to 'Electronic Fuel SystemDiagnostic Codes' table for fault code descriptions.

LO

HI

1852

2 FLASHES 3 FLASHES 5 FLASHES 1 FLASH1 FLASH

AMBER (CEL)

AMBER (CEL)

RED (SEL)

RED (SEL)

RED (SEL)

PAUSE PAUSE PAUSE PAUSE

CODE 235

1841

A special diagnostic data reader (INSITE) is available that can beplugged into the engine computer memory to extract information relatedto the cause of the problem. Once the malfunction has been corrected,the Electronic Fuel System will return the engine to normal operation. Thedata reader can now distinguish between active codes and those storedin the historic code memory (inactive codes). Inactive codes can only beviewed using the data reader. The fault code recorded in the ECMmemory will remain until it is erased by a technician.

3-25


Maintenance MonitorThe maintenance monitor uses data received from the ECM todetermine the amount of fuel burned and the time the engine hasbeen operating to determine when it is time to change the oil.

Note: Maintenance monitor is designed to alert the operator of theneed for a routine maintenance stop. Maintenance records must stillbe maintained for historical purposes.

Note: Whenever an electrical fault has occurred, the maintenancemonitor data can be inaccurate.

'Severe' oil drain interval duty cycle is the default setting for themaintenance monitor, however this can be adjusted by usingdiagnostic tools, to suit duty cycle and oil type used.

The maintenance monitor warning symbol will illuminate on the VDUscreen when it is active.

Resetting the Maintenance Monitor - There are two ways to resetthe maintenance monitor, depending on the engine ECU calibration.

1. Park the machine on level ground, block the road wheels, apply theparking brake and switch off the engine.

2. Turn the key to position '1'.

3. Press the engine diagnostic switch on for a minimum of 3 seconds,then switch off.

4. Press the engine diagnostic switch on/off quickly, twice (less than 1second per cycle).

5. Press the engine diagnostic switch on for a minimum of 3 seconds,then switch off.

6. The maintenance warning symbol will flash three times. Thismeans the maintenance monitor is reset.


8. Remove blocks from the road wheels.

575

1853

LO

HI

1852

NOTICEIf the maintenance warning symbol doesnot flash as described, the resetsequence must be performed again.

01

3-26


Alternative method of resetting maintenance monitor is as follows:

1. Park the machine on level ground, block the road wheels, apply theparking brake and switch off the engine.

2. Turn the keyswitch to position '1'.

3. Press the engine diagnostic switch on.

4. Press and hold the throttle pedal at 100% for three seconds, thenrelease it.

5. Press the throttle pedal 100% On then Off quickly, twice.

6. Press and hold the throttle pedal at 100% for three seconds, thenrelease.

7. The maintenance Warning symbol will flash three times.

8. Press the engine diagnostic switch off.


10. Remove blocks from the road wheels.

575

1541

1853

LO

HI

1852

NOTICE

If the maintenance warning symbol doesnot flash as described, the resetsequence must be performed again.

01

3-27


ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODESError Code Description Fault Lamp

111 ECM Hardware Internal Failure - Mission disabling Red115 Engine Speed Sensor - Both signals lost Red121 Engine Speed Sensor - One signal lost Amber122 Boost Pressure Sensor - Component shorted high Amber123 Boost Pressure Sensor - Component shorted low Amber131 Throttle Position Sensor - Component shorted high Red132 Throttle Position Sensor - Component shorted low Red133 Remote Accelerator Pedal Position Sensor- Circuit shorted high Red134 Remote Accelerator Pedal Position Sensor- Circuit shorted low Red135 Oil Pressure Sensor - Component shorted high Amber141 Oil Pressure Sensor - Component shorted low Amber143 Oil Pressure Sensor - Data below normal range Amber144 Engine Coolant Temperature Sensor - Component shorted high Amber145 Engine Coolant Temperature Sensor - Component shorted low Amber147 Throttle Position Sensor - Circuit low frequency Red148 Throttle Position Sensor - Circuit high frequency Red151 Engine Coolant Temperature Sensor - Data above normal range Amber153 Intake Manifold Temperature Sensor - Component shorted high Amber154 Intake Manifold Temperature Sensor - Component shorted low Amber155 Intake Manifold Temperature Sensor - Data above normal range Amber187 Sensor Supply Voltage #2 - Circuit shorted low Amber211 Additional OEM/Vehicle Diagnostic Codes have been logged None212 Oil Temperature Sensor - Component shorted high Amber213 Oil Temperature Sensor - Component shorted low Amber214 Oil Temperature - Data above normal range Red219 Low Oil Level in Make up tank Maint.221 Ambient Air Pressure Sensor - Component shorted high Amber222 Ambient Air Pressure Sensor - Component shorted low Amber223 Engine Oil Burn Valve Solenoid - Circuit shorted low Amber227 Sensor Supply Voltage #2 - Circuit shorted high Amber234 Engine Speed - Data above normal range Red235 Engine Coolant Level - Data below normal range Amber237 External Speed Input (Multiple Unit Sychronization) - Data incorrect Amber241 Vehicle Speed Sensor Circuit - Data incorrect Amber242 Vehicle Speed Sensor Circuit - Tampering has been detected Amber245 Fan Clutch - Circuit shorted low Amber254 Fuel Shutoff Value - Component shorted low Red255 Fuel Shutoff Value - Component shorted high Amber285 SAE J1939 Multiplexing PGN timeout error Amber286 SAE J1939 Multiplexing configuration error Amber287 SAE J1939 Multiplexing accelerator pedal sensor system error Red288 SAE J1939 Multipexing Remote throttle data error Red293 Auxiliary Temperature Sensor Input #1 - Circuit shorted high Amber294 Auxiliary Temperature Sensor Input #1 - Circuit shorted low Amber295 Ambient Air Pressure Sensor - Circuit data incorrect Amber297 Auxiliary Pressure Sensor Input #2 - Circuit shorted high Amber298 Auxiliary Pressure Sensor Input #2 - Circuit shorted low Amber299 Engine Shutdown - Commanded by J1939 Amber311 Injector Solenoid Valve Cylinder #1 Circuit - Grounded circuit Amber312 Injector Solenoid Valve Cylinder #5 Circuit - Grounded circuit Amber313 Injector Solenoid Valve Cylinder #3 Circuit - Grounded circuit Amber314 Injector Solenoid Valve Cylinder #6 Circuit - Grounded circuit Amber315 Injector Solenoid Valve Cylinder #2 Circuit - Grounded circuit Amber319 Real Time Clock - Power interrupt Maint321 Injector Solenoid Valve Cylinder #4 Circuit - Grounded circuit Amber322 Injector Solenoid Valve Cylinder #1 Circuit - Open circuit Amber323 Injector Solenoid Valve Cylinder #5 Circuit - Open circuit Amber324 Injector Solenoid Valve Cylinder #3 Circuit - Open circuit Amber325 Injector Solenoid Valve Cylinder #6 Circuit - Open circuit Amber331 Injector Solenoid Valve Cylinder #2 Circuit - Open circuit Amber332 Injector Solenoid Valve Cylinder #4 Circuit - Open circuit Amber341 ECM - Data lost Amber343 ECM - Warning internal hardware failure Amber346 ECM - Warning software error Amber349 Transmission Output Shaft Speed High - Warning Amber352 Sensor Supply Voltage #1 - Circuit shorted low Amber381 Error detected in intake air heater relay circuit Amber386 Sensor Supply Voltage #1 - Circuit shorted high Amber387 Accelerator Pedal Position Sensor Supply Voltage - Circuit shorted high Amber388 Less than 6 VDC detected at engine brake circuit 1 Amber392 Less than 6 VDC detected at engine brake circuit 2 Amber

3-28


412 Data transmission error on J1587/J1922 datalink None414 Data transmission error on J1587/J1922 datalink None415 Oil Pressure Sensor - Data indicates very low oil pressure Red418 Water in Fuel Indicator High Maint419 Error in intake manifold pressure sensor signal detected by ECM Amber422 Engine Coolant Level Sensor Signals - Data invalid Amber426 SAE J1939 datalink - cannot transmit None427 Data transmission on J1939 datalink not occuring at an acceptable rate None428 Water in Fuel Sensor - Circuit shorted high Amber429 Water in Fuel Sensor - Circuit shorted low Amber431 Accelerator Pedal Idle Validation Circuit - Data incorrect Amber432 Accelerator Pedal Idle Validation Circuit - Out of calibration Red433 Intake Manifold Pressure Sensor - Circuit data incorrect Amber434 Power Lost without ignition off Amber435 Engine Oil Pressure Sensor - Circuit data incorrect Amber441 Battery Voltage Low - Warning Amber442 Battery Voltage High - Warning Amber443 Accelerator Pedal Position Sensor Supply Voltage - Circuit shorted low Amber465 High voltage detected at wastegate actuator No. 1 circuit Amber466 Less than 6 VDC detected at wastegate actuator No. 1 circuit Amber489 Transmission Output Shaft Speed Low - Warning Amber491 High voltage detected at wastegate actuator No. 2 circuit Amber492 Less than 6 VDC detected at actuator No. 2 circuit Amber497 Error detected in multiple unit synch control sw. input pins 34 & 32 of OEM harness Amber527 Auxiliary Input/Output #2 - Circuit shorted high Amber528 OEM Alternate Torque Validation Switch - Data incorrect Amber529 Auxiliary Input/Output #3 - Circuit shorted high Amber551 Accelerator Pedal Idle Validation - Circuit shorted low Amber581 Fuel Supply Pump Inlet Pressure Sensor - Circuit shorted high Amber582 Fuel Supply Pump Inlet Pressure Sensor - Circuit shorted low Amber583 Fuel Supply Pump Inlet Pressure Low - Warning level Amber596 Electrical Charging System Voltage High - Warning level Amber597 Electrical Charging System Voltage Low - Warning level Amber598 Electrical Charging System Voltage Low - Critical level Red611 Engine Hot Shutdown None951 Cylinder Power Imbalance between cylinders None

ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODESError Code Description Fault Lamp

3-29


EST-37 Automatic Shift Transmission

The EST-37 transmission is equipped with an electronic control unit(ECU) which continually monitors the transmission and shift systemelectrical components and warns the operator when a problemdevelops. It also takes action to prevent damage to the transmission,and provides the serviceman with diagnostic capabilities so thatproblems can be corrected quickly and easily.

When a fault occurs, a two digit error code will be displayed on theLCD display on the dash panel. The error code is also recorded inthe transmission ECU, and can be accessed by the serviceman byplugging in a data reader to extract information relating to the fault.The error code recorded in the ECU memory will remain until it iserased by a technician.

If a major fault is detected, it is the operator’s responsibility to shutdown the machine as soon as it is safe to do so. The machine shouldnot be restarted until the fault has been diagnosed and corrected.

Refer to 'Description of Fault Codes Ergocontrol' table for a list offault codes and checks on page 3-32.

The EST-37 transmission control has been designed to provide thedriver with maximum operational flexibility, by allowing the choice ofautomatic or manual gear selection to optimize vehicle performanceunder all operating conditions.

The transmission provides six forward gears, three reverse gearsand a neutral position. The gear positions are indicated on the VDUscreen and on the LCD display located to the right of the operator onthe dash panel beside the gearshift controller (refer to page 3-32 fordetails). When the lever is in the automatic range, shifts will occurautomatically between 1st and 6th gear, depending on operatingrequirements. The reverse gears 1st through 3rd are manual modeonly.

Note: When in manual mode, if the engine speed drops below thelock up disengaging speed, the transmission will automaticallydownshift to the next lowest gear. A manual upshift will only beaccepted if the transmission is in lock up.

Note: To perform a stall test, manual upshifts can be selected withoutlock up being engaged by special activation of the auto/manualbutton on the gearshift controller. Described on page 3-29.

Before any welding isdone on a machineequipped with an EST-37shift system, disconnectthe following in thisorder: battery earth cable,battery supply cable,alternator earth cables,alternator supply cablesand electricalconnections at the engineECM, transmission ECU,hydraulic ECU, VDU ECUand cab bulkhead toavoid damage to electricalcomponents. Turn off thebattery master switch toisolate the bateries beforedisconnecting anycomponents.

After welding connect allof the above in reverseorder.

NOTICE

3-30


N

VTS-3 Shift Controller

The shift controller has 3 positions the lever can rest in, Forward,Neutral (N) and Reverse.

The shift controller has a 'Function' button on the top of the leverwhich is used to switch between automatic and manual modes.Press the function button in 'NEUTRAL', then move the lever forwardto select automatic mode, when driving normal upshifting anddownshifting will occur. If required, a gear can be held in manualmode by pressing the function button once, to resume full automaticmode the function button should be pressed again. Manual gearscan also be selected by pushing the lever to the left for lower gearsor to the right for higher gears, again by pressing the function buttononce automatic mode will be resumed.

Note: A manual upshift will only be accepted if the speed is highenough to maintain lock up. In manual mode, if transmission entersconverter mode it will downshift automatically to prevent overheatingfrom operating in converter mode.

Note: The transmission will only allow gearshifting when thepredetermined values have been reached.

Note: There is no shift inhibitor in the gear shift control, therefore, noresistance would be felt while moving through the gear ranges.

When performing a stall test a certain procedure has to carried out toallow selection of 6th gear with the truck at standstill. The procedureis as follows:

1. Press the function button in neutral and move the gear leverforward to select automatic mode.

2. Press function button 5 times within 4 seconds.

3. Manually select gear by pushing the lever to the right.

The gear lever housing sends a signal to the electronic control unit,which in turn will only allow the engine to be started when the gearlever is in the 'NEUTRAL' position. The gear shift lever must alwaysbe placed in 'NEUTRAL' and the parking brake applied when startingthe engine, or whenever the machine is left unattended.

When shifting from 'NEUTRAL' to start from a standstill, or to reversedirection, decelerate the engine to idle speed before selecting theproper gear. When 'REVERSE' is selected, the 'Reverse Alarm'sounds and the 'Reverse Light' illuminates to warn personnel to therear of the machine that reverse gear has been selected.

During reversing operations it is recommended to reduce the enginespeed. Use only 1st or 2nd gear and never exceed 10 km/h (6.2 mile/h).

The electronic control system distinguishes between the throttleposition (or load ranges) depending on the governor position(injection pump). On a light throttle opening, the transmission willgive earlier upshifts and later downshifts than when operating at fullthrottle.

Do not allow the vehicle tocoast in Neutral. Thispractice can result insevere transmissiondamage.

1173

NOTICE

3-31


Always select Neutral andapply the parking brakebefore leaving theoperators' seat.

A kickdown facility, which can be used when automatic mode isselected, allows for the possibility of selecting a lower gear by pressingdown fully on the throttle pedal and holding. This can be used to providea downshift on demand provided that the vehicle speed is within therange allowable. That is, the vehicle is not travelling at a speed thatwould result in the engine overspeeding in the lower gear. When drivingwith kickdown, the transmission will give earlier downshifts and laterupshifts. To disengage the transmission kickdown, release the throttlepedal and allow it to return to a light throttle position.

When operating in automatic range with the display indicating that thetransmission has downshifted to 2nd gear, there are two options forproviding a further downshift as conditions indicate.

1. 1st gear can be manually selected by pushing the shift lever to theleft.

2. Kickdown can be selected from 2nd automatic, when thetransmission will downshift to 1st gear, depending upon the vehiclespeed.

When the kickdown is released, the transmission will upshift to 2nd

automatic, provided that the forward speed has increased sufficientlyto allow this to happen, and that the shift lever is in the automaticmode.

A dashboard display is provided which indicates gear selected anddriving direction as follows:

Manual Mode - When driving with shift selector in manual range, thebars only are shown in position 1, and, driving direction and gearselected are indicated in positions 2 and 3.

Automatic Mode - When driving with shift selector in automaticrange, a full display of bars and arrows are shown in position 1, and,driving direction and gear selected are indicated in positions 2 and 3.

Under certain conditions, the transmission may start to 'hunt' betweengears when in automatic mode. The transmission changes up anddown between two gears at short intervals because there is notsufficient power to sustain driving in the higher gear, but is sufficientfor upshifting from the lower gear. By using the shift display, it can beestablished which gears are involved and in these circumstances thelower gear should be selected using the shift control lever. Automaticmode should be reselected at the earliest opportunity.

During machine operation, watch for wide deviations from normalreadings on the transmission oil temperature gauge. If the gaugeshows the oil temperature rising above 120 °C during normaloperation, or above 145 °C during retarder operation, the machinemust be stopped and inspected for external oil leakage. If no leaksare found, shift to 'NEUTRAL' and operate the engine at 1200 - 1500rev/min. If the transmission oil temperature does not decrease into thenormal range within 2 or 3 minutes, the cause of the overheatingshould be corrected before the machine is operated further.

Note: In cold weather, the transmission oil should be warmed up by

STOP

1 2 3

1 - Bars show gear ranges and full display (as'shown) indicates driving in automatic mode.

2 - Display shows actual gear in use.

3 - Display shows actual driving direction.

612

1509

IDLE

FULL LOAD/THROTTLE

KICK/HOLD DOWN

1855

3-32


Do not attempt to adjust the steering wheel while the machineis moving. Loss of control may result. Stop the machine;apply park brake; then carry out adjustments.

Always select the correct drive direction and gear beforereleasing the parking brake.

Never allow the machine to coast with the transmission in'NEUTRAL'.

When running down a gradient the engine speed should notbe allowed to drop below 1200 rev/min, at which point lockupwould disengage preventing retarder operation.

In the event of a loss of electric power to the gear shiftcontrol, the transmission will automatically shift to'NEUTRAL'. If this occurs, stop the machine using servicebrakes.The Park brakes will be applied automatically whenthe speed reduces to below 1m/h. Do not operate the vechicleuntil the fault is corrected.Apply Park brake switch beforeleaving the vehicle.

Always select ‘NEUTRAL’ before leaving operator seat

The retarder will automatically disengage when the oiltemperature reaches 150 °C (302 °F), irrespective of enginespeed.

running the engine at idle speed with the gear selector in neutral, sincethe system will not operate satisfactorily if the oil is too cold.

When the vehicle is stopped, such as for yielding the right of way to aloaded machine, the transmission can be left in the selected range andthe machine held stationary with the service brakes.

When the vehicle is stopped for extended period with the engine leftrunning, shift the transmission to Neutral so that the parking brake isautomatically applied, and to avoid unnecesary heat buildup.

3-33


DESCRIPTION OF FAULT CODES ERGOCONTROLCode Operator Action Mode Meaning Service Action1 1 Stop and investigate Range signal: abnormal Electrical problem on ECU input Check cables from gear1 2 Direction signal: no operation from gear selector selector to ECU

1 A

1 B

1 C

1 D

1 E

1 F

2 3 Drive truck to Normal Electrical problem on analog ECU Check cables to load sensor/2 4 next service input temp. sensors, check setting2 5 of load sensor2 62 72 8

3 1 Drive truck to Substitute mode (controlled Electrical problem on speed sensors Check cables and setting of3 2 next service pressure ramps, converter sensors3 3 lockup clutch disengages3 4 during gear shifts)3 53 63 73 83 93 A3 B3 C3 E

5 6 Drive truck to Substitute mode (controlled Electrical problem on CANBUS Check cables to engine ECU5 7 next service pressure ramps, converter5 8 lockup clutch disengages

during gear shifts)

6 5 Drive truck to Substitute mode (controlled Electrical problem on CANBUS Check cables to engine ECU6 6 next service pressure ramps, converter6 9 lockup clutch disengages6 A during gear shifts)6 B6 E Drive truck to Normal Electrical problem on CANBUS Check cables to engine ECU6 F next service

7 1 Stop and investigate Limp home Electrical problem on transmission Check cables to transmission7 2 solenoids control valve7 37 47 57 67 77 87 9

8 1 Stop and investigate Limp home Electrical problem on transmission Check cables to transmission8 2 solenoids control valve8 38 48 58 68 78 88 9

9 1 Drive truck to No converter lockup clutch, Electrical problem on peripheral Check cables to converter9 2 next service difflock, retarder solenoids. lockup clutch,difflock,retarder9 39 A9 B9 C9 D9 E9 F

3-34


DESCRIPTION OF FAULT CODES ERGOCONTROLCode Operator Action Mode Meaning Service ActionA 1 Drive truck to No converter lockup clutch, Electrical problem on peripheral Check cables to converterA 2 next service difflock, retarder solenoids. lockup clutch, difflock,A 3 retarderA 4A 5A 6

B 1 Stop and investigate Limp home Mechanical or hydraulic problem in Check transmission pressure,B 2 clutches or faulty speed reading speedB 3B 4B 5B 6B 7B 8B 9B AB BB DB EB F

C 3 Stop and investigate Normal - No reaction High oil temperature at T.C. Allow truck to cool. Check oillevel and temperature sensor

D 1 Stop No operation Electrical problem on power supply Check fuses/cables of powerD 2 supplyD 3D 4D 5D 6

E 3 Drive truck Normal Electrical problem at display Check cables to displayE 4

F 1 Stop F1-F5: No operation General fault (F6) Start AEB, else replaceF 3 ECUF 5F 6

Abbreviations: ECU = Electronic Control Unit T.C. = Torque ConverterAEB = Self Calibration Clutches

Operator Warning Codes Code Meaning Action

A F Parking Brake Off Relay coil ground is open circuit Park brake and service brake will apply automatically.(Refer to Fault codes in Maintenance Manual)

W E Will show when engine speed is above 2500 rev/min. Reduce engine speed, apply brakes / retarder

L R Limp home in reverse Shows as a consequence having a ‘B’ code. See above

L F Limp home in forward Shows as a consequence having a ‘7’, ‘8’ or ‘B’ code. See above

W S Warning sump High oil temperature in sump. Reduce engine power and speed

W R Warning retarder temperature Reduce vehicle speed, apply brakes

W T Warning torque converter temperature High oil temperature at T.C. Reduce engine power and speed

N N Selector not in neutral position when switched on Code clears by moving selector to neutral

E E ECU heavily damaged or program faulty No drive, system completely disabled

Note: Operator Warning Codes give pre-warning indication of a potential fault

3-35


LO

HI

Differential LockThe differential lock switch (1) engages the differential lock in thetransmission, for improved traction when operating in soft or slipperyconditions. The amber 'differential lock' warning light on theinstrument panel will illuminate when the transmission differentiallock is requested.

For more extreme conditions the axle differential lock footswitch (2)engages the cross axle differential locks fitted to each axle.

Note: The axle differential lock footswitch (2) is only active when thetransmission differential lock switch (1) is pressed ‘ON’.

To apply the differential locks, slow the machine with the servicebrakes and operate the differential lock switch(s). Stop the machineand disengage the differential locks as soon as conditions allow.

Note: It should only be necessary to engage the differential locks inextreme conditions.

Note: On trucks using Ergotraction software, the differential lock lampwill illuminate briefly whenaccelerating quickly from rest and whenthe engine brake is activated. In both cases this identifies that thedifferential lock is engaging due to the level of torque/brake torque,and is normal. Ergotraction software, where fitted, monitors thetorque/speed output to front and rear drives, and if the differenceexceeds design parameters the TCU sends a signal to apply thedifferential lock automatically, locking the front and rear outputs andresulting in 1:1 drive.

1839

1840 22222

11111

NOTICEBefore driving in soft or slipperyconditions, stop and engagedifferential locks. Spinning wheelscan result in damage to thedropbox and axle differentials.

NOTICEDisengage differential locks whendriving on firm ground.

3-36


NOTICEBefore any welding isdone on a machineequipped with a TOC8hydraulic system,disconnect the followingin this order: batteryearth cable, batterysupply cable, alternatorearth cables, alternatorsupply cables andelectrical connections atthe engine ECM,transmission ECU, bodycontrol lever, hydraulicsECU and cab bulkheadto avoid damage toelectrical components.Turn off battery masterswitch to isolate thebatteries beforedisconnecting anycomponents.

After welding connect allof the above in thereverse order.

Hydraulic ControlsThe braking, steering, body control and transmission oil cooler areall contolled by the main hydraulic valve, which is mounted on thechassis. However, the body control and transmission oil cooler areelectronically monitored by the TOC8 ECU mounted in the cab underthe passenger seat. The ECU warns the operator when a problemdevelops, and helps to diagnose errors.

There are two LEDs on the ECU. The top LED when green indicatespower on, and the bottom LED flashes either red or yellowdepending on status. If there are no errors, the bottom LED flashesyellow to indicate normal status. If LED flashes red, this indicates anerror has occurred. The rate of flashing gives an immediatediagnosis as to the nature of the error. Further information can beobtained from the TOC8 ECU by plugging in a diagnostic datareader to the RS232 diagnostic test point.

1854

1552

Error Errorcode1 Output errors

2 Input errors

3 VREF error

4 Supply voltageerror

5 Temp critical orchecksum error

6 Fatal softwareerror

Flash (red light)

Status

Normal (no errors)

Flash (yellow light)

3-37


SteeringThe steering wheel position can be adjusted as required for the mostconvenient operating position. To adjust, pull out adjustment lock andtilt steering wheel up or down as desired. Release the lever to lockthe adjustment.

To steer the machine, rotate the steering wheel in the desireddirection to the required radius of turn. The machine will turn only asthe steering wheel is turned and at a rate of turning directlyproportional to steering wheel speed. The machine will stop and holdposition when the steering wheel is stopped. To return the machine tothe straight ahead position or to the opposite direction, turn thesteering wheel in the opposite direction.

1724

1725

Do not attempt to adjust the steering wheelwhile the machine is moving. Loss of controlmay result. Stop the machine; apply parkbrake; then carry out adjustments.

3-38


Body ControlThis lever operates the body hoist cylinders. The three operatingpositions of the lever are -

Raise - Pulling the lever back and holding in this position will raisethe body. When released, the lever will spring back to the 'neutral'position.

Neutral - If the body is above the body proximity switch, the lever inthis position will stop and hold the body at any desired height. If thebody is below the proximity switch, the ECU defaults the mainhydraulic valve to the float position. The body should be fully loweredand in the 'neutral' position while the machine is in motion. The leverwill remain in the 'neutral' position when released.

Power Down - Pushing the lever forward provides hydraulic force topower down the body. Pushing the lever fully forward will engage theelectric detent. When the body reaches the proximity switch, the leversprings back to the 'neutral' position and power down is ramped backto allow a smooth transition to the float position.

Note: In the event of an engine, hydraulic or hydraulic ECU failure thebody can be lowered using the body lower emergency switch in thecab. If hydraulic AND electrical power is lost, the body can be loweredusing an emergency procedure detailed in the Maintenance Manual,Section 230-0000, Body System Schematic.

1675

1512

NOTICEThe body must remain lowered with lever in the 'neutral'position until it is necessary to operate the body again. Failureto comply to this could result in overheating the hydraulic oiland failure of the hydraulic system components.

NOTICEIn the event of an engine, hydraulic or hydraulic ECU failure thebody can be lowered using the body lower emergency switch inthe cab. If hydraulic AND electrical power is lost, the body canbe lowered using an emergency procedure detailed in theMaintenance Manual, Section 230-0000, Body SystemSchematic.

3-39


Tilting CabThe operators cab can be tilted to improve accessibility tocomponents below, by using hydraulic hand pump (1) housed insidethe battery box.

To tilt the cab, remove the 4 cab mounting bolts on the left hand side.Using the lever in the hand pump, charge hydraulic cylinder until thecab is fully tilted and hold in place with cab prop (2)and install cabprop retaining pin (3).

To lower the cab, ensure the weight of cab is off the safety prop,remove cab prop and slowly open valve on hand pump to gentlylower cab until holes in cab line up with holes in mounts. Reinstall the4 cab mounting bolts.

2176

2177

2178

Do not work under or near an unblockedor unsupported raised operator’s cab.Always use the operator’s cab safety propwith the locking pin.

2

1

2

3

3-40



4-1

Operating the Truck

4 - Operating the Truck

4-2

Operating the Truck


4-3

Operating the Truck

3. Radiator Header Tank - Check coolant level when cold.

SCALDING HAZARDPartially unscrew cap to slowly release pressure beforeremoving cap completely. Fill to bottom of filler neck.

Checks described in the drawing opposite and on the followingpages.

Component Checks1. Engine - With engine off, check oil level. The level should bebetween the two marks on the dipstick. Up to the upper mark ispreferable. Add oil if low.

OPERATING THE TRUCKPre-Starting Inspection* Make sure all safety signs are free of

damage, and are fullyreadable,replace as necessary.

* Before the engine is started ensurethe machine is ready for operation.

* The machine should be in a levelposition to permit accurate checkingof fluid quantities in the engine andother components.

* Make sure parking brake is set andblock wheels if necessary to preventaccidental movement of the machinewhile checking component levels.

* Test all lights and horn for properoperation.

* Walk around the machine and carryout the Inspections and Component 1517

1554 1

2037

1375 3

2. Fuel Filter/Water Separator - Drain sediment and water until fuelruns clear.

ENGINECheck oil level.Check for leaks

RADIATOR HEADER TANKCheck coolant level.Check for leaks.

WHEEL PLANETARIESCheck for leaks.

WHEEL PLANETARIESCheck for leaks.

DIFFERENTIALCheck for leaks.

STEERING CYLINDERSCheck for debris, leaksand damage. Check hoses for wear and leaks.

FRONT SUSPENSIONCheck for debrisand damage.

OPERATORS COMPARTMENTAND STEPSCheck for cleanliness.Check seat belts.

SHOCK ABSORBERSCheck for debris, leaks anddamage.

WHEELS AND TYRESCheck condition, inflation, wheel nuts and for damaged rims.

WHEELS AND TYRESCheck condition, inflation, wheel nuts and for damaged rims.

TRANSMISSIONCheck oil level.Check for leaks.Check indicator.

HYDRAULIC TANKCheck oil level.Check for leaks.

BODY CYLINDERSCheck for debris, leaksand damage. Check hosesfor wear and leaks.

INTERLEAF MOUNTINGSCheck for damage.

SUSPENSION LINKSCheck for damage.

DIFFERENTIALCheck for leaks.

HAND PUMPCheck oil level.

FUEL FILTER/WATERSEPARATORDrain sediment and water.

AIR CLEANER DUST VALVECheck for plugged dust cap.

ACCUMULATORSCheck for leaks.

NOTICEIn subfreezing temperatures,be sure that the coolantcontainssufficient antifreeze.

FS1212

4-4

Operating the Truck

NOTICEIn subfreezing temperatures,be sure that the coolantcontainssufficient antifreeze.

4. Engine Air Cleaner Dust Valve - Check for plugged dust cap valve.Unplug valve and clean air cleaner dust cup if required. 1519 4

51572

1521 6a

1522 6b

041 7

5. Transmission - Cold Oil Level - Engine Off- This check is madeonly to determine if the transmission contains sufficient oil for safestarting. Make sure oil level is well above the upper mark on thedipstick. Add oil if low.

6. Hydraulic Tank - Oil Level Check - Operate the body hoistcylinders to their fully-extended positions to charge cylinders and linesthen lower the body. With the engine off, oil should show in the sightgauge (6a). Add oil, if low, through tank filler cap (6b). Check the filterrestriction indicator/gauge, with the oil at operating temperature. If theneedle is in the green section of the gauge, the filter condition isacceptable. If the needle is in the red section, the differential pressureacross the filter has exceeded 1.2 bar and the filter element must berenewed. It is not unusual for the gauge needle to be in the red sectionwhen the oil is cold, which is acceptable, and therefore only performthis check when the oil is at operating temperature.

7. Tyres - Carefully inspect all tyres for cuts, bruises, or otherdamage, and, proper inflation for the loads to be carried. Inflate alltyres to the recommended pressure while cold.

COLD FILL LEVELMINIMUM -

ENGINE OFF

HOTLEVELBAND -

ENGINE RUNNINGCOLD FILL

LEVELMINIMUM -

ENGINERUNNING

MAX

152mm(6") Min

MIN

4-5

Operating the Truck

1857 8

1754 9

8. Check fuel level gauge - Fuel tank should be filled at end of eachshift.

9. Seat and Seat Belts - Adjust the seat position as required, to allowcomplete machine control at all times with minimum fatigue. Makesure the seat belt does not restrict movement for proper machineoperation.

Fuel Level

Voltmeter

0

8 12 16 20 24 28 32

25 50 75

50 75 100 125 150

100


4-6

Operating the Truck

Engine Operation

Never start the engine indoors unless proper exhaustventilation is provided to remove deadly exhaust gases. Oncethe engine is running, move the machine outdoors as soonas possible. Exhaust gases are hazardous and can causeunconsciousness and death.

NOTICEDo not place engine under FULL LOAD at FULL SPEEDIMMEDIATELY after starting. ALWAYS allow the engine to fullycirculate lubricant and warm up gradually before operating at fullspeed and full load.Operate engine at top rated speed when maximum power isneeded for the load. Operation of the engine below top ratedspeed can occur during gear shifting due to the difference ofratios between transmission gears, but engine operation MUSTNOT be sustained more than 30 seconds at full throttle below toprated speed.NEVER idle the engine for more than 5 minutes at a time; shut itoff.

If any gauge operates outwith its normal operating range, or awarning light illuminates, shut engine down immediately andreport to service or maintenance personnel.

NOTICEOperating the engine beyond high idle speed can cause severeengine damage. The engine speed must not exceed 2300 rev/min under any circumstances. When descending a steepgrade, use a combination of transmission gears, retarder,engine brake and service brakes to control the vehicle andengine speed.

4-7

Operating the Truck

Starting the EngineAttention to the warning lights and instruments when starting theengine, and operating, will help the operator monitor the machinesystems and components.

1. Make sure park-emergency brake lever is in 'PARK' position. (Button pushed ‘In’)

1715 1

1524 2

1713 5

1525 3

1526 4

6575

2. Turn master switch, located inside panel on battery box, to 'ON'position.

3. Make sure the body control lever is in the 'NEUTRAL' position.

4. Make sure the transmission gear shift control is in the 'NEUTRAL'position.

N

5. Press horn control to sound horn.

Always sound horn before starting engine operating anycontrol.

6. Insert switch key and turn clockwise to position '1' to switch on theignition.

01

4-8

Operating the Truck

7407

1738 8

PSTOP

1

2

1 2

8. The amber 'Check Engine' (2) and red 'Stop Engine' (1) lights shouldcome on, and then go out after 6 - 10 seconds. If the amber 'CheckEngine' light does not go out, have the system checked out as soon aspossible. If the red 'Stop Engine' light does not go out after 6 - 10seconds, or illuminates during operation, stop the engine immediately.

7. Turn key farther clockwise against spring pressure to position '2' tocrank engine; release key as soon as engine starts firing.

Never crank the engine more than 30 seconds continuosly.Allow starter at least 2 minutes cooling time between longcranking periods to avoid overheating.

01

2

4-9

Operating the Truck

Starting the Engine with Jumper Cables

Batteries contain sulfuric acid and can emit hydrogen gas.Check for required voltage and polarity connections todischarged batteries.

Excessive booster voltage and/or incorrect jumper cableconnections, open flames, lighted cigars, or other ignitionsources can cause battery explosion/fire. Do not lean overbatteries, and always wear safety glasses, face shield, safetygloves, and any other appropriate safety equipment whenworking with or near battery.

Do not jump start a vehicle by using arc welding equipment.Currents and voltages are dangerously high and cannot besufficiently reduced to make the method safe.

Be sure machines are not touching each other. Use cablesthat are equal to cable size on the machine. Booster batteryshould be the same specification as discharged battery.

If jumper cables are used to start an engine, be sure to follow thisprocedure:

Connect one end of a jumper cable, usually coloured red, to thedischarged battery 'POSITIVE' (+) post. Connect the other end of thesame cable to the 'POSITIVE' (+) post on the booster or chargedbattery.

Connect one end of the second cable, usually coloured black, to the'NEGATIVE' (-) post of the booster battery. Connect the other end of the'NEGATIVE' (-) cable to machine frame for grounding so that if a sparkoccurs, it is away from battery fumes (explosive hydrogen).

Check for cause of failure on the dead battery.

4-10

Operating the Truck

1520 1

1572 1b

1790

Pre-Operating ChecksMake sure all cab glass, mirrors and lights are clean. Test all controlsto ensure they are functioning properly. Move transmission gear shiftcontrol momentarily to 'REVERSE' to make sure the reverse alarmsounds.

1. Transmission - Hot Oil Level - The parking brake must be appliedand the machines wheels securely blocked while carrying out thischeck. With the engine idling, transmission in 'NEUTRAL' and atnormal operating temperature 80° C (176° F), the oil level should beup to, but not over, the upper mark on the dipstick. Add oil if low.

2. Mirrors - Ensure mirrors are positioned correctly to maximisevisibility.

COLD FILL LEVELMINIMUM -

ENGINE OFF

HOTLEVELBAND -

ENGINE RUNNINGCOLD FILL

LEVELMINIMUM -

ENGINERUNNING

MAX

152mm(6") Min

MIN

4-11

Operating the Truck

Brake Function ChecksIn addition to the above checks, the following brake function checkscan be carried out to determine if both the service and emergencybrake systems are functional before operating the machine.

Make sure the area around the machine is clear of personneland obstructions before carrying out these checks.

Note: The following checks are NOT intended to measure maximumbrake holding ability. If NEW brake pads are fitted, they MUST beburnished as per the manufacturers recommendations before carryingout the checks.

Service Brake Holding Ability CheckDepress service brake pedal and move transmission gear shift toDrive. Pull the parking-emergency brake control out to release thebrakes. Depress accelerator control and accelerate engine to 1 350rev/min. The machine should not move. Decelerate engine, shifttransmission to 'NEUTRAL' and apply parking brake switch beforereleasing the service brake pedal.The parking brake will applyautomatically.

Emergency Brake Holding Ability CheckPush parking-emergency brake control in to apply 'EMERGENCY'brakes and move transmission gear shift to Drive. Depressaccelerator control and accelerate engine to 1 350 rev/min. Themachine should not move. Decelerate engine, move gear shift controlto 'NEUTRAL' and pull out the parking emergency brake control. Theparking brake is applied automatically when the transmission isshifted to ‘NEUTRAL’.

Note: Brake holding effort required to hold a machine static at aspecific rev/min, can vary from machine to machine due to differencesin engine performance, powertrain efficiencies, etc., as well asdifferences in brake holding ability.

Note: As an indication of system deterioration, the engine rev/min atwhich point the machine moved, with the service or emergencybrakes applied, can be compared against the engine rev/min yourspecific machine was able to hold to on a previous check.

If the machine moves during the above checks, stop themachine, apply the parking brake and do not operate until thefault is corrected.

4-12

Operating the Truck

1525 1

1756 2

1682 3

Driving and StoppingBefore driving off observe all instruments and warning lights. Allinstruments should operate in their normal range and all warninglights should be out except possibly the Direction Indicator, HeadlightMainbeam and Differential Lock warning lights.

Make sure the area around the machine is clear of personnel andobstructions before driving off.

In the first few minutes of travel check carefully for the requiredsteering, braking, engine and transmission power response formaximum operating safety.

1. Make sure the body is fully down and the body control lever is inthe 'NEUTRAL' position.

2. Apply the service brake and release the parking brake switch.

3. Select the driving direction and the required gear.

4. Sound horn; two blasts for forward and three blasts for reverse.

5. Release the service brake, apply the accelerator and move off. Thetransmission will automatically shift up and down the gears as speedand conditions allow. If necessary the machine should be slowed byuse of the service brake and/or the retarder and/or engine brake.

41713

1740 5

4-13

Operating the Truck

6. To stop the machine release the accelerator and depress theservice brake pedal. Release the service brake as the machine slowsuntil, when stopped, the pedal is depressed just enough to hold themachine stationary. Do not 'FAN' the pedal.

7. When the machine has stopped, apply the parking brake switch, shiftthe transmission to 'NEUTRAL' and release the service brake.

8. If the service brake does not stop the machine, apply the parking-emergency brake. This should only be applied to stop the machine inan emergency.

1741 6

1757 7

1742 8There is no mechanical connection between the engine andwheels on machines with converter transmissions. Theparking brake must always be applied when the engine isswitched off.

4-14

Operating the Truck

Stopping the Engine1. Make sure parking-emergency brake control is in 'PARK' position.

2. Make sure the transmission is in 'NEUTRAL'.

3. Allow the engine to run between idle and 1 000 rev/min with noload for 4 or 5 minutes. This allows the engine to cool and theturbocharger to slow down. Shutdown the engine.

4. Turn ignition key switch to the 'OFF' position. This cuts off the powersupply to the engine management system which in turn shuts down theengine.

5. Make sure body control lever is in 'NEUTRAL'.

6. Turn master switch 'OFF'. This prevents batteries being drained.

11758

21526

0

5

1015

20

25

min-1x100

30

31534

01

281 4

51525

61535

NNOTICEStopping a turbocharged engine immediately after high speedoperation may cause damage to the turbocharger as it willcontinue to turn without an oil supply to the bearings.

4-15

Operating the Truck

Parking

When parking the machine overnight, or for an extended period, thefollowing procedure in addition to that given in 'Stopping the Engine'will help maintain it in good condition for subsequent use:

1. Fill the fuel tank completely before parking the machine overnightor for extended periods, to prevent condensation. If security kit issupplied, keep it locked.

2. Always park on level ground where possible. If it must be parkedon a grade, position machine at right angles to the grade and blockwheels securely.Lock the Doors.

3. If below freezing temperatures are expected, make sure the coolingsystem has sufficient antifreeze to prevent the coolant freezing. Ifantifreeze cannot be added to the cooling system, drain the systemcompletely.

Check all tyres, hoses, wiring, tubing and fittings for cuts, plyseparation, abrasion, fraying, or other damage or deterioration.Inspect for structural damage to the cab, body and chassis. Attachwarning signs to the steering wheel or to a control to alert others iflubricant has been drained, batteries removed etc.

1857 1

Fuel Level

Voltmeter

0

8 12 16 20 24 28 32

25 50 75

50 75 100 125 150

100


2037 2

4-16

Operating the Truck


5-1

Working the Truck

5 - Working the Truck

5-2

Working the Truck


5-3

Working the Truck

Holding Truck Stationary1758

2023 Minimize Bucket Swing

2024 Loading From Rear

2025 Manoeuvring In Restricted Areas

2026 Semicircular Loading

WORKING THE TRUCKOff-highway articulated trucks are used on a variety of hauling jobs,from sand and gravel pits to road construction and mining. Every truckoperation, regardless of the type of job, can be divided into fourphases; loading, hauling, dumping and the empty return.

Note: After coming to a stop for loading or unloading the truck, thepark/emergency brake control can be pushed in to hold the brakes inthe applied position as though the foot brake is depressed.

Loading

Should the vehicle be fitted with a tailgate, cohesive materialmust not be loaded into the body. There is a risk of injury tothe driver if a tailgate is used with a cohesive material.

NOTICE

When loading, the operator should be diligent and alwaysaware of the material which is to be loaded onto the vehicle. Atany time, should he feel that a load constitutes an obvioussafety hazard, he has the right and duty to refuse to load thisonto the vehicle.

The most common methods of loading articulated trucks are withhydraulic excavators, and front end loaders. The trucks can be loadedequally well from the rear or the side using hydraulic excavators or ropeshovels. Ideally, excavators should require 90° or less swing. With abackhoe excavator a very efficient loading method is with the backhoeon top of the bank loading over the rear of the truck at the base of thebank. Backhoe slew angles can be small, leading to very short cycletimes.

For maximum material movement, the truck operator must help theloading machine operator to keep loading time to a minimum. Theshorter the distance the loading unit bucket must travel between the cut,or stockpile and the truck body, the more passes it can make in a givenperiod of time and the quicker the truck can be loaded.The fewer manoeuvres the truck must make to get into the loadingposition, the sooner loading can start. In restricted areas it may benecessary to turn and reverse the truck into the loading position.

If the required space is available the truck can travel round without theneed to reverse. Waiting trucks should stay about two truck lengthsbehind the one being loaded to avoid any spillage from the loadingmachine bucket or truck body. The operator of the waiting truck is alsoable to judge the best spot for the truck when it is his/her turn to beloaded.

5-4

Working the Truck

2027 Loading Both Sides

Loading With Front End Loader2028

Watch Cleanup Machine2029

On some jobs, the loading machine might work most efficiently whentrucks are positioned on both sides of the loader. Thus, while one truckis being loaded, another can move into position on the opposite side ofthe loader and the loading machine can swing over to load the nexttruck with a minimum of lost time. Since the truck is usually backed intothe loading position with this method, the operator must be alert andcareful while backing.

For fastest, most accurate loading, when being loaded by a front endloader, the truck operator should stop the truck on the most level areaand at an angle to the face of the bank or stockpile. This minimizesloader travel time, particularly with a raised, full bucket. Where possible,the truck should also locate downwind of the loader when dusty materialis being loaded on a windy day. This practice improves both workingconditions and visibility for the loader operator.

A cleanup dozer or small loader is often worked in conjunction with themain loading machine to keep the area clear of bucket spillage formaximum efficiency of the loading operation. The truck operator mustalways be alert to the position of the cleanup machine when enteringthe loading area to avoid congestion, and, for maximum safety.

Avoid rocks and other shovel spillage that can needlesslydamage tyres or other truck components. Allow the cleanupmachine sufficient time to clear up such debris.

Do not move the truck into loading position with the shovelbucket swinging overhead. Large rocks that might fall fromthe bucket can be dangerous to both the operator and thetruck.

Keep your head and arms inside the cab during loading toavoid the danger of falling rocks or other shovel spillage.

When the loader operator signals that the truck is loaded, sound twoblasts on the horn for forward movement and three blasts for reversemovement. Select the correct gear and release the brakes. Move out ofthe loading area and onto the haul road, with the least possible delay, toallow any waiting truck to move into the loading position as soon aspossible.

5-5

Working the Truck

LO

HI

Driving On Soft Or Slippery Conditions1839

Hauling

While travelling the haul road, always maintain a safe speed for the haulroad conditions and grades. Never allow the truck to move or coast withthe transmission in 'NEUTRAL'!

When approaching or encountering extremely soft or slipperyconditions, stop the truck and engage the differential locks. Do notengage the differential locks when the truck is moving or wheels arespinning. Disengage the locks as soon as conditions return to normal.

When approaching downgrades, select the proper transmission gearrange and use the retarder and service brakes as required to maintainsafe descent speed, without over-speeding the engine, or gainingexcess travel speed. Generally, the transmission range required forascending is also correct for descending a grade.

Always remain a safe distance behind the machine ahead,particularly on downgrades. A good rule-of-thumb to follow is to allowtwo truck-lengths between machines for each 16 km/h (10 mile/h) oftravel speed under normal operating conditions. Under adverseconditions, allow more room for safe operation. On jobs on whichminimum distance between machines is specified for the haul road,be sure to observe the regulations at all times. Such regulations areestablished for the safety of everyone on the job.

Pay attention to haul road conditions to avoid rocks, holes, or otherobstacles. Such obstacles not only present hazards to safe operation,but can needlessly damage tyres and suspensions if not avoided.

Be sure to reduce speed and come to a full stop, as required, atintersections, railroads, public highways etc. Where a 'FLAGMAN' isstationed to direct traffic, always stay alert and follow his/herdirections.

Maintain Safe Speeds2030

2031 Safety First

2032 Avoid Obstacles

10

10

20

3040

50

60

70

80

km/h

20 30

40mph

500 00000000000

TWO MINIMUM

5-6

Working the Truck

2033 Manoeuvring To Dump

2034 Keep A Safe Distance From The Edge

2035 Keep Wheels Level

Dumping

When dumping the operator should steer the vehicle ensuring that it isstraight and with the loaded body on level ground. The dumpingoperation usually depends upon the type of material being hauled. Forinstance, overburden and other waste material is usually dumped overa spoil bank or piled into large mounds. The dumping on a job of thistype might be controlled by a dump 'SPOTTER', 'FLAGMAN' or'BANKSMAN' or second person who directs the truck to its dumpingarea. While backing to dump, the operator must watch the 'SPOTTER'at all times and follow his/her direction. Under no circumstances shouldthe operator leave the seat to gain better visibility while backing.Always remain seated to maintain maximum machine control.

Mineral ores, blasted rock etc., are usually dumped into a hopper, orcrusher, where it is processed. When dumping into a hopper, theoperator, in order to avoid excess wear on the tyres, must avoid hittingthe protecting rail at the hopper. If a DRIVEOVER HOPPER is used,the operator must avoid rubbing the tyre inner sidewalls.

When hauling dirt or rock from a borrow pit into a fill area such as anearth-fill dam, the load is usually dumped in a string with other loadsand the loads smoothed out with a crawler tractor. When dumping on afill of this type, the operator usually works alone and picks his/her owndumping place. To save bulldozer work and cleaning up, the loadshould be dumped as close as possible to the preceding load. Theoperator should pull past the preceding load, turn in line with the stringand back the truck until it is within a few feet of the last load. Thisassures that the load will fall in the right place. No matter what kind ofjob the operator is working, there are a few things which are common toall jobs and which the operator should observe -

NOTICEBefore raising the body, make sure that the rear wheels are onfirm level ground. If one wheel is higher than the other, atwisting strain is imposed upon the body hinge pins, hoistsand chassis. Stop the truck, allow the engine to slow to idle,shift the transmission to 'NEUTRAL' so that the parking brakeis applied automatically and the vechicle is held stationary.

When dumping over a spoil bank without a 'SPOTTER',know how close the truck can safely approach the edgeunder all weather conditions. If in doubt as to dumpingsafety, dump the load a safe distance from the edge so thatit can be pushed over the edge later.

5-7

Working the Truck

Make Sure Body is Fully Down2192

1525 Keep Control Lever in 'NEUTRAL'

2036 Don't Jump Dump

Push the body control lever back into the 'RAISE' position andaccelerate the engine. Decelerate the engine to slow the raising speedas the hoists approach their maximum extension. When the body hasbeen raised to the desired height, release the control lever into the‘NEUTRAL’ (Hold) position until the body is to be lowered. Do not holdthe lever in the 'RAISE' position when the hoists are fully extended toprevent unnecessary hydraulic system relief valve operation.

NOTICENever 'JUMP DUMP' the truck by bouncing the rear tyresagainst a stop block, or otherwise jarring the body in its raisedposition, to dislodge stuck or frozen material. The tremendousloads that this practice develops on the body pin area, chassisand hydraulic system can cause needless, extensive stresses.

Once the load has been dumped, push the control lever fully forwardinto the detent 'POWER DOWN' position and accelerate the engine. Asthe hoists approach their fully retracted positions, decelerate theengine. At a predetermined body height a proximity sensor causes thebody control lever to spring back to 'NEUTRAL' position, allowing thebody to float onto the chassis under it's own weight.

Empty Return

Make sure the body is completely lowered, the body control lever is inthe 'NEUTRAL' position and transmission is in correct gear rangebefore releasing the brakes and moving away from the dump site.

Do NOT drive the truck with the body up. No articulated truckis stable in this condition and, apart from the risk of a rear-endtopple, there can be severe danger from contacting overheadelectric cables, trees, or bridges over the haul route.

Except for the above, the procedure for returning empty to the loadingarea is the same as that given earlier for 'HAULING'.

5-8

Working the Truck


6-1

Roading

6 - Roading

6-2

Roading


6-3

Roading

ROADING

These machines are equipped with cylinders containingcompressed nitrogen gas. Transportation of these machinesby any method may require a special permit from theappropriate authority of the country involved. Consult yourDealer for details.

General'ROADING' (operating a truck over public highways) requires specialcare and attention. Trucks, because of their large size, are slowerand less manoeuvrable than most other machines encountered onthe road. Yet, while on the road, they must be operated for extendedperiods of time at, or near, maximum speeds.

Before 'ROADING' a truck for an extended distance between jobs, orbetween widely scattered sections of a job, the machine must beproperly equipped and in good condition. It is also recommended tocarry a 'Warning Triangle'.

The operator must use extra care while on the public highways andremain constantly alert, especially for overhead cables and lowbridges.

Necessary permits must be obtained from the proper authoritiesbefore the machine is 'ROADED' on public highways.

Preparation Prior to RoadingLubricationThoroughly lubricate and service all components and systems asdescribed under 'LUBRICATION AND SERVICING' in this handbookand/or maintenance manuals for this machine.

InspectionPerform all pre-starting and post-starting checks described in thisHandbook. Pay particular attention to the function of all instrumentsand lights, and make any repairs necessary.

NOTICEImproper tyre inflation during over-the-road operation cancause rapid tyre deterioration by overheating. Tyre pressuresincrease with heat. Always check pressures while tyre is cold.Consult your tyre dealer for proper pressures and tyre speedlimits for roading.

Check the inflation pressures of all tyres, while cold, with an accuratetyre pressure gauge. Inflate tyres if necessary, while cold, to therecommended pressure for 'ROADING'. Inspect all tyres thoroughlyand carefully for stones or other debris embedded in the treads or

NOTICEMake sure the body islowered and bodycontrol lever is in the'NEUTRAL' position.Failure to comply to thiscould result inoverheating the hydraulicoil and failure of thehydraulic systemcomponents.

Make sure the differentiallock switch remains inthe 'OFF' position whenroading. Failure tocomply to this couldresult in damage to thetransmission and axlecomponents.

6-4

Roading

carcasses. Inspect for cuts, bruises, burned beads abnormal wearand damaged wheels rims. Replace any damaged or excessivelyworn tyres.Check all hoses, drain cocks, fuel level check cocks, and other potentialsources of leaks. Make sure that all leaks are repaired and that all draincocks are sufficiently tightened to avoid subsequent loosening. Makesure that all warning flags, oversize load signs etc. are in place andsecure.

Clean all glass and adjust the seat for proper operation of all controls.

Check the lights, horn, windscreen wipers, heater, defroster, headlightdip control, and all controls for proper operation.

Make sure the truck body is empty, fully lowered and the body controllever is in the 'NEUTRAL' position.

Make sure the differential lock switch is in the 'OFF' position.

Drive transmission through all gears while slowly accelerating engine.

In Case of Trouble

If trouble develops on route, move machine off the road at the first safeparking place, and shut off the engine. Carefully note as many of thesymptoms of the trouble as possible, such as rough engine operationwith loss of power and overheating, or loss of speed and transmissionclutch pressure with normal engine operation etc.

If the area in which the trouble occurs requires that the machine be leftunattended while the trouble is reported by phone, disconnect a batterycable and apply security locks, if so equipped, before leaving theparked machine. Make sure body is completely lowered and theparking brake is applied.

Report the following data as soon as possible:

1. Exact location.

2. Destination.

3. Truck Serial Number

4. The nature of the trouble (with as many details as possible) and the time and conditions under which it happened.

5. The telephone number at which the machine operator can be reached.

NOTICEDo not attempt to restart or operate the machine unlessinstructed to do so. An engine, pump, transmission or othercomponent that develops a minor defect can be completelydestroyed in just a few extra minutes of unnecessaryoperation.

7-1

Moving a Disabled Truck

7 - Moving a Disabled Truck

7-2



7-3


MOVING DISABLED TRUCKAny unusual power train noises noted while operating the truck shouldbe reported to those responsible for maintenance. Should the powertrain, hydraulic or electrical systems fail, the vehicle should be stoppedand shut down immediately until suitable repairs can be made. If thefailure is in the power train and the truck must be moved to a servicearea or workshop to make required repairs, it is advisable to carry outthe following procedures to prevent any possible additional damage,which may be caused by the wheels turning the power train as thevehicle is driven or towed.

If the transmission or drop box is at fault, disconnect the drivelines tothe axles and dropbox before moving the vehicle.

If a differential or planetary is at fault, carry out the following procedurefor the component concerned: Disconnect drivelines, remove planetarycovers and remove the axle shafts. Remove the pinion gears from theircovers. Replace the planetary pins in the covers, and refit the planetarycovers on the drive wheels to retain lubricant and prevent ingress of dirt.

If possible, start the engine to provide the required hydraulic pressurefor steering and braking. If the nature of the trouble prevents engineoperation, repairs must be made on the site of the breakdown, orspecial arrangements made for towing the vehicle safely to the repairarea without braking and steering power.

Never allow riders on a vehicle being towed without sufficienthydraulic pressure for safe braking.

If the parking brake must be released, but the engine cannot beoperated to provide the required hydraulic pressure or if there iselecrical failure, the brake can be released manually by following thisprocedure:

Block all wheels securely. Turn the hex-head on the parking brakeactuator anticlockwise until the brake pads are free from the disc. Whenthe hydraulic system is repaired, return the actuator to its originalposition by turning the hex-head fully clockwise.

Connect a suitable towing bar to one of the lugs on the tractor frame ofthe disabled vehicle and reverse another vehicle, in a straight and in-line manoeuvre, towards the disabled vehicle. Connect the oppositeend of the towing bar to the towing pin of the recovery vehicle andensure that it is securely locked.

Note: An alternative method of towing a disabled vehicle is byconnecting an A-Frame arrangement to the lugs on the tractorframe of the disabled vehicle and the towing pin of therecovery vehicle.

Removing the drivelinebetween the parkingbrake and the rear axlesor removing the axleshafts and planetarycovers or pinion gearsfrom the axles will makethe parking brakeineffective.

Uncontrolled vehiclemovement hazard.There is no mechanicalconnection between thevehicle wheels and theengine when theparking brake isreleased. Beforereleasing the parkingbrake, make sure thevehicle wheels aresecured with chockblocks to prevent orrestrict unexpectedvehicle movement.

When moving thevehicle with insufficienthydraulic pressure, forsafe braking andsteering, use extremecaution to ensurepersonnel and propertysafety.

Make sure the parkingbrake actuator isreturned to its originalposition, and theparking brake isoperating correctly,before removing thechock blocks from thewheels.

7-4



8-1

Lubrication and Servicing

8 - Lubrication and Servicing

8-2



8-3


SAFETYDo not allow unauthorized personnel to service or maintain thismachine. Study the Operator’s Handbook and Maintenance Manualbefore starting, operating or servicing this machine. Always followprocedures and safety precautions detailed in the Maintenance Manual.

Always attach a 'DO NOT OPERATE' or similar warning sign to ignitionswitch or a control and lockout before cleaning, lubricating or servicingthe machine.

Never allow anyone to work on the machine while it is moving. Makesure no one is on the machine before working on it.

Do not work under or near unblocked or unsupported body. Always usethe body safety prop. Body prop must only be used when the body isempty.

Do not work under or near any unblocked or unsupported linkage, partor machine.

Always shut down machine according to the procedure under 'StoppingThe Engine', described on Page 4-14. Turn off the master switch beforecleaning, lubricating or servicing the machine except as called for in thisHandbook or Maintenance Manual.

Always install steering lock bar before adjusting or servicing themachine with the engine running. Refer to 'General' safety section onPage 2-4.

Always relieve pressure before servicing any pressurized system.Follow the procedures and safety precautions detailed in the relevantMaintenance Manual section.

Escaping fluids under pressure can penetrate skin.

When changing oil in the engine, transmission and hydraulic systems,or removing hydraulic lines, remember that the oil may be hot and cancause burns to unprotected skin.

When working on or around exhaust components, remember that thecomponents may be hot and can cause burns to unprotected skin.

Always deflate tyre before attempting to remove any embedded objectsor removing the tyre and rim assembly from the machine.

Always use a self-attaching chuck with a long airline and stand to oneside while the tyre is inflating. Refer to Section 160-0050, Wheel Rimand Tyre in the Maintenance Manual.

EXPLOSION HAZARD

when working around battery area, keep all flames and sparks away from batteries.

SAFETY

MANUAL

1767

DO NOT

OPERATE

1775

1781

15333273

Injection Hazard.Escaping fluid under pressurecan penetrate skin, causingserious injury.

Relieve pressure beforedisconnecting hydraulic lines.Keep away from leaks and pinholes. Use a piece of cardboard or paper to searchfor leaks. Do not use hand.

Fluid injected into the skin must besurgically removed within a fewhours by a doctor familiar with this type of injury or gangrenewill result.

WARNING

8-4


LUBRICATION AND SERVICING

Lubrication is an essential part of preventive maintenance. It isimportant that the instructions regarding types of lubricants and thefrequency of their application be followed to prolong the useful life ofthe machine. Periodic lubrication of moving parts reduces to aminimum the possibility of mechanical failures.

Thoroughly clean all fittings, caps, and plugs, to prevent dirt fromentering the system while servicing.

Lubricants must be at operating temperature when draining.

Do not operate any system unless oil level is within the operatingrange as indicated on oil level dip stick, sight gauge or level plug.

Small circles on the following illustrations represent points at whichlubrication or servicing must take place, at the intervals indicated onthe left-hand side of the lubrication chart.

The numbered circles on the illustrations contain reference numberswhich correspond to the 'Ref. Points' column of the chart.

All change and service periods are recommendations based onaverage operating conditions. Lubricants showing evidence ofexcessive heat, oxidation or dirt should be changed more frequentlyto prevent these conditions. Lubricant change and service periodsmust be established on the basis of individual job conditions.

8-5


2191

Lubrication and Servicing Points


Interval Ref. No. of Lubricant or

Hours Points Identification Service Instructions Points Coolant Service/Quantities

1 Engine Check oil level. Add if low. 1 EO As Required

2 Transmission Check oil level. Add if low. 1 EO As Required3 Hydraulic Tank Check oil level. Add if low. 1 HO As Required

10 4 Radiator Expansion Tank Check coolant level. Add if low. 1 Ethylene

(Daily) Glycol6 Fuel Filter/Water Separator Drain. 1 -

7 Engine Air cleaner Check. Renew element if required. 1 -18 Drive Belts Visual inspection for damage 2 - -

1 Engine Crankcase Breather Inspect and clean if required. 1 -3 Hydraulic Filter Restriction Gauge Check. Renew element if required. 1 - -

24 Tyres Check condition and pressure. 6 - Maintenance Manual,

Sec 160-0050

9 Oscillation Bushes Lubricate 2 EP, NLGI See Note 3

12 Suspension Beam Bushings Lubricate 2 EP, NLGI See Note 3

50 10 Steering Cylinder Pins Lubricate 4 EP, NLGI See Note 3

(Weekly) 11 Body Cylinder Pins Lubricate 4 EP, NLGI See Note 313 Body Hinge / Tailgate Pins Lubricate 2 EP, NLGI See Note 3

15 Wheel Rim Nuts Check torque. 72 - 600 Nm (442 lbf ft.)

30 Cab Fresh Air Filter Inspect and clean if required. 1 -

14 Panhard Rod Bearings Lubricate 4 EP, NLGI See Note 38 Battery Electrolyte Check level. Add Electrolyte if low. 2 - As Required

19 Wheel Planetaries Check oil level. Add if low 6 EPL As Required

20 Differentials Check oil level. Add if low 3 EPL As Required

250 21 Oscillation Pivot Check end float. Adjust if required. 1 -

(Monthly) 25 Articulation Bearings Lubricate 2 EP, NLGI See Note 3

27 Parking Brake Pads Check wear. Renew if required. 2 - -

18 Drive Belts Check tension. Tighten if required 2 - -

35 Front Axle (IFS) Lubricate 1 EP, NLGI See Note 3

12

17

33

8 6 16 7 29 2 28 35 10 11 9 21 19 23 15 26

34

14

24

132027222531

3032

18

1

5

4

3

8-6


Note: Use 'Lubrication and Service Chart' in conjunction with 'Notes on Lubrication and Service Chart' and 'MiscellaneousServicing' contained on the following pages.

Notes on Lubrication and Service Chart

Note 1 - Capacities given are approximate - work todipstick, sight gauges or level plugs.

Note 2 - Capacity of front and rear differentials is28 l (7.4 US gal). Capacity of centre

differential is 31 l (8.2 US gal).

Note 3 - Lubricate slowly until excess lube is seen.

Note 4 - Remove the plug from the port on theunderside of the oscillation hub. The plug isremoved to drain the cavity of any oil thatenters the cavity when filling. Remove thegrommet and level plug on the side of theoscillation hub. Add oil if required. Refit allplugs.

Note 5 - Clean radiator and cooler fins more oftenwhen operating under extremely dustyconditions.

Note 6 - Change safety element after every thirdprimary element service.

Note 7 - Independent Front Suspension (IFS) greasepoints (2). Remove excess grease from the greaseholes in the pivot blocks (8 per side) and at thedamper pins (2 per side).

Lubricate the left-hand IFS grease manifolduntil excess is observed exiting through thegrease holes in the pivot blocks (8) and at thedamper pins (2).

Lubricate the right-hand IFS grease manifold untilexcess is observed exiting through the grease holesin the pivot blocks (8) and at the damper pins (2).

Note 8 - This service interval is dependant on fuel quality. If alesser grade of fuel is used than that specified withinthe recommended lubricants, the service intervalshould be reduced accordingly.

Note 9 - Check the air cleaner restriction gauge andoperate the vacuator valve. Renew the elementif the indicator denotes a blockage.

EO - Engine Oil. Refer to 'Recommended Lubricants' and'Engine Oil Drain Intervals'.

LUBRICATION AND SERVICE CHART (continued)Interval Ref. No. of Lubricant or

Hours Points Identification Service Instructions Points Coolant Service/Quantities

500 1 Engine Drain oil and refill with new oil 1 EO -

(3 Monthly) 16 Engine Oil Filter Renew 1 - -

2 Transmission Drain oil and refill with new oil 1 EO -

2 Transmission Run AEB Starter 1 - -

1000 3 Hydraulic Tank Breather Renew 1 - Refer Service Manual

(6 Monthly) 6 Fuel Filter/Water Separator Renew 1 - -

17 DCA4 Coolant Filter Renew. 1 - -

2 Transmission Breather Clean if required 1 - -

28 Transmission Oil Filters Renew. 2 - -

29 Transmission Internal Strainer Clean. 1 - -

22 Drive shaft Bearings Check oil level. Add if low. 1 EPL See Note 4.

30 Cab Fresh Air Filter Renew. 1 - -

32 Fuel Tank Renew cap filter / cartridge. 1 - -

3 Hydraulic Tank Drain oil and refill with new oil. 1 HO -

19 Brake Packs Check brake wear 6 - Refer Service Manual

2000 19 Wheel Planetaries Drain oil and refill with new oil 6 EPL

(Annually) 20 Differentials Drain oil and refill with new oil 3 EPL See Note 2.

25 Articulation Pivot Nut Check torque. 1 - 1425 Nm (1050 lbf ft.)

31 Hydraulic Oil Filter Renew. 1 - -

3 Hydraulic Tank Strainer Clean 1 - -

23 Drive lines Check for leaks and damage. 5 - -

1 Engine Mounting Bolts Check torque. 4 - 298 Nm (220 lbf ft.)

2 Transmission Mounting Bolts Check torque. 3 - 920 Nm (679 lbf ft.)

1 Turbocharger Mounting Bolts Check torque. 4 - 65 Nm (50 lbf ft.)

1 Engine Water Pump Inspect drain hole. Clean if required. 1 -

34 Axle Mounting Bolts Check torque 24 - 671 Nm (495 lbf ft.)

4000 5 Cooling System Drain, flush and refill with new - - -

coolant

33 Air Conditioning Compressor Drain, flush and refill with new 1 PAG Oil -

refrigerant oil

8-7


MISCELLANEOUS SERVICING

WHEN REQUIRED

Seat Belts - Inspect for damage. Replace if required.

Replace seat belts at least once every three years,regardless of appearance.

Windscreen Wipers And Washers - Replace wiperblades and top up reservoirs.

Wheel Rim Nuts - After first 10 hours (1 day) of operationre-torque nuts to 550 Nm (406 lbf ft). Check torque every250 hours (monthly) thereafter.

Engine - Steam clean the engine prior to performing anyrepair or service work on it, and if heavily contaminateddue to prevailing site conditions.

Electrical and electronic connections, the EngineECM and harness connections should be protectedor not directly steam cleaned when on or removedfrom the engine.

Note: The engine and its components that are scheduled tobe checked, serviced or replaced must be cleaned inaccordance with the manufacturer's recommendations.

EVERY 10 HOURS OF OPERATION (DAILY)

Walk Around Inspection - Inspect the vehicle as describedin Section 4 of the Operator’s Handbook.

Engine - Visually check engine for damage, loose or frayedbelts and listen for any unusual noises.

Engine Air Cleaner - Change air cleaner element onlywhen air restriction gauge locks up in the red. Servicevacuator valves daily. Inspect and remove anyobstructions from the vacuator valve lips which should beopen and pliable with the engine stopped.

Note: Service air cleaners more often when operatingunder extremely dusty conditions.

Engine Crankcase - Check oil level and add oil if low. Withthe engine off, the oil should be between the lower andupper marks on the dipstick, up to the upper mark ispreferable.

Transmission - Check oil level and add oil if low. Refer toService Manual Section 120-0010, Transmission andMounting, for correct oil level check procedure.

Hydraulic Tank - Check oil level and add oil if low. With the

engine off and the body down the oil should be visible in thesight gauge.

Radiator Header Tank - Check coolant level when cold and addif low. Fill the radiator header tank with coolant until coolantreaches the bottom of the filler neck and holds that level.

NOTICE

Any time a significant amount of coolant

is added, the coolant inhibitor MUST be

checked. If the concentration is low,

engine damage will result. Conversely,

over-inhibiting antifreeze solutions can

result in silicate dropout.

AFTER FIRST 250 HOURS OF OPERATING NEW

OR REBUILT COMPONENTS

Wheel Planetaries - Drain oil and refill.

Differentials - Drain oil and refill.

Axles - Check all visible nuts and bolts for loosening.Retorque planetary fill/drain plugs to 55 Nm (40.5 lbf ft)

AFTER FIRST 500 HOURS OF OPERATING NEW

OR REBUILT COMPONENTS

Transmission - Drain oil, replace filter, clean internal filter andfinger magnet. Refill the transmission.

Note: When refilling transmission ensure that transmissioncooler is primed to prevent damage.

Engine - Replace DCA4 coolant filter and check DCA4 coolantadditive concentration.

EVERY 250 HOURS OF OPERATION (MONTHLY)

Oil Can Points - Oil working parts with engine oil.

General Inspection - Check entire dumptruck for leaks, loosebolts and nuts or damaged parts. Examine the dumptruck,particularly the chassis, for cracks or broken welds. Repairwhere necessary.

Engine Air Intake - Check air intake system for wear points ordamage to piping, loose clamps and leaks.

Parking Brake - Check pads and disc for wear. Adjust orreplace if required. Test for proper function. Friction materialthickness should never be allowed to wear below 3 mm(0.12 in).

EVERY 500 HOURS OF OPERATION (3

MONTHS)

Differentials - Check Oil level and add if low.The correct oillevel is up to the rim of the oil filler and level-check hole. Refer torelevant Differential section within the service manual forspecific details.

Planetaries - Check oil level and add if low.Oil level should beat the lower bottom edge of the thread, with the wheel huborientated so that the oil drain plugs are positioned horizontallyin the middle of the axle. Refer to relevant Planetary sectionwithin the service manual for specific details.

HO - Hydraulic Transmission Oil. Refer to'Recommended Lubricants'.

EPL - Extreme Pressure Gear Lubricant. Refer to'Recommended Lubricants'

EP, NLGI - Extreme Pressure Lithium No. 2Grease (without 'Molybdenum').

PAG Oil - Polyalklene Glycol (PAG) Compressor

Lubricating Oil - Low Viscosity (ISO46).

8-8


* - Capacities given are approximate, work to dipstick, sight gauges or level plugs.

Note 1 - The use of low viscosity oils, such as 10W-30 or 5W-30, can be used to aid in starting the engine and providing sufficient oilflow at low ambient temperatures. Continuous use of low viscosity oils can decrease engine life due to wear.

Note 2 - Operation below the minimum temperatures listed for the oil used without proper preheat or warm-up results in greatlyreduced transmission life. Proper warm-up requires 20 minutes minimum operation in neutral (with engine at part throttle) beforeoperating the transmission in gear.

Note 3 - Hydraulic Transmission Oil meeting Specification EMS19058 is suitable for use in the hydraulic system.

EVERY 2000 HOURS OF OPERATION(ANNUALLY)Hydraulic Oil Tank - Drain oil, remove and clean filter screenassemblies. Reinstall filter screens and refill tank.

Hydraulic Oil Filter - Clean filter housing and install newelement when the filter restriction gauge reads in red zone, orafter 2 000 hours of operation, whichever comes first.

Drivelines -Visually check Low Maintenance drivelines forleaking or damaged seals.

Note: Low Maintenance drivelines can be identified by havingplugs fitted to the spiders, not grease nipples.

Multi Disc Brakes - Check operation and brake wear is withinthe prescribed limit. refer to Service Manual Section 160-0030

for details

Differentials - Drain oil and refill. Perform oil change when oil iswarm. For specific details of oil fill and drain plug locations, refer tothe relevant differential section contained within the servicemanual for details.

Planetaries - Drain oil and refill. Perform oil change when oil iswarm and simultaneously with the differential. For specific detailsof oil fill and drain plug locations and steps, refer to the relevantplanetary section contained within the service manual for details.Re-torque fill and drain plugs to 55 Nm (40.5 lbf ft).

RECOMMENDED LUBRICANTSCOMPONENT LUBRICANT *CAPACITY SPECIFICATIONS API CODE SAE GRADE

Engine Crankcase Engine Oil with 1.00% 41 l CH-4 15W-40(Including Filters) sulphated ash limit is (10.8 US gal) (See Note 1)

recommended. Sulphated ashmust not exceed 1.85% limit

Transmission Engine Oil with 1.85% 63 l (See Note 2) CH-4 15W-40(Including cooler) max. sulphated ash limit (16.6 US gal) See Trans.

Oil Table.

Transmission Engine Oil with 1.85% 8.25 l (See Note 2) CH-4 15W-40Cooler max. sulphated ash limit (2.18 US gal) See Trans.

Oil Table.

Hydraulic System Hydraulic Transmission Oil 202 l See Hydraulic Oil Table(Including Lines) (53.4 US gal) (See Note 3)

Cooling System Anti-freeze, Ethylene Glycol 54 l(14.3 US gal)

Differential Extreme Pressure 28 l each MIL-L-2105 GL-5 80W-90 H(Front [non IFS] Gear Lubricant (7.4 US gal)and Rear)

Differential Extreme Pressure 26 l MIL-L-2105 GL-5 80W-90 H (Front, IFS) Gear Lubricant (7 US gal)

Differential Extreme Pressure 31.0 l MIL-L-2105 GL-5 80W-90 H(Centre) Gear Lubricant (8.2 US gal)

Planetaries Extreme Pressure 11.0 l each MIL-L-2105 GL-5 80W-90 H(Front) Gear Lubricant (2.9 US gal) (See Notes 5 and 6)

Planetaries Extreme Pressure 7.5 l each MIL-L-2105 GL-5 80W-90 H(Centre & Rear) Gear Lubricant (2.0 US gal) (See Notes 5 and 6)

Fuel Tank Diesel Fuel Oil with 390 l DIN EN590max. sulphur 0.5% (103 US gal)

Grease Nipples Extreme Pressure No.2Lithium Grease Consistency

Driveshaft through Extreme Pressure (See Note 4 - Page 8-6) MIL-L-2105 GL-5 80W-90Bearings Gear Lubricant

Articulation Extreme Pressure EMS 19057Bearings Lithium Complex

Air Conditioning Polyalklene Glycol (PAG) 0.125 l ISO46Compressor Compressor Lubricating Oil - (0.033 US gal) SP 10

Low Viscosity

8-9


ENGINE OIL DRAIN INTERVALSEngine oil drain intervals are dependant on working environment and oil type used. Refer to table below for enginemanufacturer's recommended oil drain intervals.

LUBRICANT GRADE SELECTION GUIDE AT AMBIENT (START-UP) TEMPERATURESm - 637HYDRAULIC OIL

TRANSMISSION OIL

(See Note 5)

Note - Consult your lubricant supplier for correct viscosity of lubricant when ambient temperatures areconsistently above or below those listed.

Sm - 639

ENGINE OIL

APISAE CODE MIL-SPEC

1 - - MIL-H-5606A2 DEXRON Auto Trans. Fluid3 10W CC/CD MIL-L-2104 B/C4 20W/20 CC/CD MIL-L-2104 B/C5 30 CC/CD MIL-L-2104 B/C

ENGINE OIL DRAIN INTERVALS BY DUTY CYCLE (HOURS)Severe Heavy Medium Light

Fuel Consumption > 13 gal/hr 10 to 13 gal/hr 8.5 to 10 gal/hr < 8.5 gal/hr

API CF-4 150 200 250 300

API CG-4 250 300 400 500

API CH-4 or ACEA E5 300 350 500 600

CES20076 or CES20077 350 400 550 700

Note 4 - Automatic Transmission Fluids (ATF) may only be used when the ambient temperature is less than -10° C (14° F). Shouldthe temperature increase, it is necessary to switch to engine oil.

Note 5 - Maximum 1.5% of Lubrizol (TEREX Part No. 15250489), may be added to planetary capacity to prevent brake squeal.

Any increase in the stated volume of Lubrizol will result in a decrease in brake performance.

Note 6 - Volume of Lubrizol to each planetary is as follows:Front: Maximum 1.5% = 165 ml (5.57 oz)Centre and Rear: Maximum 1.5% = 110 ml (3.71 oz)

8-10


****

AIR CONDITIONING RE-START PROCEDUREIf the machine has been idle for an extended period of time (2 weeks), the refrigerant in the air conditioning unit converts from a gas toa liquid. This puts the compressor unit under a great deal of strain trying to compress a liquid instead of a gas, and could cause a failurein the air conditioning unit. The following commissioning procedure allows the air conditioning unit to achieve normal operatingparameters.

1. Start the machine and allow it to run until the engine is at a normal operating temperature of 80 °C (176 °F)2. Turn the blower control to setting 1.3. Turn on the air conditioning unit on for 5 seconds then off for 5 seconds.4. Repeatedly switch the air conditioning on and off for at least 1 minute. This should be at least 12 repetitions.5. Commissioning the air conditioning unit is complete and ready for use.

TYRE PRESSURESTyre pressures on this pages apply to the truck serial number range specified only, Gross Vehicle Weight (G.V.W.) and axle weightsmay vary between truck derivatives. Tyre pressure should be recalculated if not shown for a particular truck. Contact TEREX forassistance.

The tyre inflation pressures listed are manufacturers’ recommendations for G.V.W. travelling at maximum speed. TEREX Advise thatoperators check tyre inflation pressures with tyre manufacturers to ensure correct setting for each particular application.

Front Centre RearTruck Brand Size Pattern b lbs/in2 b lbs/in2 b lbs/in2

TA27 Bridgestone 23.5 R25 VLT 4.4 64 4.4 64 4.4 64A889 Bridgestone 23.5 R25 VMT 4.4 64 4.4 64 4.4 64A892 Bridgestone 23.5 R25 VKT 4.4 64 4.4 64 4.4 64

Michelin 23.5 R25 XADT 3.8 55 3.4 50 3.8 55Double Coin 23.5 R25 REM2 4.5 65 4.5 65 4.5 55Triangle 23.5 R25 TB516 5.2 76 5.2 76 5.2 76Triangle 23.5 R25 TM518 5.2 76 5.2 76 5.2 76Triangle 23.5 R25 TL528 5.2 76 5.2 76 5.2 76Bridgestone 30/65 R25 VLT 3 43 3 43 3 43Michelin 30/65 R25 XADN 3.1 45 2.8 40 2.8 40Michelin 750/65 R25 XAD 65 3.1 45 2.8 40 2.8 40

TA30 Bridgestone 23.5 R25 VLT 4.8 69 4.8 69 4.8 69A894 Bridgestone 23.5 R25 VMT 4.8 69 4.8 69 4.8 69A908 Bridgestone 23.5 R25 VKT 4.8 69 4.8 69 4.8 69A897 Michelin 23.5 R25 XADT 4.1 60 4.1 60 4.1 60A911 Double Coin 23.5 R25 REM2 4.5 65 4.5 65 4.5 65

Triangle 23.5 R25 TB516 5.2 76 7.2 76 5.2 76Triangle 23.5 R25 TM518 5.2 76 5.2 76 5.2 76Triangle 23.5 R25 TL528 5.2 76 5.2 76 5.2 76Bridgestone 30/65 R25 VLT 3.2 46 3.2 46 3.2 46Michelin 30/65 R25 XADN 3.1 45 3.1 45 3.1 45Michelin 750/65 R25 XAD 65 3.1 45 3.1 45 3.1 45

9-1

Technical Data

9 - Technical Data

9-2

Technical Data


9-3

Technical Data

GENERATION

2 400 (7-9)

2 200 (7-2)

1 310 (4-4)

2 945 (9-8)

4 930 (16-2)

5 000 (16-5)

1 690 (5-6)

1 410 (4-9)

2 175 (7-0)

725 (2-3)

2 740(8-11)

2 685(8-10)

2 895 (9-6)

9 755(32-0)

2 895(9-6)

3 420(11-2)

3 120(10-3)

405(1-6)

1 580(5-3)

3 450(11-3)

1 240(4-1)

6 015 (19-9)

45˚

65˚

Max.BodyDepth

SAE Turning Radius Clearing Radius

8 470mm (27-9)8 950mm (29-4)

Dimensions in mm (ft-in)

TECHNICAL DATA TA27

2187

ENGINEMake/Model ................................................... Cummins QSM 11Type:Four cycle diesel, turbocharged with air-to-air charge cooling, water-cooled.Electronic management.

Gross power at 1800 rev/min.................................272 kW (365 hp)Net power at 2100 rev/min.....................................238 kW (319 hp)

Note: Gross power rated to SAE J1995 Jun 90. Engine emission meets USA EPA/CARB Tier III and EU NRMM (non-road mobile machinery) Tier III directive.

Maximum Torque.....................................................1673 Nm (1234 lbf ft) at 1400 rev/minNumber of cylinders/configuration ................. 6, in lineBore x Stroke ................................................. 125 x 147 mm (4.92 x 5.79 in)Piston Displacement ..................................... 10.8 litres (661 in³)Air cleaner........................................................... Dry type, double elementStarting .......................................................... ElectricMaximum Speed (No load) ............................ 2350 rev/minMaximum Speed (Full load) .......................... 2100 rev/minIdle Speed ..................................................... 750 rev/min

9-4

Technical Data

TRANSMISSIONMake/Model ..... ZF 6WG 260 RPC Automaticwith manual override. The transmission assembly consists of a torque converterclose-coupled to a countershaft-type gearbox with integral output transfer gearing.Automatic shifting throughout the range, with kickdown feature. Lockup action inall forward gears. A torque proportioning output differential transmits drivepermanently to front and rear axles. This differential may be locked by the driverfor use in difficult traction conditions. Optional integral hydraulic retarder whichautomatically operates should the engine overspeed. Blocked filter indicator andfilter bypass system provide valve block with additional protection from unfilteredoil.Pressures:

Main............................................................. 16 + 2 bar (232 + 30 lbf/in²)Lockup (Wk)................................... ............ 14 ± 1 bar (190 ± 15 lbf/in²)Converter 'IN'.............................................. 10.5 bar (152 lbf/in²) at 2300 rev/minConverter 'OUT'................................................ 4.8 bar (70 lbf/in²) at 2300 rev/minConverter Relief Valve.................................8.5 bar (123 lbf/in²)Retarder.............................................................5.5 bar (80 lbf/in²)

Temperatures:Normal........................................................ 80° - 110° C (176° - 230° F)Maximum....................................................... 120° C (248° F)

Stall Speed...........................................................1718 rev/minRatios:

Torque Converter ............................................1.84:1Transmission.....................................................Refer to table below

ForwardGear 1 2 3 4 5 6km/h 5.6 8.7 13.6 21.1 31.0 51.0mile/h 3.5 5.4 8.5 13.1 19.3 31.7

ReverseGear 1 2 3km/h 5.6 13.6 31.0mile/h 3.5 8.5 19.3

9-5

Technical Data

AXLESThree axles in permanent all-wheel drive with differential couplingbetween each axle to prevent driveline wind-up. Heavy duty axleswith fully-floating axle shafts and outboard planetary reductiongearing.

Transverse differential locks are activated by a request from the footoperated switch. When transverse differential locks are actuated thetransmission output differential lock will activate also.

Ratios:Differential .................................................. 3.875:1Planetary .................................................... 5.71:1Total Reduction .......................................... 22.12:1

SUSPENSIONFront (Serial Numbers A889****): The axle is carried on the leading

arms of a sub-frame which pivots on the main frame. Suspension byrubber elements with two heavy duty hydraulic dampers.

Front (Serial Numbers A892****): The axle is mounted to the frontchassis frame through the top plate of the front axle housing. Thecomplete unit is pivoted through the front frame. Suspension isprovided by four spring and damper assemblies (two per side)which are linked to lower wishbones and which are secured at theirupper ends to the front frame via spring mounts. Bumpstops limit thetravel of the suspension assemblies when fully loaded.

Rear: Each axle is coupled to the frame by three rubber- bushed linkswith lateral restraint by a transverse link. Pivoting inter-axle balancebeams equalize the load on each axle. Suspension movement iscushioned by rubber/metal laminated compression units betweeneach axle and underside of balance beam ends. Pivot points onrear suspension linkages are rubber-bushed and maintenance-free.

WHEELS AND TYRESWheels:5-piece earthmover rims with 12 stud fixingSize:

Standard . 25 x 19.50 in for 23.5 R25** tyresOptional25 x 22.00 in for 750/65 R25** tyres

Tyres:Standard.................................................................23.5 R25**Optional.................................................................750/65 R25**

Inflation Pressures (Bridgestone):Front Rear

23.5 R25**4.35 bar (63 lbf/in²)4.35 bar (63 lbf/in²)750/65 R25**3.0 bar (44 lbf/in²)3.0 bar (44 lbf/in²)

Inflation Pressures (Michelin):Front Rear


9-6

Technical Data

Inflation Pressures (Pirelli):Front Rear

23.5 R25**4.3 bar (62 lbf/in²)4.3 bar (62 lbf/in²)

Inflation Pressures (Continental):Front Rear


Note: Tyre pressures should be regarded as nominal only. It isrecommended that for tyres both listed and unlisted, the user shouldconsult the tyre manufacturer and evaluate all job conditions in order tomake the proper selection.

HYDRAULIC SYSTEMBraking, steering and body hoist systems are controlled by a manifoldblock mounted on frame. Systems are supplied with oil from a commontank by the main hydraulic pump, driven from power takeoff ontransmission. System components are protected by full flow filtration onthe return line.

Pump:Type............................................................ PistonCapacity at 2100 rev/min.................................4.9 litre/s (77.4 US gal/min)

BrakesFull hydraulic braking system with enclosed, oil-immersed multiple discson each wheel. Independent circuits for front and rear brake systems.Warning lights and audible alarm indicate low brake system pressure.Brake system conforms to ISO 3450, SAE J1473.

Actuating Pressure ..................................... 60 bar (870 lbf/in²)

Braking surface ........................................... 22000 mm2 (34.1 in2)

Parking: Spring-applied, hydraulic-released disc on rear driveline.

Emergency: Automatic application of driveline brake should pressure fallin main brake hydraulic system. Service brakes may also be appliedusing the parking-emergency brake control.

Retardation: Standard engine brake and optional hydraulic retarderintegral with transmission.

SteeringHydrostatic power steering by two single-stage, double-acting, cushionedsteering cylinders. Emergency steering pressure is provided by a grounddriven pump mounted on the rear of the transmission. An audible alarmand warning light indicates should the emergency system activate.Conforms to ISO 5010, SAE J53.

9-7

Technical Data

System Pressure ........................................... 241 bar (3500 lbf/in²)Steering Angle to either side ......................... 45°Lock to Lock Turns, steering wheel ............... 4Vehicle Clearance Circle (SAE) .................... 16.9 m (55 ft)

Body HoistTwo single-stage, double-acting hoist rams, cushioned at both ends of stroke.Electro servo assisted hoist control.

System Pressure ........................................... 220 bar (3 200 lbf/in²)Control Valve .................................................... Pilot Operated, Closed CentreBody Raise Time (loaded) ............................. 12 secBody Lower Time (power down) .................... 7.5 sec

ELECTRICAL SYSTEMType.................................................................... 24 volt, Negative GroundBattery............................................................... Two, 12 Volt, 143 Ah eachAccessories ................................................... 24 VoltAlternator ....................................................... 70 Amp

BODYOf all welded construction, fabricated from high hardness (min. 360 BHN) 1000 MPa (145000 lbf/in²) yield strength steel. 25° tail chute angle providesgood load retention without tailgate.

Plate Thicknesses:Floor and Tailchute ..................................... 14 mm (0.55 in)Sides .......................................................... 12 mm (0.47 in)Front ........................................................... 8 mm (0.31 in)

Volume:Struck (SAE) ............................................... 12.5 m³ (16.4 yd³)Heaped 2:1 (SAE)....................................... 15.5 m³ (20.3 yd³)

SERVICE CAPACITIESFuel tank ....................................................... 398 litre (103 US gal)Hydraulic System .......................................... 202 litre (53.4 US gal)Engine Crankcase and filters ........................ 34 litre (9.0 US gal)Cooling System ............................................. 55 litre (14.5 US gal)Transmission (including Cooler) ................... 63 litre (16.6 US gal)Transmission Cooler ..................................... 8.25 litre (2.18 US gal)Differential - Front, IFS........................................ 26 litre (7 US gal)Differentials - Front [not IFS] and Rear (each) 28 litre (7.4 US gal)Differential - Centre ....................................... 31 litre (8.2 US gal)Planetaries (Front) ......................................... 11 litre (3.0 US gal)Planetaries - Centre & Rear (each) ............... 7.5 litre (2.0 US gal)Hand Pump Tank................................................... 1 litre (0.26 US gal)

9-8

Technical Data

Vehicle Weights 23.5 R25 Tyres

Standard Vehicle kg lbNet DistributionFront Axle 11724 25793Centre Axle 5205 11451Rear Axle 5276 11709Vehicle, Net 22205 48953Payload 25000 55115Gross DistributionFront Axle 15880 34936Centre Axle 15592 34302Rear Axle 15733 34830Vehicle, Gross 47205 104068Bare Chassis 17335 38213Body 4100 9040Body Hoists (Pair) 530 1170

Ground PressuresAt 15% sinkage of unloaded radius and specifiedweights23,5 R25 Net Loaded

Front 118 kPa (17.1 psi) 161 kPa (23.3 psi)Rear 53 kPa (7.6 psi) 158 kPa (22.9 psi)750/65 R25 Net LoadedFront 87 kPa (12.6 psi) 119 kPa (17.3 psi)Rear 40 kPa (5.8psi) 119 kPa (17.3 psi)

VIBRATION

Note: The whole body vibrations onconstruction machines are influenced bymany factors independent of machinedesign, for example ground conditions,working methods, correct seat adjustment,operator input to vehicle speed.The single whole-body emission value listedabove is determined under particularoperating and terrain conditions. Inaccordance with EN474, it is not intended tobe used to determine the whole-bodyvibration exposure to the operator using thismachine.

Whole Body Vibration TA27 TA30Vibration Emission Value a 0.53 m/s2 0.52m/s2

Uncertainty K 0.26 m/s2 0.26 m/s2

Operating Mode:

Value Obtained under simulated field duty cycle.

Hands and Arm VibrationThe weighted root mean square accelerationto which hand and arms of the operator areexposed is less than 2.5 m/s2 under normaloperating conditions.

Note: It is recognized that the appropriatedesign of the operator's seat is the mosteffective construction measure to minimizethe whole - body vibration emission of aparticular machine family.This machine is equipped with an operator'sseat which meets the criteria of EN ISO 7096representing vertical vibration under severeoperating conditions.The seat is this machine has been testedwith input spectral class EMI and has a seattransmissibility factor SEAT > 1.1.

9-9

Technical Data

Sound Power Level ISO6395 TA27 TA30A - Weighted sound power level Lwa in decibels 108 109 Uncertainty Kwa, in decibels 0.4 0.4Sound Pressure Level at Operators Station ISO6396 TA27 TA30A - Weighted emission sound pressure level Lpa in decibels 77 75 Uncertainty Kwa, in decibels 2.47 2.47

The sound level values are in compliance with Directive 2000/14/EC and BS EN 474.

NOISE EMISSIONS

Note: The above result is for the mode giving the highest exterior sound level when measuredand operated as per the prescribed procedures of the standard. Results shown are for thevehicle in base configuration.

Note: Noise Exposure Level to the operator and bystander personnel may be higherdepending upon proximity to buildings, rock piles, machinery, etc.. The actual job site NoiseExposure Level must be measured and applicable regulations complied with in respect toEmployee Hearing Protection.

9-10

Technical Data

GENERATION

2 400 (7-9)

2 200 (7-2)

1 310 (4-4)

2 945 (9-8)

4 920 (16-2)

5 010 (16-5)

1 690 (5-6)

1 410 (4-9)

2 175 (7-0)

725 (2-3)

2 895(9-6)

2 685(8-10)

2 895 (9-6)

9 755(32-0)

2 895(9-6)

3 420(11-2)

3 325(10-10)

405(1-6)

1 580(5-3)

3 450(11-3)

1 445(4-9)

6 110 (20-0)

45˚

65˚

Max.BodyDepth


8 470mm (27-9)8 950mm (29-4)

Dimensions in mm (ft-in)

TECHNICAL DATA TA30

2188

ENGINEMake/Model ................................................... Cummins QSM11Type.....Four cycle diesel, turbocharged with air-to-air charge cooling, water-cooled.Electronic management.

Gross power at ................................................. 1800 rev/min 287 kW (385 hp, 390 PS)Net power at ............................................ .... ....... 2100 rev/min 248 kW (333 hp, 338 PS)

Note: Gross power rated to SAE J1995 Jun 90. Engine emission meets USA EPA/CARBTier III and EU NRMM (non-road mobile machinery) Tier III directive.

Maximum Torque ............ ............................... 1 775 Nm (1 309 lbf ft) at 1 400 rev/minNumber of cylinders/configuration ................. 6, in lineBore x Stroke ............................ ...............125 x 147 mm (4.92 x 5.79 in)Piston Displacement ..................................... 10.8 litre (661 in³)Air cleaner ..................................................... Dry type, double elementStarting .......................................................... ElectricMaximum Speed (No load) ............................ 2350 rev/minMaximum Speed (Full load) .......................... 2100 rev/minIdle Speed ..................................................... 750 rev/min

9-11

Technical Data

TRANSMISSIONMake/Model ..... ZF 6WG 310 RPC Automaticwith manual override. The transmission assembly consists of a torque converter close-coupled to a countershaft-type gearbox with integral output transfer gearing. Automaticshifting throughout the range, with kickdown feature. Lockup action in all forward gears. Atorque proportioning output differential transmits drive permanently to front and rear axles.This differential may be locked by the driver for use in difficult traction conditions. Standardintegral hydraulic retarder which automatically operates should the engine overspeed.Blocked filter indicator and filter bypass system provide valve block with additionalprotection from unfiltered oil.Pressures:

Main ............................................................ 16 + 2 bar (232 + 30 lbf/in²)Lockup (Wk) ................................................ 12 ± 2 bar (174 ± 30 lbf/in²)Converter 'IN' .............................................. 10.5 bar (152 lbf/in²) at 2300 rev/minConverter 'OUT' .......................................... 4.8 bar (70 lbf/in²) at 2300 rev/minConverter Relief Valve ................................ 8.5 bar (123 lbf/in²)Retarder ...................................................... 5.5 bar (80 lbf/in²)

Temperatures:Normal ........................................................ 80° - 110° C (176° - 230° F)Maximum(Retarder Mode) .......................... 145° C (293° F)

Stall Speed.................................................... 1805 rev/minRatios:

Torque Converter ........................................ 1.84:1Transmission .............................................. Refer to table below

AXLESThree axles in permanent all-wheel drive with differential coupling between each axle toprevent driveline wind-up. Heavy duty axles with fully-floating axle shafts and outboardplanetary reduction gearing.

Transverse differential locks are activated by a request from the foot operated switch.When transverse differential locks are actuated the transmission output differential lockwill activate also.



9-12

Technical Data


SUSPENSIONFront (Serial Numbers A894****): Axle is carried on the leading

arms of a sub-frame which pivots on the main frame. Suspension isby rubber elements with two heavy duty hydraulic dampers.

Front (Serial Numbers A897****): The axle is mounted to the frontchassis frame through the top plate of the front axle housing. Thecomplete unit is pivoted through the front frame. Suspension isprovided by four spring and damper assemblies (two per side)which are linked to lower wishbones and which are secured at theirupper ends to the front frame via spring mounts. Bumpstops limit thetravel of the suspension assemblies when fully loaded.

Rear: Each axle is coupled to the frame by three rubber- bushed linkswith lateral restraint by a transverse link. Pivoting inter-axle balancebeams equalise load on each axle. Suspension movement iscushioned by rubber/metal laminated compression units betweeneach axle and underside of balance beam ends. Pivot points onrear suspension linkages are rubber-bushed and maintenance-free.



Tyres:Standard ..................................................... 23.5 R25**Optional ...................................................... 750/65 R25**




23.5 R25**4.0 bar (58 lbf/in²)4.0 bar (58 lbf/in²)750/65 R25**3.0 bar (44 lbf/in²)3.0 bar (44lbf/in²)




23.5 R25**5.0 bar (73lbf/in²)5.0 bar (73 lbf/in²)

Note: Tyre pressures should be regarded as nominal only. It is

9-13

Technical Data

recommended that for tyres both listed and unlisted, the user should consult thetyre manufacturer and evaluate all job conditions in order to make the properselection.

HYDRAULIC SYSTEMBraking, steering and body hoist systems are controlled by a manifold blockmounted on frame. Systems are supplied with oil from a common tank by themain hydraulic pump, driven from power takeoff on transmission. Systemcomponents are protected by full flow filtration on the return line.Pump:

Type............................................................ PistonCapacity at 2100 rev/min................................... 4.9 litre/s (77.4 US gal/min)

BrakesFull hydraulic braking system with enclosed, oil-immersed multiple discs oneach wheel. Independent circuits for front and rear brake systems. Warninglights and audible alarm indicate low brake system pressure. Brake systemconforms to ISO 3450, SAE J1473.




Emergency: Automatic application of driveline brake should pressure fall inmain brake hydraulic system. Service brakes may also be applied using theparking-emergency brake control.

Retardation: Standard engine brake and optional hydraulic retarder integralwith transmission.

SteeringHydrostatic power steering by two single-stage, double-acting, cushionedsteering cylinders. Emergency steering pressure is provided by a ground drivenpump mounted on the rear of the transmission. An audible alarm and warninglight indicates should the emergency system activate. Conforms to ISO 5010,SAE J53.

System Pressure........................................ 241 bar (3500 lbf/in²) Steering Angle to either side....................... 45° Lock to Lock Turns, steering wheel ............ 4

Body HoistTwo single-stage, double-acting hoist rams, cushioned at both ends of stroke.Electro servo assisted hoist control. System Pressure ........................................ 220 bar (3200 lbf/in²)Control Valve ................................................ Pilot Operated, Closed CentreBody Raise Time (loaded)............................. 12 secBody Lower Time (power down).................... 7.5 sec

9-14

Technical Data

ELECTRICAL SYSTEMType .............................................................. 24 volt, Negative GroundBattery ........................................................... Two,12 Volt, 143 Ah eachAccessories ................................................... 24 VoltAlternator ....................................................... 70 Amp

BODYOf all welded construction, fabricated from high hardness (min. 360 BHN) 1000 MPa (145000 lbf/in²) yield strength steel. 25° tail chute angle provides good load retention withouttailgate.Plate Thicknesses:

Floor and Tailchute ..................................... 14 mm (0.55 in)Sides .......................................................... 12 mm (0.47 in)Front ........................................................... 8 mm (0.31 in)


SERVICE CAPACITIESFuel tank ....................................................... 398 litre (103 US gal)Hydraulic System .......................................... 202 litre (53.4 US gal)Engine Crankcase and filters ........................ 34 litre (9.0 US gal)Cooling System ............................................. 55 litre (14.5 US gal)Transmission (including cooler) .................... 63 litre (16.6 US gal)Transmission Cooler ..................................... 8.25 litre (2.18 US gal)Differential - Front, IFS........................................ 26 litre (7 US gal)Differentials - Front [not IFS] and Rear (each) 28 litre (7.4 US gal)Differential - Centre ....................................... 31 litre (8.2 US gal)Planetaries (Front) ......................................... 11 litre (3.0 US gal)Planetaries - Centre & Rear (each) ............... 7.5 litre (2.0 US gal)Hand Pump Tank .......................................... 1 litre (0.26 US gal)Air Conditioning Compressor ........................ 0.125 litre (0.033 US gal)

9-15

Technical Data


Standard Vehicle kg lbNet DistributionFront Axle 11753 25913Centre Axle 5315 11718Rear Axle 5417 11942Vehicle, Net 22485 49573Payload 28000 61730Gross DistributionFront Axle 16821 37086Centre Axle 16740 36904Rear Axle 16924 37313Vehicle, Gross 50 485 111303Bare Chassis 17555 38703Body 4400 9700Body Hoists (Pair) 530 1170


Front 119 kPa (17.2 psi) 170 kPa (24.6 psi)Rear 54 kPa (7.8 psi) 170 kPa (24.6 psi)750/65 R25 Net LoadedFront 90 kPa (13.1 psi) 128 kPa (18.6 psi)Rear 41 kPa (5.9 psi) 128 kPa (18.6 psi)

VIBRATION






Operating Mode:


9-16

Technical Data



NOISE EMISSIONS



9-17

Technical Data

TECHNICAL DATA TA30 RS

GENERATION

2 400 (7-9)

2 200 (7-2)

1 310 (4-4)

2 945 (9-8)

4 920 (16-2)

5 010 (16-5)

1 690 (5-6)

1 410 (4-9)

2 175 (7-0)

725 (2-3)

2 895(9-6)

2 685(8-10)

2 895 (9-6)

9 755(32-0)

2 895(9-6)

3 420(11-2)

3 325(10-10)

405(1-6)

1 580(5-3)

3 450(11-3)

1 445(4-9)

6 110 (20-0)

45˚

65˚

Max.BodyDepth


8 470mm (27-9)8 950mm (29-4)

Dimensions in mm (ft-in)2188

ENGINEMake/Model ................................................... Cummins QSM 11TypeFour cycle diesel, turbocharged with air-to-air charge cooling, water-cooled.Electronic management.

Gross power at 1800 rev/min...............................272 kW (365 hp)Net power at 2100 rev/min...................................... 238 kW (319 hp)

Note: Gross power rated to SAE J1995 Jun 90. Engine emission meets USA EPA/CARB Tier III and EU NRMM (non-road mobile machinery) Tier III directive.

Maximum Torque..............................................1673 Nm (1234 lbf ft) at 1400 rev/minNumber of cylinders/configuration ................. 6, in lineBore x Stroke ................................................. 125 x 147 mm (4.92 x 5.79 in)Piston Displacement ..................................... 10.8 litres (661 in³)Air cleaner....................................................... Dry type, double elementStarting .......................................................... ElectricMaximum Speed (No load) ............................ 2350 rev/minMaximum Speed (Full load) .......................... 2100 rev/minIdle Speed ..................................................... 750 rev/min

9-18

Technical Data

TRANSMISSIONMake/Model...............................................................ZF 6WG 260 RPC Automaticwith manual override. The transmission assembly consists of a torque converterclose-coupled to a countershaft-type gearbox with integral output transfer gearing.Automatic shifting throughout the range, with kickdown feature. Lock up action inall forward gears. A torque proportioning output differential transmits drivepermanently to front and rear axles. This differential may be locked by the driver foruse in difficult traction conditions. Optional integral hydraulic retarder whichautomatically operates should the engine overspeed. Blocked filter indicator andfilter bypass system provide valve block with additional protection from unfilteredoil.Pressures:

Main............................................................ 16 + 2 bar (232 + 30 lbf/in²)Lockup (Wk)................................... ............ 14 ± 1 bar (190 ± 15 lbf/in²)Converter 'IN'............................................. 10.5 bar (152 lbf/in²) at 2300 rev/minConverter 'OUT'................................................ 4.8 bar (70 lbf/in²) at 2300 rev/minConverter Relief Valve................................ 8.5 bar (123 lbf/in²)Retarder........................................................ 5.5 bar (80 lbf/in²)

Temperatures:Normal........................................................ 80° - 110° C (176° - 230° F)Maximum....................................................... 120° C (248° F)

Stall Speed.........................................................1718 rev/minRatios:

Torque Converter.............................................1.84:1Transmission.................................................Refer to the table below



9-19

Technical Data

AXLESThree axles in permanent all-wheel drive with differential couplingbetween each axle to prevent driveline wind-up. Heavy duty axleswith fully-floating axle shafts and outboard planetary reductiongearing.

Transverse differential locks are activated by a request from the footoperated switch. When transverse differential locks are actuated thetransmission output differential lock will activate also.


SUSPENSIONFront: Axle is carried on the leading arms of a sub-frame which

pivots on the main frame. Suspension by rubber elements with twoheavy duty hydraulic dampers.

Rear: Each axle is coupled to the frame by three rubber- bushed linkswith lateral restraint by a transverse link. Pivoting inter-axle balancebeams equalise load on each axle. Suspension movement iscushioned by rubber/metal laminated compression units betweeneach axle and underside of balance beam ends. Pivot points onrear suspension linkages are rubber-bushed and maintenance-free.



Tyres:Standard...............................................................23.5 R25**Optional...............................................................750/65 R25**









9-20

Technical Data

Note: Tyre pressures should be regarded as nominal only. It is recommended thatfor tyres both listed and unlisted, the user should consult the tyre manufacturer andevaluate all job conditions in order to make the proper selection.

HYDRAULIC SYSTEMBraking, steering and body hoist systems are controlled by a manifold blockmounted on frame. Systems are supplied with oil from a common tank by the mainhydraulic pump, driven from power takeoff on transmission. System componentsare protected by full flow filtration on the return line.

Pump:Type............................................................ PistonCapacity at 2100 rev/min................................... 4.9 litre/s (77.4 US gal/min)

BrakesFull hydraulic braking system with enclosed, oil-immersed multiple discs on eachwheel. Independent circuits for front and rear brake systems. Warning lights andaudible alarm indicate low brake system pressure. Brake system conforms to ISO3450, SAE J1473.




Emergency: Automatic application of driveline brake should pressure fall in mainbrake hydraulic system. Service brakes may also be applied using the parking-emergency brake control.

Retardation: Standard engine brake and optional hydraulic retarder integral withtransmission.

SteeringHydrostatic power steering by two single-stage, double-acting, cushioned steeringcylinders. Emergency steering pressure is provided by a ground driven pumpmounted on the rear of the transmission. An audible alarm and warning lightindicates should the emergency system activate. Conforms to ISO 5010, SAE J53.

System Pressure ........................................... 241 bar (3500 lbf/in²)Steering Angle to either side ......................... 45°Lock to Lock Turns, steering wheel ............... 4Vehicle Clearance Circle (SAE) .................... 16.9 m (55 ft)

9-21

Technical Data

Body HoistTwo single-stage, double-acting hoist rams, cushioned at both ends of stroke. Electroservo assisted hoist control.

System Pressure ........................................... 220 bar (3200 lbf/in²)Control Valve .................................................... Pilot Operated, Closed CentreBody Raise Time (loaded) ............................. 12 secBody Lower Time (power down) .................... 7.5 sec

ELECTRICAL SYSTEMType.................................................................... 24 volt, Negative GroundBattery............................................................... Two, 12 Volt, 143 Ah eachAccessories ................................................... 24 VoltAlternator ....................................................... 70 Amp

BODYOf all welded construction, fabricated from high hardness (min. 360 BHN) 1000 MPa(145000 lbf/in²) yield strength steel. 25° tail chute angle provides good load retentionwithout tailgate.Plate Thicknesses:

Floor and Tailchute ..................................... 14 mm (0.55 in)Sides .......................................................... 12 mm (0.47 in)Front ........................................................... 8 mm (0.31 in)


SERVICE CAPACITIESFuel tank ....................................................... 398 litre (103 US gal)Hydraulic System .......................................... 202 litre (53.4 US gal)Engine Crankcase and filters ........................ 34 litre (9.0 US gal)Cooling System ............................................. 55 litre (14.5 US gal)Transmission (including cooler) .................... 63 litre (16.6 US gal)Transmission Cooler ..................................... 8.25 litre (2.18 US gal)Differentials - Front and Rear (each) ............. 28 litre (7.4 US gal)Differential - Centre ....................................... 31 litre (8.2 US gal)Planetaries (Front) ......................................... 11 litre (3.0 US gal)Planetaries - Centre & Rear (each) ............... 7.5 litre (2.0 US gal)Hand Pump Tank .......................................... 1 litre (0.26 US gal)Air Conditioning Compressor ........................ 0.125 litre (0.033 US gal)

9-22

Technical Data


Standard Vehicle kg lbNet DistributionFront Axle 11753 25913Centre Axle 5315 11718Rear Axle 5417 11942Vehicle, Net 22485 49573Payload 28000 61730Gross DistributionFront Axle 16821 37086Centre Axle 16740 36904Rear Axle 16924 37313Vehicle, Gross 50485 111303Bare Chassis 17555 38703Body 4400 9700Body Hoists (Pair) 530 1170


Front 119 kPa (17.2 psi) 170 kPa (24.6 psi)Rear 54 kPa (7.8 psi) 170 kPa (24.6 psi)750/65 R25 Net LoadedFront 90 kPa (13.1 psi) 128 kPa (18.6 psi)Rear 41 kPa (5.9 psi) 128 kPa (18.6 psi)

VIBRATION






Operating Mode:


9-23

Technical Data



NOISE EMISSIONS



9-24

Technical Data


10-1

Symbol Identification

10 - Symbol Identification

10-2



10-3


SYMBOL IDENTIFICATION

These pages explain the meaning of symbols that may appear on your machine.

Basic SwitchWarning 'Off' Hourmeter LockSymbol

Pressurised Negative Fast BasicCompartment Ground Engine

Master Ammeter Slow EngineSwitch Starter

Switch Circuit Lock Engine'On' Breaker Rev/Min

Engine 'Off' Basic Transmission Minimum Transmission Convertor or

Lockup Low

Emergency Transmission Air MaximumEngine Oil Pressure orShut Off High

Engine Transmission Air Filter BasicOil Oil or Hydraulic

Pressure Restriction Oil Symbol

Engine Transmission Starter HydraulicOil Oil Air OilPressure Temperature Pressure Filter

Engine Transmission Oil level HydraulicOil Oil Filter Oil FilterFilter Pressure

10-4


P

S

N

Hot Heating Light Flood HornHydraulic

Coolant Fuel Gauge Light Low WindshieldTemperature Or Beam Wiper

Fill tube

Coolant 'cold' Fuel Filter Light High Windshield Beam Defroster

Coolant 'Hot' Fuel Instrument Windshield Shut-Off Panel light Washer

Cooling Basic Lamp Test Blower Fan Lights Symbol

Heater Parking Low Steering Body 'Hold'Brake Pressure

Air Brake Oil High Speed BodyConditioner Temperature or Level 'Lower'

Inside Turn Left Low Speed BodyAir or Level Float'Circulation

Outside Turn Right Body Up DumpertruckAir 'Retarder'

Parking Brake Tilt Steering Body 'Raise' Neutral

10-5


STOPLift Point Clutch Bowl Engine

'Disengaed' Suspension Stop

Brake Trans.Do Not Lift Applied Maintenance Over speed

ClutchEngaged

Forward Brake Battery Applied Transmission Power Clutch Convertor Disengaged

Reverse Water in Brake air Engine Fuel Pressure Air Filter

Clutch Wait to Engine Brake'Engaged' Start Check Cooling

OilPressure

L

H

Brake Cooling Body up Trans. DropboxOil Temp. Oil Temp. Oil Temp.

Dropbox Oil Trans. Engine DropboxPressure Retarder Brake Low Ratio

DropboxHigh Ratio

10-6


NOTES

10-7


NOTES

10-8


NOTES

Documents

OHE897 cover - Terexconstructionsupport.terex.com/_library/technical... · and articulation pivot joint between the tractor and trailer units. Articulation is achieved by frame steering