camion de obra tr35 tier iii ohe877 om

TEREX Equipment Limited Operator Handbook

Ope

rato

r H

andb

ook

TR

35

Tie

r3

CLICK HERE TO RETURN TO MAIN LIBRARY INDEX15503183

OHE877

Blank Page

TEREX Equipment Limited Operator Handbook Re-Order

Ope

rato

r H

andb

ook

TR3

5 T

ier3

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

OHE877

Re-Order Part Number15503183

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

revision August 2006

Blank Page

TEREX Equipment Limited Operator Handbook - Introduction

OperatorHan

dbook

TR35Tier3

For further information on the subject matter detailed within this operator handbook,please refer to Terex Equipment Limited Service 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 thebest of our knowledge, were correct at the time of print. The right to changespecifications, equipment and maintenance instructions at any time without notice, isreserved as part of the Terex Equipment Limited policy of continuous developmentand 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 toensure that information is current.

Blank Page

ONLY TRAINED PERSONNEL SHOULD BEALLOWED TO OPERATE THIS VEHICLEThe operator is responsible and must be

familiar with the contents of the Operator'sHandbook and any local regulations prior to

operating this vehicle.

Blank Page

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, chemicalsknown to the State of California to causecancer and reproductive harm.Wash hands after handling.

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.

MANUFACTURERS NAME AND FULL ADDRESSTEREX EQUIPMENT LIMITED,MOTHERWELL,SCOTLAND,ML1 5RY

DESCRIPTION OF MACHINERY DIRECTIVES COMPLIED WITHMAKE: TEREX 87/404/EEC 97/23/ECMODEL: TR35 RIGID TRUCK 89/336/EEC

98/37/EEC2000/14/EC

UNIT SERIAL NO. DATE OF MANUFACTURE:INSPECTOR:THE ABOVE MACHINERY, TAKING INTO ACCOUNT THE STATE OF THE ART,COMPLIES WITH, OR IS DESIGNED AND CONSTRUCTED AS FAR AS POSSIBLE TO COMPLY WITH,THE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS OF THE MACHINERY DIRECTIVE.

FOR AND ON BEHALF OF THE MANUFACTURER:

NAME: PAUL DOUGLAS SIGNATURE:POSITION: CHIEF ENGINEER

EC DECLARATION OF CONFORMITY

1-1

CONTENTS1. INTRODUCTION

Introduction 1-5Safety Precautions 1-5Machine Identification 1-6Theft Deterrent Practices 1-6

2. SAFETY PRECAUTIONSGeneral 2-4Vehicle 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 2-10Wheels and Tyres 2-13

Avoid Tyre Explosion Hazard 2-133. CONTROLS AND OPERATING

Controls and Instruments 3-3Basic Data 3-4

Warning Lights 3-4Instruments 3-6Switches 3-7Controls 3-9Heater 3-10Air Conditioner 3-10Operator's Seat -

Air Suspension 3-11Seat Belt 3-12

Machine Controls .............. 3-13Braking ............................ 3-13Service Brake ................ 3-13Park/Emergency Brake . 3-13Retarder ........................ 3-14

Engine ............................. 3-16Electronic Foot Control .. 3-16Quantum Fuel System... 3-16Description .................... 3-17Operation....................... 3-18

Steering ........................... 3-20Transmission ................... 3-21Description and Operation 3-22Gearshift Controller ....... 3-23

Body Control ................... 3-29Raising the Body ........... 3-30Lowering the Body......... 3-30

1-2

Blank Page

1-3

4. OPERATING THE TRUCKPre-Starting Inspection 4-3Component Checks 4-4Suspension Ride Struts 4-6Engine Operation 4-7Starting the Engine 4-8Starting the Engine with

Jumper Cables 4-10Pre-Operating Checks 4-11Brake Function Checks 4-12Driving and Stopping 4-13Stopping the Engine 4-14Parking 4-16

5. WORKING THE TRUCKWorking the Truck 5-2

Loading 5-2Hauling 5-4Dumping 5-5Empty Return 5-7

6. ROADINGRoading 6-2

General 6-2Preparation Prior to Roading 6-2In Case Of Trouble 6-4

7. MOVING DISABLED TRUCKMoving Disabled Truck 7-2

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

9. TECHNICAL DATATechnical Data - TR35 9-3

10. SYMBOL IDENTIFICATION

1-4

Blank Page

1-5

INTRODUCTIONThis Handbook is provided as a guide to familiarize the operator andserviceman with the controls, recommended inspections, start-up,operating, shutdown and parking procedures for TR45 & TR60 RigidTrucks.

Look for the safety alert symbol to point out important safetyprecautions. It means:

ATTENTION! BECOME ALERT! YOUR SAFETY AND THESAFETY OF OTHERS IS INVOLVED!

Safety PrecautionsThe machine should be properly operated and maintained to keep itin safe, efficient operating condition. Be sure that all controls are freeof mud, grease, or other matter that might cause slips hazardous tothe operator, serviceman, or other personnel or equipment. Reportall malfunctions to those responsible for maintenance, and, do notoperate the equipment until corrected. Normal service ormaintenance performed as required can prevent unexpected andunnecessary 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, forother than normal conditions or situations, and therefore, servicemenand operators must be safety conscious and alert to recognizepotential servicing or operating safety hazards at all times, and take,necessary precautions to assure safe servicing and operation of themachine.

WARNINGThese 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 thispublication are based on the latest product information available atthe time of publication. The right is reserved to make changes at anytime without notice.

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

This Handbook contains lubrication and routine servicinginstructions, most of which can be performed in the field.Maintenance manuals containing repair/rebuild procedures can beobtained from your dealer.

Introduction

Safety alert symbol

1-6

1860

Intended use of machineThis product and its approved attachments are primarily intended tobe used as described in this manual.Use of this product in any other way is prohibited and contrary to itsintended use.

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

Information regarding the machine model, code and chassis serialnumber is found on the unit serial number plate on the rear right ofthe front frame. The machine model and serial number shouldalways be referenced in any correspondence with your dealer orfactory.

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.

Theft Deterrent PracticesGeneralThe owner/operator should take the following precautions todiscourage theft, to aid in the recovery in the event that the machineis stolen, 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-vandalismand anti-theft devices on the machine.

Introduction

1-7

Immobilise the machine by removing a critical electrical or startingsystem device.

Upon receipt of a machine, record the machine serial number andthe serial numbers of all major components and attachments. Keepthis list up to 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 andask the local law enforcement authorities to make frequent checksaround the storage yard or work site.

Establish liaison with neighbours and ask them to watch equipmentleft at job sites and to report any suspicious activities to the local lawenforcement authorities.

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 enforcementauthorities having jurisdiction. Provide the investigating officer withname, type of equipment, chassis and serial numbers of majorattachments and components. It is helpful to show the investigatingofficer an Operators Handbook, photographs, and advertising, tofamiliarize him with the appearance of the machine.

Report the theft to the insurance company. Provide the model and allserial numbers.

Report the model and serial numbers of the stolen machine to adealer handling the respective line of equipment. Request that thedealer forward this same information to the equipment manufacturer.

Introduction

1-8

Blank Page

2-1

Safety Precautions

2 - Safety Precautions

2-2

Safety Precautions

Blank Page

2-3

Safety Precautions

SAFETY

Safety Alert SymbolThe safety alert symbol is used to alert you to a potential personalinjury hazards. Obey all safety messages that follow this symbol toavoid possible injury or death.

Hazard ClassificationA multi-tier hazard classification system is used to communicatepotential personal injury hazards. The following signal words usedwith the safety alert symbol indicate a specific level of severity of thepotential hazard. Signal words used without the safety alert symbolrelate to property damage and protection only. All are used asattention getting devices throughout this manual as well as on dealsand labels fixed to the machinery to assist in potential hazardrecognition and prevention.

Safety alert symbol

DANGER

WARNING

CAUTION

CAUTION

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

WARNING indicates an potentially hazardous situation which,if not avoided, could result in death or serious injury.

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

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

2-4

Safety Precautions

SAFETY PRECAUTIONSGeneral* Read this Operators Handbook and learn the operating

characteristics and limitations of the vehicle. Know what operatingclearances the vehicle requires.

* 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 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 toavoid fire 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 thepassenger seat.

WARNINGThe 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.

1782

1768

SAFE

TY

MANU

AL

1767

1769

2-5

Safety Precautions

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

wheels blocked, steering and oscillation lock bar connected, andthe parking brake disengaged.

* 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 further information.

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.

1042

1043

Vehicle Lifting Instructions

Vehicle Tie Down Instructions

2-6

Safety Precautions

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 loose orleaking lines, fittings etc..

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

* Dont 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 parking andleaving the vehicle unattended.

Flammable Fluid Precautions* Dont 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 checking forfluid 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 spout istouched 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 all volatileinhibitor fluids and compounds used.

FUEL

1770

1789

2-7

Safety Precautions

* Follow manufacturers recommendations when handling andusing engine-starting fluids and disposing of spent containers. Donot puncture or burn empty containers. These fluids are explosiveand 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 system toavoid danger of fire-causing sparks. Disconnect battery groundcable first and reconnect last.

* Always disconnect batteries & alternator leads before carryingout 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 manufacturers recommendations for use to avoid electricaland/or fire hazards.

Mounting and Dismounting* Only use steps and hand holds provided to mount or dismount

the vehicle. Do not grasp steering wheel.

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

* Always use care when mounting the vehicle with oil covered,frosted, or iced fenders, decks, hand holds or steps.

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

1771

1772

2-8

Safety Precautions

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-X 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 vehicles neutral-start system. The neutral-start system must be repaired if it malfunctions.

* Start and operate the vehicle only from the operators 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.

* In the event of a loss of steering pump output pressure, a fully-pressurized accumulator provides a maximum of two lock to lockturns of the front wheels. A red warning light on the instrumentpanel illuminates when steering pressure falls below 83 bar (1 200lbf/in) If this light illuminates, indicating a loss of steering power,

1773

1861

DO NOT

OPERATE

1775

1862

2-9

Safety Precautions

the machine must be stopped immediately and no furtheroperation attempted until the fault is corrected.

* 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.

* Watch for ground crew and other personnel on foot. Soundhorn as 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, dustor similar hazards limit visibility. Do not overdrive your headlights.

* 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 maintain safespeed with the service brakes or/and retarder. Always maintainsafe speeds for haul road operating conditions for maximumcontrol. 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, apply the parkingbrake and do not operate until the fault is corrected.

* 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 indicates a fault in the brakingsystem.

* 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. 1779

1778

1774

2-10

Safety Precautions

Roading* Match speed to road conditions.

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

* Stay as close to the side of the road as possible. Pass otherequipment only when the road is clear and enough room / space topass 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 Operators Handbook and the MaintenanceManual before starting, operating or servicing this vehicle. Alwaysfollow procedures and safety precautions detailed throughout theMaintenance 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 must onlybe used when the body is empty.

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

Body Safety Pins1863

1780

1777

Operating (continued)* Always apply the brakes with the Parking-Emergency brake

control when the vehicle is being loaded or when dumping a load.

* 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 page 4-14 before leaving the vehicle unattended. If on a grade wheelsshould be blocked.

Pending Image

2-11

Safety Precautions

* 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 the vehicleexcept as called for in this Operators Handbook or theMaintenance Manual.

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

* When changing oil in the engine, transmission and hydraulicsystems, or removing hydraulic lines, remember that the oil may behot 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 from thevehicle.

* 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 raisedoperators cab. Ensure any lifting devices are adequate for the jobwhich they are intended.

2-12

Safety Precautions

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.

NOTICETYRES ON THIS VEHICLE ARE FACTORY INFLATED WITHDRY NITROGEN. IT IS RECOMMENDED THAT DRYNITROGEN BE USED EXCLUSIVELY FOR ALL TYREPRESSURE ADJUSTMENTS AS WELL AS INFLATION OFREPLACEMENT TYRES.

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.

WARNINGNever mix components of one manufacturers 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.

2-13

Safety Precautions

Avoid Tyre Explosion Hazard

WARNINGWhenever a vehicles 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 stayclear of 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 (1 500 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.

172

AT LEAST460 m (1 500 ft)AT LEAST

15 m (50 ft)

2-14

Safety Precautions

Blank Page

3-1

Controls and Operating

3 - Controls and Operating

3-2


Blank Page

3-3


CONTROLS AND INSTRUMENTS

1698

1 2 3 4 5 6 7 8 9 10 12 1311 14 15 16

17

1819

20

21

24252627

28

2930

31

323334

35

36

22

2337

38

CONTROLS AND INSTRUMENTS

1. Face Vent/Side Window Demister2. Warning Lights3. Tachometer/Hourmeter4. Engine Water Temperature Gauge5. Engine Oil Pressure Gauge6. Air Pressure Gauge7. Fuel Gauge8. Warning Lights9. Transmission Oil Pressure Gauge

10.Transmission Oil Temperature Gauge11.Speedometer/Odometer12.Warning Lights13.Face Vent14.Cup Location15.Windscreen Demister16.Side Window Demister17.Document Holder18.Fuse Box Cover19.Transmission Gear Shift Selector20.Ignition and Starter Key Switch21.Braking Control Valve

22.Retarder Control23.Park/Emergency Brake Control24.Switches25.Blower Control26.Air Conditioner Control27.Heater Control28.Accessory Lamp Socket29.Accelerator Control30.Service Brake Control31.Steering Wheel32.Steering Wheel Adjustment Lock33.Headlight Dipper, Direction Indicator,

Windscreen Wiper/Washer and HornControl

34.Radio/Cassette Player35.N/A36.Foot Rest37.Body Control Lever38.Electric Window Switch39.Interior Light (Not Shown). Located above

dash.40.Cup Holder (Not Shown). Located on

back wall.

3-4


BASIC DATA

1626

BASIC DATAWarning Lights1. Alternator Charging (Red) - Illuminates to indicate when thealternator is not charging.2. Engine Water Temperature (Red) - Illuminates when the enginewater temperature rises above the safe operating temperature.3. Engine Water Level (Amber) - Illuminates when the engine waterlevel drops below the safe operating level.4. Air Cleaner Restriction (Amber) - Illuminates to indicate that theair filters are needing cleaned or replaced.5. Engine Oil Pressure (Red) - Illuminates when the engine oilpressure drops below the safe operating pressure.6. Engine Stop Light (Red) - When the 'Stop' light comes on, thecomputer has detected a major malfunction in the engine thatrequires immediate attention. Stop the machine when this lightilluminates and do not operate until the fault is corrected.7. Engine Warning Light (Yellow) - When the 'Warning' light comeson, the computer has detected a fault in the engine which may resultin a power loss. The fault should be diagnosed and corrected at theearliest opportunity.8. Engine Protection Fluid Light (Amber) - Illuminates when a faulthas been detected in the engine. Light remains on as long as the faultis occurring. The fault should be diagnosed and corrected at the earliestopportunity. If the fault continues to get worse the light will flash and theengine power and/or speed will be gradually reduced. Stop the machineand do not operate until the fault is corrected.9. Low Air Pressure (Red) - Illuminates when the air systempressure drops below 5.5 bar (80 lbf/in). An alarm also sounds. Theservice brakes will automatically apply if air pressure drops toapproximately 3.1 bar (45 lbf/in). Stop the machine if this lightilluminates and do not operate until the fault is corrected.

STOP

P

1 2

1

2

3

4

5

6

7

8

9 10 11 12

13 14 15 1617

18

19

20

21

22

23

24

3-5


Warning Lights (continued)

10. N/A11. Low Steering Pressure (Red) - Illuminates when the steeringsystem oil pressure drops below 83 bar (1200 lbf/in). Stop themachine when this light illuminates and do not operate until the faultis corrected.12. Steering Tank Low Oil Level (Red) - Illuminates when the levelin the tank falls below the safe operating level. Stop the machinewhen this light illuminates and do not operate until the fault iscorrected.13. Parking Brake (Green) - Illuminates when the parking brake isapplied.14. Headlight Main Beam (Blue) - Illuminates when headlights areoperated on main beam.15. Direction Indicator (Green) - Flashes when the indicator lightsare operating.16. Body-up (Amber) - Illuminates to indicate that the body is NOTresting on the chassis. Never move the machine until this light goesOUT.17. Transmission Oil Temperature (Red) - Illuminates when thetransmission oil temperature rises above the safe operatingtemperature.18. N/A19. Retarder Indicator (Amber) - Illuminates when the retarder isapplied.20. N/A21. Check Trans (Red) - Illuminates to alert of a fault in thetransmission shift system or abnormal transmission temperature.The light will illuminate when the ignition keyswitch is turned toposition '1' to provide a bulb and system check and should go off afew seconds after the engine is started.22. Steering Filter Restriction (Amber) - Illuminates when the filteris restricted, indicating that a filter change is required.23. N/A24. N/A

Gustavo.PasqualeHighlight



3-6


Instruments

1652

1. Engine Water TemperatureGauge - This gauge should read in the greenzone, after the engine has warmed. If gaugereads in the red zone, stop the engine until thefault is corrected.2. Tachometer/Hourmeter - Driven from theengine ECM, the tachometer indicates the enginespeed in revolutions per minute. The needleshows the variations in engine operating speed.Never accelerate the engine to speeds indicatedby the red zone on the dial face. A digitalhourmeter is incorporated in the tachometer torecord total hours of engine operation. Thereadings can be used for operating and servicerecords.3. Engine Oil Pressure Gauge - This gaugeshould read in the green zone at normal operatingspeeds. Stop the engine if the needle does notrise above the red zone until the fault is corrected.4. Fuel Gauge - Indicates the level in the fueltank. Fill the tank before parking the machineovernight to minimize condensation in the tank.Avoid a dry tank condition which requiresbleeding the fuel system.5. Air Reservoir Pressure Gauge - Indicates airpressure in the main air tanks. The gauge shouldread within the green zone during truck operation.This amount of pressure should be available toeffectively slow or stop the machine. If the needleremains in the red zone, do not operate themachine until the fault is corrected.6. Transmission Oil PressureGauge - Indicates transmission clutch applicationoil pressure. The reading will vary during shiftsand with varying speeds and loads. The needleshould remain in the green zone during normaloperation.The needle may fall momentarily intothe lower red zone.If the needle remains in the red zone for extendedperiods, stop the machine until the fault iscorrected.7. Speedometer/Odometer - Driven by a signalfrom the transmission, the speedometer indicatestravel speed in kilometres per hour and miles perhour. A digital odometer is incorporated in thespeedometer to record the distance travelled bythe vehicle at any given time.

1653

0

5

1015

20

25

RPM x100

30

ENGWATER TEMP

ENGOIL PRESS

P

1

1

2 3

4

0

10

3020

40

km/h50

MPH2020

20

20

OIL TEMPTRANS50 150

120 140

OIL PRESSTRANS

P

1

AIR PRESSSERVICE 5

6

7

8

WARNINGNever release the parking brake to movethe machine until at least7.2 bar (105 lbf/in) reservoir air pressureis indicated on the gauge. (Needle wellinto the green zone).

3-7


Left Hand Panel1700

Switches1. Hazard Warning Lights - Press bottom of switch to make turnindicators flash simultaneously as hazard warning lights. The light inthe switch and direction indicator warning light on the right hand dashpanel will flash. To switch hazard lights off; press the top of theswitch.2. Position not used.3. Position not used.4. Position not used.5. Engine Brake - Allows the operator to request the engine brake. Itis a 3 position switch. When pressed at the top is the off position.Centre position selects engine brake low setting. Pressed in at thebottom selects engine brake high.6. Retarder Request Switch - Allows the operator to request thetransmission retarder.

7. Sidelight and Headlight - Press bottom of switch to the firstposition to operate side, tail and panel lights. The lights in the otherswitches will illuminate. Press switch to the second position tooperate the headlights. To switch lights off; press the top of theswitch.8. Position not used.9. Warning Light Test Switch - Pressing the switch with the ignitionswitched on will illuminate warning lights 1, 2, 3, 4, 5, 9, 10, 11, 17,18, 20, 22 and 23 and the buzzer will sound, to provide a bulb andsystem check. Refer to 'Warning Lights' section on pages 4, 5 and 6for details. The light in the switch will illuminate with the panel lights.10. Diagnostic Request 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', 'Warning' and 'Fluid' lightswill illuminate and stay on. If active codes are recorded the 'Stop','Warning' and 'Fluid' lights will illuminate momentarily. The yellow'Warning' and red 'Stop' lights will begin to flash the code of therecorded fault. Refer to pages 25 & 26 for details of the fault codes.Note: If switch is pressed 'ON' during normal operation, the 'Stop'light will illuminate, however, this does not indicate an enginemalfunction and the light will go out when the switch is pressed'OFF'.

1478 Right Hand Panel

TEST

7 8 9 10 11 12

8. Transmission Oil Temperature Gauge - This gauge should readin the green zone during normal operation. When using the retarderor during converter mode the needle may enter the yellow zone. Ifthe needle enters the red zone stop the vehicle and investigate.

HAZARD

1 2 3 4 5 6

M

3-8


17

11. Diagnostic Search Switch - When the engine is in diagnosticmode this switch is used to search through a list of fault codes, ie.pressing the top of the switch momentarily will advance to the nextactive fault code, pressing the bottom of the switch will go back to theprevious code.On machines which have a Low Idle Adjustment feature, this switchcan also be used to increase or decrease (in increments of 25 RPM)the idle or intermediate speed of the engine.12. Position not used.13. Ignition and Starter Key Switch - The combined switchoperates the ignition and starter motor. The key can only bewithdrawn from position '0'.'0' - Ignition switched off. Disconnects the batteries making allelectrical systems inoperative (with the exception of a supply to theECM & CEC memory, interior light and to the radio). This positionalso cuts off fuel to shut down the engine.'1' - Turn key clockwise to connect the batteries to the electricalsystems.'2' - 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.

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

14. Remote Diagnostic Test Point - (Located on the front of theinstructor seat). Plug in connector for diagnostic tooling.15. Electric Window Switch - Press bottom of switch to lowerwindow; press top of switch to raise window.

01

2

3

1031 13

1765 14

1174

15

3-9


ControlsHeadlight Dipper, Direction Indicator, Windscreen Wiper/Washerand Horn

1. Headlight Dipper and Flasher:Control downwards = Main BeamNeutral Position = Dipped BeamControl Upwards = Headlight Flash

2. Direction Indicator:Control rearwards = Left IndicatorsControl forwards = Right Indicators

3. Windscreen Wiper/Washer:Position J = Intermittent WipePosition 0 = Neutral PositionPosition 1 = Wiper Slow SpeedPosition 2 = Wiper Fast SpeedRing Pushed = Windscreen Wash

4. Horn:Button pushed in = Horn Sounds

340 1

341 2

342 3

343 44444

3-10


HeaterBlower control (2) is rotated to select one of three blower speeds.Temperature control (1) is rotated to vary heater output temperature.Heater output air is unheated with the control turned fullyanticlockwise and heated by turning clockwise.Heater/air conditioner outlets (4) may be adjusted to control air flowoutput by opening and closing the control flaps. Air direction can beadjusted by rotating complete outlet.

Air ConditionerKeep all windows and vents closed.Blower control (2) is rotated to select one of three blower speeds.The air conditioning will not operate if the blower control is notswitched on.Temperature control (3) adjusts the air conditioner outputtemperature. Rotating the control to the right provides maximumcooling.Heater/air conditioner outlets (4) may be adjusted to control air flowoutput by opening and closing the control flaps. Air direction can beadjusted by rotating complete outlet.

1 2 3

1 2 3

1105

1389

4 4 4

3-11


Operator's Seat - Air SuspensionThe air seat only reacts when the driver sits on the seat. Whenunoccupied the seat sinks to the lowest position to allow easier access.The incorporated suspension block out maintains seat in position fordriving.

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

1. Height and slope adjustment, front.

2. Height and slope adjustment, rear.

3. Backrest adjustment.

4. Horizontal adjustment.

5. Weight adjustment

6. Air lumber support adjustment. Press buttons to inflate or deflate thetwo air cushions in the back of the seat, to suit the exact shape of thedrivers back.

WARNINGDo not attempt to adjust the seat or seat belt while the machineis moving. Loss of control may result. Stop the machine; applythe brakes; then adjust.

6

1

2

4

3

5

1650

3-12


Seat BeltA 4-Point integrated Harness is installed on the operators seat. Theoperators belt should be buckled up and adjusted via the lapbelttension on the sides of the seat.

A retractable seat belt installed on the jump seat.The jump seat beltrequires no external adjustment. Both belts allow freedom ofmovement for proper manipulation of all controls.

WARNINGSAlways 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 seat belt at least once every three years, regardlessof appearance.Do not attempt to adjust seat or seat belt while machine ismoving.Loss of control may result. Stop machine; apply brakes; thenadjust.

1657 Operators Seatbelt

1656 Pasenger Seatbelt

Trainer / Instructor SeatThe trainer / instructor seat has only to be used when operatortraining or instruction is being performed or for service personnelperforming service diagnostics.Note: The trainer / instructor seat is NOT for continuous passengeruse.

3-13


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

A 'Front Brake Accumulator' warning light and a 'Rear BrakeAccumulator' warning light are located on the instrument panel. If anyof these lights illuminate during operation, stop the machine, applythe parking brake and do not operate until the fault is corrected.

Service BrakeThis is a floor mounted pedal operated by the right foot. Depress thepedal as required by speed, load and road conditions to slow or stopthe machine. Release the pedal as the machine slows until, whenstopped, the pedal is depressed just enough to hold it stationary.

Braking Control ValveUnder normal operating conditions, the braking control valve shouldbe in the 'DRY' position so that the brakes on all wheels are appliedwith equal air pressure. On soft or slippery surfaces, the brakecontrol valve should be placed in the 'SLIPPERY' position. Thisreduces the air pressure directed to the front wheels to aid machinecontrol under such adverse conditions.

Note: Be sure to return the brake control valve to the 'DRY' positionwhen operating under normal conditions.

Parking/Emergency BrakeThe service brakes are applied and locked in the applied position forparking by the Parking/Emergency Brake lever on the centreconsole.For normal operation the lever should always be in the 'RELEASE'position which permits normal braking with the service brake pedal.To lock the service brakes in the applied position for parking, movethe Parking/Emergency lever to the 'EMERGENCY' position for 3seconds and then to the 'PARK' position. The 3 second pause in'EMERGENCY' releases the brake chamber locking mechanism andapplies the brakes; and moving the lever to the 'PARK' positionprevents accidental release of the locked up service brakes byapplication of the foot pedal.To release the service brakes from the locked 'PARK' position, withthe system fully charged, move the control lever to the'EMERGENCY' position for 3 seconds and then to 'RELEASE'. If thebrakes do not release, make a full pedal brake application for 5seconds.

251

072

050



3-14


WARNINGDo not use the retarderfor parking the vehicle.Only use the parking-emergency brakecontrol for this purpose.

RetarderThe control lever (1) is used to apply retardation to the truck.Retardation is the term used for applying a continuous braking forceto hold the truck to a safe steady speed when descending grades.Retardation of this truck may be achieved by using theTRANSMISSION RETARDER. The retarder has 6 stages ofretardation available, depending upon the severity of braking which isrequested by the operator.The retarder is OFF when the lever is fully forward and is APPLIEDas the lever is pulled back. Maximum retardation is obtained whenthe lever is in the fully back position. The retarder may be usedanytime to slow down. If additional braking is required apply theservice brakes. The retarder is not meant for bringing the machine toa halt, or for sudden deceleration - the service brakes should beemployed for this purpose.When the retarder is applied, the 'Retarder Indicator Light' on theinstrument panel will illuminate and an orange coloured warning lightat the rear of the truck will illuminate to warn following vehicles.The operator should select the correct gear range to match the siteconditions.Note: In order to obtain the maximum retardation and cooling effectduring retardation, the engine speed should be maintained as highas possible without exceeding the maximum recommendation.Retarder OperationBefore the machine crests the top of a grade and starts down, theoperator should slow the machine with the service brakes anddownshift to the gear range which would be used to ascend thegrade. The retarder should be applied before starting the descent.Machine downgrade speed (with the retarder applied as required) in

Moving the lever to the 'EMERGENCY' position while moving willapply the service brakes as described above, but this practice isrecommended only for emergencies; never for normal braking. The'EMERGENCY' position can be used to hold the machine stationarywhen loading or dumping .If air system pressure drops to 5.5 bar (80 lbf/in) the low air pressurewarning light will illuminate to alert the operator that the system islosing pressure and that an automatic brake application can beexpected. The machine should then be stopped and parking brakeapplied to hold it stationary until the cause of pressure loss iscorrected and air system recharged.

WARNINGAlways apply the parking brake before leaving the operator'sseat.

1699

1

2

3-15


the gear range selected should be high enough to keep the engineoperating at governed speed with the throttle closed (operator's footoff the accelerator pedal). This will ensure maximum oil circulationand cooling. If the rate of descent is too slow, the transmissionshould be upshifted to the next highest gear range. If the rate ofdescent is too fast, the gear range selected is too high and theoperator must slow the machine by using the service brakes, thendownshift into a lower gear range which will allow a safe descent andefficient retarder operation.

Oil Temperature - TransmissionDuring normal operation the transmission oil temperature gaugeshould read in the green zone. However, during transmissionretarder operation oil temperature can enter the yellow 'RETARDERON' zone but should not enter the red zone. Do not allow thetemperature to stay at or near the top of the yellow zone for morethan 3 minutes. Reduce downgrade travel speed to avoid the oiloverheating and possible damage to the transmission.

WARNINGGreat care should beused if applying theretarder when roadsurfaces are slippery.Retarder braking effectwill occur only at thedriving axle and couldmake vehicle controldifficult.

Engine BrakeThe engine brake is activated by pressing the engine brake switch(5). Pressing the switch to the first position will engage low enginebrake. Should an increased level of braking be desired, pressing thethe engine brake switch to the second position will engage highbraking effort. The engine brake applies a continuous braking forceto hold the truck to a safe steady speed when descending grades, toreduce the need for service brake applications, thus reducing servicebrake wear and preventing overheating. The engine brake may beused any time to slow down. To slow the machine even further,apply the service brakes. The engine brake is not meant for bringingthe machine to a halt, or for sudden deceleration - the service brakesshould be employed for this purpose.OperationBefore the machine starts down the grade, request the engine brakeand release the accelerator. The gear selected should be highenough to keep the engine operating at governed speed. Generallythe gear used to ascend a grade is also correct for its descent. If therate of descent is too slow, the transmission should be upshifted tothe next highest gear. If the rate of descent is too fast, the servicebrakes should be applied and the transmission shifted into a lowergear which will allow a safe descent and efficient engine braking. Iffurther braking is required, apply the service brakes.

Left Hand Panel1700

HAZARD

1 2 3 4 5 6

M

3-16


EngineElectronic Foot PedalThe electronic foot pedal provides an electronic signal to the engine'sfuel control system in proportion to the degree of pedal actuation.

Note: The electronic controlled engine will override the electronicfoot pedal position until the engine is warmed up to the correctoperating temperature. The engine MUST be started with the foot'OFF' the electronic foot pedal.

QUANTUM Electronic Fuel SystemThis machine is equipped with the Quantum Electronic Fuel System,an electronic engine control system, which continually monitors theengine and warns the operator when a problem develops. Thesystem also takes action to prevent damage to the engine and,provides the serviceman with diagnostic capabilities so that problemscan be corrected quickly and easily.

WARNINGBefore any welding is done on a machine equipped with theQuantum Electronic Fuel System, disconnect the following inthis order: Battery earth cable, battery supply cable,alternator earth cables, alternator supply cables,transmission connector, ECM interface harness connector(30 pin RHS), ECM powerharness connector (5 pin RHS) andECM sensor harness connector (30 pin LHS). Turn offignition key switch to isolate the batteries beforedisconnecting any components.After welding connect all of the above in the reverse order.

255

3-17


1486

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

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

7 - 'Fluid' Light8 - Diagnostic Test Points9 - Diagnostic Switches

STOP

TEST

4

5

6

7

8

3

1,2

8

9

QUANTUM Electronic Fuel System - Description1. Electronic Control Module (ECM) - Receives electronic inputs from the driver as well asfrom sensors that provide information electronically, such as oil pressure and temperature andintake manifold pressure. This information is used to control both the quantity of fuel injectedand injection timing.

2. Programmable Read Only Memory (PROM) - Located in the ECM and encoded with theoperating software. Additional information is programmed into the EEPROM. This informationcontrols the horsepower rating, torque curve, maximum engine speed and engine protectiondevices. The ECM processes this information and sends electronic signals to the ElectronicFuel System Injectors where the precise amount of fuel is injected into the engine.

3. Electronic Fuel System Injectors - The injector is a lightweight, compact unit that injectsdiesel fuel directly into the combustion chamber. The amount of fuel injected and the beginningof injection timing is determined by the ECM. The ECM sends a command pulse whichactivates the injector solenoid.

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 the load.c - Atomizes the fuel for mixing with the air in the combustion chamber.d - Permits continuous fuel flow for component cooling.

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

Note: Never apply 12 or 24 volts directly to terminals on the injector or engine sensors as theywill burn out. Before removing injectors, the fuel passages must be blown out to prevent fuelflow from entering the cylinder head.

3-18


QUANTUM Electronic Fuel System - OperationWhen the 'Stop' light on the dash panel illuminates, the computer hasdetected a major malfunction in the engine that requires immediateattention. It is the operators responsibility to shut down the engine toavoid serious damage.The machine is equipped with an engine protection derate system,which records fault codes when an out-of-range conditions is found.The 'Fluid' light illuminates when the engine protection derate system isinitiated. The engine power and speed will be gradually reduceddepending on the level of severity of the out-of-range condition. The'Fluid' light will start to flash if the out-of-range condition continues toget worse. The operator MUST shut down the engine to avoid seriousdamage.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.Conditions that will cause the amber 'Fluid' light to come on are; Lowcoolant level, High coolant temperature, Idle validation/throttle pedalswitch mismatch, High intake manifold temperature, Low oil pressureand High fuel rail pressure.Whenever the 'Stop', 'Warning' or 'Fluid' light comes on, the ElectronicFuel System computer will determine where the problem is and willstore this information in its memory. If the malfunction is intermittent,the lights will come on and go off as the computer senses the changingengine condition.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.The data reader can now distinguish between active codes and thosestored in the historic code memory (inactive codes). Inactive codes canonly be viewed using the data reader. The fault code recorded in theECM memory will remain until it is erased by a technician.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, all three ('Stop', 'Warning' & 'Fluid') lights will comeon and stay on. If active codes are recorded, all three lights will comeon momentarily. The yellow ('Warning') and red ('Stop') lights will beginto flash the code of the recorded fault. The fault codes flash in thefollowing sequence: the yellow light flashes once, then there is a pausewhere both lights are off. Then the numbers of the recorded fault codeflash in red. There is a pause between each number. When the numberis done, the yellow light flashes again. e.g. yellow flashes once - pause- red flashes twice - pause - red flashes three times - pause - redflashes five times - pause - yellow flashes once, indicates fault code235. The number will repeat in the same sequence until the system isadvanced to the next active fault code or the diagnostic switch isswitched to the 'OFF' position. Refer to 'Electronic Fuel SystemDiagnostic Codes' table for fault code descriptions.

3-19


WARNINGSThe operator of a DDEC-equipped vehicle mustnot attempt to use orread a DDR of any kindwhile the vehicle isoperating. Doing so canresult in loss of control,which may causevehicle damage and mayresult in personal injury.

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

2 FLASHES 3 FLASHES 5 FLASHES 1 FLASH1 FLASH

AMBER (CEL)

AMBER (CEL)

RED (SEL)

RED (SEL)

RED (SEL)

PAUSE PAUSE PAUSE PAUSE

CODE 2351841

3-20


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

3-21


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

3-22


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 lever to lockadjustment.The steering system provides full-time hydraulic power with acontinuous-running pump and a pressurized accumulator. Theaccumulator helps maintain a constant flow of hydraulic power tooperate the steering cylinders.To steer the front wheels, rotate the steering wheel in the desireddirection to the required radius of turn. The front wheels will turn onlyas the steering wheel is turned and at a rate of turning directlyproportional to steering wheel speed. The front wheels will stop andhold position when the steering wheel is stopped. To return the frontwheels to the straight ahead position or to the opposite direction, turnthe steering wheel in the opposite direction.

WARNINGIn the event of loss of steering pump output pressure, a fully-pressurized accumulator provides a maximum of two lock tolock turns of the front wheels. A red warning light on theinstrument panel illuminates and a buzzer sounds whensteering pressure falls below 83 bar (1200 lbf/in). If thiswarning light illuminates, indicating a loss of steering power,the machine must be stopped immediately and no furtheroperation attempted until the fault is corrected.The accumulator slowly bleeds down after engine shut-off toprevent accidental steering. However, accumulator pressureshould be dissipated after engine shut-off by turning thesteering wheel in both directions to avoid accidental steeringduring bleed down.Improper steering control unit repair or hose connectionscan cause sudden and forceful steering wheel movementwhen engine is started. Keep hands off steering wheel whenstarting engine.

1118

1390

3-23


In addition, the following systems are designed to protect theoperator and mechanical components:REVERSE INHIBIT - Prevents gear selection if engine is operating atmore than 20% throttle.HOIST INTERLOCK - The ECU will shift the transmission fromReverse to Neutral if the body control lever is moved to the 'Raise'position.

BODY UP INTERLOCK - When the body is raised, system will onlyallow the transmission to operate in First gear.

PARKING BRAKE INTERLOCK - If the parking brake is appliedwhile the transmission is in Neutral, the system will prevent a shiftout of Neutral to protect the brake components. If the parking brakeis applied while the transmission is in gear, the parking brakeinterlock will not function and normal shifts will occur.

Allison Series 4000 Automatic Shift TransmissionThe Allison Series 4000 transmission is equipped with an electroniccontrol unit (ECU) which continually monitors the transmission andshift system electrical components and warns the operator when aproblem develops. It also takes action to prevent damage to thetransmission, and provides the serviceman with diagnosticcapabilities so that problems can be corrected quickly and easily.When a fault occurs, the 'check transmission' lamp will illuminate andan error code will be generated. The error code can be accessedthrough the 4th GEN gearshift lever. The error code is also recordedin the 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 operators 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 'Transmission 4th GEN control fault codes' table for a list offault codes.

The Series 4000 transmission with 4th GEN control has beendesigned to provide the driver with six forward gears, one reversegear and a neutral position. The gear position is indicated by theLCD display on the gearshift lever. The transmission is full automaticcontrol.

Before any welding isdone on a machineequipped with 4th GENcontrol shift system,disconnect the followingin this order: Batteryearth cable, batterysupply cable, alternatorearth cables, alternatorsupply cables andelectrical connections atthe engine ECM,transmission ECU,hydraulic ECU, VDU ECUand cab bulkhead toavoid damage to electricalcomponents. Turn offbattery master switch toisolate the bateries beforedisconnecting anycomponents.After welding connect allof the above in reverseorder.

WARNING


3-24


Description and Operation1. Electronic Control Unit (ECU) - Contains an electronicmicrocomputer. The ECU receives information in the form ofelectronic signals from switches and sensors, processes theinformation, and sends electronic signals to the appropriatesolenoids which control the transmission.

2. Vehicle Interface Power Module (VIPM)- Contains control fusesand relays.

RELEASEEM

ERGENC

YDW

ELL 3

SECONDS IN

EMERG

ENCY

TO APPLY

OR R

ELEASE

CHARGE SYSTEM

IN PAR

K

PARK

PARKING&

EMERGENCY

BRAKECO

NTROL

1234D

MODE

100% 50%FRONT

6

3

4

12

5

1. Electronic Control Unit (ECU)2. Interface Box3. Gear Shift Selector4. Digital Data Line5. N/A6. Check Trans Warning Light

3-25


1. Hold override 4. Range attained2. Mode button 5. Display mode3. Range selected button

4th GEN Shift ControllerThe 4th GEN shift controller has 6 forward ranges and 1 reverserange as well as a neutral position.The shift selector has a two digit LED display, that during normaloperation will display the range selected and the range attained.Diagnostic information can be displayed on the two digit LED displayby pressing the diagnostic mode button. There is a hold overridebutton on the lever that must be pressed when shifting betweenDrive (D), Neutral (N) and Reverse (R). The hold override button isreleased when the desired selector position is reached. The selectorcan move between Drive (D) and the number of ranges withoutpressing the hold override button.The transmission upshifts and downshifts automatically between firstrange and the highest range selected on the range selector in directresponse to the throttle position and transmission output speed.

When reverse range is selected the 'Reverse alarm' sounds and the'Reverse light' illuminates to warn personnel at the rear of themachine that reverse gear has been selected.

When drive (D) is selected, the transmission automatically upshiftsand downshifts through all six forward ranges as required by loadsand travel speeds. Selecting a lower range (4th, 3rd etc.) limits thehighest range to which the transmission will automatically upshift. If alower range is selected while moving forward, the transmissionautomatically downshifts sequentially to the selected lower range atmaximum controlled engine speeds. Downshifts will not occur untilmachine is slowed by use of the service brakes and/or retarder.When shifting from neutral to start from a standstill, or to reversedirection, decelerate the engine to idle speed. To move forward,select Drive (D) and accelerate the engine to the machine load andspeed requirements. The transmission will automatically upshift from1st through 6th ranges as travel speed increases.With the throttle fully depressed, and the Mode Button in the'POWER' (primary shift schedule) position, the transmission upshiftsto the next higher range when the engine attains maximum ratedspeed, since maximum power train output is needed under thiscondition. At lower throttle settings where minimum power trainperformance is required, the transmission will upshift to the nexthigher range at less than maximum rated engine speed.

Upgrades or soft spots might slow travel speed, even at full throttle,requiring transmission downshifts to maintain maximum powertrainperformance. When this occurs, the transmission downshiftsautomatically.

Shift the transmission to the next lowest range if transmission'Hunting' or 'Shift Cycling' occurs.

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

WARNING

MOD

E

SELECT

MONITOR

1 2 3 4 5 D N R

3

1

2

45

1793



3-26


When temporarily stopped, such as for yielding the right of way to aloaded machine, the transmission can be left in the selected rangeand the machine held stationary with the service brakes. Whenstopped for a more extended period with the engine left running,shiftthe transmission to Neutral to avoid unnecesary heat buildup, andapply the parking brake.

The mode button gives the option to select between transmission'POWER' (primary shift schedule) and 'ECONOMY' (secondary shiftschedule). The transmission must be in Neutral before the switchwill function. Proper selection of these shift schedules permits vehicleoperation to be tailored towards maximised performance or fueleconomy.

The primary shift schedule is the default setting each time the vehicleis started. The secondary shift shedule can be requested by pressingthe mode button. A red LED on the display indicates that thesecondary schedule is active.

The 'POWER' mode is designed for applications involving heavyloads and hilly duty cycles where performance is of primeimportance.The 'ECONOMY' mode is designed for applications involving lighterloads and level duty cycles or where fuel economy is more importantthan performance. This mode allows earlier upshifts at a lower RPM.

Displaying DataOil level information can be displayed on the gear shift diplay. Toaccess the oil information sequence, press the Display Mode buttononce on the gear shift lever. A 2 minute countdown begins when thefollowing conditions of the vehicle systems are met -

1. Engine at idle.2. Oil is at operating temp. within range 82-104C (140-220F).3. Transmission is in Neutral 'N'.4. Transmission output shaft is stationary.

The oil level will be displayed at at the end of the 2 minutecountdown. During the countdown, the display flashes out anumerical value starting at '8' in 15 second intervals, decreasing innumber value by 1 each time in the sequence ie. 8,7,6,5,4,3,2,1.After the number sequence, the display will then sequentially flashthe oil level information, 2 characters at a time.

oL ; oK Oil level OK. oL ; Lo 1 Oil level is low 1 quart - or as many quarts as required. oL ; HI 1 Oil level is high 1 quart - or as many quarts overfilled.

(1 US quart = 0.95 litre = 0.2 gallon)

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

WARNING

1509

IDLE

FULL LOAD/THROTTLE

3-27


Note: Failure to meet any of the previous conditions 1-4, will stop the2 minute countdown. The gear shifter will display one of the followingcodes -

oL0X : Setting time too short oL70 : Sump fluid temp too low

oL50 : Engine RPM too low oL79 : Sump fluid temp too high

oL59 : Engine RPM too high oL89 : Output shaft rotation detected

oL65 : Neutral not selected oL95 : Oil level sensor failed

Displaying Diagnostic Fault CodesDiagnostic codes can be displayed on the gear shift lever display. Toaccess the diagnostic code sequence, press the Display Modebutton twice on the gear shifter. Each code consists of 4 sequentialelements; each being either 1 or 2 characters. The display for eachcode will repeat continuously until the next code is displayed (ifpresent). To display the next code if present, press the modebutton. The following cycle illustrates the display cycle:

d1 Code list position (d1 newest, d5 oldest) P 27 14

Code repeats until the next code (d2) is accessed by pressing themode button

Clearing Diagnostic Codes To clear active codes, press and hold mode button for 3 to 5seconds. To clear inactive codes, press and hold mode button for 8 to 10seconds.

Exiting Diagnostic ModeAny of the following methods may be used to exit the diagnosticdisplay mode: Momentarily press the display mode button. Move the gear shift lever to any other position than the oneselected when the diagnostic display mode was activated. Wait until time out (approx. 10 minutes). The system automaticallyreturns to normal operating mode. Turn off the vehicle - illuminating power to transmission ECU.

3-28


C1312 Retarder Request Sensor Failed LowC1313 Retarder Request Sensor Failed HighP0122 Pedal Position Sensor Circuit Low VoltageP0123 Pedal Position Sensor Circuit High VoltageP0218 Transmission Fluid Over temperatureP0561 System Voltage Low PerformanceP0562 System Voltage LowP0563 System Voltage HighP0602 TCM Not ProgrammedP0610 TCM Vehicle Options Error (Trans ID)P0613 TCM ProcessorP0614 Torque Control Mismatch (ECM/ TCM)P0634 TCM Internal Temperature Too HighP063E Auto Configuration Throttle Input Not PresentP063F Auto Configuration Engine Coolant Temperature Input Not

PresentP0658 Actuator Supply Voltage 1 Low (HSD 1 open/gnd)P0659 Actuator Supply Voltage 1 High (HSD 1 batt)P0701 Transmission Control System PerformanceP0702 Transmission Control System Electrical (Trans ID)P0703 Brake Switch CircuitP0708 Transmission Range Sensor Circuit - High InputP070C Transmission Fluid Level Sensor Circuit - Low InputP070D Transmission Fluid Level Sensor Circuit - High InputP0711 Transmission Fluid Temp. Sensor Circuit PerformanceP0712 Transmission Fluid Temperature Sensor Circuit Low InputP0713 Transmission Fluid Temperature Sensor Circuit High InputP0716 Turbine Speed Sensor Circuit PerformanceP0717 Turbine Speed Sensor Circuit No SignalP071D General Purpose Input FaultP071A RELS Input Failed OnP0720 Output Speed Sensor CircuitP0721 Output Speed Sensor Circuit PerformanceP0722 Output Speed Sensor Circuit No SignalP0726 Engine Speed Input Circuit PerformanceP0727 Engine Speed Input Circuit No SignalP0729 Incorrect 6th Gear RatioP0730 Incorrect Gear RatioP0731 Incorrect 1st Gear RatioP0732 Incorrect 2nd Gear RatioP0733 Incorrect 3rd Gear RatioP0734 Incorrect 4th Gear RatioP0735 Incorrect 5th Gear Ratio

Code Meaning of code / Possible Cause of FaultAllison 4th GEN Diagnostic Codes

3-29


P0736 Incorrect Reverse RatioP0741 Torque Convertor Clutch System Stuck OffP0776 Pressure Control Solenoid 2 Controlled Clutch Stuck OffP0777 Pressure Control Solenoid 2 Controlled Clutch Stuck OnP0796 Pressure Control Solenoid 3 Controlled Clutch Stuck OffP0797 Pressure Control Solenoid 3 Controlled Clutch Stuck OnP0842 Transmission Pressure Switch Solenoid 1 Circuit LowP0843 Transmission Pressure Switch Solenoid 1 Circuit HighP0880 TCM Power Input SignalP0881 TCM Power Input Signal Performance (Battery Voltage)P0882 TCM Power Input Signal Low (Battery Voltage)P0883 TCM Power Input Signal High (Battery Voltage)P0960 Main Pressure Modulation Solenoid Control Circuit OpenP0961 Main Pressure Modulation Solenoid System PerformanceP0962 Main Pressure Modulation Solenoid Control Circuit LowP0963 Main Pressure Modulation Solenoid Control Circuit HighP0964 Pressure Control (PC) Solenoid 2 Control Circuit OpenP0965 Pressure Control (PC) Solenoid 2 System PerformanceP0966 Pressure Control (PC) Solenoid 2 Control Circuit LowP0967 Pressure Control (PC) Solenoid 2 Control Circuit HighP0968 Pressure Control (PC) Solenoid 3 Control Circuit OpenP0969 Pressure Control (PC) Solenoid 3 System PerformanceP0970 Pressure Control (PC) Solenoid 3 Control Circuit LowP0971 Pressure Control (PC) Solenoid 3 Control Circuit HighP0972 Shift Solenoid (SS) 1 Control Circuit OpenP0973 Shift Solenoid (SS) 1 Control Circuit LowP0974 Shift Solenoid (SS) 1 Control Circuit HighP0975 Shift Solenoid (SS) 2 Control Circuit OpenP0976 Shift Solenoid (SS) 2 Control Circuit LowP0977 Shift Solenoid (SS) Control Circuit HighP0989 Retarder Pressure Sensor Failed LowP0990 Retarder Pressure Senosr Failed HighP1739 Incorrect Low Gear RatioP1891 Throttle Position Sensor PWM Signal Low InputP1892 Throttle Position Sensor PWM Signal High InputP2184 Engine Coolant Temperature Sensor 2 Circuit LowP2185 Engine Coolant Temperature Sensor 2 Circuit HighP2637 Torque Management Feedback Signal (SEM)P2641 Torque Management Feedback Signal (LRTP)P2670 Actuator Supply Voltage 2 Low (HSD 2 gnd)P2671 Actuator Supply Voltage 2 High (HSD 2 batt/open)P2685 Actuator Supply Voltage 3 Low (HSD 2 gnd)


3-30


P2686 Actuator Supply Voltage 3 High (HSD 3 batt/open)P2714 Pressure Control Solenoid 4 Controlled Clutch Stuck OffP2715 Pressure Control Solenoid 4 Controlled Clutch Stuck OnP2718 Pressure Control (PC) Solenoid 4 System OpenP2719 Pressure Control (PC) Solenoid 4 System PerformanceP2720 Pressure Control (PC) Solenoid 4 Control Circuit LowP2721 Pressure Control (PC) Solenoid 4 Control Circuit HighP2723 Pressure Control Solenoid 1 Controlled Clutch Stuck OffP2724 Pressure Control Solenoid 1 Controlled Clutch Stuck OnP2727 Pressure Control (PC) Solenoid 1 System OpenP2728 Pressure Control (PC) Solenoid 1 System PerformanceP2729 Pressure Control (PC) Solenoid 1 Control Circuit LowP2730 Pressure Control (PC) Solenoid 1 Control Circuit HighP2736 Pressure Control (PC) Solenoid 5 System OpenP2737 Pressure Control (PC) Solenoid 5 System PerformanceP2738 Pressure Control (PC) Solenoid 5 Control Circuit LowP2739 Pressure Control (PC) Solenoid 5 Control Circuit HighP2740 Retarder Oil Temperature HotP2742 Retarder Oil Temperature Sensor Circuit - Low InputP2743 Retarder Oil Temperature Sensor Circuit - High InputP2761 TCC PCS Control Circuit OpenP2762 TCC PCS Control Circuit Range/ PerformanceP2763 TCC PCS Control Ciruit HighP2764 TCC PCS Control Circuit LowP278A Kickdown Input Switch CircuitP2793 Gear Shift Direction CircuitP2808 Pressure Control Solenoid 6 Controlled Clutch Stuck OffP2809 Pressure Control Solenoid 6 Controlled Clutch Stuck OnP2812 Pressure Control (PC) Solenoid 6 System OpenP2813 Pressure Control (PC) Solenoid 6 System PerformanceP2814 Pressure Control (PC) Solenoid 6 Control Circuit LowP2815 Pressure Control (PC) Solenoid 6 Control Circuit HighU0001 Hi Speed CAN Bus Reset Counter Overrun (CAN2/IES CAN)U0010 CAN Bus Reset Counter Overrun (CAN1/J1939)U0100 Lost Communication with ECM / PCM "A"U0103 Lost Communication With Gear Shift Module 1U0115 Lost Communication with ECM / PCM "B"U0291 Lost Communication with Gear Shift Module 2U0292 Invalid Data received from Gear Shift Control Module 2U0304 Software Incompatability With Gear Shift Control Module 1U0333 Software Incompatability With Gear Shift Control Module 2U0404 Invalid Data received from Gear Shift Control Module 1U0592 Invalid Data received from Gear Shift Control Module 2


3-31


Body ControlThe lever to the left of the operators seat controls the hydraulic valvewhich operates the body hoist cylinders. The four operating positionsof the lever from front to rear are as follows:

'LOWER' - This position provides hydraulic force to power-down thebody. It is needed when the body cannot be started downward fromthe fully raised position by gravity. When the body starts lowering bygravity, the lever should be moved to the 'FLOAT' position.

'FLOAT' - The lever should be moved to this position while the bodyis lowering by gravity and should remain in this position until the bodymust be operated again. The control lever should always be kept in'FLOAT' while the machine is in motion.

'HOLD' - Moving the lev

camion de obra tr35 tier iii ohe877 om

Documents