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TEREX Equipment Limited Operator Handbook

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Original Operating Instructions

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TEREX Equipment Limited Operator Handbook Re-order

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Issued by;Customer Support Department

Terex Equipment LimitedNewhouse Industrial Estate

Motherwell, ML1 5RYScotland

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

www.terex.com

OHE972/975/982

Re-order Part Number15504536

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

Revision: April 2010

Dealer:

15504536OHE972/975/

982

TEREX Equipment Limited Operator Handbook - Introduction

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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 prior permission 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 be familiarwith the contents of the Operator's Handbookand any Local / National regulations prior tooperating this vehicle.

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.

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:

Paul Douglas,


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: Paul Douglas

General Manager

Motherwell, Scotland

POSITION:

PLACE:

CERTIFICATE NUMBER:

LRQ 0925301/A

FOR AND ON BEHALF OF THE MANUFACTURER:

DATE OF MANUFACTURE:

SIGNATURE:

DATE:

TA350/400 Articulated Truck

EC DECLARATION OF CONFORMITY

MANUFACTURERS NAME AND FULL ADDRESS:

Terex Equipment Limited,


Motherwell,

Scotland.

ML1 5RY

DESCRIPTION OF MACHINERY:

MAKE: TEREX

2000/14/EC

2004/108/EC

2006/42/EC

Name:

Address:

Paul Douglas,


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: Paul Douglas

General Manager

Motherwell, Scotland

POSITION:

PLACE:

CERTIFICATE NUMBER:

LRQ 0925301/A

FOR AND ON BEHALF OF THE MANUFACTURER:

DATE OF MANUFACTURE:

SIGNATURE:

DATE:

TA350/400 Articulated Truck

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 Lock 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 3-21Detroit Diesel Electronic Control 3-21Description 3-22Operation 3-23

1-2


1-3

3. CONTROLS AND OPERATING (cont.)Allison Series 4000 AutomaticShift Transmission 3-304th GEN Shift Controller 3-31Dropbox 3-37Differential Lock 3-37Hydraulic Controls 3-38Steering 3-39Body Control 3-40Tilting Cab 3-41Hood 3-42

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 8-10

9. TECHNICAL DATATA350 9-3TA400 9-15

10. SYMBOL IDENTIFICATION

1-4


1-5

INTRODUCTION

Introduction

The Terex TA350/400 articulated haulers are 3 axle types with an

oscillation and articulation pivot joint between the tractor and trailer

units. Articulation is achieved by frame steering. The machine has part

time or full time 6 wheel drive controlled by operator. The machine range

capacities vary from 37.5 US ton - 41.88 US ton or 27.5 yd3 - 30yd3.

This Handbook is provided as a guide to familiarize the operator and

serviceman with the controls, recommended inspections, start-up,

operating, shutdown and parking procedures for TA350/TA400

Articulated Trucks. It is essential that operators read and understand the

manual before operating the machine

Safety Alert Symbol

The Safety Alert System identifies important safety messages in this

manual. 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 potential

personal injury hazards. The following signal words used with the safety

alert symbol indicate a specific level of severity of the potential hazard.

Signal words used without the safety alert symbol relate to property

damage and protection only. All are used as attention getting devices

throughout this handbook as well as on decals and labels fixed to the

machinery to assist in potential hazard recognition and prevention.

Introduction

Safety alert symbol

2226

1-6

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

1. Loading2. Hauling3. Dumping

Introduction

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

CAUTION

CAUTION

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.

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

WARNING indicates a potentially hazardous situation which, ifnot avoided, 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.

1-7

Product Identification Number - Plate Location

Information regarding the machine model, code and chassis serialnumber is found on the unit serial number plate on the rear right of thefront frame. The machine model and serial number should always bereferenced in any correspondence 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.

Introduction


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 andanti-theft devices on the machine.

Immobilize the machine by removing a critical electrical or startingsystem device, 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 listup 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 equipment leftat 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 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 allserial numbers.

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

2-1

Safety

2 - Safety

2-2

Safety


2-3

Safety

SAFETY

Safety

The machine should be properly operated and maintained to keep it in

safe, 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 to those responsible for maintenance, and, do not

operate the equipment until corrected. Normal service or

maintenance performed as required can prevent unexpected and

unnecessary downtime.

This Handbook describes general inspections, servicing and

operation with the normal safety precautions required for normal

servicing and operating conditions. It is not a guide however, for other

than normal conditions or situations, and therefore, servicemen and

operators must be safety conscious and alert to recognize potential

servicing or operating safety hazards at all times, and take necessary

precautions 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

publication are based on the latest product information available at the

time of publication. The right is reserved to make changes at any time

without notice.

Continuing improvement and advancement of the design may cause

changes to your machine which may not be included in this publication.

Each publication is reviewed and revised, as required, to update and

include these changes in later editions.

This Handbook contains lubrication and routine servicing instructions,

most of which can be performed in the field. Maintenance manuals

containing repair/rebuild procedures can be obtained from your dealer.

2-4

Safety

SAFETY PRECAUTIONS

General

* Read this Operator’s Handbook and learn the operatingcharacteristics 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 suchas wires, bridges, etc., for operating safely.

* Be especially aware of overhead power lines.

* Always know all traffic rules, signs, flags and hand signals used onthe job and know who has the responsibility forsignalling.

* Be aware of operating hazards that weather changes cancreate on the job. Know proper procedures to follow when asevere rain or 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 typevests, 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 toavoid fire and slipping hazards.

* Clean any mud, grease or oil from controls, handrails, laddersand decks. Lash necessary tools securely and remove allloose items before operating the vehicle. Never rush. Walk, donot run.

* Never carry more than one person and only in the instructor/trainerseat.

1782

1768

SAFETY

MANUAL

1767

1769

2-5

Safety

The protection offered by the roll over and falling object

protective structure may be impaired if it has been subjected

to any modification or damage. Unauthorized modification

will void certification.

Articulation and Oscillation Lock

* Always connect the articulation and oscillation lock bar before

working in the articulation area, before lifting the vehicle and

during transportation of this vehicle by trailer/vessel.

* Always disconnect the articulation and oscillation lock bar and

secure in the 'Stowed' position before operating the vehicle.

The vehicle would not be free to steer otherwise.

Articulation and Oscillation

Lock - 'Locked' Position1743

Articulation and Oscillation

Lock - 'Stowed' Position1762

Vehicle Lifting Precautions

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

wheels blocked, articulation and oscillation lock bars connected.

* The vehicle should be lifted using a spreader bar if possible. Lift

using FOUR slings from the lifting points provided at the bumper

end of the front chassis and at the rear of the body.

Note: Be aware that this vehicle is free to oscillate if not lifted

correctly. 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 trailer

chassis and the tow pin at the rear of the trailer chassis.

2232

CENTRE

FRONT

REARVehicle Tie Down Instructions1744

TIE DOWN POINTS

LIFTING POINTS

2-6

Safety

Preventing Fire Hazards

General 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,

the vehicle.

* Clean all dirt, oil, grease and other fluids from systems and

components to minimize fire hazards and aid in identifying

loose or leaking lines or fittings.

* Check the engine compartment for rubbish, oily rags or other

debris that could cause fires before starting the engine.

* Make sure that no greasy, oily rags or similar hazards

accumulate in the cab.

* If the vehicle has been operated with an under inflated tyre, make

sure that the tyre has cooled sufficiently before parking and leaving

the vehicle unattended.

Flammable Fluid Precautions

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

purposes. Use approved, solvents only.

* 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 checking

fuel, lubricant, coolant and battery fluid levels, or when

checking for fluid leaks. Use a flashlight or other safe lighting

only.

* Shut off engine and use extra caution if engine is hot when

refuelling. Ground the hose spout to prevent sparks when

spout is touched to fuel tank filler tube.

* Never smoke while checking or adding fuel or other fluids or

handling fluid containers and lines.

* Use care and do not stand downwind when adding fuel or

other flammable fluids to tanks and reservoirs to avoid fluids

being blown or splashed onto clothing.

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

system.

* When preparing vehicles or components for storage, seal and

tape all openings and close containers tightly to seal in all

volatile inhibitor fluids and compounds used.

FUEL

1770

1789

2-7

Safety

* Follow manufacturer’s recommendations when handling and

using engine-starting fluids and disposing of spent containers.

Do not puncture or burn empty containers. These fluids are

explosive 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 vehicle

for adequate ventilation of explosive gas (hydrogen) produced.

* Always disconnect batteries before repairing electrical system to

avoid danger of fire-causing sparks. Disconnect the battery

ground cable first and reconnect it last.

* Always disconnect batteries, alternator leads, engine ECM,

hydraulic system ECU, body control lever, transmission ECU,

instrument panel ECU and all harness connections at the front

of the cab before carrying out any welding on the vehicle.

* Never check the battery charge by placing metal objects across

the battery posts, to avoid sparks at battery posts.

* Use jumper cables only as recommended. Improper use can

result in battery explosion or unexpected vehicle motion.

* Never operate the engine starter for more than 30 seconds, and

allow two minutes between long cranking periods for cooling.

An overheated starter could cause a fire.

* If electric coolant or lubricant heaters are used, be sure to follow

heater manufacturer’s recommendations for use to avoid

electrical or fire hazards or both.

Mounting and Dismounting

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

the vehicle. Do not grasp the steering wheel.

* Always face the access system and maintain at least three

points of support to mount or dismount the vehicle (two hands and

one foot, or two feet and one hand.

* Ensure walkways, stairways, platforms, handrails and handholds

are free of frost, ice, oil, water or anything else that could cause slip,

trip or falls.

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

vehicle.

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 described

on 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

or operating the vehicle.

* Adjust, secure and latch the seat and fasten the seat belt before

starting the vehicle.

* Sound horn before starting the engine or beginning to move the

vehicle; 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 can

result in battery explosion or unexpected vehicle motion.

* Always obey 'Starting the Engine' instructions described on

page 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 are

properly set / positioned.

* Always keep cab floor clear of anything that could restrict full

operation of pedals.

* Always make sure all gauges, warning/indicator lights and

controls are working properly before operating the vehicle.

* Always perform 'Pre-Operating Checks' described on page 4-10

to ensure the vehicle is ready for operating.

* Always wear seat belts when operating the vehicle.

* Do not operate if exposed personnel enter the immediate work

area.

* Sound horn before starting engine or beginning to move the

vehicle; two blasts for forward and three blasts for reverse.

1773

DO NOT

OPERATE

1775

1790

1776

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

˚F

LH

2-9

Safety

* Watch for ground crew and other personnel on foot. Sound horn

as a warning before setting the vehicle in motion and when

approaching ground crew.

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

* Always try to face or look in the direction the vehicle is

travelling.

* Use extreme caution and turn on lights at night or when fog, dust

or similar hazards limit visibility. Do not overdrive your

headlights.

* Observe instruments frequently. Report any defects or unusual

noises in the vehicle during operation.

* Stay in gear when driving downhill. Do not coast with

transmission in neutral. Select the proper gear and maintain

safe speed with the service brakes or/and retarder. Always

maintain safe speeds for haul road operating conditions for

maximum 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 this

occurs, stop the vehicle using the service brakes.

Apply Parking / Emergency brake.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 with

other vehicles. Stop in authorized areas only, except in

emergency.

* Brake firmly in one application. Do not FAN the pedal. Never

operate the vehicle if a warning light or parkbrake service alarm

is on. It indicates a fault in the braking system.

* Always give loaded vehicles the right-of-way when your vehicle

is empty.

* Always watch for holes, soft edges or other hazards when

backing to dump over a spoil bank.

* Always stay in cab when being loaded.

* Always lower the body and shut down the vehicle according to

the procedure under 'Stopping The Engine' described on page

4-14 before leaving the vehicle unattended. If on a grade wheels

should 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 other

equipment only when the road is clear and enough room / space

to pass and reserve power is available.

* Stop at appropriate intervals to inspect the vehicle and allow the

tyres to cool. Tyre air pressure will rise during operation. Do not

reduce 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

Maintenance Manual before starting, operating or servicing

this vehicle. Always follow procedures and safety precautions

detailed throughout the Maintenance Manual.

* Always attach a 'DO NOT OPERATE' or similar warning sign to

the 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

only be used when the body is empty.

* Do not work under or near any unblocked or unsupported

linkage, part or vehicle.

* Always install the steering lock bar before making adjustments

or 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 the

master switch before cleaning, lubricating or servicing the

vehicle except as called for in this Operator’s Handbook or the

Maintenance Manual.

Body Safety Prop1794

1780

1777

2-11

Safety

* Always relieve pressure before servicing any pressurised

system. Follow the procedures and safety precautions detailed

in the relevant Maintenance Manual section.

* When changing oil in the engine, transmission and hydraulic

systems, or removing hydraulic lines, remember that the oil may

be hot and can cause burns to unprotected skin.

* When working on or around exhaust components, remember

that the components may be hot and can cause burns to

unprotected skin.

* Always deflate the tyre before attempting to remove any

embedded objects or removing the tyre and rim assembly from

the vehicle.

* Always use a self-attaching chuck with a long airline, and, stand

to 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 raised

operator’s cab. Always use the operator’s cab safety prop with

the locking pin.

Scrapping the Machine

At the end of its life, the machine should be disassembled by a

competent person using safe working practices, wearing the

appropriate Personal Protective Equipment and working in accordance

with local regulations.

The appropriate lifting equipment, chocks and stands must be used

to maintain a stable machine as components are removed and the

machines centre of mass changes. Fluids must be drained off into

suitable containers and if possible recycled or otherwise disposed of

an environmentally friendly in accordance with local regulations.

Care must be taken when dealing with flammable liquids and the

machine parts that contained those liquids. Any process that could

ignite flammable materials must not be used on components that

have contained flammable liquids in them or have residual flammable

liquids on them.

Fire extinguishers must be readily available if cutting/welding

equipment is to be used.

When possible recyclable materials should be separated out and

processed in accordance with local regulations using an authorised

agent.

1993

Operators Cab Safety Prop & Locking Pin

With Cab Raised

1727 Operators Cab safety Prop

2-12

Safety

Mirrors and CCTV

The operator must survey their surroundings before entering the machine, and

check their field of vision prior to and during operation of the machine. All

mirrors must be adjusted when installed, and prior to operating the machine, to

achieve optimum visibility and thus minimize the risk of injury to themself and

others. Site management should utilize appropriate jobsite organization to

minimize hazards due to restricted visibility. Modifications made to the machine

may restrict 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 these

mirrors are folded out from the cab to form an angle of 90O . These brackets may be folded parallel

to the cab for transportation of the vehicle. Set the mirrors in the defined position shown in the

illustration.

2118

2115

A B C D

140

120

190

155

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. The area surrounding the machine is to be considered as two

distinct fields of view, ilustrated below as areas 1 to 9 in the immediate

vicinity, and areas 10 to 15 at a radius of 12 m from the operator when

seated. The operator MUST adjust the mirrors, and set the CCTV camera,

to achieve visibility as identified below:

* Areas 2, 8 and 10 can be directly viewed from the operator’s

seating 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.

2117

2116

2500 mm

1000

mm

1000

mm

1000mm

1

59

8 6

2 43

7

15

14

1110

13

12

R 1

2 m

2-14

Safety

Wheels and Tyres

If tyres on the vehicle were inflated at the factory with dry nitrogen gas,

the tyre walls will be marked 'N' and the following factory installed decal

will be found mounted on the fenders.

NOTICE

TYRES ON THIS VEHICLE ARE FACTORY INFLATED WITH

DRY NITROGEN. IT IS RECOMMENDED THAT DRY NITROGEN

BE USED EXCLUSIVELY FOR ALL TYRE PRESSURE

ADJUSTMENTS AS WELL AS INFLATION OF REPLACEMENT

TYRES.

Nitrogen gas improves tyre pressure retention, increases tyre life by

reducing carcass oxidation from within, minimizes rim rust, and has no

known detrimental effect on the tyre. It also reduces the potential of a tyre

explosion because it is an inert gas and will not support combustion

inside the tyre. The same tyre inflation pressure used for air inflation

should be used for nitrogen inflation. Refer to Section 160-0050, Wheel,

Rim and Tyre of the vehicle Maintenance Manual for recommended

procedures for inflating and pressure adjusting tyres with dry nitrogen

gas. Only proper nitrogen charging equipment operated by personnel

trained in its use should be used.

Never mix components of one manufacturer’s rims with those ofanother. Using the rim base of one manufacturer with the lockring of another or vice versa is dangerous. The lock ring of onemay not fully engage with the lock ring groove of the other.Always consult the rim manufacturers for proper matching,

assembly and safety instructions. Also, use and servicing of

damaged, worn out or improperly assembled rim assemblies isa very dangerous practice. Failure to comply with the abovewarnings could result in an explosion from tyre pressure causing

serious property damage and serious personnel injury or death.

2-15

Safety

Avoid Tyre Explosion Hazard

Whenever a vehicle’s tyre(s) is (are) exposed to

excessive heat such as a vehicle fire or extremely

hot brakes, the hazard of a subsequent violent

tyre explosion must be recognized. All nearby

persons must avoid approaching the vehicle so

as not to be physically endangered in the event

of an explosion of the tyre and rim parts. The

vehicle should be moved to a remote area, but

only when this can be done with complete safety

of the operator operating or towing the vehicle.

All other persons should stay clear of the vehicle.

The fire or overheated brakes, wheel, etc., should

be extinguished or cooled from a safe distance.

Do not attempt to extinguish the fire or cool the

vehicle by use of hand-held fire extinguishers. Ifit is absolutely necessary to approach a vehiclewith a suspect tyre, approach only from the frontor the back. Stay at least 15 m (50 ft) from the treadarea. Keep observers out of the area and at least460 m (1500 ft) from the tyre sidewall. Refer to theaccompanying sketch. The tyre(s) should beallowed at least eight (8) hours cooling time afterthe vehicle is shut down or the fire extinguishedbefore approaching closer.

AT LEAST

15m (50ft)

AT LEAST

460m (1 500ft)

172

2-16

Safety

Emergency Exit from Cab

Normal access to, and egress from, the cab is facilitated

via the door on the left-hand side. However, in an

emergency, an alternative exit can be gained via the

side windows. A hammer is provided to break the left-

hand or right-hand side window glass to facilitate safe

egress.

The hammer is mounted on a bracket on the rear wall

of the cab, and can be easily lifted off in an emergency.

2082

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

Exercise extreme care when breaking thewindow glass to protect your face andbody from airborne glass particles.

Be careful when passing through thewindow aperture to avoid contact with

shards of glass that may remain attachedto the frame, or loose within or outside ofthe cab.

2-17

Safety

2227

Decals and Instruction Plates

Decals and instruction plates fitted to

vehicles may vary from country to

country to suit local needs. These pages

contain a brief description and the

location of the decals and instruction

plates that may appear on your vehicle.

1. Hook Point

2. Battery Earth

3. CE Machine Safety

4. Hydraulic Control

5. Steering Column

6. Accumulator Charging

7. CAB Fuse

8. Emergency Exit

9. Parking Brake Operation

10. Hood Raise/Lower

11. Lift Instruction

12. Retarder

13. Sound Power 110dB

14. Articulation Warning

15. Crush Hazard Warning

16. Decline TA350/400 Warning

17. Accumulators Warning

18. Parking Brake Warning

19. Skin Injection Warning

20. Operator Handbook Warning

21. Hood Raise Warning

22. Hot Surface Warning

23. Radiator Notice

24. Anti-freeze Notice

25. Cab Tilt Notice

26. Filters Notice

27. Jump Start Notice

28. Nitrogen Notice

29. Power Down Notice

30. Welding Notice

31. Cab Jacking Notice

32. Reversing Warning

33. Battery Danger

34. Power Lines Danger

35. Accumulator Warning

36. Fall Hazard Warning

37. Service Panel ISO

38. Serial Plate

39. Diagnostic Points

40. Fall Hazard

41. Harness Anchor Location

42. Anchor Position

2228

11 33 2 30 27 37 26 28 14 36 1 15 28

22 212515

41 40

1

1 3232

24

23

22

42

31

25

1 1

HEADER TANK

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

210

250

120 60

140

275 320390

135 165

200

˚C

˚F

˚C

˚F

L H

INSTRUCTOR SEAT

SUPPORT RAIL

10

ON

WINDOW

7

9

12

16

420

29

13

8

ON WINDOW8

1834

5

6

1735

19 22

33839

2-18

Safety

Pictorial Decal Set

9271069

Hook Point (1797)

9361787

Battery Earth (1798)CE Marking (1799)

15314811

Body Control (1800)

15318464

Steering Column

Adjustment (1801)

15321634

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

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

TA250/300 Fuse Relay Box (2223)


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

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 Accumulator

Nitrogen Precharge

(1831)

15333287

11500 PSI103 bar

21500 PSI103 bar

31500 PSI103 bar

TA350 Accumulator

Nitrogen Precharge

(1832)

15334426

11500 PSI103 bar

31500 PSI103 bar

21500 PSI103 bar

TA27/30 Accumulator

Nitrogen Precharge

(1979)

15334887

1

2

3

4

5

6

TA350/400

Transmission Retarder

(1981)

15353607

I . D kg

TA250

TA300

21900 kg ( 48280 lb )

224020 kg ( 49430 lb )

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 TA250/300/350/400(2169)

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

Hydraulic Oil (1980)

Lift Instruction (1807)

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 safety

prop (1874)

15334759

N2

PSI / BAR

0

Accumulator Warning, Maintain nitrogen

precharge for proper operation (1875)

N

15334761

P1. 2.

Crush Hazard Warning, Apply park

brake, Shift to neutral (1876)

15334765

Entanglement Warning, Stop

engine before servicing (1879)

15334764

Read And Understand Operator

Handbook (1878)

15334766

Hot Surface Warning, Allow to cool

before servicing (1880)

15334754

1 .

2 .

Crush From Articulation Warning, Use

safety lock (1873)

Skin Injection Warning, Relieve pressure before

service, 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)

15334762

2-22

Safety

15334767

Burn Hazard, allow to cool before

opening (1881)

15334768

Anti-freeze Notice, See handbook

for correct concentration (1882)

15334770

Filters Notice, See handbook for

replacement intervals (1884)

15334771

Jump Start Notice, Jump start using

identical battery pack (1885)

15334772

N

Nitrogen Filled Tyres, Use nitrogen

only to fill (1886)

15334774

Welding Notice, See handbook for

welding procedures (1888)

15334777

Cab Jack Notice (1889)


15334769

1.

2.

Cab Tilt Notice, Raise hood before

tilting cab (1883)

15335080

Fall Hazard Warning, Use access

system provided (1894)

15334780

Reverse Warning, Keep clear of

truck when it is reversing (1890)

15356710

Fall Hazard Warning, Use Safety

Harness provided (2219)

2-23

Safety


Batteries Warning, Explosive, keep

all flames and sparks away (1891)

15335077

Hydraulic Tank Pressurization Warning (2022)

15343325

PSI / BAR

0

15334773

Power Down Notice, Power down

truck when not in use (1887)

Power Lines Warning, Maintain required

clearance (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, Do

not 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


F

R

PTP1

TP3

CT21

F

R

F

R

3

2

1

15352081

HI

LO

R


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


10 2 14 9 10 4 32 20


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

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 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.

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

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

EPL - EXTREME PRESSUREGEAR LUBRICANT. REFER TO "RECOMENDED LUBRICANTS".

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

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

LUBRICATION AND SERVICE CHART

INTERVAL

HOURS

NO.

PTSREF

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

REF. ENGINE 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. 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

LUBE

CHECK WEAR. RENEW IF REQ'D

CHECK TENSION. TIGHTEN IF REQ'D

LUBE

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 ELECTROLITE

LUBE

LUBE

LUBE

LUBE

LUBE

CHECK TORQUE

INSPECT & CLEAN IF REQUIRED

LUBE

CHECK LEVEL. ADD ELECTRO IF LOW

15347627

500

3 MONTH

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 MONTH

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

CAB FRESH AIR FILTER

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



CHEK TORQUE

RENEW

CLEAN

CHECK FOR LEAKS & DAMAGE

CHECK TORQUE

CHECK TORQUE

CHECK TORQUE

INSPECT DRAIN HOLE.

CLEAN IF REQUIRED

CHECK TORQUE

17

33

8

6

16

7

29

2

28

35

10

11

9

21

19

23

12

15

26

34

14

24

13

20

27

22

25

31

30

32

18

1

5

4

3

TA25/27/30 Service Lubrication Chart (2191)


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.

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)


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

1

31

5

733 32 4 3 30 15 2 12 21 14 34 22 26 17 20 8 23

13

28

35

24

29 11 9 12 18 19 25 17 16 10

6

27

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 (9USGAL)

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".

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

EPL - EXTREME PRESSURE LUBRICANT SPEC. MIL-L21058.

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

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

LZ - LUBRIZOL 6178

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

LUBRICATION AND SERVICE CHART

INTER-VAL

HOURS

NO.OF

PTS

REFNO.

SERVICEINSTRUCTIONS

SERVICEQUANTITIES

LUBRICANTOR COOLANT

IDENTIFICATION

10

DAILY

11234

51432

116

27

11111

111

16

EO

TRANSYNDHOETHYLENE GLYCOL

AS REQUIRED

SEE NOTE 2AS REQUIREDAS REQUIRED

SEE NOTE 7AS REQUIRED

ENGINEENGINE CRANKCASE BREATHERTRANSMISSIONHYDRAULIC TANKRADIATOR EXPANSION TANK

PRIMARY FUEL FILTER/WATER SEPDROPBOXOCDB TANK

ENGINE AIR CLEANERDRIVE BELTTYRES

CHECK OIL LEVEL. ADD OIL IF LOWINSPECT AND CLEAN IF REQUIREDCHECK OIL LEVEL. ADD OIL IF LOWCHECK OIL LEVEL. ADD OIL IF LOWCHECK COOLANT LEVEL. ADD IF LOW

CHECK. DRAIN AS REQUIREDCHECK OIL LEVEL. ADD OIL IF LOWCHECK OIL LEVEL. ADD OIL IF LOW

CHECK. RENEW ELEMENT IF REQUIREDVISUAL INSPECTION FOR DAMAGECHECK CONDITION & PRESSURE

25

151617181925

6

111362121

EPL & LZEPL EP LI COMP

AS REQUIREDAS REQUIREDSEE NOTE 3 & 4

TRANSMISSION BREATHERPRIMARY FUEL FILTER/WATER SEPSECONDARY FUEL FILTERDIFFERENTIALSWHEEL PLANETARIESARTICULATION BEARINGSOSCILLATION PIVOTPARKING BRAKE PADSDRIVE BELT

CLEAN IF RQUIREDRENEWRENEWCHECK OIL LEVEL. ADD IF LOWCHECK OIL LEVEL. ADD IF LOWLUBECHECK END FLOAT. ADJUST IF REQUIREDCHECK WEAR. REPLACE IF REQUIREDCHECK TENSION. TIGHTEN IF REQUIRED

1131414

1211

EO

EO

32 LITRES / 8.4 US GAL


ENGINEENGINE OIL FILTERSDROPBOXDROPBOX OIL FILTERS

DRAIN OIL AND REFILL WITH NEW OILRENEWDRAIN OIL AND REFILL WITH NEW OILRENEW


50

WEEKLY

250

MONTHLY

16171128

929303126

36

11111

EPL & LZEPL

EPL

SEE NOTE 59 LITRE / 2.4 US GAL

SEE NOTE 6

DIFFERENTIALSWHEEL PLANETARIESENGINE AIR CLEANERCOOLANT ADDATIVECAB FRESH AIR FILTERFUEL TANK BREATHERHYDRAULIC TANK BREATHEROCDB TANK BREATHERDRIVESHAFT BEARINGS

DRAIN OIL AND REFILL WITH NEW OILDRAIN OIL AND REFILL WITH NEW OILRENEW ELEMENTRENEWRENEWRENEWRENEWRENEWCHECK OIL LEVEL. ADD IF LOW

1000

6 MONTH

336

24

34211

1111

1222

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 TANKHYDRAULIC OIL FILTERDRIVE BELTCOOLING SYSTEM

ARTICULATION PIVOT NUTTRANSMISSION MTG. BOLTSTURBOCHARGER MTG. NUTSENGINE MOUNTING BOLTS

DRAIN OIL AND REFILL WITH NEW OILRENEWRENEW BELTCHECK CONCENTRATION. ADD BOOSTER

CHECK TORQUE (TORQUE SEAL)CHECK TORQUE (TORQUE SEAL)CHECK TORQUE (TORQUE SEAL)CHECK TORQUE (TORQUE SEAL)

2000

ANNUALLY

500

3 MONTH

32

3333

1

11

TEXTRAN TDHPREMIUM

EOTEXTRAN TDHPREMIUM

OCDB TANK

OCDB FILTEROCDB STRAINER

DRAIN OIL AND REFILL WITH NEW OIL

RENEWCLEAN

1500

9 MONTH

12 2TRANSMISSION OIL FILTERS RENEW3000

2 1TRANSMISSION DRAIN OIL AND REFILL WITH NEW OIL6000

0.125 LITRES PAG OIL 35 1

61 LITRES / 16 US GAL TRANSYND1

AIR CONDITIONING COMPRESSOR DRAIN FLUSH AND REFILL WITH NEW OIL4000

789

101920212223

21141422442

EP. NLGIEP, NLGIEP, NLGIEP, NLGIEP, NLGIEP, NLGI

AS REQUIRED600 Nm / 442 lbf ft

SEE NOTE 3SEE NOTE 3SEE NOTE 3SEE NOTE 3SEE NOTE 3SEE NOTE 3

BATTERY ELECTROLITEWHEEL RIM NUTSCAB FRESH AIR FILTERPANHARD ROD BEARINGSOSCILLATION BUSHSUSPENSION BEAM BUSHINGSSTEERING CYLINDER PINSBODY CYLINDER PINSBODY HINGE PINS/TAILGATE PINS

CHECK LEVEL. ADD ELECTROLITE IF LOWCHECK TORQUEINSPECT AND CLEAN IF REQUIREDLUBELUBELUBELUBELUBELUBE

15353114

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)

3-1

Controls and Operating

3 - Controls and Operating

3-2



3-3


1704

1. Side Window Demister

2. Storage Pocket

3. Hazard Switch

4. Lights Switch

5. Engine fault Diagnostic Switch

6. Low Ratio Switch

7. Front Work Lights Switch

8. Wash/Wipe Switch

9. Visual Display Unit (VDU)

10. N/A

11. Retarder Request Switch

12. Engine Brake Low Request Switch

13. Engine Brake Medium / High Request

Switch

14. Diff-lock Switch

15. Retarder Lever

16. Heated Mirrors Switch

17. Rear Working Lights Switch

18. Flashing/Rotating Beacon Switch

19. Rear Fog Lamp Switch

20. Park/Emergency Brake Control

21. Heater Vent

22. Transmission Gear Shift Control

23. Body Control Lever

24. Cup Holder

25. N/A

26. Fuse Box

27. Accelerator Control

28. Radio/CD Player

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

CONTROLS AND INSTRUMENTS

37. Rear View Camera

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 HMENU SELECT DN UP + -

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

16171819

20

21

22

23

26

2729

303132

333435 28

36

2124

25

37

3-4


FUSE / RELAY BOX

1. Ignition sensed equipment 20A FL. Hood raise/lower actuator 15A

2. Keyswitch 15A FM. Instrument cluster / CPU Battery 10A

3. Hazard warning lights 7.5A FK. Auxiliary 12V supply 20A

4. Rear wash/wipe 10A FJ. Automatic Lubrication (Option) 5A

5. Horn front wash/wipe 10A A. Not used

6. Air seat compressor 10A B. Engine overspeed K66

7. Dipped beam lights 10A C. Range inhibit K48

8. Main beam lights 10A D. Service brake status K25

9. Front wiper motor park 7.5A E. Air conditioner / heater ignition K23

10. Transmission TCU battery 15A F. Wiper / ignition K23

11. Transmission TCU ignition 10A G. Horns K34

12. Reverse alarm/lights 7.5A H. Headlights K15

13. IFM controller ignition 30A I. Reverse alarm / lights K17

14. Cab interior light 5A J. Neutral start K14

15. Direction indicators 5A K. Park brake OFF K71

16. Emergency/park brake 3A L. Retarder warning light K63

17. Instrument cluster/CPU ign. 7.5A M. Brake lights K50

18. Heated mirrors 15A N. Engine ECU ignition K23

19. Ignition sensed relays 3A O. Mid axle differential lock K27

20. 24V work socket battery 15A P. Indicator flasher unit K4

21. Neutral start 3A Q. Engine brake K32

22. Front washer pump 3A R. Body proximity switch K52

23. Rear washer pump 3A S. Dropbox differential lock K64

24. Horns 10A T. Radio / auxiliary function K23

25. Ignition sensed equipment 30A

26. Air conditioner/heater 15A

27. Reverse camera/monitor 10A

28. Front working lights 15A

29. Rear working lights 15A

30. Rotating/flashing beacon 5A

31. Engine ECU ignition 10A

32. Engine ECU battery 30A

33. Proximity switch 10A

34. Dropbox/Diff Lock controls 15A

35. Brake pedal controls 5A

36. 24V/12V Voltage Converter 15A

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

3-5


BASIC DATA

PSTOP

1

2

1 102 93 8

4 75 6

1694 Instrument Panel - 'Warning Lights'

Warning Lights

1. Front Brakes System Pressure (Red) - Illuminates to warn of low

pressure in the front brake system. A buzzer also sounds. If light

illuminates, stop machine and investigate the cause.

2. Rear Brakes System Pressure (Red) - Illuminates to warn of low

pressure in the rear brake system. A buzzer also sounds. If light


3. Main Beam (Blue) - Illuminates when headlights are switched on

and dip control is not engaged.

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

are operating.

5. Engine Stop Light (Red) - When the 'Stop Engine' light comes on,

the computer has detected a major malfunction in the engine that

requires immediate attention. It is the operators responsibility to shut

down the engine to avoid serious damage. This lamp is also used to

flash out active fault codes in diagnostic mode.

6. Engine Check Light (Amber) - When the 'Check Engine' light

comes on, the computer has detected a fault in the engine. The fault

should be diagnosed and corrected at the earliest opportunity. Indiagnostic mode, the 'Check Engine' light will flash out inactive fault

codes.

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

applied.

8. Transmission Check Light (Amber) - Illuminates when the

computer has detected a fault in the transmission. The fault should be

diagnosed and corrected at the earliest opportunity.

9. Emergency Steering (Red) - Illuminates to warn of a fault in the

steering system supply pressure. Illuminates when the ignition is

turned on and should go out when the engine starts. If light


10. Differential Locks (Amber) - Illuminates when the differential

locks are applied.

3-6


VDU - 'Warning Screen'2175

Warning Symbols

Note: Contained on the Warning screen of the VDU, this displays all

possible symbols displayed on 3-lines ( top to bottom) as shown.

1. Low Fuel - Indicates that the level of fuel in the system should be

monitored and action to rectify this is imminent.

2. Alternator Charging - Indicates that the system batteries are in a

state of overcharging, undercharging or battery voltage low.

3. Hydraulic Oil Filter Change - Notifies the operator that the hydraulic

oil filter is restricted and should be replaced.

4. Engine Air filter Change - Notifies the operator that the air filter is

restricted and should be cleaned / replaced accordingly.

5. Oil Brake Cooling Pressure - Indicates that the brake cooling

pressure is outwith the prescribed operating range and should be

investigated.

6. Hydraulic Oil Level - Notifies the operator that the hydraulic oil level

in the hydraulic tank is low, replenish the hydraulic oil accordingly.

7. Brake Cooling Oil Temperature - Indicates that brake cooling oil

temperature is outwith the prescribed operating range and should be

investigated.

8. Body Up - Indicates the body has been raised and is off the chassis

bed. Transmission upshift is restricted while this light is illuminated.

9. Transmission Oil Temperature High - Indicates that the temperature

of the oil in the transmission is at a critical level, outwith the prescribed

operating range for the system and should be investigated.

10. Transmission Drop Box Oil Temperature High - Indicates that

drop box oil temperature is at a level outwith the prescribed operating

range and should be investigated.

11. Transmission Drop Box High/ Low Oil Pressure - Indicates that

the drop box oil pressure is outwith the prescribed operating range and

should be investigated.

12. Retarder - Indicates that the retarder has been requested and is

active. It will remain till the retarder is deactivated.

13. Engine Brake - Indicates that the engine jake brake has been

requested and is active. It will remain till the brake is deactivated.

14. Transmission Dropbox, Low Ratio Selected - Indicates that the

drop box is engaged in low ratio.

15. Transmission Drop box, High Ratio Selected - Indicates that the

drop box is engaged in high ratio.

L H

1 2 3 4 5

896

107

15

11121314

3-7


Instruments

2174 Instrument Panel

1. Engine Water Temperature Gauge - This gauge should read in

the green sector after the engine has warmed. If the gauge reads

above this, (the red sector) stop the engine and investigate the cause.

2. Speedometer - The speedometer indicates travel speed in

kilometres per hour (displayed grey) and miles per hour, (displayed

white). A digital odometer is centred at the base of the speedometer,

consiting of a 2-line LCD. The upper line displays 7-digits, which

show the total miles travelled. The lower line displays a 4-digit

reading which displays the trip mileage. The trip mileage can be reset

by pressing the reset button for approximately 1 second. The

readings can be used for operating and service records.

3. Tachometer - Driven from the engine ECU, the tachometer

indicates the number of engine crankshaft revolutions per minute.

The needle shows the variations in engine operating speed. Never

accelerate the engine to speeds indicated by the red zone on the dial

face.

4. Transmission Oil Temperature Gauge - Indicates transmission

oil operating temperature. Gauge should read in the green sector

during normal operation and may enter the yellow sector when using

the retarder or in converter mode. If the gauge reads above this (the

red area), stop the vehicle and investigate the cause.

5. Visual Display Unit (VDU) - Monochrome LCD display. Centred in

the instrument panel. This unit is the primary monitor within the

instrument panel. The screen holds and displays critical systems

information based on the inputs which are received from the various

vehicle sensors and monitors.

6. Dimming Button - To dim or increase the illumination for the

instruments 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

0000000

0000

L H

1 48 7 6 5

2 3

3-8


8. Reset Button - Trip counter reset button, when depressed for

approx. 1 second, will reset the trip.

'Start-Up' Screen1692a

'Warning' Sceen2175

Fuel Level

Voltmeter

00000

0

8 12 16 20 24 28 32

25 50 75

50 75 100 125 150

100

Brake Cooling

L H

1

2

3

8764 5'Main' Screen1692c

The following show the multi-level display in its 3 possible

conditions. On initial starting of the vehicle, the VDU will display the

screens and scroll through them in the order in which they are

displayed here, assuming the system is in correct working order.

Screen 1- Displays the TEREX logo and program part number.

Screen 2- Displays the Warning screen, consisting of Warning

symbol graphics which have been pre-programmed into the system.

(These are described in the BASIC DATA, Warning lights/symbol

section prior to this.)

Screen 3 - Main Screen, this is the default screen which will remain

active at all times, unless another screen has been activated via a

warning or is triggered by the operator requesting a screen change

using the request button. If an active warning is present the VDU will

toggle between screen 3 and screen 2. The screens will toggle

between 'warning' and 'main' screen until the warning light

disappears. The main screen contains information / monitoring of the

following vehicle functions-

1. Fuel level - Bargraph monitors fuel level within the tank. Should

the fuel level drop below 25% a warning light (1) on the instrument

display will light. Capacity 450 litres (119 US gal). Fill the tank

overnight to minimise condensation in the tank. Avoid a dry tank

condition which requires bleeding the fuel system.

2. System Voltage - Monitors the potential voltage on the system.

Should the level drop to a critical level, indicating a discharged

battery / fault, a warning light (2) on the instrument display will light.

3. Brake Cooling - Monitors brake oil temperature, should the temp

rise above 60°C (140°F), a warning light (7) will illuminate.

4. Retarder - Indicates that the transmission retarder has been

requested and is active.

Visual Display Unit (VDU)

L H

1 2 3 4 5

896

107

15

11121314

3-9


1692c

5. Engine Brake - Indicates that the engine jake brake has been

requested and is active.

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

engine.

7. Transmission Drop box, Low Ratio Selected - Indicates that the

drop box is engaged in low ratio.

8. Transmission Drop box, High Ratio Selected - Indicates that the

drop box is engaged in high ratio.

Fuel Level

Voltmeter

00000

0

8 12 16 20 24 28 32

25 50 75

50 75 100 125 150

100

Brake Cooling

L H

1

2

3

8764 5'Main' Screen

Switches

1. Hazard Warning Lights - Press bottom of switch to make

indicators flash simultaneously as hazard warning lights. The

direction indicator warning lamp on the instrument panel will flash. To

switch hazard lights off; press the top of the switch.

2. Main Lights - Press the bottom of switch to the first postion to

operate side, tail and panel lights. The lights in the other switches will

illuminate. Press switch to the second position to operate the

headlights. To switch lights off; press the top of the switch.

3. Engine Diagnostic Switch - To check for active fault codes:a. - Turn the ignition key switch to position ‘1’.

b. - Press the diagnostic switch to the 'ON' position.

Any active codes will then be flashed out on the engine ‘STOP’ light

followed by any inactive codes being flashed out on the engine

‘CHECK’ light. A flash code ‘25’ indicates that the engine ECU is

clear of any faults. Refer to pages 3-23 to 3- 29 for details of the fault

codes.

4. Drop box - Low Ratio Request Switch - Pressing bottom of

switch engages the low gear ratio in the dropbox. With the switch in

the off position the drop box defaults to the high ratio.

Note: It is only possible to select ratio when certain conditions are

met; (See page 3-37)

The relevant high/low ratio symbol will illuminate on the VDU.

5. Front Working Lights - Press bottom of switch to operate the front

work lights. To switch off, press top of switch.

6. Rear Wash/Wipe - Press bottom of switch to operate the rear

screen wiper. Press the switch again for wash. To switch Off; press

the top of the switch.

2139 Left of instrument panel

H

1

2

3

4

5

6

3-10


7. Retarder Request Switch - Press bottom of switch to request the

transmission retarder. To disengage the retarder press the switch to

the off position. The retarder symbol will illuminate on the VDU when

the retarder is activated.

8. Engine Brake Low Request Switch - Press bottom of switch to

request the engine brake 'Low'. The engine brake symbol will

illuminate on the VDU when the engine Jake brake is activated.

9. Engine Brake - Medium / High Request Switch - Different levels

of engine braking can be attained by using this switch when the

engine brake request switch has been activated. Pressing the top of

the switch forward once will request 'medium' braking, pressing the

top of the switch forward to the second switch position will then

request engine brake 'high'. Only when the engine brake request

switch is pressed and active will the switch for greater levels of

braking be operative. Otherwise switch will be inactive.

10. Differential Lock Request Switch - Press bottom of switch to

engage the inter-axle differential locks. The differential lock warning

lamp on the instrument panel will illuminate. Pressing the switch to

the off position will disengage the differential locks.

11. Retarder Lever - The transmission retarder has six stages of

retardation. When the retarder is engaged it is at its maximum level

when the retarder lever is in its downmost position. When the lever is

at its uppermost position the retarder is Off.

12. Heated Mirrors - Press bottom of switch to activate the heated

mirrors. To switch off; press top of switch.

13. Rear Working Lights - Press bottom of switch to operate rear

working lights. To switch off; press top of switch.

14. Flashing/Rotating Beacon - Press bottom of switch to operate

flashing/rotating beacon. To switch off; press top of switch.

15. Rear Fog Lamp - Press bottom of switch to operate rear fog lamp.

To switch off; press top of switch.

16. Body Lower Emergency Switch - Not currently fitted to

TA350/400 machines.

2140 Right of instrument panel

161501

2141 Right Bank

7

8

9

10

11

1213 14 15

3-11


1765

17. Ignition and Starter Key Switch - The combined switch operates

the ignition and starter motor.

'0' - Ignition switched off. All electrical systems are inoperative. This

position also cuts off fuel to shut down the engine.

'1' - Ignition switched on, instruments, gauges and warning lights

register as appropriate. All electrical systems are operative. The key

must remain in this position whilst operating the machine.

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

position '1'.

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

18

191709

18. Diagnostic Test Point - (Located at the right hand side of the

instructor or trainer seat). Plug in connector for engine, transmission

and instrument panel / VDU diagnostic equipment.

19. Battery Master Switch - (Located at the left hand side of the truck

at the battery box.) Turn key clockwise to connect the batteries to the

electrical circuits. Switch key off and remove when leaving machine

unattended.

01

2

407 17

3-12


Controls

Headlight Dipper, Direction Indicator, Windscreen Wiper/Washer

and Horn

1. Headlight Dipper and Flasher:

Neutral Position = Dipped Beam

Control Rearwards = Headlight Flash

Control Rearwards

with main lights on = Main beam

1710 1

1711 2

1712 3

1713 44444

3. Windscreen Wiper/Washer:

Position 0 = Neutral Position

Position 1 = Intermittent Sweep

Position 2 = Wiper Slow Speed

Position 3 = Wiper Fast Speed

Slide grip inward = Windscreen Wash

2. Direction Indicator:

Control Downwards = Left Indicators

Control Upwards = Right Indicators

4. Horn:Button pushed in = Horn Sounds

3-13


Heater

Blower control (3) is rotated to select one of three blower speeds. Air

direction can be adjusted by turning direction controls (4 & 5).

Temperature control (1) is rotated to vary heater output temperature.

Heater output air is unheated with the control turned fully

anticlockwise and heated by turning clockwise.

Heater/air conditioner outlets (6) may be adjusted to control air flow

output by opening and closing the control flaps. Air direction can be

adjusted by rotating complete outlet.

Air Conditioner

Keep all windows and vents closed.

Blower control (3) is rotated to select one of three blower speeds. The

air conditioning will not operate if the blower control is not switched

on. Air direction can be adjusted by turning direction controls (4 & 5).

Turning control (2) to the right switches on the air conditioning. Air

conditioner output temperature can be contolled using temperature

control (1).

Heater/air conditioner outlets (6) may be adjusted to control air flow

output by opening and closing the control flaps. Air direction can be

adjusted by rotating complete outlet.

Note: When the air conditioning is switched on, the engine cooling

fan automatically engages.

1731

1

2 3

321

17304

5

1714

6 6 6 6

AIR CONDITIONING RE-START PROCEDURE

If the machine has been idle for an extended period of time (2 weeks), the refrigerant in the air

conditioning unit converts from a gas to a 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 failure in the air conditioning unit.

The following commissioning procedure allows the air conditioning unit to achieve normal operating

parameters.

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.

NOTICE

Follow the instructions given above,

otherwise the machine may be damaged.

3-14


Operator's Seat - Air Suspension

The air seat only reacts when the driver sits on the

seat. When unoccupied, the seat sinks to the lowest

position to 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).

2081

Do not attempt to adjust the seat or the seat beltwhile the machine is moving. Loss of control mayresult. Stop the machine; apply the brakes; thencarry out adjustments.

6

9

10

(behind)

115

3

2

4

1

87

3-15


Operator's Seat - Operation

To achieve the most comfortable driving position,

adjust the seat as follows;

1. Sit in the seat.

2. Pull up and immediately release the height and

weight adjustment (1) handle - this will set the seat

to cater for the operator’s weight. Sit completely

still while carrying out the adjustment . The seat

position is now adjusted correctly to cater for the

operator’s weight. Further lifting or pressing down

on this lever will raise or respectively lower the

seat, if the height requires adjustment.

NOTICE

Do not operate the height and weight

adjustment lever for a period longer than one

minute, otherwise the inbuilt compressor maybe damaged.

3. Angular adjustment of the base cushion (seat

pan) about the horizontal axis is achieved by lifting

lever 8 and exerting pressure on front or rear of the

seat pan to tilt it to the desired horizontal attitude.

Release the handle when the required position is

achieved.

4. Pull up the depth adjustment handle (7) to

facilitate movement of the seat forwards or

backwards. Release the handle when the required

position is achieved.

5. If adjustment of the armrest angles is desired,

this can be achieved turning the rotary adjusters

(10). If the armrests are not required, they can be

folded up out of the way. This is achieved by

removing the caps (11) on each side of the frame,

undoing the hexagon nuts thus exposed, and

hinging the armrest upwards. Tighten the nuts and

refit the caps (11) on completion.

6. Pull up (or push down) the headrest (6) to the

required height. This can be achieved, by

increments, up to its end stop. The angle of the

headrest (6) can also be adjusted, by pushing or

pulling it in the desired direction, and completely

removed by lifting it off over the end stop.

The cab is for protection of the operator

and adheres to the mandatory standard forRoll Over Protection Structure (ROPS).

A prerequisite for protection is that theoperator remains in the cab, with the seat

belt securely fastened. Should the vehicle

begin to roll, hold on to the steering wheel.

2081

6

9

10

(behind)

115

3

2

4

1

87

3-16


7. The height and curvature of the backrest cushion can be adjusted by rotation 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 more readily absorbed by the driver’s seat. (Forward position - off, rearmost

position - on.)

10. If necessary carry out fore/aft seat adjustments by first lifting the lever (2), moving the driver to the

required position, then lowering the lever again until it locks. It should not be possible to move the

driver’s seat in the forward/rearward plane with the lever in its locked position.

11. Engage the seat belt (4).

3-17


1. Typical Retractable Seat Belt

Seat Belt

Retractable seat belts (1) are installed on both the operator’s seat and

the trainer/instructor seat. The seat belts require no external adjustment

and allow freedom of movement for proper manipulation of all controls.

Note: To extract the trainer/instructor seat belt, the button on housing

must be pressed.

Always wear the seat belt when operating the machine.

Always check the condition of the seat belts and mounting

hardware before operating the machine.

Any signs of looseness or wear should be reported to your

Service Department or Dealer for repair or replacement

immediately.

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

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

495

Trainer / Instructor Seat1656

Trainer/Instructor SeatThe trainer/instructor seat has only to be used when operator training

or instruction is being performed or for service personnel performing

service diagnostics.

To access the compartment below the Trainer/Instructor seat, lift the

seat (1) and use the strap to hold the seat in position (2). The seat

backrest can be folded down when not in use. Pull the seat release

catch, located on the side of the seat, to unlock the backrest (3). The

backrest can now be folded down (4).

1 4321972

1

NOTICE

The backrest must be

unlocked using the release

catch before attempting tofold it down. Failure to dothis will damage the seat.

The Trainer/instructor seat isNOT for continuous passenger

3-18


MACHINE CONTROLS

Braking

The dual circuit brake system is applied during normal operation by

using the Service Brake Pedal or, in an emergency, by using the Park/

Emergency Brake Control.

'Front Brake System' warning light and 'Rear Brake System' warning

light are located on the instrument panel. A buzzer will also sound if

the brake pressure is low. If any of these lights illuminate and/or the

buzzer sounds, stop the machine, apply parking brake and do not

operate until the fault is corrected.

Service Brake

This is a cab wall mounted pedal operated by the right foot. Depress

the pedal as required by speed, load and road conditions, to slow or

stop the machine. Release the pedal as the machine slows until, when

stopped, the pedal is depressed just enough to hold it stationary. Do

not 'FAN' the pedal.

Note: Pedal movement will be experienced when applying or

releasing the Park/Emergency Brake Control when the engine is

running.

1716

1715

Park/ Emergency BrakePushing the control in will apply the spring operated driveline

mounted parking brake and the service brakes at all wheels. The

parking brake warning light on the instrument panel will illuminate

when the control is pushed in. Turn the control clockwise and put the

transsmission in gear to release the park brakes

Always apply theparking brake beforeleaving the operator's

seat.

NOTICE

The Park/Emergency Brake Control should only be used to stop

the machine in an emergency, or, for applying the parking brakeonce the machine has been stopped. For normal braking theservice brake pedal should be employed.

3-19


Transmission Retarder

This switch (1) is used to request the transmission retarder. The

retarder is engaged when the bottom of the switch is pressed,

provided that the transmission 'Check' warning light is 'OUT', the

transmission is in 'lockup' and the accelerator is released (off gas).

The retarder lever (2) is then used to determine the level of

retardation required. It is a six stage retarder that is at its maximum

when the retarder lever is in its downmost position. To disengage

the retarder; press the top of the switch (1) or re-apply accelerator

pedal (on gas).

The retarder is used to apply a continuous braking force to hold the

truck to a safe steady speed when descending grades, to reduce the

need for service brake applications, thus reducing service brake

wear and preventing overheating. The retarder may be used any

time to slow down. If additional braking is required apply the engine

brake. The retarder is not meant for bringing the machine to a halt, or

for sudden deceleration - the service brakes should be employed for

this purpose.

Retarder Operation

Before the machine starts down the grade, request the retarder and

release the accelerator (off gas). For maximum retardation, oil

circulation and cooling, the machine downgrade speed (retarder

applied) gear range should be manually selected and should be

high enough to keep the engine operating at governed speed.

Generally the gear used to ascend a grade fully laden is also correct

for its descent. If the rate of descent is too fast, the engine brake

should be applied which will allow a safe descent and efficient

retarder operation. If further braking is required still, apply the service

brakes.

For recommended downgrade speed gear selection, please refer to

the gradeability chart.

Frequent use of the retarder will result in higher transmission oil

temperatures. Therefore, the oil temperature gauge should be

checked frequently. During normal operation the gauge should read

in the green sector. However, during converter mode, and during

retarder operation, temperatures may reach the yellow sector.

NOTICE

The transmission check warning light and transmission

temperature warning symbol on the vdu screen willilluminate when the transmission sump oil temperaturereaches 1210C (250 0F). The retarder will automatically

disengage when the oil temperature 1660C (330 0F), a

transmission ‘CHECK’ warning light will illuminate and a faultcode will be displayed and recorded by the ECU. The speed

must be reduced by using the service brakes so that the oil

is cooled down. Reduce downgrade travel speed to avoidthe oil overheating and possible damage to transmission.

2144 1

2145 2

3-20


Engine Brake

The engine brake is activated by pressing the engine brake request

switch (1). This will engage 'low' engine brake level. Should

increased levels of braking be desired, pressing the engine

brake - medium / high switch (2) forward once will engage 'medium'.

Pushing the switch a second time will engage 'high' braking effort.

Only when the engine brake request switch (1) is pressed and active

will the switch (2) for greater levels of braking be operative. Otherwise

switch (2) will be inactive. The engine brake applies a continuous

braking force to hold the truck to a safe steady speed when

descending grades, to reduce the need for service brake applications,

thus reducing service brake wear and preventing overheating. The

engine brake may be used any time to slow down. If additional

braking is required, apply the service brakes. The engine brake is not

meant for bringing the machine to a halt, or for sudden deceleration -

the service brakes should be employed for this purpose.

Operation

Certain conditions must be met before the engine will allow the

engine brake to become active; accelerator released (off gas), engine

speed greater than 1300 rev/min and the transmission must be in

lockup. If these conditions are met, the engine brake will become

active if it has been requested by the operator.

Before the machine starts down the grade, request the engine brake

and release the accelerator (off gas). It is recommended to manually

select the correct downgrade speed gear range before decent. For

recommended downgrade speed gear selection, please refer to the

gradeability chart. Generally the gear used to ascend a grade fully

laden is also correct for its descent. If the rate of descent is too fast,

the transmission retarder should be applied which will allow a safe

descent and efficient engine braking. If further braking is required still,

apply the service brakes.

If the vehicle is approaching an overspeed condition, the engine

brake is automatically applied and throttle inhibited to decrease

engine speed. The engine brake will automatically apply at

2350 rev/min and disengage at 1950 rev/min.


2146

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


10 2 14 9 10 4 32 20

1 2

3-21


Engine

Electronic Foot Pedal

The electronic foot pedal provides an electrical signal to the

engine's fuel control system in proportion to the degree of

pedal actuation.

Note: The engine MUST be started with foot 'OFF' the electronic

foot pedal.

Do not place engine under full load at full speed immediately

after starting. Always allow the engine to fully circulate

lubricant and warm up gradually before operating at full

speed and full load. Operate engine at top rated speed when

maximum power is needed for the load.

Detroit Diesel Electronic Control (DDEC)

This machine is equipped with the Detroit Diesel Electronic

Control (DDEC) which continually monitors the engine and

warns the operator when a problem develops. The DDEC

system also takes action to prevent damage to the engine

and provides the serviceman with diagnostic capabilities so

that problems can be corrected quickly and easily.

1720

NOTICE

Before any welding is done on a machine equipped with theDDEC System, disconnect the following in this order: Batteryearth 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 battery master switch to isolate the batteries before

disconnecting any components.

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

3-22


DDEC V Description

1. Electronic Control Module (ECM) - Receives electronic inputs from the driver

as well as from sensors that provide information electronically, such as oil

pressure and temperature and intake manifold pressure. This information is used

to control both the quantity of fuel injected and injection timing.

2. Programmable Read Only Memory (PROM) - Located in the ECM and

encoded with the operating software. Additional information is programmed into

the EEPROM. This information controls the horsepower rating, torque curve,

maximum engine speed and engine protection devices. The ECM processes this

information and sends electronic signals to the Electronic Unit Injectors (EUI)

where the precise amount of fuel is injected into the engine.

3. Electronic Unit Injectors (EUI) - The EUI is a lightweight, compact unit that

injects diesel fuel directly into the combustion chamber. The amount of fuel

injected and the beginning of injection timing is determined by the ECM. The

ECM sends a command pulse which activates the injector solenoid.

The EUI 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.

1 - Electronic Control Module (ECM) 4 - Electronic Foot Pedal 7- Diagnostic / Override2 - Programmable Read Only Memory (PROM) 5 - 'Stop' Light Switch3 - DDEC System N3 Injectors 6 - 'Check' Light 8 - Diagnostic Test Point

2147

PSTOP

1

2

H

5

78

4

1,2

3

6

3-23


Electronic unit injectors are self compensating and virtually eliminate

engine tune-ups.

DDEC V Operation

The DDEC system operates from a 24 volt supply. However, in the event

of a loss of power supply, the system will operate at reduced voltage. At

reduced voltage the electronic control system will detect a malfunction and

the ‘check engine light’ on the dash panel will illuminate.

At this point the ECM will go into backup control and a change in engine

operation will be noticed. The engine will operate only at reduced

rev/min until the battery voltage reaches a point where it will no longer

function and the engine will shut down. The machine can still be

operated when the check engine light is illuminated, however, the fault

should be diagnosed and corrected at the earliest possible opportunity.

The machine is equipped with the DDEC engine protection system, which

records the stop engine malfunction in the ECM. The stop engine and

check engine lights illuminate when the engine protection system is

initiated. The engine will immediately reduce to 70% of the available

torque. Rampdown then commences over a 30 second period and

reduces the engine to 40% of the available torque.

To allow for the possibility of the engine protection system being activated

while the machine is operating in a critical situation, a stop engine

override switch (7) is provided. If the switch is pressed and released

during rampdown, the 30 second timer will reset, restoring torque to the

level immediately following illumination of the stop engine and check

engine lights. The switch must be pressed and released again to obtain a

subsequent override.

Note: The operator must continue to reset the automatic engine

protection system by pressing and releasing the stop engine override

switch at intervals of approximately 15 to 20 seconds. The ECM will

record the number of times the override is activated after the fault occurs.

Available Torque is the actual torque available from the engine when

the fault occurred based on the actual rev/min when the fault occurred.

NOTICE

The engine overrideswitch should only be

used in a safety critical

situation.

NOTICE

Never apply 12 or 24 Volts directly to terminals on the injector

or engine sensor as they will be burn out. Before removing the

injectors, the fuel passages will be blown out to prevent fuel

flow from entering the cylinder head.

NOTICE

When the stop engine 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.

3-24


The operator of a

DDEC-equipped vehicle

must not attempt to use

or read a DDR of any

kind while the vehicle is

operating. Doing so can

result in loss of control,

which may cause

vehicle damage and

may result in personal

injury.

When engine or

electronics system

diagnosis is required on

a DDEC-equippedvehicle, this must bedone by a person otherthan the operator. Theoperator must maintaincontrol of the movingvehicle while theassistant performs thediagnosis.

The engine should not be restarted after it has been shut down after

activation of the engine protection system unless the problem has

been diagnosed and corrected.

Conditions that will cause the Stop Engine Light to come on are; Low

Coolant Level, High Coolant Temperature, Low Oil Pressure and

High Oil Temperature.

Whenever the check engine light or stop engine light comes on, the

DDEC computer will determine where the problem is and will store

this information in its memory. If the malfunction is intermittent, the

lights will come on and go off as the computer senses the changing

engine condition.

A special diagnostic data reader (DDR) or laptop based Detroit

Diesel Diagnostic Link (DDDL) are available that can be plugged

into the engine computer memory to extract information related to the

cause of the problem. Once the malfunction has been corrected, the

DDEC system will return the engine to normal operation. The DDR

and DDDL can distinguish between active codes and those stored in

the historic code memory. The malfunction code recorded in the

ECM memory will remain until it is erased by a technician.

When the engine is not running and the ignition is on, or, the engine

is idling and not in an engine protection condition, engine faults can

be diagnosed by the operator. Pressing and releasing the diagnostic

request switch will cause the check engine light or stop engine light

to flash a code number indicating the fault, e.g. flash twice - pause -

flash five times - pause indicates a code 25. Code 25 indicates all

systems are operating correctly. Pressing the switch a second time

will stop the engine codes flashing. Refer to 'DDEC V Diagnostic

Codes' table for other code descriptions.

Note: Only one light will be flashing at any one time. When code flashing

is initiated, the active codes (or code 25) will be flashed on the stop

engine light, then the inactive codes (or code 25) will be flashed on the

check engine light. When all of the inactive codes have been flashed,

the process of flashing the codes will repeat until the conditions for

code flashing are no longer satisfied.

1 FLASH

SHORT

PAUSE

½ SEC

SHORT

PAUSE

½ SEC

LONG

PAUSE

3 SEC

CODE 13

ACTIVE

CODE 21

INACTIVE

3 FLASHES 2 FLASHES 1 FLASH

RED - SEL YELLOW - CEL

Flash code example 1792

2148

H

3-25


DDEC V DIAGNOSTIC CODES

DDEC Code

# (Flashed) PID SID FMI DDEC Description

- 240 - 2 Fram checksum incorrect

- 251 - 10 Clock module abnormal rate

- 251 - 13 Clock module fault/failure

- - 253 13 Incompatible calibration version

- - 254 0 External failed RAM

- - 254 1 Internal failed RAM

- - 254 6 Entered boot via switches

11 187 - 4 VSG sensor voltage low

11 187 - 7 VSG switch system not responding

12 187 - 3 VSG sensor high

13 111 - 4 Coolant level sensor input voltage low

13 111 - 6 Add coolant level sensor input voltage low

14 110 - 3 Coolant temperature sensor input voltage high

14 175 - 3 Oil temperature sensor input voltage high

15 110 - 4 Coolant temperature sensor input voltage low

15 175 - 4 Oil temperature sensor input voltage low

16 111 - 3 Coolant level sensor input voltage high

16 111 - 5 Add coolant level sensor input voltage high

21 91 - 3 TPS input voltage high

22 91 - 4 TPS input voltage low

23 174 - 3 Fuel temperature sensor input voltage high

24 174 - 4 Fuel temperature sensor input voltage low

25 - - - Reserved for 'No Codes'

26 - 25 1 Auxiliary shutdown #1 active

26 - 61 11 Auxiliary shutdown #2 active

27 171 - 3 Ambient air temperature sensor input voltage high

(Release 2.00 or later only)

27 172 - 3 Air temperature sensor input voltage high

27 105 - 3 Intake manifold temperature sensor input voltage high

28 171 - 4 Ambient air temperature circuit failed low


28 172 - 4 Air temperature sensor input voltage low

28 105 - 4 Intake manifold temperature sensor input voltage low

31 - 51 3 Aux. output #3 open circuit (high side) (E-49)

31 - 51 4 Aux. output #3 short to ground (high side) (E-49)

31 - 51 7 Aux. output #3 mechanical system fail (E-49)




32 - 238 4 SEL open circuit

32 - 238 3 SEL short to battery (+)

32 - 239 3 CEL short to battery (+)

32 - 239 4 CEL open circuit

33 102 - 3 Turbo boost pressure sensor input voltage high

34 102 - 4 Turbo boost pressure sensor input voltage low

35 100 - 3 Oil pressure sensor input voltage high

36 100 - 4 Oil pressure sensor input voltage low

37 94 - 3 Fuel pressure sensor input voltage high

37 95 - 3 Fuel restriction sensor input voltage high

3-26



DDEC Code


38 94 4 Fuel pressure sensor input voltage low

38 95 - 4 Fuel restriction sensor input voltage low

41 - 21 0 Too many SRS (missing TRS)

42 - 21 1 Too few SRS (missing SRS)

43 111 - 1 Coolant level low

44 110 - 0 Coolant temperature high

44 172 - 0 Air inlet temperature high

44 175 - 0 Oil temperature high

27 105 - 3 Intake manifold temperature sensor input voltage high

28 171 - 4 Ambient air temperature circuit failed low


28 172 - 4 Air temperature sensor input voltage low

28 105 - 4 Intake manifold temperature sensor input voltage low







32 - 238 4 SEL open circuit

32 - 238 3 SEL short to battery (+)

32 - 239 3 CEL short to battery (+)

32 - 239 4 CEL open circuit

33 102 - 3 Turbo boost pressure sensor input voltage high

34 102 - 4 Turbo boost pressure sensor input voltage low

35 100 - 3 Oil pressure sensor input voltage high

36 100 - 4 Oil pressure sensor input voltage low

37 94 - 3 Fuel pressure sensor input voltage high

37 95 - 3 Fuel restriction sensor input voltage high

38 94 4 Fuel pressure sensor input voltage low

38 95 - 4 Fuel restriction sensor input voltage low

41 - 21 0 Too many SRS (missing TRS)

42 - 21 1 Too few SRS (missing SRS)

43 111 - 1 Coolant level low

44 110 - 0 Coolant temperature high

44 172 - 0 Air inlet temperature high

44 175 - 0 Oil temperature high

44 105 - 0 Intake manifold temperature high

45 100 - 1 Oil pressure low

46 - 155 4 Injector Vreg voltage failed low

46 168 - 1 ECM battery voltage low

46 - 211 1 Vehicle sensor supply voltage low (V-11, V-12)

46 - 212 4 Injector Vslope voltage failed low

46 - 214 1 RTC backup battery voltage low

46 - 221 4 Injector Ipullin voltage failed low

46 - 232 1 Engine sensor supply voltage low (E-12, E-26)

47 94 - 0 Fuel pressure high

47 102 - 0 Turbo boost pressure high

47 106 - 0 Air inlet pressure high

3-27



DDEC Code


48 94 - 1 Fuel pressure low

48 106 - 1 Air inlet pressure low

52 - 254 12 A/D conversion fail

53 - 253 2 Memory check failed on startup

53 - 253 12 Memory write error - single location

53 - 253 13 Calibration memory error

53 - 253 14 Memory write error - all locations

54 84 - 12 Vehicle speed sensor fault

55 - 216 14 Missing other ECU information

55 - 231 12 J1939 data link fault

56 - 250 12 J1587 data link fault

58 92 - 0 Torque overload

61 - xxx 0 Injector xxx response time long

61 - xxx 6 Injector xxx circuit short to ground

62 - 26 3 Aux. output #1 short to battery (+) (V-04)

62 - 26 4 Aux. output #1 open circuit (V-04)















62 - 259 3 Aux. output #11 short to battery (+) (E-13)

62 - 259 4 Aux. output #11 open circuit (E-13)

62 - 26 7 Aux. output #1 mechanical system failure (V-04)








62 - 259 7 Aux. output #11 mechanical system failure (E-13)

63 - 57 3 PWM #1 short to battery (+) (V-52)

63 - 57 4 PWM #1 open circuit (V-52)

63 - 58 3 PWM #2 short to battery (+) (V-46)

63 - 58 4 PWM #2 open circuit (V-46)

63 - 59 3 PWM #3 short to battery (+) (E-01)

63 - 59 4 PWM #3 open circuit (E-01)



3-28



DDEC Code






63 - 57 0 PWM #1 above normal range (V-52)

63 - 57 1 PWM #1 below normal range (V-52)

63 - 58 0 PWM #2 above normal range (V-46)

63 - 58 1 PWM #2 below normal range (V-46)

63 - 59 0 PWM #3 above normal range (E-01)

63 - 59 1 PWM #3 below normal range (E-01)







63 - 57 7 PWM #1 mechanical system failure (V-52)

63 - 58 7 PWM #2 mechanical system failure (V-46)

63 - 59 7 PWM #3 mechanical system failure (E-01)




64 103 - 8 Turbo speed sensor input failure

64 103 - 0 Turbo overspeed

65 107 - 3 Air filter restriction sensor voltage high

65 107 - 4 Air filter restriction sensor voltage low

66 - 99 3 Oil filter restriction sensor voltage high

66 - 99 4 Oil filter restriction sensor voltage low

67 109 - 3 Coolant pressure sensor input voltage high

67 109 - 4 Coolant pressure sensor input voltage low

67 106 - 3 Air inlet pressure sensor input voltage high

67 106 - 4 Air inlet pressure sensor input voltage low

68 - 230 6 TPS idle validation circuit fault (short to ground)

68 - 230 5 TPS idle validation circuit fault (open circuit)

71 - xxx 1 Injector xxx response time short

72 84 - 0 Vehicle overspeed

72 84 - 11 Vehicle overspeed (absolute)

73 107 - 0 Air filter restriction high

74 99 - 0 Oil filter restriction high

75 - 155 3 Injector Vreg voltage failed high

75 168 - 0 ECM battery voltage high

75 - 211 0 Vehicle sensor supply voltage failed high (V-11, V-12)

75 - 212 3 Injector Vslope voltage failed high

75 - 214 0 RTC backup battery voltage high

75 - 221 3 Injector Ipullin voltage failed high

75 - 232 0 Engine sensor supply voltage high (E-12, E-26)

76 121 - 0 Engine overspeed with engine brake

77 21 - 0 ECU temperature above range

77 21 - 1 ECU temperature below range

3-29



DDEC Code


77 21 - 3 ECU temperature failed high

77 21 - 4 ECU temperature failed low

77 100 - 0 Oil pressure high

77 102 - 1 Turbo boost pressure low

77 108 - 0 Barometric pressure high

77 108 - 1 Barometric pressure low

77 171 - 0 Ambient air temperature high

77 171 - 1 Ambient air temperature low

77 174 - 0 Fuel temp high

77 251 - 10 Clock incorrect

77 251 - 13 Clock failure

77 252 - 10 Date incorrect

77 252 - 13 Clock/Date failure

81 98 - 3 Oil level sensor input voltage high

81 173 - 3 Exhaust temperature sensor input voltage high

82 98 - 4 Oil level sensor input voltage low

82 173 - 4 Exhaust temperature sensor input voltage low

83 173 - 0 Exhaust temperature high

83 173 - 4 Exhaust temperature sensor input voltage low

83 73 - 0 Pump pressure high

84 98 - 1 Oil level low

85 190 - 0 Engine overspeed

86 73 - 3 Pump pressure sensor input voltage high

86 108 - 3 Barometric pressure sensor input voltage high

87 73 - 4 Pump pressure sensor input voltage low

87 108 - 4 Barometric pressure sensor input voltage low

88 109 - 1 Coolant pressure low

89 95 - 0 Fuel restriction high

89 111 - 12 Maintenance alert coolant level fault

3-30


Allison Series 4000 Automatic Shift Transmission

The Allison Series 4000 transmission is equipped with an electronic

control unit (ECU) which continually monitors the transmission and

shift system electrical components and warns the operator when a

problem develops. It also takes action to prevent damage to the

transmission, and provides the serviceman with diagnostic

capabilities so that problems can be corrected quickly and easily.

When a fault occurs, the 'check transmission' lamp will illuminate and

an error code will be generated. The error code can be accessed

through the 4th GEN gearshift lever. The error code is also recorded

in the transmission ECU, and can be accessed by the serviceman by

plugging in a data reader to extract information relating to the fault.

The error code recorded in the ECU memory will remain until it is

erased by a technician.

If a major fault is detected, it is the operators responsibility to shut

down the machine as soon as it is safe to do so. The machine should

not be restarted until the fault has been diagnosed and corrected.

Refer to 'Transmission 4th GEN control fault codes' table for a list of

fault codes (page 3-34 to 3-36).

The Series 4000 transmission with 4th GEN control has been

designed to provide the driver with six forward gears, one reverse

gear and a neutral position. The gear position is indicated by the LCD

display on the gearshift lever. The transmission is full automatic

control.

Before any welding is

done on a machine

equipped with 4th GEN

control shift system,

disconnect the following

in this order: Battery earth

cable, battery supply

cable, alternator earth

cables, alternator supply

cables and electrical

connections at the engine

ECM, transmission ECU,

hydraulic ECU, VDU ECU

and cab bulkhead to

avoid damage to electrical

components. Turn off

battery master switch toisolate the bateries beforedisconnecting anycomponents.After welding connect allof the above in reverseorder.

NOTICE

3-31


4th GEN Shift Controller

The 4th GEN shift controller has 6 forward ranges and 1 reverse

range as well as a neutral position.

The shift selector has a two digit LED display, that during normal

operation will display the range selected and the range attained.

Diagnostic information can be displayed on the two digit LED display

by pressing the diagnostic mode button. There is a hold override

button on the lever that must be pressed when shifting between

Drive (D), Neutral (N) and Reverse (R). The hold override button is

released when the desired selector position is reached. The selector

can move between Drive (D) and the number of ranges without

pressing the hold override button.

The transmission upshifts and downshifts automatically between first

range and the highest range selected on the range selector in direct

response 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 the

machine that reverse gear has been selected.

When drive (D) is selected, the transmission automatically upshifts

and downshifts through all six forward ranges as required by loads

and travel speeds. Selecting a lower range (4th, 3rd etc.) limits the

highest range to which the transmission will automatically upshift. If a

lower range is selected while moving forward, the transmission

automatically downshifts sequentially to the selected lower range at

maximum controlled engine speeds. Downshifts will not occur until

machine is slowed by use of the service brakes and/or retarder.

When shifting from neutral to start from a standstill, or to reverse

direction, decelerate the engine to idle speed. To move forward,

select Drive (D) and accelerate the engine to the machine load and

speed requirements. The transmission will automatically upshift from

1st 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 upshifts to the next

higher range when the engine attains maximum rated speed, since

maximum power train output is needed under this condition. At lower

throttle settings where minimum power train performance is required,

the transmission will upshift to the next higher 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 powertrain

performance. When this occurs, the transmission downshifts

automatically.

MO

DE

SELECT

MONIT

OR

1 2 3 4 5 D N R

3

1

2

45

1793

1. Hold override 4. Range attained

2. Mode button 5. Display mode

3. Range selected button

Do not allow the vehicle to

coast in Neutral. This

practice can result in

severe transmission

damage.

NOTICE

3-32


Shift the transmission to the next lowest range if transmission 'Hunting'

or 'Shift Cycling' occurs.

When the vehicle is temporarily stopped, such as for yielding the right

of way to a loaded machine, the transmission can be left in the

selected range and the machine held stationary with the service

brakes.

When the vehicle is stopped for extended period with the engine left

running, shift the transmission to neutral so that the parking brake is

atomatically applied, and to avoid unnecesary heat buildup.

The mode button gives the option to select between transmission

'POWER' (primary shift schedule) and 'ECONOMY' (secondary shift

schedule). The transmission must be in Neutral before the switch

will function. Proper selection of these shift schedules permits vehicle

operation to be tailored towards maximised performance or fuel

economy.

The primary shift schedule is the default setting each time the vehicle

is started. The secondary shift shedule can be requested by pressing

the mode button. A red LED on the display indicates that the

secondary schedule is active.

The 'POWER' mode is designed for applications involving heavy

loads and hilly duty cycles where performance is of prime importance.

The 'ECONOMY' mode is designed for applications involving lighter

loads and level duty cycles or where fuel economy is more important

than performance. This mode allows earlier upshifts at a lower

rev/min.

Displaying Data

Oil level information can be displayed on the gear shift display. To

access the oil information sequence, press the Display Mode Buttononce on the gear shift lever. A 2 minute countdown begins when the

following conditions of the vehicle systems are met -

1. Engine at idle.

2. Oil is at operating temperature within range 82-104°C (140-220°F).

3. Transmission is in Neutral 'N'.

4. Transmission output shaft is stationary.

The oil level will be displayed at the end of the 2 minute countdown.

During the countdown, the display flashes out a numerical value

starting at '8' in 15 second intervals, decreasing in number 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 flash the 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.

Always select Neutral and

apply the parking brake

before leaving the

operators' seat.

1509

IDLE

FULL LOAD/THROTTLE

3-33


Note: Failure to meet any of the previous conditions 1-4, will stop the

2 minute countdown. The gear shifter will display one of the following

codes -

• oL0X : Setting time too short • oLTL : Sump fluid temp too low

• oLEL : Engine RPM too low • oLTH : Sump fluid temp too high

• oLEH : Engine RPM too high • oLSH : Output shaft rotation

detected

• oLSN : Neutral not selected • oLFL : Sensor failed

Displaying Diagnostic Fault CodesDiagnostic codes can be displayed on the gear shift lever display. To

access the diagnostic code sequence, press the Display Modebutton twice on the gear shifter. Each code consists of 4 sequential

elements; each being either 1 or 2 characters. The display for each

code will repeat continuously until the next code is displayed (if

present). To display the next code if present, press the mode button.

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 the

mode button

Clearing Diagnostic Codes• To clear active codes, press and hold mode button for 3 to 5

seconds.

• To clear inactive codes, press and hold mode button for 8 to 10

seconds.

Exiting Diagnostic ModeAny of the following methods may be used to exit the diagnostic

display mode:

• Momentarily press the display mode button.

• Move the gear shift lever to any other position than the one

selected when the diagnostic display mode was activated.

• Wait until time out (approx. 10 minutes). The system automatically

returns to normal operating mode.

• Turn off the vehicle - illuminating power to transmission ECU.

• oL ; HI 1 Oil level is high 1 quart - or as many quarts overfilled.

(1 US quart = 0.95 litre = 0.2 gallon)

3-34


C1312 Retarder Request Sensor Failed Low

C1313 Retarder Request Sensor Failed High

P0122 Pedal Position Sensor Circuit Low Voltage

P0123 Pedal Position Sensor Circuit High Voltage

P0218 Transmission Fluid Over temperature

P0561 System Voltage Low Performance

P0562 System Voltage Low

P0563 System Voltage High

P0602 TCM Not Programmed

P0610 TCM Vehicle Options Error (Trans ID)

P0613 TCM Processor

P0614 Torque Control Mismatch (ECM/ TCM)

P0634 TCM Internal Temperature Too High

P063E Auto Configuration Throttle Input Not Present

P063F Auto Configuration Engine Coolant Temperature Input Not

Present

P0658 Actuator Supply Voltage 1 Low (HSD 1 open/gnd)

P0659 Actuator Supply Voltage 1 High (HSD 1 batt)

P0701 Transmission Control System Performance

P0702 Transmission Control System Electrical (Trans ID)

P0703 Brake Switch Circuit

P0708 Transmission Range Sensor Circuit - High Input

P070C Transmission Fluid Level Sensor Circuit - Low Input

P070D Transmission Fluid Level Sensor Circuit - High Input

P0711 Transmission Fluid Temp. Sensor Circuit Performance

P0712 Transmission Fluid Temperature Sensor Circuit Low Input

P0713 Transmission Fluid Temperature Sensor Circuit High Input

P0716 Turbine Speed Sensor Circuit Performance

P0717 Turbine Speed Sensor Circuit No Signal

P071D General Purpose Input Fault

P071A RELS Input Failed On

P0720 Output Speed Sensor Circuit

P0721 Output Speed Sensor Circuit Performance

P0722 Output Speed Sensor Circuit No Signal

P0726 Engine Speed Input Circuit Performance

P0727 Engine Speed Input Circuit No Signal

P0729 Incorrect 6th Gear Ratio

P0730 Incorrect Gear Ratio

P0731 Incorrect 1st Gear Ratio

P0732 Incorrect 2nd Gear Ratio

P0733 Incorrect 3rd Gear Ratio



Code Meaning of code / Possible Cause of Fault

Allison 4th GEN Diagnostic Codes

3-35


P0736 Incorrect Reverse Ratio

P0741 Torque Convertor Clutch System Stuck Off

P0776 Pressure Control Solenoid 2 Controlled Clutch Stuck Off

P0777 Pressure Control Solenoid 2 Controlled Clutch Stuck On



P0842 Transmission Pressure Switch Solenoid 1 Circuit Low

P0843 Transmission Pressure Switch Solenoid 1 Circuit High

P0880 TCM Power Input Signal

P0881 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 Open

P0961 Main Pressure Modulation Solenoid System Performance

P0962 Main Pressure Modulation Solenoid Control Circuit Low

P0963 Main Pressure Modulation Solenoid Control Circuit High

P0964 Pressure Control (PC) Solenoid 2 Control Circuit Open

P0965 Pressure Control (PC) Solenoid 2 System Performance

P0966 Pressure Control (PC) Solenoid 2 Control Circuit Low

P0967 Pressure Control (PC) Solenoid 2 Control Circuit High

P0968 Pressure Control (PC) Solenoid 3 Control Circuit Open




P0972 Shift Solenoid (SS) 1 Control Circuit Open

P0973 Shift Solenoid (SS) 1 Control Circuit Low

P0974 Shift Solenoid (SS) 1 Control Circuit High

P0975 Shift Solenoid (SS) 2 Control Circuit Open

P0976 Shift Solenoid (SS) 2 Control Circuit Low

P0977 Shift Solenoid (SS) Control Circuit High

P0989 Retarder Pressure Sensor Failed Low

P0990 Retarder Pressure Senosr Failed High

P1739 Incorrect Low Gear Ratio

P1891 Throttle Position Sensor PWM Signal Low Input

P1892 Throttle Position Sensor PWM Signal High Input

P2184 Engine Coolant Temperature Sensor 2 Circuit Low

P2185 Engine Coolant Temperature Sensor 2 Circuit High

P2637 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)



3-36


P2686 Actuator Supply Voltage 3 High (HSD 3 batt/open)



P2718 Pressure Control (PC) Solenoid 4 System Open














P2740 Retarder Oil Temperature Hot

P2742 Retarder Oil Temperature Sensor Circuit - Low Input

P2743 Retarder Oil Temperature Sensor Circuit - High Input

P2761 TCC PCS Control Circuit Open

P2762 TCC PCS Control Circuit Range/ Performance

P2763 TCC PCS Control Ciruit High

P2764 TCC PCS Control Circuit Low

P278A Kickdown Input Switch Circuit

P2793 Gear Shift Direction Circuit







U0001 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 1

U0115 Lost Communication with ECM / PCM "B"

U0291 Lost Communication with Gear Shift Module 2

U0292 Invalid Data received from Gear Shift Control Module 2

U0304 Software Incompatability With Gear Shift Control Module 1

U0333 Software Incompatability With Gear Shift Control Module 2





3-37


Drop box

The drop box is a remote mounted two speed transfer gearbox, taking

drive from the engine and transmission and feeding it to the front and

centre axles via a lockable differential. It has self contained hydraulic

gear selection and differential locking mechanisms.

The dropbox is equipped with two gear ratios; high and low. To select

the low ratio use the following procedure:

1. Bring the vehicle to a stop with the service brakes. Maintain

pressure on the service brake.

2.The Transmission is in neutral.

3.The park/emergency brake will now automatically apply.

4. Engine rev/min must be less than 750.

5. Press the bottom of the low ratio request switch.

6. Low ratio will be activated.

7. Release the service brake pedal.

8. The park/emergency brake will automatically disengage when the

drive is selected.

To return to high ratio use the same procedure except on step 5 press

the top of the low ratio request switch.

High Ratio: Used where high speed is required.

Low Ratio: Should only be used in adverse conditions to give more

control.

Note: In electrical failure drop box will fail to the last preselected ratio.

Note: The transmission will inhibit the selection of any gear and park

brake will not release until the change is completed.

Note: If the ratio does not fully engage during selection, movement of

the steering wheel left and right should allow the gear to mesh,

engaging the desired ratio.

Differential Lock

The differential lock switch engages the differential lock in the

dropbox and the centre axle thru-drive differential for improved

traction when operating in soft or slippery conditions. The amber

'differential lock' warning light on the instrument panel will illuminate

when the differential locks are actually engaged.

Note: Automatically - acting limited slip differentials in each axle will

retain traction on most surfaces, therefore it should only be necessary

to engage the differential locks in extreme conditions.

To apply the differential locks, stop the machine with the service

brakes and operate the differential lock switch. Stop the machine and

disengage the differential locks as soon as conditions allow.

Note: The diferential locks can be preselected when the machine is

moving however, they will only engage on the move when the vehicle

speed is below 5 km/hr.

2149

2150

NOTICE

Before driving in soft orslippery conditions, stop and

engage differential locks.Spinning wheels can result in

damage to the dropbox andaxle differentials.

NOTICE

Disengage differential locks

when driving on firm ground.

H

3-38


LED Colour Status Description

- Off No Operating Voltage

Orange 1 X on Initialisation or reset checks

5Hz No operating system Loaded

Green 0.5Hz Run,CANopen;PREOPERATIONAL

2Hz Run,CANopen;OPERATIONAL

Constant Stop,CANopen;PREPARED

Red 0.5Hz Run with error

(CANopen;PREOPERATIONAL)

2Hz Run with error

(CANopen;OPERATIONAL)

On Fatal error or stop with error

Blue 0.5Hz Internal communication, Extended

Controller

NOTICE

Before any welding is

done on a machine

equipped with an IFM

hydraulic system,

disconnect the following

in this order: Battery

earth cable, battery

supply cable, alternator

earth 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 all

of the above in thereverse order.

Hydraulic Controls

The braking, steering, body control, engine cooling fan drive and

transmission oil cooler fan drive are all controlled by the main

hydraulic valve, which is mounted on the chassis. However, the body

control, engine cooling fan drive and transmission oil cooler fan drive

are electronically monitored by the IFM CR0020 ECU. The IFM

communicates with a variety of input and output devices. The ECU

continuously monitors the system and warns the operator when a

fault develops and also helps diagnose the nature of the fault. The

ECU is located inside the cab, underneath the passenger seat.

A three colour LED on the ECU is used to give the status of the ECU

and system. The following colours indicate the status levels:

The ECU has a RS232 interface which plugs directly into a laptop.

This allows communication with the ECU using IFM software to gain

more information about the ECU's status.

1734

3-39


Steering

The steering wheel position can be adjusted as required for the most

convenient operating position. To adjust, pull out adjustment lock and

tilt steering wheel up or down as desired; release lever to lock

adjustment.

To steer the machine, rotate the steering wheel in the desired

direction to the required radius of turn. The machine will turn only as

the steering wheel is turned and at a rate of turning directly

proportional to steering wheel speed. The machine will stop and hold

position when the steering wheel is stopped. To return the machine to

the straight ahead position or to the opposite direction, turn the

steering 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.

3-40


Body Control

This lever operates the body hoist cylinders. The three operating

positions of the lever are -

Raise - Pulling the lever back and holding in this position will raise the

body. When released, the lever will spring back to the 'neutral' position.

Neutral - If the body is above the body proximity switch, the lever in this

position will stop and hold the body at any desired height. If the body is

below the proximity switch, the ECU defaults the main hydraulic valve to

the float position. The body should be fully lowered and in the 'neutral'

position while the machine is in motion. The lever will remain in the

'neutral' position when released.

Power Down - Pushing the lever forward provides hydraulic force to

power down the body. Pushing the lever fully forward will engage the

electric detent. When the body reaches the proximity switch, the lever

springs back to the 'neutral' position and power down is ramped back to

allow a smooth transition to the float position.

1726

1512

NOTICE

The 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.

3-41


Tilting Cab

The operators cab can be tilted to improve accessibility to

components below, by using hydraulic hand pump (1) housed under

the hood on the left hand side.

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 the

cab is fully tilted and hold in place with cab prop (2)and install cab

prop 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 gently

lower cab until holes in cab line up with holes in mounts. Reinstall the

4 cab mounting bolts.

2176

2177

2178

Do not work under or near an unblocked

or unsupported raised operator’s cab.

Always use the operator’s cab safety propwith the locking pin.

2

1

2

3

3-42


Hood

The vehicle is fitted with an electrically powered hood. The hood is

activated from the hood control switch. The hood control switch is

located in the cab on the passenger seat support rail. It is a three

position switch; Centre:off; Up:raise; Down:lower. Operating the

hood control switch will send an electrical signal to the motor fitted to

the actuator. As the motor is powered the actuator extends outwards

to raise the hood or retracts inwards to lower the hood. 1791

Do not lower the hood when the cab is

tilted.

NOTICE

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.

Component Checks

1. Engine - With engine off, check oil level. The level should be

between the two marks on the dipstick. Up to the upper mark is

preferable. Add oil if low.

OPERATING THE TRUCK

Pre-Starting Inspection

* Make sure all safety signs are free of

damage, and are fully readable,

replace as necessary.

* Before the engine is started ensure

the machine is ready for operation.

* The machine should be in a level

position to permit accurate checking

of fluid quantities in the engine and

other components.

* Make sure parking brake is set and

block wheels if necessary to prevent

accidental movement of the machine

while checking component levels.

* Test all lights and horn for proper

operation.

* Walk around the machine and carry

out the Inspections and Component 2154

1748 1

1375 3

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

runs clear.

037 2

NOTICE

In subfreezing temperatures,be sure that the coolant

containssufficient antifreeze.

SCALDING HAZARD

Partially unscrew cap to slowly release pressure before

removing cap completely. Fill to bottom of filler neck.

ENGINECheck oil level.Check for leaks

HYDRAULIC TANKCheck oil level.Check for leaks.

FRONT SUSPENSIONCheck for debris anddamage.

WHEEL PLANETARIESCheck for leaks.

ACCUMULATORSCheck for leaks.

DROPBOXCheck oil level.Check for leaks.

HAND PUMPCheck oil level.

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

RADIATOR HEADER TANKCheck coolant level.Check for leaks.

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.

FUEL FILTER/WATERSEPARATORDrain sediment and water.

AIR CLEANER DUST VALVECheck for plugged dust cap.

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

INTERLEAF MOUNTINGSCheck for damage.

SUSPENSION LINKSCheck for damage.

DIFFERENTIALCheck for leaks.

BRAKE COOLING OIL TANK Check oil level.Check for leaks.

FS1212

Checks described in the drawing opposite and on

the following pages.

4-4

Operating the Truck

4. Engine Air Cleaner Dust Valve - Check for plugged dust cap

valve. Unplug valve and clean air cleaner dust cup if required.

1749 4

51750

2155 6A

5. Transmission - Cold Oil Level - Engine Off - This check is made

only 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 hoist cylinders

to their fully-extended positions to charge cylinders and lines then lower

the body. With the engine off, oil should show in the sight gauge (refer to

6A). Add oil, if low, through the hose adapter on the top of the tank (refer

to 6B). The larger tank filler cap, should not be used for tank

replenishment, and features a lockable hinged cover to prevent its

removal.

The hydraulic tank is pressurized from the engine inlet manifoldduring normal operation, and remains pressurized for 1-2 hoursafter the engine is stopped. Before working on the tank, or

replenishing it with oil, relieve the tank pressure by opening the

miniature ball valve adjacent to the pressure regulator. Closethis valve after the pressure has been relieved.

COLD

ADD

COLD

FULL

HOT

FULL

HOT

ADD

2116 6B

4-5

Operating the Truck

Fuel Level

Voltmeter

00.00 00.00.00

0

8 12 16 20 24 28 32

25 50 75 100

Brake Cooling

1754 10

8. Tyres - Carefully inspect all tyres for cuts, bruises, or other damage

and proper inflation for the loads to be carried. Inflate all tyres to the

recommended pressure while cold.

9. Check the Fuel Level Gauge - The fuel tank should be filled at end

of each shift.

10. Seat and Seat Belts - Adjust the seat position as required, to allow

complete machine control at all times with minimum fatigue. Make sure

the seat belt does not restrict movement for proper machine operation.

2167 7B

1752

8

7. Brake Cooling Tank - Oil Level Check - With the engine off, oil

should show in the sight gauge (refer to 7A). Add oil, if low, through the

tank filler cap(refer to 7B).

2155 7A

9

041

4-6

Operating the Truck

Engine Operation

Never start the engine indoors unless proper exhaust

ventilation is provided to remove deadly exhaust gases. Once

the engine is running, move the machine outdoors as soon

as possible. Exhaust gases are hazardous and can cause

unconsciousness and death.

NOTICE

Operating the engine beyond high idle speed can cause severe

engine 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 and

engine speed.

NOTICE

Do not place engine under FULL LOAD at FULL SPEED

IMMEDIATELY after starting. ALWAYS allow the engine to fully

circulate lubricant and warm up gradually before operating at full

speed 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.

4-7

Operating the Truck

Starting the Engine

Attention to the warning lights and instruments when starting the

engine, and operating, will help the operator to monitor the machine

systems and components.

1. Make sure park/emergency brake lever is in 'PARK' position.

(Button pushed ‘In’)

1715 1

1737 2

1713 5

1525 3

MO

DE

SELECT

MONIT

OR

1 2 3 4 5 D N R

1733 4

2. Turn master switch, located behind 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.

5. Press horn control to sound horn.

Always sound horn before starting engine operating any

control.

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

ignition.

01

575 6

4-8

Operating the Truck

1738

7. Turn key farther clockwise against spring pressure to position '2' to

crank 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 long

cranking periods to avoid overheating.

8. The amber 'Check Engine' (2) and red 'Stop

Engine' (1) lights should come on, and then go out

after 6 - 10 seconds. If the amber 'Check Engine'

light does not go out, have the system checked out

as soon as possible. If the red 'Stop Engine' light

does not go out after 6 - 10 seconds, or illuminates

during operation, stop the engine immediately.

407

01

2

7

PSTOP

1

2

1 2

8

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 to

discharged batteries.

Excessive booster voltage and/or incorrect jumper cable

connections, open flames, lighted cigars, or other ignition

sources can cause battery explosion/fire. Do not lean over

batteries, and always wear safety glasses, face shield, safety

gloves, and any other appropriate safety equipment when

working with or near battery.

Do not jump start a vehicle by using arc welding equipment.

Currents and voltages are dangerously high and cannot be

sufficiently 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 this

procedure:

Connect one end of a jumper cable, usually coloured red, to the

discharged battery 'POSITIVE' (+) post. Connect the other end of the

same cable to the 'POSITIVE' (+) post on the booster or charged

battery.

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 spark

occurs, it is away from battery fumes (explosive hydrogen).

Check for cause of failure on the dead battery.

4-10

Operating the Truck

1755 1

1750 1b

COLD

ADD

COLD

FULL

HOT

FULL

HOT

ADD

2160

Pre-Operating Checks

Make sure all cab glass, mirrors and lights are clean. Test all controls

to ensure they are functioning properly. Move transmission gear shift

control momentarily to 'REVERSE' to make sure the reverse alarm

sounds.

1. Transmission - Hot Oil Level - The parking brake must be applied

and the machines wheels securely blocked while carrying out this

check. With the engine idling, transmission in 'NEUTRAL' and at

normal operating temperature 80° C (176° F), the oil level should be

up to, but not over, the upper mark on the dipstick. Add oil if low.

2. Mirrors and CCTV- Ensure mirrors and CCTV are positioned

correctly to maximise visibility. (Refer to section “Safety” for adjustment)

4-11

Operating the Truck

Brake Function Checks

In addition to the above Pre-operating checks, the following brake

function checks must be carried out to determine if both the service and

emergency brake systems are functional before operating the machine.

Make sure the area around the machine is clear of personnel

and obstructions before carrying out these checks.

Note: The following checks are NOT intended to measure maximum

brake holding ability.

Service Brake Holding Ability Check

Depress service brake pedal and move transmission gear shift to

Drive. Pull the parking-emergency brake control out to release the

brakes. Depress accelerator control and accelerate engine to 1 350

rev/min. The machine should not move. Decelerate engine, shift

transmission to 'NEUTRAL' so that the parking brake is applied

automatically, before releasing the service brake pedal.

Emergency Brake Holding Ability Check

Push parking-emergency brake control in to apply 'EMERGENCY'

brakes and move transmission gear shift to Drive. Depress accelerator

control and accelerate engine to 1 350 rev/min. The machine should not

move. Decelerate engine, move gear shift control to 'NEUTRAL' so

that the parking brake is applied automatically, before releasing the

service brake pedal.

Note: Brake holding effort required to hold a machine static at a

specific rev/min, can vary from machine to machine due to differences

in engine performance, powertrain efficiencies, etc., as well as

differences in brake holding ability.

Note: As an indication of system deterioration, the engine rev/min at

which point the machine moved, with the service or emergency

brakes applied, can be compared against the engine rev/min your

specific machine was able to hold to on a previous check.

If the machine moves during the above checks, stop the

machine, apply the parking brake and do not operate until thefault is corrected.

4-12

Operating the Truck

1525 1

1756 2

1739 3

Driving and Stopping

Before driving off observe all instruments and warning lights. All

instruments should operate in their normal range and all warning

lights should be out except possibly the Direction Indicator, Headlight

Mainbeam and Differential Lock warning lights.

Make sure the area around the machine is clear of personnel and

obstructions before driving off.

In the first few minutes of travel check carefully for the required

steering, braking, engine and transmission power response for

maximum operating safety.

1. Make sure the body is fully down and the body control lever is in

the '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. The

transmission will automatically shift up and down the gears as speed

and conditions allow. If necessary the machine should be slowed by

use 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 the

service brake pedal. Release the service brake as the machine slows

until, when stopped, the pedal is depressed just enough to hold the

machine stationary. Do not 'FAN' the pedal.

7. When the machine has stopped, apply parking brake switch.Shift the

transmission to 'NEUTRAL' and release the service brake.

8. If the service brake does not stop the machine, apply the park/

emergency brake. This should only be applied to stop the machine in

an emergency.

1741 6

1757 7

1742 8

There 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 Engine

1. Make sure park/emergency brake control is in 'PARK' position.

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

3. Allow the engine to run between idle and 1000 rev/min with no load

for 4 or 5 minutes. This allows the engine to cool and the turbocharger

to slow down. Shutdown the engine.

4. Turn ignition key switch to the 'OFF' position. This cuts off the power

supply to the DDEC system which in turn shuts down the engine.

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

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

11758

MO

DE

SELECT

MONIT

OR

1 2 3 4 5 D N R

21733

0

5

1015

20

25

min-1

x100

30

31534

51525

61709

281 4

01

NOTICE

Stopping a turbocharged engine immediately after high speed

operation may cause damage to the turbocharger as it will

continue 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, the

following 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 overnight

or for extended periods, to prevent condensation. If security kit is

supplied, keep it locked.

2. Always park on level ground where possible. If it must be parked

on a grade, position machine at right angles to the grade and block

wheels securely. Lock the doors.

3. If below freezing temperatures are expected, make sure the cooling

system has sufficient antifreeze to prevent the coolant freezing. If

antifreeze cannot be added to the cooling system, drain the system

completely.

Check all tyres, hoses, wiring, tubing and fittings for cuts, ply

separation, abrasion, fraying, or other damage or deterioration.

Inspect for structural damage to the cab, body and chassis. Attach

warning signs to the steering wheel or to a control to alert others if

lubricant has been drained, batteries removed, or the vehicle has

been immobilized by any other means.

Fuel Level

Voltmeter

00.00 00.00.00

0

8 12 16 20 24 28 32

25 50 75 100

Brake Cooling

1752 1

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

WORKING THE TRUCK

Off-highway articulated trucks are used on a variety of hauling jobs,

from sand and gravel pits to road construction and mining. Every truck

operation, regardless of the type of job, can be divided into four

phases; loading, hauling, dumping and the empty return.

Note: After coming to a stop for loading or unloading the truck, the

park/emergency brake control can be pushed in to hold the brakes in

the applied position as though the foot brake is depressed.

Loading

Should the vehicle be fitted with a tailgate, cohesive material

must not be loaded into the body. There is a risk of injury to

the driver if a tailgate is used with a cohesive material.

NOTICE

When loading, the operator should be diligent and always

aware of the material which is to be loaded onto the vehicle. At

any time, should he feel that a load constitutes an obvious

safety hazard, he has the right and duty to refuse to load this

onto the vehicle.

The most common methods of loading articulated trucks are with

hydraulic excavators, and front end loaders. The trucks can be loaded

equally well from the rear or the side using hydraulic excavators or

rope shovels. Ideally, excavators should require 90° or less swing.

With a backhoe excavator a very efficient loading method is with the

backhoe on top of the bank loading over the rear of the truck at the

base of the bank. Backhoe slew angles can be small, leading to very

short cycle times.

For maximum material movement, the truck operator must help the

loading machine operator to keep loading time to a minimum. The

shorter 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

given period of time and the quicker the truck can be loaded.

The fewer manoeuvres the truck must make to get into the loading

position, the sooner loading can start. In restricted areas it may be

necessary to turn and reverse the truck into the loading position.

If the required space is available the truck can travel round without

the need to reverse. Waiting trucks should stay about two truck

lengths behind the one being loaded to avoid any spillage from the

loading machine bucket or truck body. The operator of the waiting

truck is also able to judge the best spot for the truck when it is his/her

turn to be loaded.

Holding Truck Stationary1758

2023 Minimize Bucket Swing

2024 Loading From Rear

2025 Manoeuvring In Restricted Areas

2026 Semicircular Loading

5-4

Working the Truck

On some jobs, the loading machine might work most efficiently whentrucks are positioned on both sides of the loader. Thus, while one

truck is being loaded, another can move into position on the opposite

side of the loader and the loading machine can swing over to load the

next truck with a minimum of lost time. Since the truck is usually

backed into the loading position with this method, the operator must

be alert and careful 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 area

and at an angle to the face of the bank or stockpile. This minimizes

loader travel time, particularly with a raised, full bucket. Where

possible, the truck should also locate downwind of the loader when

dusty material is being loaded on a windy day. This practice improves

both working conditions and visibility for the loader operator.

A cleanup dozer or small loader is often worked in conjunction with

the main loading machine to keep the area clear of bucket spillage formaximum efficiency of the loading operation. The truck operator must

always be alert to the position of the cleanup machine when entering

the loading area to avoid congestion, and, for maximum safety.

Avoid rocks and other shovel spillage that can needlessly

damage tyres or other truck components. Allow the cleanup

machine sufficient time to clear up such debris.

Do not move the truck into loading position with the shovel

bucket swinging overhead. Large rocks that might fall from

the bucket can be dangerous to both the operator and the

truck.

Keep your head and arms inside the cab during loading to

avoid the danger of falling rocks or other shovel spillage.

When the loader operator signals that the truck is loaded, sound two

blasts on the horn for forward movement and three blasts for reverse

movement. Select the correct gear and release the brakes. Move out of

the loading area and onto the haul road, with the least possible delay, to

allow any waiting truck to move into the loading position as soon as

possible.

2027 Loading Both Sides

Loading With Front End Loader2028

Watch Cleanup Machine2029

5-5

Working the Truck

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 with

the transmission in 'NEUTRAL'!

When approaching or encountering extremely soft or slippery

conditions, stop the truck and engage the differential locks. Do not

engage the differential locks when the truck is moving or wheels are

spinning. Disengage the locks as soon as conditions return to normal.

When approaching downgrades, select the proper transmission gearrange and use the retarder, engine brake and service brakes as

required to maintain safe descent speed, without over-speeding the

engine, or gaining excess travel speed. Generally, the transmission

range required for ascending 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 allow

two truck-lengths between machines for each 16 km/h (10 mile/h) oftravel speed under normal operating conditions. Under adverse

conditions, allow more room for safe operation. On jobs on which

minimum distance between machines is specified for the haul road,

be sure to observe the regulations at all times. Such regulations are

established for the safety of everyone on the job.

Pay attention to haul road conditions to avoid rocks, holes, or other

obstacles. 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, at

intersections, railroads, public highways etc. Where a 'FLAGMAN' is

stationed to direct traffic, always stay alert and follow his/her

directions.

Maintain Safe Speeds2030

2031 Safety First

2032 Avoid Obstacles

2150 Driving On Soft Or Slippery Conditions

10

10

20

3040

50

60

70

80

km/h

20 30

40mph

500 0000000

0000

TWO MINIMUM

5-6

Working the Truck

Dumping

When dumping the operator should steer the vehicle ensuring that it

is straight and with the loaded body on level ground. The dumping

operation usually depends upon the type of material being hauled.

For instance, overburden and other waste material is usually dumpedover a spoil bank or piled into large mounds. The dumping on a job of

this type might be controlled by a dump 'SPOTTER', 'FLAGMAN' or

'BANKSMAN' or second person who directs the truck to its dumping

area. While backing to dump, the operator must watch the

'SPOTTER' at all times and follow his/her direction. Under no

circumstances should the 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, or

crusher, where it is processed. When dumping into a hopper, the

operator, in order to avoid excess wear on the tyres, must avoid

hitting the 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 an

earth-fill dam, the load is usually dumped in a string with other loadsand the loads smoothed out with a crawler tractor. When dumping on

a fill of this type, the operator usually works alone and picks his/her

own dumping place. To save bulldozer work and cleaning up, the

load should be dumped as close as possible to the preceding load.

The operator should pull past the preceding load, turn in line with the

string and back the truck until it is within a few feet of the last load.

This assures that the load will fall in the right place. No matter what

kind of job the operator is working, there are a few things which arecommon to all jobs and which the operator should observe.

Push the body control lever back into the 'RAISE' position and

accelerate the engine. Decelerate the engine to slow the raising speed

2033 Manoeuvring To Dump

2034 Keep A Safe Distance From The Edge

2035 Keep Wheels LevelNOTICE

Before raising the body, make sure that the rear wheels are on

firm level ground. If one wheel is higher than the other, a

twisting strain is imposed upon the body hinge pins, hoists

and chassis. Stop the truck, allow the engine to slow to idle,

shift the transmission to 'NEUTRAL' so that the parking brake

is applied automatically and the vehicle is held stationary.

When dumping over a spoil bank without a 'SPOTTER',

know how close the truck can safely approach the edge

under all weather conditions. If in doubt as to dumpingsafety, dump the load a safe distance from the edge so that

it can be pushed over the edge later.

5-7

Working the Truck

as 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

hold the lever in the 'RAISE' position when the hoists are fully

extended to prevent unnecessary hydraulic system relief valve

operation.

NOTICE

Never 'JUMP DUMP' the truck by bouncing the rear tyres

against a stop block, or otherwise jarring the body in its raised

position, to dislodge stuck or frozen material. The tremendous

loads that this practice develops on the body pin area, chassis

and 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. As

the hoists approach their fully retracted positions, decelerate the

engine. At a predetermined body height a proximity sensor causes the

body control lever to spring back to 'NEUTRAL' position, allowing the

body 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 range

before 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-end

topple, there can be severe danger from contacting overhead

electric cables, trees, or bridges over the haul route.

Except for the above, the procedure for returning empty to the loading

area is the same as that given earlier for 'HAULING'.

1525 Keep Control Lever in 'NEUTRAL'

2036 Don't Jump Dump

2229 Make sure Body is Fully Down

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 slower andless manoeuvrable than most other machines encountered on the road.Yet, while on the road, they must be operated for extended periods oftime 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 authorities beforethe 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 instruments andlights, and make any repairs necessary.

NOTICE

Improper 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 orcarcasses. Inspect for cuts, bruises, burned beads abnormal wear

NOTICE

Make 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

and damaged wheels rims. Replace any damaged or excessivelyworn tyres.

Check all hoses, drain cocks, fuel level check cocks, and otherpotential sources of leaks. Make sure that all leaks are repaired andthat all drain cocks are sufficiently tightened to avoid subsequentloosening. Make sure that all warning flags, oversize load signs etc.are in place and secure.

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 abattery cable and apply security locks, if so equipped, before leavingthe parked 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.

NOTICE

Do 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 followingprocedure for the component concerned: Disconnect drivelines,remove planetary covers and remove the axle shafts. Remove thepinion gears from their covers. Replace the planetary pins in thecovers, and refit the planetary covers on the drive wheels to retainlubricant 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.When the hydraulic system is repaired, return the actuator to itsoriginal position by turning the hex-head fully clockwise.

Connect a suitable towing bar to one of the lugs on the tractor frameof the disabled vehicle and reverse another vehicle, in a straight andin-line manoeuvre, towards the disabled vehicle. Connect theopposite end of the towing bar to the towing pin of the recoveryvehicle and ensure 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 driveline

between 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


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 MaintenanceManual.

Always attach a 'DO NOT OPERATE' or similar warning sign toignition switch or a control and lockout before cleaning, lubricating orservicing the 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. Alwaysuse the body safety prop. Body prop must only be used when the bodyis empty.

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

Always shut down machine according to the procedure under'Stopping The Engine', described on Page 4-14. Turn off the masterswitch before cleaning, lubricating or servicing the machine except ascalled for in this Handbook 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 SERVICINGLubrication 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 contaminantsfrom entering 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 number on the illustrations contain reference numbers whichcorrespond 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


LUBRICATION AND SERVICE CHARTInterval Ref. No. of ServiceHours Points Identification Service Instructions Points Lubricant Quantities

1 Engine Check oil level. Add oil if low. 1 EO As required.10 2 Transmission Check oil level. Add oil if low 1 TranSynd / As required.

(Daily) TES 295*3 Hydraulic Tank Check oil level. Add if low. 2 HO / Textran HD10 As required.4 Radiator Expansion Tank Check coolant level. Add if low 1 Ethylene Glycol As required.5 Primary Fuel Filter / Check. Drain as required. 1 - -

Water Separator1 Drive Belt Check for damage. 1 See engine Manual27 Fuel Tank Check fuel level. Add if low. 1 - As required.1 Engine Crankcase Breather Inspect and clean if required. - -24 Cooling Fans Check for damage.6 Hydraulic Filter Restriction Check. Replace element if required. 1

IndicatorTyres Check condition and pressure. 6

14 Dropbox Check oil level. Add oil if low 1 EO As required.General Walk round vehicle, check for debris, - Refer to chart.

leaks and damage.1 Engine Air Cleaner Check. Renew element if required 1 - See Note 7

50 7 Battery Electrolyte Check level. Add electrolyte if low. 2 - As required.(Weekly) 8 Wheel rim nuts Check Torque. 114 - 600 Nm (442 Ibf ft)

9 Cab Ventilation Filter Inspect and clean if required. 110 Panhard Rod Bearings Lubricate 4 EP, NLGI See Note 1.19 Oscillation Bush Lubricate 2 EP, NLGI See Note 1.20 Suspension Beam Bushings Lubricate 2 EP, NLGI See Note 1.23 Body Hinge/Optional Tailgate Pins Lubricate 2 EP, NLGI See Note 1.21 Steering Cylinder Pins Lubricate 4 EP, NLGI See Note 1.22 Body Cylinder Pins Lubricate 4 EP, NLGI See Note 1.16 Differential Breathers Clean if required. 3

18 Articulation Bearings Lubricate 2 EP LI COMP See Notes 1 and 2.250 25 Parking Brake Pads Check wear. Renew if required. 2

(Monthly) 2 Transmission Breather Clean if required. 124 Radiator and Coolers Clean and inspect fins. See Note 6.26 OCDB Plate Check wear. Replace if required.15 Secondary Fuel Filter Renew 117 Wheel planetaries Check oil level. Add oil if low 6 EPL As required.16 Differentials Check oil level. Add oil if low 3 EPL & LZ See Note 4.5 PrimaryFuel Filter/Water Renew 1

Separator19 Oscillation Pivot Check end float. Adjust if required. 21 Drive Belt Check tension. Tighten if required 1

2153Lubrication and Servicing Points

24 35 28 27 13 11 12 21 16 18 22 19 25 22 16 20 1016 23

2320222622211215 27 345 3233311 3414 1017 8

9

8-6


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

LUBRICATION AND SERVICE CHART (Continued)Interval Ref. No. of ServiceHours Points Identification Service Instructions Points Lubricant Quantities

500 27 Fuel Tank Clean filler neck, screen and cap. 1(3 14 Dropbox Oil Filter Renew 1

Monthly) 14 Drop box Drain oil and refill with new oil. 1 EO 13 l (3.4 US Gal.)1 Engine Drain oil and refill with new oil. 1 EO 32 Litres

13 Engine Oil Filters Renew 2

9 Cab Ventilation Filters Renew 128 Coolant Additive Renew 1

1000 29 Fuel Tank Breather Renew 1(6 31 OCDB Tank Breather Renew 1

Monthly) Driveshaft Bearing Check oil level. Add if low. 1 EPL3 Hydraulic Tank Breather Renew 1

32 OCDB Tank Drain oil and refill with new oil. 1 Textran TDH1500 Premium

33 OCDB Filter Renew 133 OCDB Strainer Clean. 1

17 Wheel Planetaries Drain oil and refill with new oil. 6 EPL 9 l (2.4 US Gal.)

16 Differentials Drain oil and refill with new oil. 3 EPL and LZ See Note 4

1 Engine Mtg. Bolts Check torque. (Torque seal) 2 330 Nm (239 Ibf ft)

1 Drive Belt Renew belt3 Hydraulic Tank Drain oil and refill with new oil. HO / Textran 275 l (73 US Gal.)

1 HD102000 34 Articulation Pivot Nut Check torque. 1 1425 Nm (1050 lbf ft)

(Annually) 3 Hydraulic Oil Filter Renew. 12 Transmission Mtg. Bolts Check Torque. (Torque Seal). 2 921 Nm (680 Ibf ft).1 Turbocharger Mtg. Nuts Check Torque. (Torque Seal). 2 921 Nm (680 Ibf ft).

24 Cooling System Check concentration, add booster. - Ethylene 67 l (18 US Gal.)Glycol

3000 2 Transmission Oil Filters Renew 2

4000 35 Air Conditioning Compressor Drain flush and refill with new oil 1 PAG Oil 0.125 l

6000 2 Transmission Drain oil and refill with new oil. 1 TranSynd / 61 l (16 US Gal.)TES 295*

* - When determining whether a fluid is TES 295 approved or not look and/or ask for one of two things - The AllisonTES 295 approval number or the Allison approved logo . TES 295 approved fluids are listed on page 8-10. Ifuncertain if a fluid is approved, consult Allison Transmission for confirmation.

Note: Failure to useTerex filters and approved lubricants as illustrated may invalidate allwarranty cover.

8-7


Notes on 'Lubrication and Service Chart'Note - Capacities given are approximate - work to

dipstick, sight gauges or level plugs.

Note 1 - Lubricate slowly until excess lube is seen.

Note 2 - Remove plugs and fit lube fittings. Lubricateslowly until excess lube is seen. Remove fittings andrefit plugs.

Note 3 - Check with the engine idling and thetransmission at its normal operating temperature.

Note 4 - When refilling the centre axle ensure that the 3rddifferential unit is primed with 1 l (1.75 UK pints)of oil before filling the drive head.

Note 5 - Remove plug from the port on the underside of theoscillation hub. Plug is removed to drain thecavity of any oil that enters the cavity when filling.Remove grommet and level plug on the side of theoscillation hub. Add oil if required. Refit all plugs.

Note 6 - Clean the radiator, condenser and cooler fins moreoften when operating under extremely dustyconditions.

Note 7 - Check the air cleaner restriction gauge and operatethe vacuator valve. Renew the element if theindicator moves from the yellow to the orangesection.

EO - Engine Oil. Refer to 'RecommendedLubricants'

* - Refer to chart under 'RecommendedLubricants'

HO - Hydraulic Oil. Refer to'Recommended Lubricants'

EPL - Extreme Pressure Lubricant,specification MIL-L-2105 D

EP, NLGI - Extreme Pressure, Lithium No. 2Grease (which may, or may not,contain Molybdenum)

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

EP LI COMP - Extreme pressure Lithium ComplexGrease. Ref. EEMS 19057

LZ - Lubrizol 6178

PAG Oil - Polyalklene Glycol (PAG) CompressorLubricating Oil - Low Viscosity(ISO46).

MISCELLANEOUS SERVICING

WHEN REQUIREDSeat Belts - Inspect for damage and replace if required.

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

Windscreen Wipers and Washers - Inspect wiperblades and replace if damaged. Top up washerreservoir.

Wheel Rim Nuts - After the first 10 hours of operation,re-torque the nuts to 600 Nm (442 lbf ft).

Note: Torque should be applied in three stages. Nutsare to be torqued crosswise (opposing pairs). Check thetorque every 50 hours (weekly) thereafter.

Engine - Steam clean the engine prior to performing anyrepair or service work on it, if heavily contaminated dueto 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 to be checked, serviced or replaced must be cleaned in accordance with the manufacturer's recommendations.

Oil Cooled Disc Brakes - A squeaking noise is an indication of abnormal wear, and necessitates internal examination of the brakes.

EVERY 10 HOURS OF OPERATION (DAILY)Walk Around Inspection - Inspect the vehicle asdescribed in Section 4.

Engine - Visually check engine for damage, loose orfrayed belts and listen for any unusual noises.

Engine Air Cleaner - Change air cleaner element onlywhen the yellow band of the air restriction gauge locksup in the orange. Service vacuator valve daily. Inspectand remove any obstructions from the vacuator valvelips which should be open and pliable with the enginestopped.

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

Engine Crankcase - Check oil level and add if low.A cold level check should always be done prior tostarting the vehicle. To ensure that sufficient oil is in thesystem to allow the unit to be run to operating temp toperform a hot level check.

Transmission - Check the oil level and add oil if low.

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

Brake Coolant Tank - Check the oil level and add if low.

8-8


EVERY 500 HOURS OF OPERATION

Dropbox Oil Filter - Remove and renew.

Dropbox - Drain oil and refill with new oil.

EVERY 1000 HOURS OF OPERATION (6 MONTHS)

Brake Coolant Tank - Replace breather.

Parking Brake - Check pads and disc for wear.Adjust or replace if required. Test for properfunction. Thickness of pad friction material shouldnever be allowed to wear below 3 mm (0.12 in).

Articulation Vertical Bearings - Remove plugsand fit lube fittings. Lubricate slowly until excesslube is seen. Remove lube fittings and refit plugs.

Driveshaft Bearings - Remove plug from port onunderside of oscillation hub. Plug is removed to drainthe cavity of any oil that enters the cavity when filling.Remove grommet and level plug on side of oscillationhub. Add oil if required. Refit all plugs.

Grease Points - Grease the door hinges.

EVERY 1500 HOURS

Axles - Drain lubricant and refill to level plugs.

Note: When refilling the centre axle, ensure that the3rd differential unit is primed with 1 l (1.75 UK pints)of oil before filling the drive head.

EVERY 2000 HOURS

Drivelines - Visually check Low Maintenancedrivelines for leaking or damaged seals.

Note: Low Maintenance drivelines can be identifiedby having plugs fitted to the spiders, not greasenipples.

Note: When service is required, remove plug and fitgrease nipple. Grease spider and refit plug whenfinished. Use Type K lubricating grease inaccordance to DIN 51825-KP2-K-40.

Hydraulic Oil Tank - Drain oil, remove and cleansuction screens and strainers. Reinstall suctionscreens and strainers and refill hydraulic oil tank.

Hydraulic Oil Filter - Clean filter housing and installnew element when indicated, or after 2000 hours ofoperation, whichever occurs first.

EVERY 3000 HOURS

Transmission - Replace oil filter and lube oil filter.

EVERY 6000 HOURS

Transmission - Drain oil and refill to level.

Radiator - Check coolant level and add if low. Fill theradiator header tank with coolant until coolant reaches thebottom of the filler neck and holds at that level.

NOTICE

Any time a significant amount of coolant isadded, the coolant inhibitor MUST bechecked. If the concentration is low, enginedamage will result. Conversely, over-inhibiting antifreeze solutions can result insilicate dropout.

AFTER FIRST 100 HOURS OF OPERATING NEW ORREBUILT COMPONENTS

Differentials - Drain lubricant and refill to level plug.

Note: When refilling the centre axle ensure that 3rddifferential unit is primed with 1 l (1.75 UK pints) of oilbefore filling drive head.

Planetaries - Drain lubricant and refill to level plug.

Hydraulic Oil Filter - Clean filter housing and install newelement at 100 hours of operation, or when indicated,whichever occurs first.

Note: A 6 µm filter is used to flush the system. This isreplaced with a 12 µm filter for normal use. See vehicleParts Book for filter part numbers.

Brake Cooling Oil Filter (A972/A982/A975) - Clean filterwithin the brake coolant tank after 100 hours of operation.

AFTER FIRST 250 HOURS OF OPERATING NEW ORREBUILT COMPONENTS

Front Suspension - Check that the pre-compressedlength of the rubber mounts is 203 mm.

EVERY 250 HOURS OF OPERATION

General Inspection - Check entire vehicle for leaks,loose bolts and nuts or damaged parts. Examine thevehicle, particularly the chassis, for cracks or brokenwelds. Repair where necessary.

Parking Brake - Check pads and discs for wear and replacewhere necessary. Test for proper function.

Note: This service interval applies to normal condition.Check the pads more frequently under more severe conditions.

Oil Can Points - Oil working parts with engine oil.

8-9


AIR CONDITIONING RE-START PROCEDUREIf the machine has been idle for an extended period of time (2weeks), the refrigerant in the air conditioning unit convertsfrom a gas to a liquid. This puts the compressor unit under agreat deal of strain as it tries to compress a liquid instead of agas, and could cause a failure in the air conditioning unit. Thefollowing commissioning procedure allows the air conditioningunit to achieve normal operating parameters.

1. Start the machine and allow it to run until the engine isat a normal operating temperature of 80 °C (176 °F)

2. Turn the blower control to setting 1.3. Turn on the air conditioning unit 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 of the air conditioning unit is complete, and

it is ready for use.

ENGINES AND TRANSMISSIONSAll information contained in the 'Lubrication and ServiceChart' was extracted from the relevant manufacturer’sOperator’s Manual and was correct at time of publication.Users should ensure that information contained in thischart, regarding Engines and Transmissions, reflects theinformation shown in the relevant manufacturer’sOperator’s Manuals supplied with the vehicle.Maintenance procedures should be carried out inconjunction with any additional procedures contained inthe relevant manufacturer’s 'Operation and MaintenanceManual', at the intervals specified.

8-10


* - When determining whether a fluid is TES 295 approved or not look and/or ask for one of two things - TheAllison TES 295 approval number or the Allison approved logo { }. TES 295 approved fluids are listed on thefollowing page. If uncertain if a fluid is approved, consult Allison Transmission for confirmation.

RECOMMENDED LUBRICANTSCOMPONENT LUBRICANT *CAPACITY SPECIFICATIONS API CODE SAE GRADE

Engine Engine Oil with 1.00% 32 litre CH-4 15W-40(Including Filters) sulphated ash limit is (9.8 US gal)

recommended. Sulphated ashmust not exceed 1.85% limit

Transmission 61 litre See Trans.(Including Filters) TranSynd / TES 295 (16.1 US gal) TranSynd / TES 295 - TES 295(dry fill) Oil Table.

Hydraulic System Hydraulic Transmission Oil 330 litre Textran HD10 See Hydraulic Oil Table(Including Lines) (87 US gal) (See Note 2)

Cooling System Anti-freeze, Ethylene 67 litreGlycol (18 US gal)

Differential Extreme Pressure 33 litre MIL-L-2105 D GL-5 80W-90 LS(Front) Gear Lubricant (8.7 US gal) (See Note 3)

Differential Extreme Pressure 34 litre MIL-L-2105 D GL-5 80W-90 LS(Centre) Gear Lubricant (9 US gal) (See Note 3)

Differential Extreme Pressure 33 litre MIL-L-2105 D GL-5 80W-90 LS(Rear) Gear Lubricant (8.7 US gal) (See Note 3)

Planetaries - Extreme Pressure 9 litre each MIL-L-2105 D GL-5 80W-90 LSGear Lubricant (2.4 US gal) (See Note 3)

Dropbox Engine Oil 13 litre CH-4 15W-40(3.4 US gal)

Fuel Tank Diesel Fuel Oil with 481 litre DIN EN590max. sulphur 0.5% (127 US gal)

Grease Nipples** Extreme Pressure No.2Lithium Grease Consistency

Driveshaft through Extreme Pressure 1.50 litre MIL-L-2105 D GL-5 80W-90Bearings Gear Lubricant (0.40 US gal)

Articulation Extreme Pressure EEMS 19057Bearings Lithium Complex

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

Low Viscosity

Brake Cooling Hydraulic Transmission Oil 175 litre MIL-L-2104 E CF,CD,SFSystem (42.6 US gal) MIL-L-46152 B/C

TES295 APPROVED OILSApproval Number Approved Maker Product Brand Name

AN-011001 Castrol Heavy Duty Lubricants Transynd

AN-031002 BP Autran Syn 295

AN-031003 Cognis Corporation Emgard 2805

AN-031004 International Truck & Engine Co. Fleetrite Synthetic ATF

AN-031005 Exxon Mobile Lubricants Mobile Delvac Synthetic ATFand Petroleum Specialities Co.

8-11


DIFERENTIAL AND PLANETARY APPROVED LUBRICANTSZF Lubricant class 05C Gear oil with limited-slip-additives

Trade name (05C)ADDINOL GETRIEBEÖL GH 80W-90 LSADDINOL GETRIEBEÖL GH 85W-90 LSAGIP ROTRA MP/SARAL GETRIEBEÖL HYP LS 90AVIA HYPOID 90 LSAVIA HYPOID 90 LS, 85W-90BAYWA GETRIEBEÖL HYPOID LS 90GETRIEBEÖL LS 85W90BP ENERGEAR LIMSLIP 90FRONTOL GETRIEBEÖL LS 90MOTOREX GEAR OIL UNIVERSAL LS 80W/90CALPAM GEAR OIL LS 90CASTROL HYPOY LS 90CASTROL LSXGEARTEX LS 85W140GEARTEX LS 80W-90GEARTEX LS 85W-90CALTEX GEAR OIL ZF SAE 80W-90CLAAS AGRISHIFT BLS 90GEAR T ( 90 )TOR SUPER GEAR OIL LS 80W90ENGEN GEARLUBE EP 90 LS - SAE 80W-90AGIP ROTRA MP/S 85W-90ESSO GEAR OIL LSA 85W-90MOBILUBE LS 85W-90AVIATICON HYPOID LS 90AKCELA AXLEPOWER (80W90)AMBRA AXF 80W90AMBRA STF (80W90)TUTELA W990/LS (SAE 80W-90)TITAN GEAR LS 90YORK 698 LSLOTOS TITANIS LS GL-5 SAE 85W/140LOTOS TITANIS LS GL-5 SAE 80W/90DIC LS GEAR OIL 80W/90GULF GEAR LS 90KENDALL SPECIAL LIMITED SLIP AXLE GEAR LUBE 80W/90RTO EP 90 GLHYPOID BPA SAE 90KOMPRESSOL-HYPOID LS SAE 90GEAR OIL LS 80W-90Q8 T 45 SAE 90HYPOID GETRIEBEÖL GL 5 SAE 85W-90 LSINA HIPENOL GTL LS 90MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-90 LSPENNASOL SPERRDIFFERENTIAL HYPOID GETRIEBEOEL LS90MOL HYKOMOL LS 85W-90POSI-GRIP JDZF 80W90GEARING WONDER LS SAE 85W90OEST GETRIEBEÖL HYPOID LS 90OK CARDAN OIL MP-B-LS SAE 80W/90QUINTOL CARDAN OIL LS-90PAKELO UNIVERSAL GEAR EP/LS SAE 85W/140PAKELO UNIVERSAL GEAR EP/LS SAE 80W/90PANOLIN SUPER DUTY LS 90GALP LS 90PTT LIMITED SLIP (SAE 80W-90)RAVENOL SPERRDIFF.-GETR.-OEL LS 90CS EP AUTOBLOCANTE SAE 85W140GULF LS REAR AXLE OIL 80W-90WINTERSHALL WIOLIN RSHTEBOIL HYPOID LS SAE 80W-90ANTAR BLS 90ELF TRACTELF BLS 90FINA TRANSFLUID LS 80W-90TOTAL DYNATRANS DA 80W-90UNIL OPAL GEAR AB-EP SAE 85W90BVX LS 200

Manufacturer (05C)ADDINOL LUBE OIL GMBH, LEUNA/D

AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/DARAL AG, BOCHUM/DAVIA MINERALÖL-AG, MÜNCHEN/D

BAYWA AG, MÜNCHEN/DBLASER SWISSLUBE AG, HASLE-RÜEGSAU/CHBP INTERNATIONAL, PANGBOURNE, READING/GB

BUCHER AG LANGENTHAL, LANGENTHAL/CHCALPAM MINERALÖL-GMBH, ASCHAFFENBURG/DCASTROL INTERNATIONAL. PANGBOURNE READING/GB

CHEVRON BRASIL LTDA, RIO DE JANEIRO/BRAZILCHEVRONTEXACO, GHENT/B

CHEVRONTEXACO, SYDNEY/AUSCLAAS KGAA MBH, HARSEWINKEL/DCONDAT LUBRIFIANTS, CHASSE SUR RHONE/FDE OLIEBRON B.V., ZWIJNDRECHT/NLENGEN PETROLEUM LTD., CAPE TOWN/ZAENI S.P.A. REFINING & MARKETING DIVISIO, POME/IEXXON MOBIL CORPOATION,FAIRFAX, VIRGINIA/USA

FINKE MINERALÖLWERK GMBH, VISSELHÖVED/DFL SELENIA S.P.A., VILLASTELLONE/I

FUCHS PETROLUB AG, MANNHEIM/DGINOUVES GEORGES SA, LA FARLEDE/FGRUPA LOTOS SA, GDANSK/PL

GS CALTEX CORPORATIION, SEOUL/ROKGULF OIL INTERNATIONAL, PITTSBURG/USAHANDEL MIJ NOVIOL B.V., NIJMEGEN/NLHUILES BERLIET S.A., SAINT PRIEST/FIGOL FRANCE SA., AMIENS/FKOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/DKROON-OIL B.V.,ALMELO/NLKUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NLLIQUI MLLY GMBH, ULM/DIMAZIVA ZAGREB D.O.O., ZAGREB/HRMEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/DMINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/DMOL-LUB KFT., ALMÿSFÜZITÖ/HNORTHLAND PRODUCTS COMPANY, WATERLOO/USANOVA STILMOIL SPA, MODENA/IOEST, GEORG MINERALÖLWERK, FREUDENSTADT/DOK NEDERLAND, STAPHORST/NL

PAKELO MOTOR OIL S.R.L., SAN BONIFACIO (VR)/I

PANOLIN AG, MADETSWIL/CHPETROLGAL SA., LISBOA/PPTT PUBLIC COMPANY LIMITED, BANGKOK/THRAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/DREPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/ES.A.E.L., MADRID/ESRSA SCHMIERSTOFF VERTRIEB GMBH. SALZBERGEN/DSUOMEN PETROOLI OY, HAMINA/FINTOTAL LUBRIFANTS S.A., PARIS/F

TOTAL LUBRIFANTS S.A., PARIS/F

UNIL OPAL, SAUMUR CEDEX/FYACCO, ST PIERRE LES ELBEUF/F

Viscosity grades: SAE 75W-90 / 75W-110 / 75W-140 / 80W-90 / 80W-110 / 80W-140 / 85W-90 / 85W-110 / 85W-140 / 90

ZF Lubricant class 05D Gear oil with limited-slip-additives

Trade name (05D)AGIP HLZ, SAE 75W-140BP ENERGEAR SHX-ZR 75W-140MOBIL GEARLUBE VS 500WINTERSHALL GETRIEBFLUID BMS PLUSFINA PONTONIC MLX 75W-140TOTAL TRANSMISSION LS 75W-140

Manufacturer (05D)AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/DBP INTERNATIONAL, PANGBOURNE, READING/GBEXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USASRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/DTOTAL LUBRIFANTS S.A., PARIS/F

8-12


BRAKE COOLING SYSTEM APPROVED LUBRICANTS

ZF Lubricant class 05F Universal Tractor Transmission Oil (UTTO)

Trade name (05F)76 HYDRAULIC/TRACTOR FLUIDADDINOL UTTO SAE 10W30ARAL FLUID HGS 10W-30AVIA HYDROFLUID DLZBAYWA HYDRA HYDRAULIKFLUIDBP TERRAC SUPER TRANSMISSION 10W-30BP TERRAC SUPER TRANSMISSION CVT 10W-30BP TRACTRAN TF 10 10W-30MOTOREX POLYFARM 304CASTROL AGRI TRANS PLUS 10W-30CASTROL AGRI TRANS PLUS CVT 10W-30CATERPILLAR MULTIPURPOSE TRACTOR OIL (MTO) 10W-30CEPSA AURIGA TE 55 (SAE 10W-30)TEXTRAN TDHTEXTRAN TDH PREMIUMCLAAS AGRISHIFT GA 12CASE TRANSAXLE FLUID 80W-140NEW HOLLAND TRX FLUID 80W-140ENGEN AGRIFLUIDMOBIL AGRIFLUID 424MOBIL FLUID 424MOBIL FLUID 426AKCELA NEXPLORE (SAE 10W-30)AKCELA TRANSAXLE FLUID (SAE 89W-140)AMBRA MULTI GAMBRA TRX 20W-40AMBRA TRX 80W-140AGRIFARM UTTO MPTITAN UTTO HYDRATITAN UTTO J20CTITAN UTTO ZF SAE 20W-40YORK 6766 10W30TICMA FLUID MU SAE 80WJOHN DEERE HY-GARDKENDALL HYKEN 052Q8 T 2000Q8 T 2200HYDRAULIC-TRANSMISSION MULTIFUNCTIONAL FLUID 10W30INA TRANSHIDROL JD 50INA TRANSHIDROL ZF 20W-40OMV AUSTROMATIC IGB SAE 10W-30PAKELO UTTO FLUID 4D SAE 10W/30PAKELO UTTO FLUID 4D SAE 20W/40PANOLIN JD 303GALP TRALUB 807SRAVENOL UTTOAGRO ORION SAE 10W30SAVSOL 315 HATSHELL DONAX TD 10W-30SHELL DONAX TD 5W-30SHELL DONAX TDS 10W-30WINTERSHALL HYDROFLUID NVULCOTRAC UTTO SAE 20W-40TEBOIL WETOLANTAR TRANSAGRIA THF 16ELF TRACTELF BF 16TOTAL DYNATRANS LS 20W-40TOTAL DYNATRANS MPVWOLF UTTO 170 VOLVO BM SAE 10W30

Manufacturer (05F)76 LUBRICANTS (CON0C0PHILLIPS COMP.), HOUSTON/USAADDINOL LUBE OIL GMBH, LEUNA/DARAL AG, BOCHUM/DAVIA MINERALÖL-AG, MÜNCHEN/DBAYWA AG, MÜNCHEN/DBP INTERNATIONAL, PANGBOURNE, READING/GB

BUCHER AG LANGENTHAL, LANGENTHAL/CHCASTROL INTERNATIONAL, PANGBOURNE, READING/GB

CATERPILLAR INC. PEORIA/USACEPSA LUBRICANTS S.A., MADRID/ECHEVRONTEXACO, GHENT/B

CLAAS KGAA MBH, HARSEWINKEL/DCNH, BURR RIDGE/USA

ENGEN PETROLEUM LTD.,CAPE TOWN/ZAEXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA

FL SELENIA S.P.A., VILLASTELLONE/I

FUCHS PETROLUB AG, MANNHEIM/D

GINOUVES GEORGES SA, LA FARLEDE/FIGOL FRANCE SA, AMIENS/FJOHN DEERE, MANNHEIM/DKENDALL MOTOR OIL (CONOCOPHILLIPS C.) HOUSTON/USAKUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NI

LURICANT OIL COMPANY, SINOPEC, BEIJING/CNMAZIVA ZAGREB D.O.O., ZAGREB/HR

OMV REFINING & MARKETING GMBH, WIEN/APAKELO MOTOR OIL S.R.L., SAN BONIFACIO (VR)/I

PANOLIN AG, MADETSWIL/CHPETROGAL SA.,LISBOA/PRAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/DREPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/ESAVITA CHEMICALS LTD., MUMBAI/INDSHELL INTERNATIONAL PETROLEUM COMP LTD., LONDON/GB

SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/DSTRUB + CO AG, REIDEN/CHSUOMEN PETROOLI OY, HAMINA/FINTOTAL LUBRIFANTS S.A., PARIS/F

WOLF OIL CORPORATION N.V., HEMIKSEM/B

ZF Lubricant class 05G Universal construction- machinery oil

ZF Lubricant class 05H Biodegradable lubricants

Trade name (05G)ZF-POWERFLUID

Manufacturer (05G)ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D

Instructions on the use of biodegradable lubricants:

The oil manufacturer's change-over directives included in the product description are to be observed when change-over to biodegradable lubricants is effected.

Trade name (05H)PANOLIN BIOFLUID LS

Manufacturer (05H)PANOLIN AG, MADETSWIL/CH

Viscosity grade: SAE 75W-80

8-13


Manufacturer Brand Name SAE Viscosity

Class

Addinol Lube Oil Addinol Diesel Long life MD 1047 10W-40Addinol Diesel Long life MD 1548 15W-40Addinol Diesel Long life MD 1546 15W-40Addinol Diesel Long life MD 1547 15W-40

Anomina Petroli Italiana IP Taurus Turbo Plus 15W-40

API D Multi Diesel Turbo 15W-40

Arabi Enertech KSC Burgan Diesel CH-4 15W-40

BP p.l.c BP Vanellus C6 Global 15W-40BP Vanellus E6BP Vanellus C7 GlobalBP Vanellus Multi-FleetBP Mine Multi 15W-40

Castrol Ltd. Castrol Diesel X 15W-40Castrol Tection T 15W-40Castrol Tection Plus 15W-40

Cepsa Cepsa Euromax 15W-40

Chevron Caltex Delo Gold [ISOSYN] 15W-40Chevron RPM Heavy Duty Motor Oil 15W-40Chevron Delo 400 Multigrade 15W-40Texaco Usr a Super Plus 15W-40Texaco Usr a Super TD 10W-40Texaco Usr a Super TDS 15W-40

Exxon Mobil Essoluble XT 4 15W-40Fuchs Fuchs Titan Truck Plus 15W-40

Fuchs Titan HPE 15W-40Fuchs Titan Cargo LD 10W-40

Gulf Oil International Gulf Super fleet LE 15W-40Gulf Super fleet Supreme 15W-40

Huiles Berleit S.A RTO Maxima RD 15W-40RTO Maxima RLD 15W-40

Igol, France Trans Turbo 7X 15W-40Trans Turbo 9X 15W-40Protruck 100 X 15W-40

Imperial Oil Esso XD-3 Extra 15W-40

Indy Oil SA Indy Super Turbo Diesel 15W-40

APPROVED FLUIDS AND LUBRICANTS

Multigrade Oils - Category 2, SAE-grades 10W-40, 15W-40 for Diesel Engines

8-14


Manufacturer Brand Name SAE Viscosity

Class

Indian Oil Corp. Servo Premium (N) 15W-40

Kuwait Petroleum Q8 T 720 10W-40Q8 T 750 15W-40

Lotos Oil Turdus Powertec CI-4 15W-40 15W-40Mauran SAS Turbo land 15W-40OMV AG OMV truck LD 15W-40Pennzoil Products Penn zoil Long. Life Gold 15W-40Pertamina Meditran SMX 15W-40Petro-Canada Lubricants Duron 15W-40

Duron XL Synthetic Blend 15W-40

Petrol Ofisi PO Turbo Dizel Extra 15W-40Petro limex PetrochemicalJoint-Stock Company PLC Diesel SHPD 15W-40 15W-40Prista Oil AD Prista SHPD 15W-40RavensbergerSchmierstoffvertrieb GmbH RAVENOL Mineralo I Turbo Plus SHPD 15W-40Shanghai HIRI Lubricants HIRI 245 15W-40Shell Shell DEO Super 15W-40

Shell Rimula MV 15W-40Shell Rimula R3 X 15W-40Shell Rimula R4 L 15W-40Shell Rimula R T 4 L 15W-40Shell Rimula Super 15W-40Shell Rotella T 15W-40Shell Rotella T Multigrade 15W-40Rimula X CH-4 15W-40

Singapore PetroleumCompany SDM 900, SAE 15W40 15W-40

Sinopec Corp. Great Wall Jinpai Zunlong 15W-40

SRS Schmierstoff VertriebGmbH Winter shall Multi-Rekord top 15W-40

Winter shall Turbo Diesel Plus 15W-40Winter shall TFX 10W-40

Statoil Turbo synt 15W-40Svenska Statoil MaxWay 15W-40Total Antar Milantar PH 15W-40

Antar Milantar PX 15W-40Elf Performance Trophy DX 15W-40Elf Performance Victory 15W-40Fina Kappa Optima 15W-40Total Caprano TDH 15W-40Total Caprano TDI 15W-40Total Rubia TIR 7400 15W-40

Unil Opal Medos 700 15W-40Yacco Inboard 100 4 T Diesel 15W-40

8-15


Recommended Lubricant notes

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

** - Refer to the 'Lubrication and Service Chart' for thedifferent applications. DO NOT use on the Articulationbearings.

Note 1 - Operation below the minimum temperatures listedfor the oil used without proper pre-heat or warm-up resultsin greatly reduced transmission life. Proper warm-uprequires 20 minutes minimum operation in neutral (withengine at part throttle) before operating the transmission ingear.

Note 2 - Hydraulic Transmission Oil is suitable for use inthe hydraulic system.Typical SAE 10W oils:

SHELL DONAX TEXACO TEXTRAN KUWAIT TO4MOBILTRANS HD BP AUTRAN 4 CASTROL TFCESSO TORQUE FLUID

LUBRICANT GRADE SELECTION GUIDE AT AMBIENT (START-UP) TEMPERATURE

Sm - 637HYDRAULIC OIL

APISAE CODE MIL-SPEC

1 - - MIL-H-5606A

2 DEXRON Auto Trans. Fluid

3 10W CC/CD MIL-L-2104 B/C

4 20W/20 CC/CD MIL-L-2104 B/C

5 30 CC/CD MIL-L-2104 B/C

8-16


****

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 the correct setting for each particular application.

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

TA350 Bridgestone 26.5 R25 VLT 4.5 65 5.7 82 5.7 82Michelin 26.5 R25 XADN 3.2 47 4.5 65 4.5 65Michelin 26.5 R25 XADT 3.2 47 4.5 65 4.5 65Double Coin 26.5 R25 REM5 4.5 65 5.5 80 5.5 80Triangle 26.5 R25 TB516 4 58 5.9 86 5.9 86

TA400 Bridgestone 29.5 R25 VLT 4 58 5 73 5 73Bridgestone 29.5 R25 VMT 4 58 5 73 5 73Michelin 29.5 R25 XADN 2.8 40 3.8 55 3.8 55Triangle 29.5 R25 TB516 4 58 4.9 71 4.9 71

TYRE INFLATION PRESSURE

9-1

Technical Data

9 - Technical Data

9-2

Technical Data


9-3

Technical Data

TECHNICAL DATA TA350 (A972)

2231

ENGINE

Make/Model........................................................ Detroit Diesel Series 60

Type .......................6 Cylinder, in line , Four cycle diesel, water

cooled, turbocharged with air to air cooling, electronic engine

management.

Gross power at 2 110 rev/min..........................298 kW (400 hp, 405 PS)

Net power at 2 110 rev/min..............................289 kW (388 hp, 393 PS)

Note: Gross power rated to SAE J1995 Jun 90. Engine emission

meets USA EPA Tier 3 /CARB MOH 40 CFR 89 Tier 3 and

proposed EU NRMM (non-road mobile machinery) Tier 3 directive.

Maximum Torque........................2000 Nm (1475 lbf ft) at 1200 rev/min

Number of cylinders/configuration...............................................6, in line

Bore x Stroke..............................................133 x 168 mm (5.24 x 6.61 in)

Piston Displacement........................................................14 l (855 in³)

Air cleaner...........................................................Dry type, double element

Starting...............................................................................................Electric

Maximum Speed (No load)...................................................2300 rev/min

Maximum Speed (Full load).................................................2200 rev/min

Idle Speed................................................................................. 700 rev/min

3 206(10-6)

553(1-10)

3 494(11-5)

1 380(4-6)

3 686(12-1)

2 967(9-9)

2 414(7-11)

3 888(12-9)

3 130(10-3)

3 315(10-11)

6 872(22-7)

2 520(8-3)

1 837(6-0)

66˚

851(2-7)

Dimensions in mm (ft-in)

2 914(9-7)

1 310(4-4)

2 990(9-10)

10 944(35-11)

1 780(5-10)

1 950(6-5)

MaxBodyDepth

9-4

Technical Data

TRANSMISSION

Make/Model..........Allison 4000 Series with integral retarder mounted

directly to the engine, fully automatic transmission with planetary

gearing, lock-up in all gear ranges. Electronic control with six forward

and one reverse gear.

Main......................................................18.5 + 3.4 bar (269 + 50 lbf/in²)

Temperatures:Normal..................................................60 °C - 135° C (140 ° F- 275 °F)

Maximum........................................................................165 ° C (329 ° F)

Ratios:

Transmission .........Refer to the table below

Low Range

Forward

Gear 1 2 3 4 5 6

km/h 5.2 11.0 15.9 24.3 31.0 35.2

mile/h 3.2 6.8 9.9 15.1 19.3 21.9

Reverse

Gear 1

km/h 4.6

mile/h 2.9

High Range

Forward

Gear 1 2 3 4 5 6

km/h 7.9 16.8 24.3 37.1 47.7 53.9

mile/h 4.9 10.4 15.1 23.1 29.6 33.5

Reverse

Gear 1

km/h 7.0

mile/h 4.3

DROPBOX

Remote mounted transfer gearbox taking drive from the transmission

and feeding it via a lockable differential to the front and rear wheels.

Ratios:

Low........................................................1.129:1

High.......................................................0.738:1

Pressure:

High/Low actuation......................15 ± 0.2 bar

Differential lock actuation..............34-50 bar

Lubrication..........................................2 ± 1 bar

Temperature:

Maximum......................................100 °C (212 °F)

9-5

Technical Data

AXLES

Three axles in permanent all-wheel drive (6 X 6) with differential

coupling between each axle to prevent driveline wind-up. Heavy

duty axles with fully-floating axle shafts and outboard planetary

reduction gearing.

Automatic limited slip differentials in each axle. Centre axle

incorporates a through-drive differential to transmit drive to the rear

axle. This differential and the dropbox output differential are locked

simultaneously using one switch selected by the operator.

Ratios:

Differential ........................................ 3.70:1

Planetary .......................................... 6.35:1

Total Reduction .............................. 23.50:1

WHEELS AND TYRES

Wheels:3-piece earthmover rims with 19 stud fixingSize:

Standard............................................25 x 22.00 in for 26.5 R25** tyres

Tyres:

Standard...................................................................................26.5 R25**

Inflation Pressures :

Please refer to page 8-12 for a full list of tyre inflation pressures.

Note: Tyre pressures should be regarded as nominal only. It is

recommended that for tyres both listed and unlisted, the user should

consult the tyre manufacturer and evaluate all job conditions in order

to make the proper selection.

SUSPENSION

Front: Four trailing links and a panhard rod locate the front axle

giving a high roll centre. The optimized front axle position along with

the wide spaced main and rebound mounts, mounted directly above

the axle and long suspension travel, combine with two heavy duty

dampers each side to give excellent handling and ride.

Rear: Each axle is coupled to the frame by three rubber- bushed linkswith lateral restraint by a transverse link. Pivoting inter-axle balance

beams equalize load on each axle. Suspension movement is

cushioned by rubber/metal laminated compression units between

each axle and underside of balance beam ends. Pivot points on

rear suspension linkages are rubber-bushed and maintenance-free.

9-6

Technical Data

HYDRAULIC SYSTEM

Braking, steering and body hoist systems are controlled by a main

hydraulic valve mounted on frame. Systems are supplied with oil from

a common tank by the main hydraulic pump, driven from power

takeoff on transmission. System components are protected by full

flow filtration on the return line.Pump:

Type..................................................................................................Piston

Capacity at 2 700 rev/min..........................5.4 l/s (85.6 US gal/min)

Brakes

Full hydraulic braking system with enclosed, forced oil- cooled

multiple discs on 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....................................48 ± 2.4 bar (700 ± 35 lbf/in²)

Pump Type.......................................................................Triple stage gear

Capacity at 1 685 rev/min................................8.9 l/s (2.35 US gal/min)

Braking surface (tractor)............................590240 mm2 (914.9 in2)/brake

Braking surface (trailer).............................590240 mm2 (914.9 in2)/brake

Parking.......Spring-applied, hydraulic-released disc on rear driveline.

Emergency.................Automatic application of driveline brake should

pressure fall in main brake hydraulic system. Service brakes may

also be applied using the parking-emergency brake control.

Steering

Hydrostatic power steering by two single-stage, double-acting,

cushioned steering cylinders. Emergency steering pressure is

provided by a ground driven pump mounted on the drop box. An

audible alarm and warning light indicates should the emergency

system activate. Conforms to ISO 5010, SAE J53.

System Pressure......................................................240 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......................................................240 bar (3500 lbf/in²)

Control Valve ...........................................Pilot Operated, Closed Centre

Body Raise Time (loaded)...............................................................12.5 s

Body Lower Time (power down)..........................................................8 s

9-7

Technical Data

SERVICE CAPACITIES

Fuel tank........................................................................481 litre (127 US gal)

Hydraulic System.........................................................330 litre (87.2 US gal)

Engine Crankcase and filters..........................................32 litre (8.4 US gal)Cooling System...............................................................67 litre (17.7 US gal)

Transmission (including cooler)....................................61litre (16.1 US gal)

Dropbox............................................................................. 13 litre (3.4 US gal)

Differential - Front..............................................................33 litre (8.7 US gal)

Differential - Centre..............................................................34 litre (9 US gal)

Differential - Rear...............................................................33 litre (8.7 US gal)

Planetaries (each)............................................................9 litre(2.37 US gal)

Hand Pump Tank..............................................................1 litre (0.26 US gal)

Air Conditioning Compressor ..............................0.125 litre (0.033 US gal)

Brake cooling................................................................175 litre (42.6 US gal)

ELECTRICAL SYSTEM

Type.....................................................................24 volt, Negative Ground

Battery...............................................................Two, 12 Volt, 175 Ah eachAccessories.......................................................................................24 Volt

Alternator.........................................................................................100 Amp

BODY

Of all welded construction, fabricated from high hardness (min. 360 BHN)

1000 MPa (145 000 lbf/in²) yield strength steel. 25° tail chute angle provides

good load retention without tailgate.

Plate Thicknesses:

Floor and Tailchute..........................................................15 mm (0.58 in)

Sides..................................................................................12 mm (0.47 in)

Front.....................................................................................8 mm (0.39 in)

Volume:

Struck (SAE)................................................................15.5 m³ (20.3 yd³)

Heaped 2:1 (SAE)......................................................21.0 m³ (27.5 yd³)

Sound Power Level ISO6395 TA350 TA400

A - Weighted sound power level Lwa in decibels 110 110

Uncertainty Kwa, in decibels 0.66 0.66

Sound Pressure Level at Operators Station ISO6396 TA350 TA400

A - Weighted emission sound pressure level Lpa in decibels 74.5 74.5


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 measured

and operated as per the prescribed procedures of the standard. Results shown are for the

vehicle in base configuration.

Note: Noise Exposure Level to the operator and bystander personnel may be higher

depending upon proximity to buildings, rock piles, machinery, etc.. The actual job site NoiseExposure Level must be measured and applicable regulations complied with in respect to

Employee Hearing Protection.

9-8

Technical Data

Vehicle Weights 26.5 R25 Tyres

Standard Vehicle kg lb

Net Distribution

Front Axle 15086 32258

Centre Axle 7125 15707

Rear Axle 7068 15582

Vehicle, Net 29279 64547

Payload 34000 74956

Gross Distribution

Front Axle 17279 38094Centre Axle 23000 50705

Rear Axle 23000 50705

Vehicle, Gross 63279 139506

Bare Chassis 23669 52177

Body 4950 10915

Body Hoists (Pair) 660 1455

VIBRATION

Note: The whole body vibrations on

construction machines are influenced by

many factors independent of machine

design, for example ground conditions,

working methods, correct seat adjustment,

operator input to vehicle speed.

The single whole-body emission value listed

above is determined under particular

operating and terrain conditions. In

accordance with EN474, it is not intended tobe used to determine the whole-body

vibration exposure to the operator using this

machine.

Note: It is recognized that the appropriate

design of the operator's seat is the most

effective construction measure to minimize

the whole - body vibration emission of a

particular machine family.

This machine is equipped with an operator's

seat which meets the criteria of EN ISO 7096

representing vertical vibration under severe

operating conditions.

The seat is this machine has been testedwith input spectral class EMI and has a seat

transmissibility factor SEAT > 1.1.

Hands and Arm Vibration

The weighted root mean square acceleration

to which hand and arms of the operator are

exposed is less than 2.5 m/s2 under normaloperating conditions.

Whole body Vibration

Under simulated field duty cycle, the

weighted root mean square acceleration

emission of the machine to which the body is

subjected is less than 0.5 m/s2.

9-9

Technical Data


2231

ENGINE


Type .......................6 Cylinder, in line , Four cycle diesel, water

cooled, turbocharged with air to air cooling, electronic engine

management.

Gross power at 2110 rev/min..........................338 kW (454 hp, 460 PS)

Net power at 2110 rev/min..............................326 kW (437 hp, 443 PS)







Piston Displacement...............................................................14 l (855 in³)

Air cleaner...........................................................Dry type, double elementStarting...............................................................................................Electric




3 206(10-6)

553(1-10)

3 494(11-5)

1 380(4-6)

3 686(12-1)

2 967(9-9)

2 414(7-11)

3 888(12-9)

3 130(10-3)

3 315(10-11)

6 872(22-7)

2 520(8-3)

1 837(6-0)

66˚

851(2-7)


2 914(9-7)

1 310(4-4)

2 990(9-10)

10 944(35-11)

1 780(5-10)

1 950(6-5)

MaxBodyDepth

9-10

Technical Data

TRANSMISSION




and one reverse gear.Main......................................................18.5 + 3.4 bar (269 + 50 lbf/in²)

Temperatures:

Normal.................................................60 °C - 135 ° C (140 ° F- 275 °F)

Maximum........................................................................165 ° C (329 ° F)

Ratios:

Transmission....................................................Refer to the table below

Low Range

Forward

Gear 1 2 3 4 5 6

km/h 5.2 11.0 15.9 24.3 31.0 35.2

mile/h 3.2 6.8 9.9 15.1 19.3 21.9

Reverse

Gear 1

km/h 4.6

mile/h 2.9

High Range

Forward

Gear 1 2 3 4 5 6

km/h 7.9 16.8 24.3 37.1 47.7 53.9

mile/h 4.9 10.4 15.1 23.1 29.6 33.5

Reverse

Gear 1

km/h 7.0

mile/h 4.3

DROPBOX



Ratios:

Low...........................................................................................1.129:1

High..........................................................................................0.738:1

Pressure:

High/Low actuation.......................................................15 ± 0.2 bar

Differential lock actuation...............................................27.5 ± bar

Lubrication...........................................................................2 ± 1 bar

Temperature:

Maximum.........................................................................100 °C (212 °F)

9-11

Technical Data

AXLES




reduction gearing.



axle. This differential and the dropbox output differential are locked

simultaneously using one switch selected by the operator.

Ratios:

Differential ........................................ 3.70:1

Planetary .......................................... 6.35:1

Total Reduction .............................. 23.50:1

WHEELS AND TYRES



Tyres:

Standard...................................................................................26.5 R25**

Inflation Pressures :Please refer to page 8-12 for full list of tyre inflation pressures.





SUSPENSION






Rear: Each axle is coupled to the frame by three rubber- bushed links

with lateral restraint by a transverse link. Pivoting inter-axle balance

beams equalise load on each axle. Suspension movement is




9-12

Technical Data

HYDRAULIC SYSTEM



a common tank by the main hydraulic pump, driven from powertakeoff on transmission. System components are protected by full

flow filtration on the return line.Pump:

Type..................................................................................................Piston

Capacity at 2 700 rev/min...............................5.4 l/s (85.6 US gal/min)

Brakes





Actuating Pressure....................................48 ± 2.4 bar (700 ± 35 lbf/in²)

Pump Type......................................................................Triple stage gear

Capacity at 1 685 rev/min................................8.9 l/s (2.35 US gal/min)




Emergency.................Automatic application of driveline brake should

pressure fall in main brake hydraulic system. Service brakes may


Steering






System Pressure......................................................240 bar (3500 lbf/in²)Steering Angle to either side.................................................................45°

Lock to Lock Turns, steering wheel.........................................................4






Body Lower Time (power down)..........................................................8 s

9-13

Technical Data

SERVICE CAPACITIES

Fuel tank..................................................................481 litre (127 US gal)

Hydraulic System...................................................330 litre (87.2 US gal)

Engine Crankcase and filters....................................32 litre (8.4 US gal)

Cooling System........................................................67 litre (17.7 US gal)

Transmission (including cooler)..............................61 litre (16.1 US gal)

Dropbox....................................................................... 13 litre (3.4 US gal)

Differential - Front........................................................33 litre (8.7 US gal)

Differential - Centre.......................................................34 litre (9 US gal)

Differential - Rear.......................................................33 litre (8.7 US gal)

Planetaries (each)......................................................9 litre (2.37 US gal)

Hand Pump Tank.......................................................1 litre (0.26 US gal)

Air Conditioning Compressor.........................0.125 litre (0.033 US gal)

Brake cooling.........................................................175 litre (42.6 US gal)

ELECTRICAL SYSTEM

Type.......................................................................24 V, Negative Ground

Battery.................................................................Two, 12 V, 175 Ah each

Accessories..........................................................................................24 V

Alternator.........................................................................................100 Amp

BODY

Of 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 without tailgate.

Plate Thicknesses:


Sides..................................................................................12 mm (0.47 in)

Front.....................................................................................8 mm (0.39 in)

Volume:Struck (SAE)..................................................................15.5 m³ (20.3 yd³)

Heaped 2:1 (SAE)........................................................21.0 m³ (27.5 yd³)








NOISE EMISSIONS





depending upon proximity to buildings, rock piles, machinery, etc.. The actual job site NoiseExposure Level must be measured and applicable regulations complied with in respect to


9-14

Technical Data



Net Distribution





Payload 34000 74956

Gross Distribution



Rear Axle 23000 50705



Body 4950 10915


VIBRATION



many factors independent of machinedesign, for example ground conditions,

working methods, correct seat adjustment,

operator input to vehicle speed.




accordance with EN474, it is not intended to

be used to determine the whole-body


machine.










The seat is this machine has been tested

with input spectral class EMI and has a seat





exposed is less than 2.5 m/s2 under normal



Under simulated field duty cycle, the

weighted root mean square accelerationemission of the machine to which the body is

subjected is less than 0.5 m/s2 .

9-15

Technical Data

ENGINE


Type ......................6 Cylinder, in line , Four cycle diesel, water cooled,

turbocharged with air to air cooling, electronic engine management.

Gross power at 2110 rev/min..........................338 kW (454 hp, 460 PS)

Net power at 2110 rev/min..............................326 kW (437 hp, 443 PS)







Piston Displacement...............................................................14 l (855 in³)Air cleaner...........................................................Dry type, double element

Starting...............................................................................................Electric





2230

3 360(11-3)

605(2-0)

3 550(11-8)

1 495(4-11)

3 740(12-3)

3 140(10-4)

2 470(8-1)

3 945(12-11)

3 130(10-3)

3 315(10-11)

6 930(22-9)

2 595(8-6)

1 840(6-0)

66˚

905(2-9)


3 025(9-11)

1 310(4-4)

2 990(9-10)

11 055(36-3)

1 780(5-10)

1 950(6-5)

MaxBodyDepth

9-16

Technical Data

TRANSMISSION




and one reverse gear.

Main......................................................18.5 + 3.4 bar (269 + 50 lbf/in²)

Temperatures:

Normal..................................................60 °C - 135 °C (140 ° F- 275 °F)

Maximum........................................................................165 ° C (329 °F)

Ratios:

Transmission .............. Refer to table below

Low Range

Forward

Gear 1 2 3 4 5 6

km/h 5.5 11.7 16.9 25.8 33.0 37.5

mile/h 3.4 7.3 10.5 16.0 20.5 23.3

Reverse

Gear 1

km/h 4.8

mile/h 3.0

High Range

Forward

Gear 1 2 3 4 5 6

km/h 8.4 17.8 25.8 39.5 50.4 60.0

mile/h 5.2 11.0 16.0 24.5 31.3 37.3

Reverse

Gear 1

km/h 7.4

mile/h 4.6

DROPBOX



Ratios:

Low........................................................1.129:1

High.......................................................0.738:1

Pressure:

High/Low actuation......................15 ± 0.2 bar

Differential lock actuation................34-50 bar

Lubrication..........................................2 ± 1 bar

Temperature:

Maximum......................................100 ° C (212 °F)

9-17

Technical Data

AXLES




reduction gearing.



axle. This differential and the dropbox output differential are lockedsimultaneously using one switch selected by the operator.

Ratios:

Differential ........................................ 3.70:1

Planetary .......................................... 6.35:1

Total Reduction .............................. 23.50:1

WHEELS AND TYRES



Tyres:

Standard...................................................................................29.5 R25**

Inflation Pressures :

Please refer to page 8-12 for full list of tyre inflation pressures.





SUSPENSION






Rear: Each axle is coupled to the frame by three rubber- bushed linkswith lateral restraint by a transverse link. Pivoting inter-axle balance

beams equalise load on each axle. Suspension movement is




9-18

Technical Data

HYDRAULIC SYSTEM



a common tank by the main hydraulic pump, driven from power

takeoff on transmission. System components are protected by fullflow filtration on the return line.Pump:

Type..................................................................................................Piston

Capacity at 2700 rev/min..........................5.4 l/s (85.6 US gal/min)

Brakes





Actuating Pressure...................................48 ± 2.4 bar (700 ± 35 lbf/in²)

Pump Type...............................................................Triple stage gear

Capacity at 1 685 rev/min...............................8.9 l/s (2.35 US gal/min)




Emergency.................Automatic application of driveline brake shouldpressure fall in main brake hydraulic system. Service brakes may


Steering






System Pressure......................................................240 bar (3500 lbf/in²)Steering Angle to either side.................................................................45°Lock to Lock Turns, steering wheel.........................................................4






Body Lower Time (power down)...........................................................8 s

9-19

Technical Data

SERVICE CAPACITIES

Fuel tank......................................................................481 litre (127 US gal)

Hydraulic System......................................................330 litre (87.2 US gal)Engine Crankcase and filters......................................32 litre (8.4 US gal)

Cooling System...........................................................67 litre (17.7 US gal)

Transmission (including cooler)............................... 61litre (16.1 US gal)

Dropbox......................................................................... 13 litre (3.4 US gal)

Differential - Front...........................................................33 litre (8.7 US gal)

Differential - Centre............................................................34 litre (9 US gal)

Differential - Rear...........................................................33 litre (8.7 US gal)

Planetaries (each)..........................................................9 litre (2.37 US gal)

Hand Pump Tank............................................................1 litre (0.26 US gal)

Air Conditioning Compressor............................ 0.125 litre (0.033 US gal)

Brake cooling...............................................................175 litre (42.6 US gal)

ELECTRICAL SYSTEM

Type.........................................................................24 V, Negative Ground

Battery..................................................................Two, 12 V, 175 Ah each

Accessories............................................................................................24 V

Alternator.............................................................................................100 A

BODY

Of 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 without tailgate.

Plate Thicknesses:


Sides..................................................................................12 mm (0.47 in)

Front.....................................................................................8 mm (0.39 in)

Volume:

Struck (SAE)..................................................................17.4 m³ (22.8 yd³)

Heaped 2:1 (SAE)........................................................23.3 m³ (30.3 yd³)








NOISE EMISSIONS





depending upon proximity to buildings, rock piles, machinery, etc.. The actual job site Noise

Exposure Level must be measured and applicable regulations complied with in respect to


9-20

Technical Data



Net Distribution





Payload 38000 83775

Gross Distribution



Rear Axle 25000 55000



Body 5400 11905


VIBRATION



many factors independent of machine design,

for example ground conditions, working

methods, correct seat adjustment, operator

input to vehicle speed.




accordance with EN474, it is not intended to

be used to determine the whole-body


machine.










The seat is this machine has been tested

with input spectral class EMI and has a seat





exposed is less than 2.5 m/s2 under normal



Under simulated field duty cycle, the weighted

root mean square acceleration emission of

the machine to which the body is subjected is

less than 0.5 m/s2 .

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.

PressurisedCompartment

MasterSwitch

Switch'On'

Switch'Off'

NegativeGround

Ammeter

CircuitBreaker

Hourmeter

Basic WarningSymbol

Fast

Slow

Lock

Lock

BasicEngine

EngineStarter

EngineRev/Min

Engine'Off'

EmergencyEngineShut Off

EngineOil

EngineOilPressure

EngineOil Filter

BasicTransmission

TransmissionOil

TransmissionOilPressure

TransmissionOilTemperature

TransmissionOilFilter

TransmissionConvertorLockup

AirPressure

Air FilterorRestriction

StarterAirPressure

OilLevel

Minimumor Low

MaximumOrHigh

BasicHydraulicOil Symbol

HydraulicOil Filter

HydraulicOil FilterPressure

10-4


P

S

N

HotHydraulic

CoolantTemperature

Coolant cold'

CoolantHot

Cooling

Heating

Fuel GaugeOrFill tube

Fuel Filter

FuelShut-Off

BasicLightsSymbol

Light Flood

Light LowBeam

Light HighBeam

InstrumentPanel Light

Lamp Test

Horn

WindshieldWiper

WindshieldDefroster

WindshieldWasher

Blower Fan

Heater

AirConditioner

InsideAirCirculation

OutsideAir

ParkingBrake

Parking Brake

Brake OilTemperature

Turn Left

Turn Right

Tilt Steering

Low SteeringPressure

High SpeedOr Level

Low SpeedOr Level

Body Up

Body 'Raise'

Body 'Hold'

Body'Lower'

Body'Float'

Neutral

Dumpertruck'Retarder'

10-5


STOP

H

L

Lift Point

Do Not Lift

Forward

Reverse

Clutch'Engaged'

Clutch'Disengaged'

BrakeAppliedClutchEngaged

BrakeAppliedClutchDisengaged

Water inFuel

Wait toStart

BowlSuspension

Maintainance

TransmissionConverter

Brake airPressure

EngineCheck

EngineStop

TransOver Speed

Batterypower

EngineAir Filter

BrakeCoolingOilPressure

BrakeCoolingOilTemperature

Body Up

Trans.Oil Temp.

DropOil Temp

Drop OilPressure

Trans.retarder

EngineBrake

DropboxHigh Ratio

DropboxLow ratio

10-6


NOTES

10-7


NOTES

10-8


NOTES

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