TR35 Tier3
15503183
OHE877
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Operator Handbook
TR35 Tier3
Issued by;
Customer Support Department
Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
Scotland
Tel; +44 (0) 1698 732121
Fax; +44 (0) 1698 503210
www.terex.co.uk
OHE877
Re-Order Part Number
15503183
Blank Page
For further information on the subject matter detailed within this operator handbook,
please refer to Terex Equipment Limited Service Manuals and Product Parts Books.
Operator Handbook
TR35 Tier3
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.
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CALIFORNIA
Proposition 65 Warnings
WARNING: Diesel engine exhaust and
some of its constituents are known to the
State of California to cause cancer, birth
defects, and other reproductive harm.
WARNING: Battery posts, terminals
and related accessories contain lead
and lead compounds, chemicals
known to the State of California to cause
cancer and reproductive harm.
Wash
hands
after
handling.
EC DECLARATION OF CONFORMITY
MANUFACTURERS NAME AND FULL ADDRESS
TEREX EQUIPMENT LIMITED,
MOTHERWELL,
SCOTLAND,
ML1 5RY
DESCRIPTION OF MACHINERY
MAKE:
MODEL:
87/404/EEC
89/336/EEC
98/37/EEC
2000/14/EC
TEREX
TR35 RIGID TRUCK
97/23/EC
DATE OF MANUFACTURE:
INSPECTOR:
THE ABOVE MACHINERY, TAKING INTO ACCOUNT THE STATE OF THE ART,
COMPLIES WITH, OR IS DESIGNED AND CONSTRUCTED AS FAR AS POSSIBLE TO COMPLY WITH,
THE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS OF THE MACHINERY DIRECTIVE.
FOR AND ON BEHALF OF THE MANUFACTURER:
NAME:
PAUL DOUGLAS
POSITION:
CHIEF ENGINEER
SIGNATURE:
EC DECLARATION OF CONFORMITY
MANUFACTURERS NAME AND FULL ADDRESS
TEREX EQUIPMENT LIMITED,
MOTHERWELL,
SCOTLAND,
ML1 5RY
DESCRIPTION OF MACHINERY
MAKE:
MODEL:
87/404/EEC
89/336/EEC
98/37/EEC
2000/14/EC
TEREX
TR35 RIGID TRUCK
97/23/EC
DATE OF MANUFACTURE:
INSPECTOR:
THE ABOVE MACHINERY, TAKING INTO ACCOUNT THE STATE OF THE ART,
COMPLIES WITH, OR IS DESIGNED AND CONSTRUCTED AS FAR AS POSSIBLE TO COMPLY WITH,
THE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS OF THE MACHINERY DIRECTIVE.
FOR AND ON BEHALF OF THE MANUFACTURER:
NAME:
PAUL DOUGLAS
POSITION:
CHIEF ENGINEER
SIGNATURE:
CONTENTS
1. INTRODUCTION
Introduction
Safety Precautions
Machine Identification
Theft Deterrent Practices
1-5
1-5
1-6
1-6
2. SAFETY PRECAUTIONS
General
Vehicle Lifting Precautions
Vehicle Tie Down Precautions
Preventing Fire Hazards
Mounting and Dismounting
Pre-Starting
Starting
Operating
Roading
Lubrication and Servicing
Wheels and Tyres
Avoid Tyre Explosion Hazard
2-4
2-5
2-5
2-6
2-7
2-8
2-8
2-8
2-10
2-10
2-13
2-13
3-3
3-4
3-4
3-6
3-7
3-9
3-10
3-10
3-11
3-12
3-13
3-13
3-13
3-13
3-14
3-16
3-16
3-16
3-17
3-18
3-20
3-21
3-22
3-23
3-29
3-30
3-30
1-1
Blank Page
1-2
4-10
4-11
4-12
4-13
4-14
4-16
5-2
5-2
5-4
5-5
5-7
6. ROADING
Roading
General
Preparation Prior to Roading
In Case Of Trouble
6-2
6-2
6-2
6-4
7-2
8-3
8-4
8-5
8-7
8-8
8-8
9. TECHNICAL DATA
Technical Data - TR35
9-3
10.
4-3
4-4
4-6
4-7
4-8
SYMBOL IDENTIFICATION
1-3
Blank Page
1-4
Introduction
INTRODUCTION
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 TR45 & TR60 Rigid
Trucks.
Look for the safety alert symbol to point out important safety
precautions. It means:
ATTENTION! BECOME ALERT! YOUR SAFETY AND THE
SAFETY OF OTHERS IS INVOLVED!
Safety Precautions
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.
WARNING
These machines are equipped with cylinders containing
compressed nitrogen gas. Transportation of these machines
by any method may require a special permit from the
appropriate authority of the country involved. Consult your
dealer 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.
1-5
Introduction
1860
Introduction
Immobilise the machine by removing a critical electrical or starting
system device.
Upon receipt of a machine, record the machine serial number and
the serial numbers of all major components and attachments. Keep
this list up to date and filed in a safe location for fast retrieval.
Place a decal or notice on the machine that all serial numbers are
recorded.
Discourage the thief! Inspect the gates and fences of the machinery
storage yard or construction site. Keep machines in well-lit areas and
ask the local law enforcement authorities to make frequent checks
around the storage yard or work site.
Establish liaison with neighbours and ask them to watch equipment
left at job sites and to report any suspicious activities to the local law
enforcement authorities.
Make frequent inventories of machines to promptly detect losses or
vandalism.
Actions to Aid in Recovery of Stolen Machines
In the event of theft, immediately notify the law enforcement
authorities having jurisdiction. Provide the investigating officer with
name, type of equipment, chassis and serial numbers of major
attachments and components. It is helpful to show the investigating
officer an Operators Handbook, photographs, and advertising, to
familiarize him with the appearance of the machine.
Report the theft to the insurance company. Provide the model and all
serial numbers.
Report the model and serial numbers of the stolen machine to a
dealer handling the respective line of equipment. Request that the
dealer forward this same information to the equipment manufacturer.
1-7
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1-8
Safety Precautions
2 - Safety Precautions
2-1
Safety Precautions
Blank Page
2-2
Safety Precautions
SAFETY
Safety Alert Symbol
The safety alert symbol is used to alert you to a potential personal
injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.
Safety alert symbol
Hazard Classification
A multi-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 manual as well as on deals
and labels fixed to the machinery to assist in potential hazard
recognition and prevention.
DANGER
WARNING
CAUTION
CAUTION
2-3
Safety Precautions
SAFETY PRECAUTIONS
General
*
Read this Operators Handbook and learn the operating
characteristics and limitations of the vehicle. Know what operating
clearances the vehicle requires.
*
Always know all traffic rules, signs, flags and hand signals used
on the job and know who has the responsibility for signalling.
Never wear loose clothing, rings, watches etc., that might catch
levers and controls and cause loss of control.
Keep hands and controls free from water, grease and mud to
assure nonslip control.
2-4
TY L
FE UA
A
N
S A
M
1767
1768
1769
1782
Safety Precautions
Vehicle Lifting Precautions
*
Prior to lifting, the vehicle should be parked on a level surface,
wheels blocked, steering and oscillation lock bar connected, and
the parking brake disengaged.
*
1042
1043
2-5
Safety Precautions
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).
*
Clean all dirt, oil, grease and other fluids from systems and
components to minimize fire hazards and aid in spotting loose or
leaking lines, fittings etc..
1789
Make sure all fluid system caps, drain cocks, valves, fittings,
lines etc., are secure and leak free.
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.
FUEL
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.
2-6
1770
Safety Precautions
1771
Always use care when mounting the vehicle with oil covered,
frosted, or iced fenders, decks, hand holds or steps.
1772
2-7
Safety Precautions
Pre-Starting
*
If engine is to be started and run indoors, ensure proper
ventilation to remove deadly exhaust gases.
*
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.
1773
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.
*
DO NOT
OPE RATE
1775
Do not bypass the vehicles neutral-start system. The neutralstart system must be repaired if it malfunctions.
Start and operate the vehicle only from the operators seat.
Operating
*
Ensure all cab glass, mirrors and light lenses are clean during
vehicle operation for maximum visibility. Ensure mirrors are
properly set / positioned.
*
Always keep cab floor clear of anything that could restrict full
operation of pedals.
1862
In the event of a loss of steering pump output pressure, a fullypressurized accumulator provides a maximum of two lock to lock
turns of the front wheels. A red warning light on the instrument
panel illuminates when steering pressure falls below 83 bar (1 200
lbf/in) If this light illuminates, indicating a loss of steering power,
2-8
1861
Safety Precautions
the machine must be stopped immediately and no further
operation attempted until the fault is corrected.
*
1774
Use extreme caution and turn on lights at night or when fog, dust
or similar hazards limit visibility. Do not overdrive your headlights.
1778
1779
2-9
Safety Precautions
Operating (continued)
*
Always apply the brakes with the Parking-Emergency brake
control when the vehicle is being loaded or when dumping a load.
*
*
Roading
*
Match speed to road conditions.
*
Yield the right of way when required. Obey the rules of the
road.
2-10
1777
Pending Image
1863
1780
Safety Precautions
2-11
Safety Precautions
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.
WARNING
Never mix components of one manufacturers rims with those
of another. Using the rim base of one manufacturer with the
lock ring of another or vice versa is dangerous. The lock ring
of one may 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 is a very dangerous practice. Failure to comply
with the above warnings could result in an explosion from
tyre pressure causing serious property damage and serious
personnel injury or death.
2-12
Safety Precautions
Avoid Tyre Explosion Hazard
WARNING
Whenever a vehicles 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. If it is absolutely necessary
to approach a vehicle with a suspect tyre,
approach only from the front or the back.
Stay at least 15 m (50 ft) from the tread
area. Keep observers out of the area and at
least 460 m (1 500 ft) from the tyre sidewall.
Refer to the accompanying sketch. The
tyre(s) should be allowed at least eight (8)
hours cooling time after the vehicle is shut
down or the fire extinguished before
approaching closer.
AT LEAST
15 m (50 ft)
AT LEAST
460 m (1 500 ft)
172
2-13
Safety Precautions
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2-14
3-1
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3-2
34 33
35
5 6 7 8 9 10 11
12
13
27 26 25
15
16
24
21
28
32
14
38
22
36
31
37
23
19
18
20
30
29
17
1698
22.Retarder Control
2. Warning Lights
3. Tachometer/Hourmeter
24.Switches
25.Blower Control
27.Heater Control
7. Fuel Gauge
8. Warning Lights
29.Accelerator Control
31.Steering Wheel
11.Speedometer/Odometer
12.Warning Lights
13.Face Vent
14.Cup Location
15.Windscreen Demister
16.Side Window Demister
17.Document Holder
18.Fuse Box Cover
19.Transmission Gear Shift Selector
20.Ignition and Starter Key Switch
21.Braking Control Valve
34.Radio/Cassette Player
35.N/A
36.Foot Rest
37.Body Control Lever
38.Electric Window Switch
39.Interior Light (Not Shown). Located above
dash.
40.Cup Holder (Not Shown). Located on
back wall.
3-3
10
11
12
15
16
21
13
2
STOP
14
17
18
23
19
20
1626
BASIC DATA
Warning Lights
1. Alternator Charging (Red) - Illuminates to indicate when the
alternator is not charging.
2. Engine Water Temperature (Red) - Illuminates when the engine
water temperature rises above the safe operating temperature.
3. Engine Water Level (Amber) - Illuminates when the engine water
level drops below the safe operating level.
4. Air Cleaner Restriction (Amber) - Illuminates to indicate that the
air filters are needing cleaned or replaced.
5. Engine Oil Pressure (Red) - Illuminates when the engine oil
pressure drops below the safe operating pressure.
6. Engine Stop Light (Red) - When the 'Stop' light comes on, the
computer has detected a major malfunction in the engine that
requires immediate attention. Stop the machine when this light
illuminates and do not operate until the fault is corrected.
7. Engine Warning Light (Yellow) - When the 'Warning' light comes
on, the computer has detected a fault in the engine which may result
in a power loss. The fault should be diagnosed and corrected at the
earliest opportunity.
8. Engine Protection Fluid Light (Amber) - Illuminates when a fault
has been detected in the engine. Light remains on as long as the fault
is occurring. The fault should be diagnosed and corrected at the earliest
opportunity. If the fault continues to get worse the light will flash and the
engine power and/or speed will be gradually reduced. Stop the machine
and do not operate until the fault is corrected.
9. Low Air Pressure (Red) - Illuminates when the air system
pressure drops below 5.5 bar (80 lbf/in). An alarm also sounds. The
service brakes will automatically apply if air pressure drops to
approximately 3.1 bar (45 lbf/in). Stop the machine if this light
illuminates and do not operate until the fault is corrected.
3-4
22
24
3-5
15
10
RPM x100
20
25
30
OIL
ENG
PRESS
ENG
TEMP
WATER
1652
20
20
10
20
km/h
20
OIL
30
20
MPH
40
50
TRANS
PRESS
3-6
120
AIR
SERVICE
PRESS
50
TRANS
OIL
140
150
TEMP
1653
WARNING
Never release the parking brake to move
the machine until at least
7.2 bar (105 lbf/in) reservoir air pressure
is indicated on the gauge. (Needle well
into the green zone).
M
HAZARD
1700
9. Warning Light Test Switch - Pressing the switch with the ignition
switched on will illuminate warning lights 1, 2, 3, 4, 5, 9, 10, 11, 17,
18, 20, 22 and 23 and the buzzer will sound, to provide a bulb and
system check. Refer to 'Warning Lights' section on pages 4, 5 and 6
for details. The light in the switch will illuminate with the panel lights.
10. Diagnostic Request Switch - To check for active fault codes:
a. - turn the ignition key switch to the 'OFF' ('0') position.
b. - press the diagnostic switch to the 'ON' position.
c. - turn the ignition key switch to position '1'.
If no active codes are recorded the 'Stop', 'Warning' and 'Fluid' lights
will illuminate and stay on. If active codes are recorded the 'Stop',
'Warning' and 'Fluid' lights will illuminate momentarily. The yellow
'Warning' and red 'Stop' lights will begin to flash the code of the
recorded fault. Refer to pages 25 & 26 for details of the fault codes.
Note: If switch is pressed 'ON' during normal operation, the 'Stop'
light will illuminate, however, this does not indicate an engine
malfunction and the light will go out when the switch is pressed
'OFF'.
10
11
12
TEST
1478
3-7
1
2
1031
13
1765
14
'3' - Starter motor operates. The key when released will return to
position '2'.
14. Remote Diagnostic Test Point - (Located on the front of the
instructor seat). Plug in connector for diagnostic tooling.
15. Electric Window Switch - Press bottom of switch to lower
window; press top of switch to raise window.
15
17
1174
3-8
340
341
342
343
2. Direction Indicator:
Control rearwards
= Left Indicators
Control forwards
= Right Indicators
3. Windscreen Wiper/Washer:
Position J
= Intermittent Wipe
Position 0
= Neutral Position
Position 1
= Wiper Slow Speed
Position 2 = Wiper Fast Speed
Ring Pushed = Windscreen Wash
4. Horn:
Button pushed in = Horn Sounds
3-9
3-10
1105
1389
1
5
2
6
1650
3-11
Seat Belt
A 4-Point integrated Harness is installed on the operators seat. The
operators belt should be buckled up and adjusted via the lapbelt
tension on the sides of the seat.
A retractable seat belt installed on the jump seat.The jump seat belt
requires no external adjustment. Both belts allow freedom of
movement for proper manipulation of all controls.
WARNINGS
Always wear seat belt when operating the machine.
Always check condition of 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 seat belt at least once every three years, regardless
of appearance.
Do not attempt to adjust seat or seat belt while machine is
moving.
Loss of control may result. Stop machine; apply brakes; then
adjust.
3-12
1657
Operators Seatbelt
1656
Pasenger Seatbelt
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.
A 'Front Brake Accumulator' warning light and a 'Rear Brake
Accumulator' warning light are located on the instrument panel. If any
of these lights illuminate during operation, stop the machine, apply
the parking brake and do not operate until the fault is corrected.
Service Brake
This is a floor 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.
Braking Control Valve
Under normal operating conditions, the braking control valve should
be in the 'DRY' position so that the brakes on all wheels are applied
with equal air pressure. On soft or slippery surfaces, the brake
control valve should be placed in the 'SLIPPERY' position. This
reduces the air pressure directed to the front wheels to aid machine
control under such adverse conditions.
251
072
Note: Be sure to return the brake control valve to the 'DRY' position
when operating under normal conditions.
Parking/Emergency Brake
The service brakes are applied and locked in the applied position for
parking by the Parking/Emergency Brake lever on the centre
console.
For normal operation the lever should always be in the 'RELEASE'
position which permits normal braking with the service brake pedal.
To lock the service brakes in the applied position for parking, move
the Parking/Emergency lever to the 'EMERGENCY' position for 3
seconds and then to the 'PARK' position. The 3 second pause in
'EMERGENCY' releases the brake chamber locking mechanism and
applies the brakes; and moving the lever to the 'PARK' position
prevents accidental release of the locked up service brakes by
application of the foot pedal.
050
To release the service brakes from the locked 'PARK' position, with
the system fully charged, move the control lever to the
'EMERGENCY' position for 3 seconds and then to 'RELEASE'. If the
brakes do not release, make a full pedal brake application for 5
seconds.
3-13
WARNING
Always apply the parking brake before leaving the operator's
seat.
Retarder
The control lever (1) is used to apply retardation to the truck.
Retardation is the term used for applying a continuous braking force
to hold the truck to a safe steady speed when descending grades.
Retardation of this truck may be achieved by using the
TRANSMISSION RETARDER. The retarder has 6 stages of
retardation available, depending upon the severity of braking which is
requested by the operator.
The retarder is OFF when the lever is fully forward and is APPLIED
as the lever is pulled back. Maximum retardation is obtained when
the lever is in the fully back position. The retarder may be used
anytime to slow down. If additional braking is required apply the
service brakes. 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.
When the retarder is applied, the 'Retarder Indicator Light' on the
instrument panel will illuminate and an orange coloured warning light
at the rear of the truck will illuminate to warn following vehicles.
2
1699
The operator should select the correct gear range to match the site
conditions.
Note: In order to obtain the maximum retardation and cooling effect
during retardation, the engine speed should be maintained as high
as possible without exceeding the maximum recommendation.
Retarder Operation
Before the machine crests the top of a grade and starts down, the
operator should slow the machine with the service brakes and
downshift to the gear range which would be used to ascend the
grade. The retarder should be applied before starting the descent.
Machine downgrade speed (with the retarder applied as required) in
3-14
WARNING
Do not use the retarder
for parking the vehicle.
Only use the parkingemergency brake
control for this purpose.
WARNING
Great care should be
used if applying the
retarder when road
surfaces are slippery.
Retarder braking effect
will occur only at the
driving axle and could
make vehicle control
difficult.
M
HAZARD
1700
Operation
Before the machine starts down the grade, request the engine brake
and release the accelerator. The gear selected should be high
enough to keep the engine operating at governed speed. Generally
the gear used to ascend a grade is also correct for its descent. If the
rate of descent is too slow, the transmission should be upshifted to
the next highest gear. If the rate of descent is too fast, the service
brakes should be applied and the transmission shifted into a lower
gear which will allow a safe descent and efficient engine braking. If
further braking is required, apply the service brakes.
3-15
3-16
255
3
STOP
6
7
TEST
9
1,2
4
7 - 'Fluid' Light
8 - Diagnostic Test Points
9 - Diagnostic Switches
1486
3-18
1 FLASH 2 FLASHES
AMBER
(CEL)
PAUSE
RED
(SEL)
PAUSE
3 FLASHES
5 FLASHES
1 FLASH
RED
(SEL)
RED
(SEL)
AMBER
(CEL)
PAUSE
CODE 235
1841
PAUSE
WARNINGS
The operator of a DDECequipped 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-equipped
vehicle, this must be
done by a person other
than the operator. The
operator must maintain
control of the moving
vehicle while the
assistant performs the
diagnosis.
3-19
3-20
Description
ECM Hardware Internal Failure - Mission disabling
Engine Speed Sensor - Both signals lost
Engine Speed Sensor - One signal lost
Boost Pressure Sensor - Component shorted high
Boost Pressure Sensor - Component shorted low
Throttle Position Sensor - Component shorted high
Throttle Position Sensor - Component shorted low
Remote Accelerator Pedal Position Sensor- Circuit shorted high
Remote Accelerator Pedal Position Sensor- Circuit shorted low
Oil Pressure Sensor - Component shorted high
Oil Pressure Sensor - Component shorted low
Oil Pressure Sensor - Data below normal range
Engine Coolant Temperature Sensor - Component shorted high
Engine Coolant Temperature Sensor - Component shorted low
Throttle Position Sensor - Circuit low frequency
Throttle Position Sensor - Circuit high frequency
Engine Coolant Temperature Sensor - Data above normal range
Intake Manifold Temperature Sensor - Component shorted high
Intake Manifold Temperature Sensor - Component shorted low
Intake Manifold Temperature Sensor - Data above normal range
Sensor Supply Voltage #2 - Circuit shorted low
Additional OEM/Vehicle Diagnostic Codes have been logged
Oil Temperature Sensor - Component shorted high
Oil Temperature Sensor - Component shorted low
Oil Temperature - Data above normal range
Low Oil Level in Make up tank
Ambient Air Pressure Sensor - Component shorted high
Ambient Air Pressure Sensor - Component shorted low
Engine Oil Burn Valve Solenoid - Circuit shorted low
Sensor Supply Voltage #2 - Circuit shorted high
Engine Speed - Data above normal range
Engine Coolant Level - Data below normal range
External Speed Input (Multiple Unit Sychronization) - Data incorrect
Vehicle Speed Sensor Circuit - Data incorrect
Vehicle Speed Sensor Circuit - Tampering has been detected
Fan Clutch - Circuit shorted low
Fuel Shutoff Value - Component shorted low
Fuel Shutoff Value - Component shorted high
SAE J1939 Multiplexing PGN timeout error
SAE J1939 Multiplexing configuration error
SAE J1939 Multiplexing accelerator pedal sensor system error
SAE J1939 Multipexing Remote throttle data error
Auxiliary Temperature Sensor Input #1 - Circuit shorted high
Auxiliary Temperature Sensor Input #1 - Circuit shorted low
Ambient Air Pressure Sensor - Circuit data incorrect
Auxiliary Pressure Sensor Input #2 - Circuit shorted high
Auxiliary Pressure Sensor Input #2 - Circuit shorted low
Engine Shutdown - Commanded by J1939
Injector Solenoid Valve Cylinder #1 Circuit - Grounded circuit
Injector Solenoid Valve Cylinder #5 Circuit - Grounded circuit
Injector Solenoid Valve Cylinder #3 Circuit - Grounded circuit
Injector Solenoid Valve Cylinder #6 Circuit - Grounded circuit
Injector Solenoid Valve Cylinder #2 Circuit - Grounded circuit
Real Time Clock - Power interrupt
Injector Solenoid Valve Cylinder #4 Circuit - Grounded circuit
Injector Solenoid Valve Cylinder #1 Circuit - Open circuit
Injector Solenoid Valve Cylinder #5 Circuit - Open circuit
Injector Solenoid Valve Cylinder #3 Circuit - Open circuit
Injector Solenoid Valve Cylinder #6 Circuit - Open circuit
Injector Solenoid Valve Cylinder #2 Circuit - Open circuit
Injector Solenoid Valve Cylinder #4 Circuit - Open circuit
ECM - Data lost
ECM - Warning internal hardware failure
ECM - Warning software error
Transmission Output Shaft Speed High - Warning
Sensor Supply Voltage #1 - Circuit shorted low
Error detected in intake air heater relay circuit
Sensor Supply Voltage #1 - Circuit shorted high
Accelerator Pedal Position Sensor Supply Voltage - Circuit shorted high
Less than 6 VDC detected at engine brake circuit 1
Less than 6 VDC detected at engine brake circuit 2
Fault Lamp
Red
Red
Amber
Amber
Amber
Red
Red
Red
Red
Amber
Amber
Amber
Amber
Amber
Red
Red
Amber
Amber
Amber
Amber
Amber
None
Amber
Amber
Red
Maint.
Amber
Amber
Amber
Amber
Red
Amber
Amber
Amber
Amber
Amber
Red
Amber
Amber
Amber
Red
Red
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Maint
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Description
Data transmission error on J1587/J1922 datalink
Data transmission error on J1587/J1922 datalink
Oil Pressure Sensor - Data indicates very low oil pressure
Water in Fuel Indicator High
Error in intake manifold pressure sensor signal detected by ECM
Engine Coolant Level Sensor Signals - Data invalid
SAE J1939 datalink - cannot transmit
Data transmission on J1939 datalink not occuring at an acceptable rate
Water in Fuel Sensor - Circuit shorted high
Water in Fuel Sensor - Circuit shorted low
Accelerator Pedal Idle Validation Circuit - Data incorrect
Accelerator Pedal Idle Validation Circuit - Out of calibration
Intake Manifold Pressure Sensor - Circuit data incorrect
Power Lost without ignition off
Engine Oil Pressure Sensor - Circuit data incorrect
Battery Voltage Low - Warning
Battery Voltage High - Warning
Accelerator Pedal Position Sensor Supply Voltage - Circuit shorted low
High voltage detected at wastegate actuator No. 1 circuit
Less than 6 VDC detected at wastegate actuator No. 1 circuit
Transmission Output Shaft Speed Low - Warning
High voltage detected at wastegate actuator No. 2 circuit
Less than 6 VDC detected at actuator No. 2 circuit
Error detected in multiple unit synch control sw. input pins 34 & 32 of OEM harness
Auxiliary Input/Output #2 - Circuit shorted high
OEM Alternate Torque Validation Switch - Data incorrect
Auxiliary Input/Output #3 - Circuit shorted high
Accelerator Pedal Idle Validation - Circuit shorted low
Fuel Supply Pump Inlet Pressure Sensor - Circuit shorted high
Fuel Supply Pump Inlet Pressure Sensor - Circuit shorted low
Fuel Supply Pump Inlet Pressure Low - Warning level
Electrical Charging System Voltage High - Warning level
Electrical Charging System Voltage Low - Warning level
Electrical Charging System Voltage Low - Critical level
Engine Hot Shutdown
Cylinder Power Imbalance between cylinders
Fault Lamp
None
None
Red
Maint
Amber
Amber
None
None
Amber
Amber
Amber
Red
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Red
None
None
3-21
3-22
1118
1390
WARNING
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 to
isolate the bateries before
disconnecting any
components.
After welding connect all
of the above in reverse
order.
3-23
3
FRONT
100%
50%
MODE
& EMER
ING
G
RK KE CONT EN
RO
PA RA
B
CY
L
RELEASE
PARK
EMERGEN
CHARGE SYSTEMCY
IN
DWELL 3 SECONDS PARK
IN
EMERGENCY
OR RELEASE TO APPLY
D
4
3
2
1
1
2
3-24
WARNING
Do not allow the vehicle to
coast in Neutral. This
practice can result in
severe transmission
damage.
1
2
3
4
5
D
N
MO
NIT
OR
MO
DE
SE
LE
CT
2
3
4
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.
1. Hold override
2. Mode button
3. Range selected
4. Range attained
5. Display mode
button
1793
3-25
WARNING
Always select Neutral and
apply the parking brake
before leaving the
operators' seat.
IDLE
FULL LOAD/THROTTLE
1509
3-26
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 oL70 : Sump fluid temp too low
oL50 : Engine RPM too low
3-27
1112
'FLOAT' - The lever should be moved to this position while the body
is lowering by gravity and should remain in this position until the body
must be operated again. The control lever should always be kept in
'FLOAT' while the machine is in motion.
'HOLD' - Moving the lever to this position while the body is being
raised or lowered traps the oil in the body hoists to stop and hold the
body at any desired height. The lever will remain in the detented
'HOLD' position when released.
'RAISE' - This position directs oil to extend the body hoists and raise
the body. When released, the lever will be spring-returned to the
'HOLD' position.
WARNING
Pressurized system. Before carrying out any maintenance on
the body control system, pressure must be dissipated from
the pilot valve accumulator. Shut-off the engine and operate
the body control lever in both directions approximately 15
times to discharge the accumulator. A
078
3-31
3-32
4-1
Blank Page
4-2
STEERING CYLINDERS
Check for debris, leaks
and damage. Check lines
for wear and leaks.
ENGINE
Check oil level. Check
for leaks.
ACCUMULATOR
Check for leaks.
BODY CYLINDERS
Check for debris, leaks and
damage. Check lines for
wear and leaks.
DIFFERENTIAL
Check for leaks.
REAR RIDE CYLINDERS
Check for debris leaks and
damage.
TRANSMISSION
Check oil level.
Check for leaks.
STEERING TANK
Check oil level.
Check for leaks.
MAIN HYDRAULIC
TANK
Check oil level. Check
for leaks.
FUEL TANK
Check fuel level. Ensure
fuel tank is full. Check
that tank is securely
mounted.
WHEEL PLANETARIES
Check for leaks.
1075
4-3
259
037
640
038
041
641
2. Fuel Filters - Drain sediment and water from sump until fuel runs
clear.
WARNING
Press button in centre of cap to bleed pressure before
removing cap completely. Fill to bottom of filler neck.
4. Air Cleaner Vacuator Valve(s) - Check for proper operation.
Clean if required.
6. Fuel Level Gauge - Check fuel level. Tank should be filled at end
of each shift to prevent condensation.
4-4
1071
8. Steering Hydraulic Tank - Cold Oil Level - With the engine off,
turn the steering wheel back and forth to dissipate any pressure in
the steering accumulator. Oil should be showing in the middle sight
gauge. Add fluid, if low.
1072
160
10. Seat and Seat Belts - Adjust the seat position and lap belt 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.
472
10
4-5
TR35
11.7 (170)
143 (5.6)
5.5 (80)
TR40
13.8 (200)
168 (6.6)
7 (100)
TR45
13.8 (200)
168 (6.6)
7 (100)
TR60
13.8 (200)
168 (6.6)
8.3 (120)
TR70
17.2 (250)
158 (6.2)
8.3 (120)
TR100
16.3 (240)
158 (6.2)
8.3 (120)
Height - mm (in)
365 (14.4)
556 (21.9)
556 (21.9)
505 (19.9)
378 (14.9)
381 (15)
Note: It is advised to charge the ride struts by an additional 20 lbf/in2 to allow for pressure
lost while carrying out pressure checks.
After recharging, the machine should be operated to allow ride struts to settle. Then if ride
heights are incorrect, the oil levels should be checked.
4-6
4-7
050
0
1
1044
052
1
2
3
4
5
D
N
MO
NIT
O
SE
LE
CT
MO
DE
1733
314
0
1
2
1045
4-8
0
1
2
1175
15
10
RPM x100
20
20
10
20
30
20
MPH
20
km/h
20
40
25
0
30
50
1328
15
10
RPM x100
20
20
10
20
30
20
MPH
20
km/h
20
40
25
0
30
50
1393
10. The red 'Stop', yellow 'Warning' and amber 'Fluid' lights will
illuminate for approximately 2 seconds, one after another, to check
their operation. The lights will remain off until a fault code is
recorded.
STOP
10
1115
11. Do not release the parking brake until the main air pressure
gauge registers 7.2 bar (105 lbf/in) or more.
15
10
RPM x100
10
20
30
20
MPH
20
km/h
20
40
25
0
1325
20
20
5
30
50
11
4-9
4-10
HOT
FULL
HOT
ADD
COLD
FULL
COLD
ADD
1750
1073
1074
2. Main Hydraulic Tank - Hot Oil Level - Operate the body hoist
cylinders to their fully-extended positions to charge all cylinders and
lines then lower the body. With the engine running, and body fully
lowered, the oil level should show in the top sight gauge. Add oil if
low. Under all conditions the bottom sight gauge should show full.
3. Steering and Braking Hydraulic Tank - Hot Oil Level - With the
engine running, oil at operating temperature and accumulators
charged, oil must be between the top and middle sight gauges. Shut
down the engine and operate the steering left and right to discharge
steering accumulator. Operate treadle valve continuously to
discharge braking accumulators. Oil should show in the top sight
gauge.
4-11
4-12
052
G & EMERG
KIN E CONT ENC
RO
AR RAK
L
B
RELEASE
PARK
EMERGENCY
CHARGE SYSTEM IN PARK
DWELL 3 SECONDS IN
EMERGENCY TO APPLY
OR RELEASE
1329
1
2
3
4
5
D
N
MO
NIT
O
SE
LE
CT
MO
DE
1733
314
275
4. Sound horn; two blasts for forward and three blasts for reverse.
5. Release the service brake, apply the accelerator and move off.
4-13
276
G & EMERG
KIN E CONT ENC
RO
AR RAK
L
B
RELEASE
PARK
EMERGENCY
CHARGE SYSTEM IN PARK
DWELL 3 SECONDS IN
EMERGENCY TO APPLY
OR RELEASE
1330
086
G & EMERG
KIN E CONT ENC
RO
AR RAK
L
B
8. If the service brake does not stop the machine. Apply the parking emergency brake. This should only be applied to stop the machine in
an emergency.
RELEASE
PARK
EMERGENCY
CHARGE SYSTEM IN PARK
DWELL 3 SECONDS IN
EMERGENCY TO APPLY
OR RELEASE
WARNING
There is no mechanical connection between the engine and
wheels on machines with converter transmissions. The
parking brake must always be applied when the engine is
switched off.
050
1
2
3
4
5
D
N
MO
NIT
O
SE
LE
CT
MO
DE
1733
4-14
278
4. To stop the engine, turn the ignition key switch to position '1'.
1
2
1034
1109
052
281
4-15
641
651
4-16
5-1
Blank Page
5-2
Note: After coming to a stop for loading or unloading the truck, the
Parking-Emergency Brake control can be pushed in to hold the
brakes in the applied position as though the foot brake is depressed.
G & EMERG
KIN E CONT ENC
RO
AR RAK
L
B
RELEASE
PARK
EMERGENCY
CHARGE SYSTEM IN PARK
DWELL 3 SECONDS IN
EMERGENCY TO APPLY
OR RELEASE
086
079
080
Semicircular Loading
Loading
The most common methods of loading trucks are with hydraulic
excavators, rope shovels, and front end loaders. For maximum
material movement, the truck operator must help the loading
machine operator hold loading time to a minimum. The fewer
manoeuvres the truck must make to get into loading position, the
sooner loading can start. And 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.
Ideally, the hydraulic excavator or rope shovel should require 90o or
less swing to dump into the truck body for best loading efficiency.
Required turning and backing to position the truck for loading should
be held to a minimum. A common loading method is to have trucks
travel a semicircle in the loading area. This method eliminates all
backing. Waiting machines 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 better able to judge the best spot for his truck when it is his turn
to be loaded.
On some jobs, the loading machine might work most efficiently when
trucks 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 end
loader, the truck operator should spot his machine 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-type material is being loaded on a windy day. This
practice improves both working conditions and visibility for the loader
operator.
5-3
082
083
5-4
Hauling
While travelling the haul road, always maintain a safe speed for the
haul road conditions and grades. Never allow the machine to move
or coast with the transmission in 'NEUTRAL'!
When approaching downgrades, select the proper transmission
range and use the retarder 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 (2) truck-lengths between machines for each 15 km/h (10 mile/h)
of travel 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
would be 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.
084
Load Downwind
085
087
5-5
TWO MINIMUM
088
Safety First
089
Avoid Obstacles
090
Watch Spotter
Mineral ores, blasted rock etc., are usually dumped into a hopper or
crusher where it is processed before shipment. 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 loads
and the loads smoothed out with a crawler tractor. When dumping on
a fill of this type, the operator usually works alone and picks his 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 his 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 are common to all jobs and which the operator should
observe When dumping over a spoil bank without a 'SPOTTER', know how
close the machine can safely approach the edge under all weather
conditions. If in doubt as to dumping safety, dump the load a safe
distance from the edge so that it can be pushed over the edge
later.
5-6
Before raising the body, make sure 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
machine, allow the engine to slow to idle, shift the transmission to
'NEUTRAL' and apply the brakes with the Parking-Emergency
Brake control to hold the machine stationary.
091
092
093
094
052
Push the body control lever back into the 'RAISE' position and
accelerate the engine. Decelerate the engine to slow the raising
speed as the hoists approach their maximum extension. When the
body has been raised to the desired height, release the control
lever into the '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.
NEVER 'JUMP DUMP' the machine 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 down into
the 'FLOAT' position to allow the body's weight to lower it to the
chassis. If the body does not begin to lower by its weight, push the
control lever down into the 'LOWER' position and power the body
down until it begins to lower by gravity. Then release the control
lever into the 'FLOAT' position.
Empty Return
Make sure the body is completely lowered, the body control lever is
in the 'FLOAT' position, and the transmission is shifted to the correct
range before releasing the brakes and moving away from the dump
site.
WARNING
DO NOT drive the truck with the body up. Apart from
effecting the stability of the truck, 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'.
5-7
Blank Page
5-8
Roading
6 - Roading
6-1
Roading
Blank Page
6-2
Roading
ROADING
WARNING
These machines are equipped with cylinders containing
compressed nitrogen gas. Transportation of these machines
by any method may require a special permit from the
appropriate authority of the country involved. Consult your
Dealer for details.
General
'ROADING' (operating a truck over public highways) requires special
care and attention. Trucks, because of their large size, are slower
and less manoeuvrable than most other vehicles encountered on the
road. Yet, while on the road, they must be operated for extended
periods of time at or near maximum speeds.
Before 'ROADING' a truck for an extended distance between jobs, or
between widely scattered sections of a job, the machine must be
properly equipped and in good condition. It is also recommended to
carry a 'Warning Triangle'.
The operator must use extra care while on the public highways and
remain constantly alert, especially for overhead cables and low
bridges.
Necessary permits must be obtained from the proper authorities
before the machine is 'ROADED' on public highways.
Preparation Prior to Roading
Lubrication
Thoroughly lubricate and service all components and systems as
described under 'LUBRICATION AND SERVICING' in this handbook
and/or service manuals for this machine.
Inspection
Perform all pre-starting and post-starting checks described in this
Handbook. Pay particular attention to the function of all instruments
and lights, and make any repairs necessary.
Note: Improper tyre inflation during over-the-road operation can
cause rapid tyre deterioration by overheating. Tyre pressures
increase with heat. Always check pressures while tyre is cold.
Consult your tyre dealer for proper pressures and tyre speed limits
for roading.
Note: Make sure the body control lever is in the 'FLOAT' position.
Failure to comply to this caution could result in overheating the
hydraulic oil and failure of the hydraulic system components.
Check the inflation pressures of all tyres, while cold, with an accurate
tyre pressure gauge. Inflate tyres if necessary, while cold, to the
recommended pressure for 'ROADING'. Inspect all tyres thoroughly
6-3
Roading
and carefully for stones or other debris embedded in the treads or
carcasses. Inspect for cuts, bruises, burned beads, abnormal wear
and damaged wheels rims. Replace any damaged or excessively
worn tyres.
Check all hoses, drain cocks, fuel level check cocks, and other
potential sources of leaks. Make sure that all leaks are repaired and
that all drain cocks are sufficiently tightened to avoid subsequent
loosening. 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 all lights and other controls for proper operation.
Make sure the truck body is empty, fully lowered and the body
control lever is in the 'FLOAT' position.
In Case of Trouble
If trouble develops en route, move machine off the road at the first
safe parking place, and shut off the engine. Carefully note as many
of the symptoms of the trouble as possible, such as rough engine
operation with loss of power and overheating, or, loss of speed and
transmission clutch pressure with normal engine operation etc..
If the area in which the trouble occurs requires that the machine be
left unattended while the trouble is reported by phone, disconnect a
battery cable and apply security locks, if so equipped, before leaving
the parked machine. Make sure body is completely lowered and the
parking brake is applied.
Report the following data as soon as possible.
1. Exact location.
2. Destination.
3. The nature of the trouble (with as many details as possible) and
the time and conditions under which it happened.
4. The telephone number at which the machine operator can be
reached.
Note: Do not attempt to restart or operate the machine unless
instructed to do so. An engine, pump, transmission or other
component that develops a minor defect can be completely
destroyed in just a few extra minutes of unnecessary operation.
6-4
7-1
Blank Page
7-2
098
WARNING
Uncontrolled machine
movement hazard. There is
no mechanical connection
between the machine
wheels and the engine
when the parking brake is
released. Before releasing
the parking brake, make
sure the machine wheels
are secured with chockblocks to prevent or restrict
unexpected machine
movement. When moving
the machine with
insufficient hydraulic
pressure and power for
safe steering and braking,
use extreme caution to
ensure personnel and
property safety.
WARNING
If using a chain or cable, be
sure it is strong enough for
the expected load and
properly secured.
When pulling, take up the
slack slowly to avoid
jerking. A chain or cable
which fails under load can
cause serious injury. Stand
clear. Do not pull through a
kinked chain or cable. Do
not pull or tow unless the
operators compartment is
guarded against or out of
reach of a whipping chain
or cable. Attach only to the
towing points. Failure to
follow these instructions
could cause serious injury
or death.
7-3
Blank Page
7-4
8-1
Blank Page
8-2
TY L
FE UA
SA AN
M
1767
D O N OT
OPE RATE
1775
1781
WARNING
Injection Hazard.
Escaping fluid under pressure
can penetrate skin, causing
serious injury.
8-3
8-4
1 15 19 5
26
21
7 23 25 9 4 24 3
19
20
20 22 23 25 7 24 9 10
18
11
19
24 13 23 17
13
14 24 17 23 16
13
1067
10
1
2
3
4
5
6
7&8
-
50
150
Engine
Transmission
Main Hydraulic Tank
Steering Hydraulic Tank
Radiator Header Tank
Fuel Filter/Water Separator
Cooling Fan
Drive Belts
Front and Rear Ride Cylinders
Air Cleaner
Air Cleaner Vacuator Valve
Tyres
Controls, Instruments and W/Lights
General Inspection
Service Instructions
No. of
Points Lubricant Service/Quantities
1
1
1
1
1
2
1
4
1
6
EO
T
HO
HO
Antifreeze
-
As Required
As Required
As Required
As Required
See Page 7
See Page 7
Man.Sec 180-0050
Man.Sec 160-0050
NLGI
NLGI
NLGI
NLGI
NLGI
NLGI
NLGI
NLGI
20 Strokes
See Note
See Note
See Note
See Note
See Note
See Note
See Note
7
8
9
10
11
12
13
14
Lube.
Lube.
Lube.
Lube.
Lube.
Lube.
Lube.
Lube.
2
4
4
2
1
2
2
4
EP,
EP,
EP,
EP,
EP,
EP,
EP,
EP,
23
24
Lube.
Lube.
12
8
8-5
Replace filters.
Check DCA concentration and replenish.
Replace filters(s) if required.
Clean.
Check condition.
Check oil level. Add if low.
Check oil level. Add if low.
Check oil level. Add if low.
Clean.
Clean.
Check belt tension. Adjust if required.
Check belt tension. Adjust if required.
Check wear. Replace if required.
2
1
1
1
1
2
1
1
1
4
DCA4
EPL
EPL
EPL
-
Man.Sec 110-0030
See Page 7
See Page 7
Ref Engine Manual
See Page 7
See Page 8
See Page 8
See Page 8
1
18
19
20
21
-
Engine
Engine Oil Filters
Fuel Tank
Air Cleaner(s)
Accumulators
Driveline Universal Joints
Driveline Slip Joints
Steering Column Universal Joints
Hydraulic & Steering Tank Breathers
1
3
3
1
EO
*EP, NLGI
*EP, NLGI
*EP, NLGI
-
See Page 8
Man.Sec 110-0030
See Note
See Note
See Note
-
15
16
17
-
2
1
1
1
2
1
EPL
EPL
EPL
EP, NLGI
See Page 7
See Page 7
Ref Engine Manual
See Page 8
See Page 8
See Page 8
See Note
2 000
3
4
18
-
1
1
4
1
1
HO
HO
Diesel
-
3000
Replace.
4 000
26
-
Cooling System
Air Conditioning Compressor
1
1
5 000
6000
25
2
Repack.
Drain and refill.
2
-
*EP, NLGI *
T
See Page 8
250
500
1 000
1 500
8-6
No. of
Points Lubricant Service/Quantities
Service Instructions
*-
Note -
EO -
EPL -
HO -
See Page 8
See Page 8
See Page 7
See Page 8
-
T-
WHEN REQUIRED
Seat Belts - Inspect seat belts and replace if damaged.
Note: Replace seat belts at least once every three years,
regardless of appearance.
Cooling Fan - Visually check the fan for cracks, loose rivets, and
bent or loose blades. Check fan mounting and tighten if required.
Replace any fan that is damaged.
8-7
SERVICE CAPACITIES
Service Capacities
Ref.
Points Identification
1
2
3
4
26
18
7
8
15
16
17
-
TR35
Lubricant
litres
US gal
EO
T
HO
HO
HO
HO
Coolant
Diesel
HO
HO
EPL
EPL
EPL
PAG Oil
33
61
83
121
30
47
90
371
14
8
2
57
30
0.135
8.7
16
22
32
8
12.4
23.8
98
3.7
2.1
0.53
15
8
0.036
Note: Capacities given are approximate. Work to dipstick, sight gauges or level
plugs. Use table in conjunction with 'Recommended Lubricants' table.
RECOMMENDED LUBRICANTS
COMPONENT
LUBRICANT
Engine
Ambient Temp
0 C and above
-10 C and above
-25 to 35 C
Transmission
Transynd / TES 295. *When determining whether a fluid Ambient temperature range of -50C to
is TES 295 approved or not look and/or ask for one of
40C
two things - The Allison TES 295 approval number or
the Allison approved logo
. If uncertain if a fluid is
approved, consult Allison Transmission for confirmation.
Cooling System
Fuel Tank
DIN EN590
Differential
Planetary Gears
Power Takeoff
SAE 80W-90
at ambient temperatures of -18 to 32 C
Grease Fittings
No. 2 Consistency
Drivelines
Steering Column
Wheel Bearings
Air Conditioning
Compressor
Ride Cylinders
(Nitrogen/Oil)
Hydraulic System
Recommendation
SAE 20W-40
SAE 15W-40
SAE 10W-30
ISO46
SP 10
SAE 10W
SAE 10W
at ambient temperatures of -18 to 32 C
SAE 30W
at ambient temps of 32 C and above
8-8
Temperature Conversions
Celsius
-32
-30
-27
-25
-20
-18
-15
-10
10
15
25
32
35
38
Fahrenheit
-26
-22
-17
-13
-4
14
32
50
59
77
90
95
45
93
190
8-9
Blank Page
8-10
Technical Data
9 - Technical Data
9-1
Technical Data
Blank Page
9-2
Technical Data
TECHNICAL DATA TR35
3 400
(11-4)
Max 1 305
Body (4-3)
Depth
3 105
(10-2)
450
(1-6)
1 240 (4-8)
2 355 (7-9)
3 470 (11-4)
6 850
(22-6)
Vehicle Clearance Diameter (SAE) 17.63m (58ft)
6 570
(21-7)
4 820
(16-1)
4 000
(13-1)
3 950
(13-2)
Optional
Spillguard
500
(1-8)
58
4 190
(13-9)
3 865
(12-8)
3 520
(11-9)
3 025
(9-11)
450 (1-6)
500 (1-8)
2 265 (7-5)
2 800 (9-2)
3 365 (11-0)
2 220 (7-4)
3 605 (11-10)
7 950 (26-3)
2 125 (7-1)
Dimensions in mm (ft-in)
1688
TECHNICAL DATA
ENGINE
Make/Model ................................... Cummins QSM11-C400
Type ..................... 4 Stroke, low emission, air to air charge,
air cooled electronic diesel engine
Gross Power at 2 100 rev/min ................... 298 kW (400 hp)
Note: Gross power rated to SAE J1995 Jun 90. Engine
emission meets USA EPA/CARB MOH Tier 3, CARB Tier
3 and EU NRMM Stage 3 emissions (non-road mobile
machinery) directive.
Maximum Torque ... 1 898 Nm (1 400 lbf ft) at 1 400 rev/min
Number of Cylinders/Configuration ....................... 6, in line
Bore x Stroke ............................ 125 x 147 mm (4.9 x 5.8 in)
Total Displacement ................................. 10.8 litres (661 in)
Starting ..................................................................... Electric
Maximum Speed, Full Load ........................... 2 100 rev/min
Maximum Speed, No Load ............................. 2 450 rev/min
Idle Speed ......................................................... 800 rev/min
Safe Operating Angle ................................ 45/100% Grade
TRANSMISSION
Make/Model ........................................ Allison 4500 ORS_R
Remote mounted in the frame with integral torque
converter, hydraulic retarder and planetary gearing. Five
speeds forward, one reverse. Automatic shifting in
forward range. Downshift and reverse inhibitors.
Automatic lockup action in all speed ranges.
Gear
Ratio
km/h
Forward
1
2
3
4
5
4.70
2.21 1.53 1.00 0.67
9.50
20.2 29.3 44.8 58.6
5.90
12.6 18.2 27.8 36.4
Reverse
1
5.55
8.4
mile/h
5.2
Gear
Ratio
km/h
mile/h
DRIVE AXLE
Heavy duty axle with full floating axle shafts, single
reduction spiral bevel gear differential and planetary
reduction at each wheel.
Ratios:
Standard
Differential ............................................ 3.13:1
Planetary .............................................. 4.59:1
Total Reduction .................................. 14.37:1
SUSPENSION
Front: King pin strut type independent front wheel
suspension uses self-contained, variable rate, nitrogen/oil
cylinders.
9-3
Technical Data
Rear: Variable rate nitrogen/oil cylinders with A-frame
linkage and lateral stabilizer bar.
Maximum Strut Stroke
Front ......................................................... 225 mm (9.0 in)
Rear .......................................................... 160 mm (6.3 in)
Maximum Rear Axle Oscillation .................... 8.0 Degrees
BRAKES
SERVICE
Dual shoe, internal expanding, mechanically actuated by
air pressure. Independent front and rear circuits actuated
by single treadle valve with auxiliary manual control.
Operator controlled wet/dry road valve reduces front brake
pressure by 50% for improved control in slippery
conditions.
Front Linings:
Diameter x Width ....................... 508 x 152 mm (20 x 6 in)
Area, Front Axle ................................... 3 459 cm (536 in)
Rear Linings:
Diameter x Width .................... 508 x 190 mm (20 x 7.5 in)
Area, Rear Axle ................................... 4 323 cm (670 in)
Total Lining Area ................................ 7 782 cm (1 206 in)
Air Compressor Capacity ............... 425 litre/min (15 ft/min)
PARKING
Service brakes act as parking brakes when applied by
manual control valve on the instrument panel.
RETARDATION
Transmission retarder and engine brake fitted as standard..
EMERGENCY
Warning light in cab indicates when air pressure drops
below 5.5 bar (80 lbf/in). Front and rear brakes
automatically actuate if system air pressure falls to 3.1 bar
(45 lbf/in).
Total brake air reservoir capacity ............ 81 litre (4 950 in)
STEERING SYSTEM
9-4
Technical Data
SERVICE CAPACITIES
Engine Crankcase and Filters ............. 33 litres (8.7 US
Transmission and Filters ...................... 61 litres (16 US
Cooling System ................................. 90 litres (23.8 US
Fuel Tank ............................................ 371 litres (98 US
Steering Hydraulic Tank ......................... 30 litres (8 US
Steering System ................................ 47 litres (12.4 US
Body Hydraulic Tank ............................ 83 litres (22 US
Body Hydraulic System ...................... 121 litres (32 US
Planetaries (Total) .................................. 30 litres (8 US
Differential ............................................ 57 litres (15 US
Front Ride Strut (Each) ........................ 14 litres (3.7 US
Rear Ride Strut (Each) .......................... 8 litres (2.1 US
Power Takeoff ................................... 2.0 litres (0.53 US
Air Conditioning Compressor ..... 0.135 litres (0.036 US
gal)
gal)
gal)
gal)
gal)
gal)
gal)
gal)
gal)
gal)
gal)
gal)
gal)
gal)
lb
9-5
Technical Data
Blank Page
9-6
Symbol Identification
10 - Symbol Identification
10-1
Symbol Identification
Blank Page
10-2
Symbol Identification
SYMBOL IDENTIFICATION
These pages explain the meaning of symbols that may appear on your machine.
Basic
Warning
Symbol
Switch
'Off'
Pressurised
Compartment
Negative
Ground
Fast
Basic
Engine
Master
Switch
Ammeter
Slow
Engine
Starter
Switch
'On'
Circuit
Breaker
Lock
Engine
Rev/Min
Hourmeter
Transmission
Convertor
Lockup
Lock
Engine 'Off'
Basic
Transmission
Minimum
or
Low
Emergency
Engine
Shut Off
Transmission
Oil
Air
Pressure
Maximum
or
High
Engine
Oil
Transmission
Oil
Pressure
Air Filter
or
Restriction
Basic
Hydraulic
Oil Symbol
Engine
Oil
Pressure
Transmission
Oil
Temperature
Starter
Air
Pressure
Hydraulic
Oil
Filter
Engine
Oil
Filter
Transmission
Oil Filter
Oil level
Hydraulic
Oil Filter
Pressure
10-3
Symbol Identification
Hot
Hydraulic
Heating
Light Flood
Horn
Coolant
Temperature
Fuel Gauge
Or
Fill tube
Light Low
Beam
Windshield
Wiper
Coolant 'cold'
Fuel Filter
Light High
Beam
Windshield
Defroster
Coolant 'Hot'
Fuel
Shut-Off
Instrument
Panel light
Windshield
Washer
Cooling
Basic
Lights
Symbol
Lamp Test
Heater
Parking
Brake
Low Steering
Pressure
Air
Conditioner
Brake Oil
Temperature
Inside
Air
Circulation
Turn Left
Low Speed
or Level
Outside
Air
Turn Right
Body Up
Tilt Steering
Body 'Raise'
Parking Brake
10-4
High Speed
or Level
Blower Fan
Body 'Hold'
Body
'Lower'
Body
Float'
Dumpertruck
'Retarder'
Neutral
Symbol Identification
Lift Point
Clutch
'Disengaed'
Brake
Applied
Clutch
Engaged
Do Not Lift
Forward
Brake
Applied
Clutch
Disengaged
Bowl
Suspension
Maintenance
Engine
Stop
Trans.
Over speed
Battery
Transmission
Power
Convertor
Reverse
Water in
Fuel
Brake air
Pressure
Engine
Air Filter
Clutch
'Engaged'
Wait to
Start
Engine
Check
Brake
Cooling
Oil
Pressure
Trans.
Oil Temp.
Dropbox
Oil Temp.
Brake Cooling
Oil Temp.
Body up
Dropbox Oil
Pressure
Trans.
Retarder
Dropbox
High Ratio
STOP
Engine
Brake
Dropbox
Low Ratio
10-5
Symbol Identification
NOTES
10-6
Symbol Identification
NOTES
10-7
Symbol Identification
NOTES
10-8