Operator Hand Book TR45-60 Tier3

7/25/2019 Operator Hand Book TR45-60 Tier3

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TEREX Equipment Li mited Operator Handbook

OperatorHandbook

T

R45

/60

Tier

3

15503109

OHE881/882


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TEREX Equipment Li mited Operator Handbook Re-Order

Ope

ratorHandb

ook

T

R45

/60

Tier

3 Issued by;Customer Support Department

Terex Equipment LimitedNewhouse Industrial Estate

Motherwell, ML1 5RY

Scotland

Tel; +44 (0) 1698 732121

Fax; +44 (0) 1698 503210

www.terex.co.uk

OHE881/882

Re-Order Part Number

15503109

This controlled document is the original instruction and

should remain with the vehicle at all times.

Revision February 2008

15503109

OHE881/882


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TEREX Equipment Li mited Operator Handbook - Introduction

OperatorHandbook

T

R45

/60

Tier

3For further information on the subject matter detailed within this operator handbook,please refer to Terex Equipment Limited Service Manuals and Product Parts Books.Alternatively, please contact;

Customer Support Department

Terex Equipment Limited

Newhouse Industrial Estate

Motherwell, ML1 5RY

Tel; +44 (0) 1698 732121

Fax; +44 (0) 1698 503210

The illustrations, technical information, data and descriptive text in this manual, to the

best of our knowledge, were correct at the time of print. The right to change

specifications, equipment and maintenance instructions at any time without notice, is

reserved as part of the Terex Equipment Limited policy of continuous development

and improvement of the product.

No part of this publication may be reproduced, transmitted in any form - electronic,

mechanical, photocopying, recording, translating or by any other means without priorpermission of Customer Support Department - Terex Equipment Limited.

Please refer to TEREX Specification Sheets or consult Factory Representatives to

ensure that information is current.


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ONLY TRAINED PERSONNEL SHOULD BEALLOWED TO OPERATE THIS VEHICLE

The operator is responsible and must befamiliar with the contents of the Operator'sHandbook and any local regulations prior to

operating this vehicle.


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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 lead

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


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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.


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

DESCRIPTION OF MACHINERY DIRECTIVES COMPLIED WITH

MAKE: TEREX 87/404/EEC 97/23/EC

MODEL: TR45 RIGID TRUCK 89/336/EEC

TR60 RIGID TRUCK 98/37/EEC

2000/14/EC

UNIT SERIAL NO. DATE OF MANUFACTURE:

INSPECTOR:

THE ABOVE MACHINERY, TAKING INTO ACCOUNT THE STATE OF THE ART,COMPLIES WITH, OR IS DESIGNED AND CONSTRUCTED AS FAR AS POSSIBLE TO COMPLY WITH,THE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS OF THE MACHINERY DIRECTIVE.

FOR AND ON BEHALF OF THE MANUFACTURER:

NAME: PAUL DOUGLAS SIGNATURE:

POSITION: CHIEF ENGINEER

EC DECLARATION OF CONFORMITY


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When carrying out repairs, alterations or fitting attachments, it is important that only genuine

spare 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 void

if non-genuine parts are used.


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

DESCRIPTION OF MACHINERY DIRECTIVES COMPLIED WITH

MAKE: TEREX 87/404/EEC 97/23/EC

MODEL: TR45 RIGID TRUCK 89/336/EEC

TR60 RIGID TRUCK 98/37/EEC

2000/14/EC

UNIT SERIAL NO. DATE OF MANUFACTURE:

INSPECTOR:

THE ABOVE MACHINERY, TAKING INTO ACCOUNT THE STATE OF THE ART,COMPLIES WITH, OR IS DESIGNED AND CONSTRUCTED AS FAR AS POSSIBLE TO COMPLY WITH,THE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS OF THE MACHINERY DIRECTIVE.

FOR AND ON BEHALF OF THE MANUFACTURER:

NAME: PAUL DOUGLAS SIGNATURE:

POSITION: CHIEF ENGINEER

EC DECLARATION OF CONFORMITY


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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 manufacturer

can be maintained.

If a General Operating Approval is issued for this machine, it may be considered null and void

if non-genuine parts are used.


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CONTENTS

1. INTRODUCTION

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

2. SAFETY PRECAUTIONSGeneral 2-4Vehicle Lifting Precautions 2-5Vehicle Tie Down Precautions 2-5

Preventing Fire Hazards 2-6Mounting and Dismounting 2-7Pre-Starting 2-8Starting 2-8Operating 2-8

Roading 2-10Lubrication and Servicing 2-10

Wheels and Tyres 2-13Avoid Tyre Explosion Hazard 2-13

Decals and Instruction Plates 2-14

3. CONTROLS AND OPERATINGControls and Instruments 3-3Basic Data 3-4

Warning Lights 3-4Instruments 3-7

Switches 3-9Controls 3-12Heater 3-13Air Conditioner 3-13Operator's Seat -

Air Suspension 3-14Seat Belt 3-15

Machine Controls .............. 3-16Braking ............................ 3-16Service Brake ................ 3-16Park/Emergency Brake . 3-16Retarder ........................ 3-17

Engine ............................. 3-19Electronic Foot Control .. 3-19

Quantum Fuel System... 3-19Description .................... 3-21Operation....................... 3-22

Steering ........................... 3-26Transmission ................... 3-27Description and Operation 3-30General Operation ......... 3-35

Body Control ................... 3-39Raising the Body ........... 3-40Lowering the Body......... 3-40


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4. OPERATING THE TRUCKPre-Starting Inspection 4-2Component Checks 4-3Suspension Ride Struts 4-5Engine Operation 4-6Starting the Engine 4-7

Starting the Engine withJumper Cables 4-9

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

5. WORKING THE TRUCKWorking the Truck 5-2

Loading 5-2

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

6. ROADINGRoading 6-2

General 6-2

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

7. MOVING DISABLED TRUCK

Moving Disabled Truck 7-28. LUBRICATION AND SERVICING

Safety Precautions 8-2Lubrication and Servicing 8-3Lubrication and Service Chart 8-5Miscellaneous Servicing 8-8

Service Capacities 8-12Recommended Lubricants 8-13

9. TECHNICAL DATATechnical Data - TR45 9-3

Technical Data - TR60 9-8

10. SYMBOL IDENTIFICATION

11. TECHNICAL LITERATURE REQUEST FORM


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INTRODUCTION

This Handbook is provided as a guide to familiarize the operator andserviceman with the controls, recommended inspections, start-up,

operating, shutdown and parking procedures for TR45 & TR60 RigidTrucks.

Look for the safety alert symbol to point out important safety

precautions. It means:

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

Safety Precautions

The machine should be properly operated and maintained to keep itin safe, efficient operating condition. Be sure that all controls are freeof mud, grease, or other matter that might cause slips hazardous tothe operator, serviceman, or other personnel or equipment. Reportall malfunctions to those responsible for maintenance, and, do not

operate the equipment until corrected. Normal service or

maintenance performed as required can prevent unexpected andunnecessary downtime.

This Handbook describes general inspections, servicing andoperation with the normal safety precautions required for normalservicing and operating conditions. It is not a guide however, for

other than normal conditions or situations, and therefore, servicemenand operators must be safety conscious and alert to recognizepotential servicing or operating safety hazards at all times, and take,necessary precautions to assure safe servicing and operation of the

machine.

WARNING

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

Continuing improvement and advancement of the design may cause

changes to your machine which may not be included in thispublication. Each publication is reviewed and revised, as required, toupdate and include these changes in later editions.

This Handbook contains lubrication and routine servicinginstructions, most of which can be performed in the field.

Maintenance manuals containing repair/rebuild procedures can beobtained from your dealer.

Introduction

Safety alert symbol


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1860

Intended use of machine

This product and its approved attachments are primarily intended tobe used as described in this manual.

Use of this product in any other way is prohibited and contrary to itsintended use

Machine Identification

While reading this handbook you will notice references to controls

and equipment which may not be found on all machines. It is

important that you know your machine and its equipment and how tooperate it properly.

Information regarding the machine model, code and chassis serialnumber is found on the unit serial number plate on the rear right ofthe front frame. The machine model and serial number should

always be referenced in any correspondence with your dealer orfactory.

There is a dealer serving every part of the world where these

products are sold. Your dealer is ready to provide you with anyadditional information needed and should be consulted for additionalpublications for this machine.

Theft Deterrent PracticesGeneral

The owner/operator should take the following precautions todiscourage theft, to aid in the recovery in the event that the machine

is stolen, or to reduce vandalism.

Actions to Discourage Theft and Vandalism

Remove all keys any time the machine is left unattended.

At night lock all doors and attach, secure or lock all anti-vandalismand

Introduction


21/1421-7

anti-theft devices on the machine.

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

Upon receipt of a machine, record the machine serial number and

the serial numbers of all major components and attachments. Keepthis list up to date and filed in a safe location for fast retrieval.Place a decal or notice on the machine that all serial numbers arerecorded.

Discourage the thief! Inspect the gates and fences of the machinerystorage yard or construction site. Keep machines in well-lit areas and

ask the local law enforcement authorities to make frequent checksaround the storage yard or work site.

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

Make frequent inventories of machines to promptly detect losses orvandalism.

Actions to Aid in Recovery of Stolen Machines

In the event of theft, immediately notify the law enforcementauthorities having jurisdiction. Provide the investigating officer with

name, type of equipment, chassis and serial numbers of majorattachments and components. It is helpful to show the investigating

officer an Operators Handbook, photographs, and advertising, tofamiliarize him with the appearance of the machine.

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

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

Introduction


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Safety Precautions

2 - Safety Precautions


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Safety Precautions

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Safety Precautions

SAFETY

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

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

and labels fixed to the machinery to assist in potential hazardrecognition and prevention.

Safety alert symbol

DANGER

WARNING

CAUTION

CAUTION

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

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

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

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

property damage.


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Safety Precautions

SAFETY PRECAUTIONS

General

* Read this Operators Handbook and learn the operatingcharacteristics and limitations of the vehicle. Know what operating

clearances the vehicle requires.

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

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

Be especially aware of overhead power lines.

* Always know all traffic rules, signs, flags and hand signals used

on the job and know who has the responsibility for signalling.

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

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

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

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

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

* Handle fuels and lubricants carefully and clean up spills toavoid fire and slipping hazards.

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

* Never carry more than one passenger and only in thepassenger seat.

WARNINGThe protection offered by the roll over and falling objectprotective structure may be impaired if it has been

subjected to any modification or damage. Unauthorizedmodification will void certification.

1782

1768

SAFE

TY

MANU

AL

1767

1769


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Safety Precautions

Vehicle Lifting Precautions

* Prior to lifting, the vehicle should be parked on a level surface,wheels blocked, steering and oscillation lock bar connected, andthe parking brake disengaged.

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

using FOUR slings from the lifting points provided at the bumperend of the front chassis and at the rear of the body.

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

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

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

2054 Vehicle Lifting Instructions

2055 Vehicle Tie Down Instructions


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Safety Precautions

Preventing Fire Hazards

General Fire Precautions

* Make sure the vehicle has a fire extinguisher and that it isaccessible and fully charged. (Not furnished with the vehicle).

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

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

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

* Dont let greasy, oily rags or similar hazards accumulate in thecab.

* If the vehicle has been operated with an under inflated tyre.Make sure that the tyre has cooled sufficiently before parking andleaving the vehicle unattended.

Flammable Fluid Precautions

* Dont use diesel fuel or other flammable fluids for cleaning

purposes. Use approved, nonflammable solvents.

* Make sure all fluid system caps, drain cocks, valves, fittings,

lines etc., are secure and leak free.

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

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

refuelling. Ground the hose spout to prevent sparks when spout istouched to fuel tank filler tube.

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

* Use care and do not stand downwind when adding fuel or otherflammable fluids to tanks and reservoirs to avoid fluids being

blown or splashed onto clothing.

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

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

FUEL

1770

1789


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Safety Precautions

* Follow manufacturers recommendations when handling and

using engine-starting fluids and disposing of spent containers. Donot puncture or burn empty containers. These fluids are explosiveand highly flammable.

Electrical Hazard Precautions

* Never smoke or allow open flames or sparks near batteries.

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

* Always disconnect batteries before repairing electrical system toavoid danger of fire-causing sparks. Disconnect battery groundcable first and reconnect last.

* Always disconnect batteries & alternator leads before carrying

out any welding on the vehicle.

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

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

* Never operate engine starter for more than 30 seconds andallow two minutes between long cranking periods for cooling. An

overheated starter could cause a fire.

* If electric coolant or lubricant heaters are used, be sure to followheater manufacturers recommendations for use to avoid electrical

and/or fire hazards.

Mounting and Dismounting

* Only use steps and hand holds provided to mount or dismountthe vehicle. Do not grasp steering wheel.

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

* Always use care when mounting the vehicle with oil covered,

frosted, or iced fenders, decks, hand holds or steps.

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

1771

1772


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Safety Precautions

Pre-Starting

* If engine is to be started and run indoors, ensure properventilation to remove deadly exhaust gases.

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

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

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

starting the vehicle.

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

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

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

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

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

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

* Start and operate the vehicle only from the operators seat.

Operating

* Ensure all cab glass, mirrors and light lenses are clean duringvehicle operation for maximum visibility. Ensure mirrors are

properly set / positioned.

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

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

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

* Always wear seat belts when operating the vehicle.

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

1773

1861

DONOT

OPERATE

1775

1862


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Safety Precautions

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

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

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

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

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

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

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

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

* Stay in gear when driving downhill. Do not coast withtransmission in neutral. Select the proper gear and maintain safespeed with the service brakes or/and retarder. Always maintain

safe speeds for haul road operating conditions for maximumcontrol. Reduce speed before turning.

* In the event of a loss of electric power to the gear shift control,the transmission will automatically lock in a gear range. If thisoccurs, stop the vehicle using the service brakes, apply the parkingbrake and do not operate until the fault is corrected.

* Always operate straight up or down slopes whenever possible,

side-hill operation can cause sideslip and possible roll-over.

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

* Brake firmly in one application. Do not FAN the pedal. Neveroperate the vehicle if a warning light indicates a fault in the braking

system.

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

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

1779

1778

1774


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Safety Precautions

Roading

* Match speed to road conditions.

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

road.

* Stay as close to the side of the road as possible. Pass otherequipment only when the road is clear and enough room / space topass and reserve power is available.

* Stop at appropriate intervals to inspect the vehicle and allow thetyres to cool. Tyre air pressure will rise during operation. Do 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 thisvehicle. Study this Operators Handbook and the Maintenance

Manual before starting, operating or servicing this vehicle. Alwaysfollow procedures and safety precautions detailed throughout theMaintenance Manual.

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

lubricating or servicing the vehicle.

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

* Do not work under or near an unblocked or unsupported body.Always use the body safety prop. The body safety prop must only

be used when the body is empty.

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

Body Safety Pins1863

1780

1777

Operating (continued)

* Always apply the brakes with the Parking-Emergency brakecontrol when the vehicle is being loaded or when dumping a load.

* Always stay in cab when being loaded.

* Always lower the body and shut down the vehicle according tothe procedure under 'Stopping The Engine' described on page 4-

14 before leaving the vehicle unattended. If on a grade wheelsshould be blocked.

9271069


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Safety Precautions

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

* Always shut down the vehicle according to the procedure under'Stopping The Engine', described on page 4-14, and turn off the

master switch before cleaning, lubricating or servicing the vehicleexcept as called for in this Operators Handbook or theMaintenance Manual.

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

* When changing oil in the engine, transmission and hydraulicsystems, or removing hydraulic lines, remember that the oil may be

hot and can cause burns to unprotected skin.

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

unprotected skin.

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

* Always use a self-attaching chuck with a long airline, and, 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 raisedoperators cab. Ensure any lifting devices are adequate for the jobwhich they are intended.


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Safety Precautions

Wheels and Tyres

If tyres on the vehicle were inflated at the factory with dry nitrogengas, 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 DRYNITROGEN BE USED EXCLUSIVELY FOR ALL TYREPRESSURE ADJUSTMENTS AS WELL AS INFLATION OF

REPLACEMENT TYRES.

Nitrogen gas improves tyre pressure retention, increases tyre life byreducing carcass oxidation from within, minimizes rim rust, and hasno known detrimental effect on the tyre. It also reduces the potential ofa tyre explosion because it is an inert gas and will not supportcombustion inside the tyre. The same tyre inflation pressure used for

air inflation should be used for nitrogen inflation. Refer to Section160-0050, Wheel, Rim and Tyre of the vehicle Maintenance Manualfor recommended procedures for inflating and pressure adjustingtyres with dry nitrogen gas. Only proper nitrogen charging equipmentoperated by personnel trained in its use should be used.

WARNINGNever mix components of one manufacturers rims with thoseof another. Using the rim base of one manufacturer with thelock ring of another or vice versa is dangerous. The lock ring

of one may not fully engage with the lock ring groove of theother. Always consult the rim manufacturers for propermatching, assembly and safety instructions. Also, use and

servicing of damaged, worn out or improperly assembled rimassemblies is a very dangerous practice. Failure to complywith the above warnings could result in an explosion fromtyre pressure causing serious property damage and seriouspersonnel injury or death.


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Safety Precautions

Avoid Tyre Explosion Hazard

WARNINGWhenever a vehicles tyre(s) is (are)exposed to excessive heat such as avehicle fire or extremely hot brakes, the

hazard of a subsequent violent tyreexplosion must be recognized. All nearbypersons must avoid approaching thevehicle so as not to be physicallyendangered in the event of an explosion ofthe tyre and rim parts. The vehicle shouldbe moved to a remote area, but only whenthis can be done with complete safety of

the operator operating or towing thevehicle. All other persons should stayclear of the vehicle. The fire or overheatedbrakes, wheel etc., should be extinguishedor cooled from a safe distance. Do notattempt to extinguish the fire or cool the

vehicle by use of hand-held fireextinguishers. If it is absolutely necessaryto approach a vehicle with a suspect tyre,approach only from the front or the back.Stay at least 15 m (50 ft) from the treadarea. Keep observers out of the area and at

least 460 m (1 500 ft) from the tyre sidewall.

Refer to the accompanying sketch. Thetyre(s) should be allowed at least eight (8)hours cooling time after the vehicle is shutdown or the fire extinguished beforeapproaching closer.

172

AT LEAST460 m (1 500 ft)AT LEAST

15 m (50 ft)


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Safety Precautions

Decals and Instruction Plates

Decals and instruction plates fitted tovehicles may vary from country tocountry to suit local needs. These pagescontain a brief description and thelocation of the decals and instructionplates that may appear on your vehicle.

1. Tyre Warning

2. Accumulator Precautions

3. Accumulator Charging Instructions

4. Operating On A Grade Instructions

5. Vehicle Parking Instructions

6. Acoustic Foam Precautions

7. Symbol Identification Chart

8. Radiator Cap Warning

9. Radiator Fill Instructions

10. Air Cleaner Information

11. Vehicle Overall Height

12. Steering Wheel Lock

13. Negative Earth

14. Battery Cable Warning

15. Ride Strut Pressure Warning 659

1

15 113, 14

2, 3

64, 5 7

11, 12

8, 9

10

660

2, 3, 4, 5, 6, 7

1

8 9

10

13

11

12

14

1615 17 14

13

18

25 24 22, 23 20, 21 19

1. Alternator Precautions

2. CEC (ATEC) Welding Warning

3. Engine Instructions4. Body Control Lever Positions

5. Retarder Positions

6. CEC (ATEC) Switches

7. Pre-operating Instructions

8. Acoustic Foam Precautions

9. Pre-operating Instructions

10. Hydraulic Oil Decal

11. Sight Gauge Plate

12. Hydraulic Oil Pressure Plate

13. Anti-Syphon Instructions

14. Instruction Plate

15. Hydraulic Oil Level

16. Instruction Decal

17. Hydraulic Oil Level

18. Lubrication Chart

19. Pressure Test Points

20. Accumulator ChargingInstructions

21. Accumulator Precautions



24. Ride Strut Pressure Warning

25. Machine Serial Plate


37/1422-15

Safety Precautions

Pictorial Decal Set

15335731

Transmission Retarder(1934)

15335732

Body Control (1897)

9361787

Battery Earth(1798)

F100% 50%15335734

50% Front Brake

Reduction (1898)

15335742

P R

F

Diagnostic PrssurePoints (1899)

I . D kg

159500lb(72500kg)TR100

116850lb(53000kg)TR70

101200lb(46000kg)TR60

89100lb (40500kg)TR45

85800lb (39000kg)TR40

57760lb (26200kg)TR35

15335767

Safety Lift Instruction (1900)

15335735

F

Diagnostic PressurePoints (1901)

15335763


15335737

R P


PRF

15335738

Diagnostic Pressure Points (1904)

P

RF

15335768

Diagnostic Pressure Points (1905)

O

15318940

Transmission RetarderLever Control (1961)

15335733

Hydraulic Oil Level(1962)

15245918

TOP

Hydraulic Oil Level(1963)

Hand Lamp (1964)


38/142


39/1422-17

Safety Precautions

15335789

Caution Cab Foam, Do not weld or burn cabstructure unless foam is removed (1921)

15334759

N2

PSI / BAR

0

Accumulator Warning, Maintain nitrogenprecharge for proper operation (1875)

15334765

Entanglement Warning, Stop enginebefore servicing (1879)

30 1C 1 0.3 30 1L 10 5

25 1C 3 1 25 2 15 9

20 1L 5 3 20 3 22 14

15 1L 9 5 15 4 28 17

10 2 15 9 10 4 34 21

5 4 30 17 5 5 54 33

0 5 55 34 0 5 55 34

15335771

% KPH MPH % KPH MPH

Gradeability Chart (1910)

15334764

Read And Understand OperatorHandbook (1878)

15334767

Burn Hazard, allow to cool beforeopening (1881)

N

15334761

P1.

2.

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


40/1422-18

Safety Precautions

Blank Page


41/1423-1

Controls and Operating

3 - Controls and Operating


42/1423-2


Blank Page


43/1423-3


CONTROLS AND INSTRUMENTS

1477

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

17

18

1920

21

22232425

26

2728

29

303132

3334

35

1. Face Vent/Side Window Demister

2. Warning Lights

3. Tachometer/Hourmeter

4. Engine Water Temperature Gauge

5. Engine Oil Pressure Gauge

6. Fuel Gauge

7. Warning Lights

8. Transmission Oil Pressure Gauge

9. Transmission Oil Temperature Gauge

10.Speedometer/Odometer

11.Warning Lights

12.Face Vent

13.Park/Emergency Brake Control

14.Cup Location

15.Windscreen Demister

16.Side Window Demister

17.Document Holder18.Fuse Box Cover

19.Transmission Gear Shift Selector

20.Retarder Control

21.Ignition and Starter Key Switch

22.Switches

23.Blower Control

24.Air Conditioner Control

25.Heater Control

26.Accessory Lamp Socket

27.Accelerator Control

28.Service Brake Control

29.Steering Wheel

30.Steering Wheel Adjustment Lock

31.Headlight Dipper, Direction IndicatoR,Windscreen Wiper/Washer and Horn Control

32.Radio/Cassette Player

33.Foot Rest

34.Body Control Lever

35.Electric Window Switch

36.Interior Light (Not Shown). Located above

dash.

37.Cup Holder (Not Shown). Located on backwall.


44/1423-4


BASIC DATA

STOP

P

1 2

1

2

3

4

5

6

7

8

9 10 11 12

13 14 15 16

17

18

19

20

21

22

23

24

1628

BASIC DATA

Warning Lights

1. Alternator Charging (Red) -Illuminates to indicate when thealternator is not charging.

2. Engine Water Temperature (Red) -Illuminates when the enginewater temperature rises above the safe operating temperature.

3. Engine Water Level (Amber) -Illuminates when the engine water

level drops below the safe operating level.4. Air Cleaner Restriction (Amber) - Illuminates to indicate that theair filters are needing cleaned or replaced.

5. Engine Oil Pressure (Red) -Illuminates when the engine oilpressure drops below the safe operating pressure.

6. Engine Stop Light (Red) -When the 'Stop' light comes on, thecomputer has detected a major malfunction in the engine that

requires immediate attention. Stop the machine when this lightilluminates and do not operate until the fault is corrected.

7. Engine Warning Light (Yellow) -When the 'Warning' light comes

on, the computer has detected a fault in the engine which may resultin a power loss. The fault should be diagnosed and corrected at theearliest opportunity.

8. Engine Protection Fluid Light (Amber) -Illuminates when a faulthas been detected in the engine. Light remains on as long as the fault

is occurring. The fault should be diagnosed and corrected at the earliestopportunity. If the fault continues to get worse the light will flash and theengine power and/or speed will be gradually reduced. Stop the machineand do not operate until the fault is corrected.

9. Front Brake Accumulator Pressure (Red) - Illuminates to warn

of low pressure in the front brakesystem accumulator. Stop themachine if this light illuminates and do not operate until the fault iscorrected.


45/1423-5


Warning Lights (continued)

10. Rear Brake Accumulator Pressure (Red) -Illuminates to warnof low pressure in the rear brake system accumulator. Stop themachine if this light illuminates and do not operate until the fault iscorrected.

11. Low Steering Pressure (Red) - Illuminates when the steeringsystem oil pressure drops below 83 bar (1200 lbf/in). Stop themachine when this light illuminates and do not operate until the faultis corrected.

12. Steering & Braking Tank Low Oil Level (Red) -Illuminateswhen the level in the tank falls below the safe operating level. Stopthe machine when this light illuminates and do not operate until thefault is corrected.

13. Parking Brake (Red) -Illuminates when the parking brake is

applied.14. Headlight Main Beam (Blue) -Illuminates when headlights areoperated on main beam.

15. Direction Indicator (Green) -Flashes when the indicator lightsare operating.

16. Body-up (Amber) -Illuminates to indicate that the body is NOTresting on the chassis. Never move the machine until this light goesOUT.

17. Transmission Oil Temperature (Red) -Illuminates when thetransmission oil temperature rises above the safe operating

temperature.18. Brake Hydraulic Oil Temperature (Red) - Illuminates if brake

cooling hydraulic oil overheats. Reduce speed and shift transmissionto the range that will maintain an engine speed as high as possible,without exceeding the maximum recommendation, to increase oilcirculation and cooling. If the trouble persists, stop the machine andhave the fault corrected.

19. Retarder Indicator (Amber) - Illuminates when the retarder isapplied.

20. In-converter Indicator (Green) - Illuminates when the

transmission is in Torque Converter drive. It goes OUT when Lockupis engaged.

21. Check Trans (Red) - Illuminates to alert of a fault in thetransmission shift system or abnormal transmission temperature.The light will illuminate when the ignition keyswitch is turned to

position '1' to provide a bulb and system check and should go off afew seconds after the engine is started.

22. Steering Filter Restriction (Amber) -Illuminates when the filteris restricted, indicating that a filter change is required.

23. Transmission Oil Filter Restriction (Amber) - Illuminates when

the filter is restricted, indicating that a filter change is required.Transmission will not upshift from first gear while this light isilluminated.

24. Transmission Overspeed Light - Illuminates when the

transmission ECU senses transmission speed above 2350 rev/min.


46/1423-6


Instruments

1387

0

5

10

1520

25

RPM x100

30

STOP

ENG

WATER TEMP

ENGOIL PRESS

P

1 2

2

1 3

4

1. Tachometer/Hourmeter - Driven from theengine ECM, the tachometer indicates the enginespeed in revolutions per minute. The needleshows the variations in engine operating speed.Never accelerate the engine to speeds indicated

by the red zone on the dial face. A digital

hourmeter is incorporated in the tachometer torecord total hours of engine operation. Thereadings can be used for operating and servicerecords.

2. Engine Water TemperatureGauge - This gauge should read in the greenzone, after the engine has warmed. If gauge

reads in the red zone, stop the engine until thefault is corrected.

3. Engine Oil Pressure Gauge - This gaugeshould read in the lower end of the green zone atnormal operating speeds and may fall to the lowerend of the yellow zone at engine idle. Stop theengine if the needle does not rise above the redzone until the fault is corrected.

4. Fuel Gauge - Indicates the level in the fueltank. Fill the tank before parking the machine

overnight to minimize condensation in the tank.Avoid a dry tank condition which requires

bleeding the fuel system.5. Transmission Oil PressureGauge - Indicates transmission clutch applicationoil pressure. The reading will vary during shiftsand with varying speeds and loads. The needleshould remain in the green zone during normal

operation but might rise into the upper red zonefor short periods under heavy loading. When theload decreases, the needle should return to thegreen zone and may fall momentarily into the

lower red zone. If the needle remains in either ofthe extreme zones for extended periods, stop themachine until the fault is corrected.

6. Transmission Oil Temperature Gauge - This

gauge should read in the green zone duringnormal operation. Refer also to 'GeneralTransmission Operation' on page 3-35 and'Retarder' section on page 3-18 for variations fromnormal.

7. Speedometer/Odometer -Driven by a signal

from the CEC, the speedometer indicates travelspeed in kilometres per hour and miles per hour.A digital odometer is incorporated in the

speedometer to record the distance travelled bythe vehicle at any given time.

1388

0

10

3020

40

km/h

50

MPH20

20

20

20

OIL TEMP

TRANS50 150

120140

OIL PRESSTRANS

P

1 2

5

7

6


47/1423-7


HAZARD 50%(0)

1 2 3 4 5 6

1163 Left Hand Panel

Switches

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

indicators flash simultaneously as hazard warning lights. The light inthe switch and direction indicator warning light on the right hand dashpanel will flash. To switch hazard lights off; press the top of theswitch.

2. Position not used.



5. Front Brake Pressure Reduction (Optional) -Press bottom ofswitch to give a 50% reduction in front brake pressure. The lowerfront pressure reduces the risk of wheel lockup in slippery conditions.To return to full front brake pressure; press the top of the switch.

6. Retarder Selection Switch - Allows the operator to select which

retarder is employed when using the retarder control lever.Pressed at top = Disc BrakePressed at bottom = Transmission

7. Sidelight and Headlight - Press bottom of switch to the firstposition to operate side, tail and panel lights. The lights in the otherswitches will illuminate. Press switch to the second position tooperate the headlights. To switch lights off; press the top of theswitch.


9. Warning Light Test Switch - Pressing the switch with the ignitionswitched on will illuminate warning lights 1, 2, 3, 4, 5, 9, 10, 11, 17,18, 20, 22 and 23 and the buzzer will sound, to provide a bulb andsystem check. Refer to 'Warning Lights' section on pages 4, 5 and 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' lightswill illuminate and stay on. If active codes are recorded the 'Stop','Warning' and 'Fluid' lights will illuminate momentarily. The yellow'Warning' and red 'Stop' lights will begin to flash the code of 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 enginemalfunction and the light will go out when the switch is pressed'OFF'.

11. Diagnostic Search Switch -When the engine is in diagnostic

mode this switch is used to search through a list of fault codes, ie.pressing the top of the switch momentarily will advance to the next

active fault code, pressing the bottom of the switch will go back to theprevious code.

1478 Right Hand Panel

TEST

7 8 9 10 11 12


48/1423-8


On machines which have a Low Idle Adjustment feature, this switchcan also be used to increase or decrease (in increments of 25 RPM)

the idle or intermediate speed of the engine.


13. Manual Mode Switch -Allows the service technician to changethe operation of the transmission from automatic to manual.

Automatic - Normal operation.Manual - Service Functions.

14. Mode Selection Switch -Allows the service technician to selectbetween the transmission 'POWER' and 'ECONOMY' shiftschedules.

15. Ignition and Starter Key Switch -The combined switch

operates the ignition and starter motor. The key can only bewithdrawn from position '0'.

'0' -Ignition switched off. Disconnects the batteries making allelectrical systems inoperative (with the exception of a supply to theECM & CEC memory, interior light and to the radio). This positionalso cuts off fuel to shut down the engine.

'1' -Turn key clockwise to connect the batteries to the electricalsystems.

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

register as appropriate. All electrical systems are operative. The keymust remain in this position whilst operating the machine.

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

16. Remote Diagnostic Test Point -(Located under the dash panel,on the steering column mounting bracket). Plug in connector fordiagnostic data reader (DDR).

17. Electric Window Switch - Press bottom of switch to lowerwindow; press top of switch to raise window.

VIEW ON FRONT OF INTERFACE BOX

1479

MANUAL AUTO POWER ECONOMY

1413

0

1

2

3

1031 15

1397 16

17

1174


49/1423-9


Controls

Headlight Dipper, Direction Indicator, Windscreen Wiper/Washerand Horn

1. Headlight Dipper and Flasher: Control downwards = MainBeam

Neutral Position= Dipped BeamControl Upwards = Headlight Flash

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

3. Windscreen Wiper/Washer:

Position J = Not usedPosition 0 = Neutral Position

Position 1 = Wiper Slow Speed

Position 2 = Wiper Fast SpeedRing Pushed= Windscreen Wash

4. Horn:Button pushed in = Horn Sounds

340 1

341 2

342 3

343 44444

Heater

Blower control (2) is rotated to select one of three blower speeds.

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

Heater/air conditioner outlets (4) may be adjusted to control air flowoutput by opening and closing the control flaps. Air direction can beadjusted by rotating complete outlet.

Air Conditioner

Keep all windows and vents closed.

Blower control (2) is rotated to select one of three blower speeds.The air conditioning will not operate if the blower control is notswitched on.

Temperature control (3) adjusts the air conditioner outputtemperature. Rotating the control to the right provides maximumcooling.

Heater/air conditioner outlets (4) may be adjusted to control air flow

output by opening and closing the control flaps. Air direction can beadjusted by rotating complete outlet.

Air Condition Commissioning Procedure

If the machine has been idle overnight or for an extended period of

time, the refrigerant in the air conditioning unit converts from a gas toa liquid. This puts the compressor unit is under a great deal of straintrying to compress a liquid instead of a gas and could cause a failurein the air conditioning unit. The following commissioning procedureallows the air conditioning unit to achieve normal operating

1 23

1 2 3

1105

1389

4 4 4


50/1423-10


parameters.

1. Start the machine and allow it to run until the engine is at a normaloperating temperature of 80C (176F)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.

Operator's Seat - Air Suspension

The air seat only reacts when the driver sits on the seat. Whenunoccupied the seat sinks to the lowest position to allow easier access.The incorporated suspension block out maintains seat in position fordriving.

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

1. Height and slope adjustment, front.

2. Height and slope adjustment, rear.

3.Backrest adjustment.

4.Horizontal adjustment.

5.Weight adjustment

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

6

1

2

4

3

5

1650


51/1423-11


WARNINGDo not attempt to adjust the seat or seat belt while themachine is moving. Loss of control may result. Stop themachine; apply the brakes; then adjust.

Seat Belt

A 4-Point integrated Harness is installed on the operators seat. Theoperators 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 beltrequires no external adjustment. Both belts allow freedom ofmovement for proper manipulation of all controls.

WARNINGSAlways wear seat belt when operating the machine.Always check condition of seat belts and mounting hardwarebefore operating the machine.Any signs of looseness or wear should be reported to your

Service Department or Dealer for repair or replacementimmediately.Replace seat belt at least once every three years, regardlessof appearance.Do not attempt to adjust seat or seat belt while machine is

moving.Loss of control may result. Stop machine; apply brakes; thenadjust.

1657 Operators Seatbelt

1656 Pasenger Seatbelt

Trainer / Instructor SeatThe trainer / instructor seat has only to be used when operatortraining or instruction is being performed or for service personnelperforming service diagnostics.

Note: The trainer / instructor seat is NOT for continuous passenger

use.


52/1423-12


MACHINE CONTROLS

Braking

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

A 'Front Brake Accumulator' warning light and a 'Rear BrakeAccumulator' warning light are located on the instrument panel. If any

of these lights illuminate during operation, stop the machine, applythe 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 thepedal as required by speed, load and road conditions to slow or stopthe machine. Release the pedal as the machine slows until, whenstopped, the pedal is depressed just enough to hold it stationary.

Park/Emergency Brake

Pushing the control in will apply the spring operated parking brakeswithin the rear brake assemblies and the service brakes at allwheels. The parking brake warning light on the instrument panel willilluminate when the control is pushed in. To release the brakes; turnthe control clockwise.

The Park/Emergency Brake Control should only be used to stop themachine in an emergency, or, for applying the parking brake once

the machine has been stopped. For normal braking the service brakepedal should be employed.

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

251

1106


53/1423-13


1480

WARNING

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

1

2

3

4

5

D

N

R1

R2

1

2

Retarder

This 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.

The retarder is OFF when the lever is fully forward and is APPLIED

as the lever is pulled back. Maximum retardation is obtained whenthe lever is in the fully back position. The retarder may be usedanytime to slow down. If additional braking is required apply theservice brakes. The retarder is not meant for bringing the machine toa halt, or for sudden deceleration - the service brakes should beemployed for this purpose.

When the retarder is applied, the 'Retarder Indicator Light' on theinstrument panel will illuminate and an orange coloured warning light

at the rear of the truck will illuminate to warn following vehicles.

Retardation of this truck may be achieved by using the DISC BRAKE

RETARDER or the TRANSMISSION RETARDER.

Machines fitted with Disc Brake and Transmission Retarders have a'Retarder Selection Switch' (2). This selects which retarder will beemployed when using the retarder control. Pressed at top = DiscBrake, Pressed at bottom = Transmission. Machines which do nothave a transmission retarder fitted do not have the selection switchfitted.

The operator should select the correct gear range to match the siteconditions. Application of the retarder gives the transmissionenhanced retardation through 6th and 5th gears until 4th gear is

attained.

Note:In order to obtain the maximum retardation and cooling effectduring retardation, the engine speed should be maintained as highas possible without exceeding the maximum recommendation.


54/1423-14


Retarder Operation

Before the machine crests the top of a grade and starts down, theoperator should slow the machine with the service brakes and

downshift to the gear range which would be used to ascend thegrade. The retarder should be applied before starting the descent.Machine downgrade speed (with the retarder applied as required) in

the gear range selected should be high enough to keep the engineoperating at governed speed with the throttle closed (operator's footoff the accelerator pedal). This will ensure maximum oil circulationand cooling. If the rate of descent is too slow, the transmission

should be upshifted to the next highest gear range. If the rate ofdescent is too fast, the gear range selected is too high and theoperator must slow the machine by using the service brakes, thendownshift into a lower gear range which will allow a safe descent andefficient retarder operation.

Oil Temperature - Disc Brake

The disc brake hydraulic temperature warning light on the instrumentpanel will illuminate and an electric horn will sound if the oil flowingthrough the disc brake assemblies overheats. If alarm is activated,reduce downgrade travel speed. If the trouble persists, stop themachine and have the fault corrected.

Oil Temperature - Transmission

During normal operation the transmission oil temperature gauge

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


55/1423-15


Engine

Electronic Foot Pedal

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

Note:The electronic controlled engine will override the electronicfoot pedal position until the engine is warmed up to the correct

operating temperature. The engine MUST be started with the foot'OFF' the electronic foot pedal.

QUANTUM Electronic Fuel System

This machine is equipped with the Quantum Electronic Fuel System,an electronic engine control system, which continually monitors theengine and warns the operator when a problem develops. Thesystem also takes action to prevent damage to the engine and,

provides the serviceman with diagnostic capabilities so that problems

can be corrected quickly and easily.

WARNING

Before any welding is done on a machine equipped with theQuantum Electronic Fuel System, disconnect the following inthis order: Battery earth cable, battery supply cable,

alternator earth cables, alternator supply cables,transmission connector, ECM interface harness connector(30 pin RHS), ECM powerharness connector (5 pin RHS) andECM sensor harness connector (30 pin LHS). Turn offignition key switch to isolate the batteries beforedisconnecting any components.

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

255


56/1423-16


1486

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

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

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

STOP

TEST

4

5

6

7

8

3

1,2

8

9

QUANTUM Electronic Fuel System - Description

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

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

3. Electronic Fuel System Injectors -The injector is a lightweight, compact unit that injects

diesel fuel directly into the combustion chamber. The amount of fuel injected and the beginningof injection timing is determined by the ECM. The ECM sends a command pulse whichactivates the injector solenoid.

The injector performs four functions:

a - Creates the high fuel pressure required for efficient injection.

b - Meters and injects the exact amount of fuel required to handle the load.c - Atomizes the fuel for mixing with the air in the combustion chamber.d - Permits continuous fuel flow for component cooling.

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

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


57/1423-17


QUANTUM Electronic Fuel System - Operation

When the 'Stop' light on the dash panel illuminates, the computer hasdetected a major malfunction in the engine that requires immediate

attention. It is the operators responsibility to shut down the engine toavoid serious damage.

The machine is equipped with an engine protection derate system,which records fault codes when an out-of-range conditions is found.The 'Fluid' light illuminates when the engine protection derate system isinitiated. The engine power and speed will be gradually reduceddepending on the level of severity of the out-of-range condition. The'Fluid' light will start to flash if the out-of-range condition continues to

get worse. The operator MUST shut down the engine to avoid seriousdamage.

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

Conditions that will cause the amber 'Fluid' light to come on are; Lowcoolant level, High coolant temperature, Idle validation/throttle pedalswitch mismatch, High intake manifold temperature, Low oil pressureand High fuel rail pressure.

Whenever the 'Stop', 'Warning' or 'Fluid' light comes on, the ElectronicFuel System computer will determine where the problem is and 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 changingengine condition.

A special diagnostic data reader (INSITE) is available that can beplugged into the engine computer memory to extract information relatedto the cause of the problem. Once the malfunction has been corrected,the Electronic Fuel System will return the engine to normal operation.The data reader can now distinguish between active codes and those

stored in the historic code memory (inactive codes). Inactive codes canonly be viewed using the data reader. The fault code recorded in theECM memory will remain until it is erased by a technician.

The operator can check for active faults by turning the ignition keyswitch to the 'OFF' position, switching the diagnostic switch 'ON' and

then turning the ignition key switch to position '1'. If no active faultcodes are recorded, all three ('Stop', 'Warning' & 'Fluid') lights will come

on and stay on. If active codes are recorded, all three lights will comeon momentarily. The yellow ('Warning') and red ('Stop') lights will beginto flash the code of the recorded fault. The fault codes flash in thefollowing sequence: the yellow light flashes once, then there is a pausewhere both lights are off. Then the numbers of the recorded fault codeflash in red. There is a pause between each number. When the numberis done, the yellow light flashes again. e.g. yellow flashes once - pause

- red flashes twice - pause - red flashes three times - pause - red

flashes five times - pause - yellow flashes once, indicates fault code235. The number will repeat in the same sequence until the system isadvanced to the next active fault code or the diagnostic switch isswitched to the 'OFF' position. Refer to 'Electronic Fuel SystemDiagnostic Codes' table for fault code descriptions.


58/1423-18


ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES

Error Code Description Fault Lamp

111 ECM Hardware Internal Failure - Mission disabling Red112 Timing Actuator - Mechanically stuck Red113 Timing Actuator - Component shorted high Yellow114 Timing Actuator - Component shorted low Yellow115 Engine Speed Sensor - Both signals lost Red116 Fuel Timing Pressure Sensor - Component shorted high Red117 Fuel Timing Pressure Sensor - Component shorted low Red118 Fuel Pump Pressure Sensor - Component shorted high Yellow119 Fuel Pump Pressure Sensor - Component shorted low Yellow121 Engine Speed Sensor - One signal lost Yellow122 Intake Manifold 1 - Component high voltage or shorted high Amber123 Intake Manifold 1 - Component low voltage or shorted low Amber131 Throttle Position Sensor - Component shorted high Red132 Throttle Position Sensor - Component shorted low Red135 Oil Pressure Sensor - Component shorted high Amber141 Oil Pressure Sensor - Component shorted low Amber143 Oil Pressure Sensor - Data below normal range Amber144 Engine Coolant Temperature Sensor - Component shorted high Amber145 Engine Coolant Temperature Sensor - Component shorted low Amber146 Engine Coolent Temperature Sensor - Data moderately above normal range Amber151 Engine Coolant Temperature Sensor - Data excessively above normal range Red

153 Intake Manifold 1 Temperature Sensor - Component shorted high Amber154 Intake Manifold 1 Temperature Sensor - Component shorted low Amber155 Intake Manifold 1 Temperature Sensor - Data above normal range Red187 Sensor Supply 2 Circuit - Component Low Voltage or shorted low Amber195 Coolent Level Sensor Circuit 1 - Component High Voltage or shorted high Amber196 Coolent Level Sensor Circuit 1 - Component Low Voltage or shorted low Amber197 Coolent Level Sensor Circuit 1 - Data below normal range, moderate severity Amber221 Ambient Air Pressure Sensor - Component shorted high Amber222 Ambient Air Pressure Sensor - Component shorted low Amber223 Engine Oil Burn Valve Solenoid - Low Voltage or shorted low Amber224 Engine Oil Burn Valve Solenoid - High Voltage orshorted high Amber227 Sensor Supply 2 Circuit - Component High Voltage or shorted high Amber231 Coolant Pressure Sensor - Component shorted high Yellow232 Coolant Pressure Sensor - Component shorted low Yellow233 Coolant Pressure, Engine Protection - Low coolant pressure Amber

234 Engine Speed - Data above normal range Red235 Engine Coolant Level - Data below normal range Red237 External Speed Input (Multiple Unit Synchronization) - Data Incorrect Amber238 Sensor Supply 3 Circuit - Component Low Voltage or shorted low Amber254 Fuel Shutoff Value - Component shorted low Red259 Fuel Shutoff Solenoid - Fuel shutoff valve stuck open Red261 Fuel Temperature, Engine Protection - Fuel temperature high Amber263 Engine Fuel Temperature Sensor 1 Circuit - Component High Voltage or shorted high Amber265 Engine Fuel Temperature Sensor 1 Circuit - Component Low Voltage or shorted low Amber271 Fuel Pump Pressurizing Assembly 1 Circuit Component Low Voltage or shorted low Amber272 Fuel Pump Pressurizing Assembly 1 Circuit Component High Voltage or shorted high Amber285 SAE J1939 Multiplexing PGN Timeout Error - abnormal update rate Amber286 SAE J1939 Multiplexing Configuration Error - Out of calibration Amber316 Fuel Pump Actuator - Component shorted high or low Yellow318 Fuel Pump Flow - Mismatch between estimated and desired pressures Yellow319 Real Time Clock Power Interrupt - Data Erratic, Intermmitant or Incorrect Maint322 Injector Solenoid Driver Cylinder 1 Circuit - Current below normal or open circuit Amber323 Injector Solenoid Driver Cylinder 5 Circuit - Current below normal or open circuit Amber324 Injector Solenoid Driver Cylinder 3 Circuit - Current below normal or open circuit Amber325 Injector Solenoid Driver Cylinder 6 Circuit - Current below normal or open circuit Amber331 Injector Solenoid Driver Cylinder 2 Circuit - Current below normal or open circuit Amber332 Injector Solenoid Driver Cylinder 4 Circuit - Current below normal or open circuit Amber342 ECM Not Calibrated - ECM software mission disabling failure Red343 ECM Hardware Failure - Bad Intelligent Device or Component Amber346 ECM Software - Read/write, checksum error - Non mission disabling Yellow351 Injector Power Supply - Bad Intelligent Device or Component Amber352 Sensor Supply 1 Circuit - Component Low Voltage or shorted low Amber386 Sensor Supply 1 Circuit - Component High Voltage or shorted high Amber415 Oil Pressure Sensor - Data indicates very low oil pressure Red418 Water in Fuel Indicator - Data Valid but only slightly above operating range Maint422 Engine Coolant Level Sensor Signals - Data invalid Yellow

423 Fuel Timing Pressure Sensor - In-range failure Yellow426 SAE J1939 Datalink - Cannot transmit Yellow427 SAE J1939 Not Fast Enough -431 Throttle Position Idle Validation Switch - Invalid Yellow432 Throttle Position Idle Validation Switch - Switch position and throttle percent mismatch Amber441 Battery Voltage, Unswitched - Data below normal engine range (moderately severe) Amber


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442 Battery Voltage, Unswitched - Data above normal engine range (moderately severe) Amber449 Injector Metering Line 1 Pressure Red451 Fuel Pressure Sensor - Component shorted high Amber452 Fuel Pressure Sensor - Component shorted low Amber455 Fuel Control Valve - Component shorted high or open Red467 Timing Fuelling Flow - Mismatch between estimated and desired timing Yellow468 Fuelling Rail Flow - Mismatch between estimated and desired rail pressure Yellow471 Engine Oil Level Low - Maintenance Maint472 Engine Oil Level #2 Low - Maintenance Maint473 Engine Oil Level #2 Low - Warning Yellow487 Start Assit Device - Canister empty (Ether injection) -488 Intake Manifiold 1 Temperature - Data Valid but only slightly above Amber

operating range (moderately severe)489 Transmission Output Shaft Speed - Data Valid but only slightly below Amber

operating range (moderetely severe)511 Fuel Control Valve - Component - shorted low Red514 Fuel Control Valve - Actuator mechanically stuck open Red524 Alternate Droop Switch Fault Yellow527 Auxiliary Input/Output #2 Circuit - Shorted high Yellow529 Auxiliary Input/Output #3 Circuit - Shorted high Yellow551 Idle Validation Circuit - No voltage detected on both off-idle and idle pins Red

546 Fuel Delivery Pressure Sensing Circuit- Component High Voltage or Ambershorted high

547 Fuel Delivery Pressure Sensing Circuit - Component Low Voltage or Ambershorted low

553 Engine Fuelling Pressure Exceeded - Data above normal range Red554 Fuel Pressure Sensor - In-range failure Yellow555 Blowby Pressure, Engine Protection - Blowby pressure high Amber559 Injector Metering Line 1 Pressure - Data Valid but only slightly below Amber

operating range (moderetely severe)611 Engine Hot Shutdown -649 Change Lubricating Oil and Filter -689 Engine Crankshaft Speed/Position - Data Erratic, Intermittant or Incorrect Amber719 Blowby Pressure Sensor - Component shorted high Yellow729 Blowby Pressure Sensor - Component shorted low Yellow731 Engine Speed/Position Camshaft and Crankshaft Misalignment- Amber

Mechanical system not responding or out of adjustment753 Engine Speed Sensor - Engine speed signals do not match Off777 Turbocharger #1 Turbibe Inlet Temperature High - Warning level Yellow

1117 Power Lost with Ignition On - Data Erratic, Intermittant or Incorrect None1357 Engine Oil Level Remote Reservoir - Data Valid but only slightly below Amber

operating range (moderetely severe)1363 Intake Manifold 1 Pressure - Data Valid but only slightly below Maint

operating range (least severe level)1376 Engine Camshaft Speed/Position Sensor - Data Erratic, Intermittant or Incorrect Maint1387 SAE J1939 Engine Commanded Shutdown -1597 Engine Control Module Critical Internal Failure - Bad Intelligent Device Maint

or Component1845 Water in Fuel Injector Sensor Circuit - Component High Voltage or Maint

shorted high1846 Water in Fuel Injector Sensor Circuit - Component Low Voltage or Maint

shorted low1852 Water in Fuel Indicator - Data Valid but only slightly above Amber

operating range (moderately severe)1891 Engine Oil Change Interval Amber1911 Injector Metering Rail 1 Pressure - Data Valid but above normal Amber

operating range (most severe level)2185 Sensor Supply 4 Circuit - Component High Voltage or shorted high Maint2186 Sensor Supply 4 Circuit - Component Low Voltage or shorted low Maint2215 Fuel Pump Delivery Pressure - Data Valid but only slightly below Amber

operating range (moderately severe)2261 Fuel Pump Delivery Pressure - Data Valid but above operating range Maint

(least severe level)2262 Fuel Pump Delivery Pressure - Data Valid but below operating range Maint

(least severe level)2265 Electric Lift Pump for Engine Fuel Supply Circuit - Component High Voltage or Amber

shorted high

2266 Electric Lift Pump for Engine Fuel Supply Circuit - Component Low Voltage or Ambershorted low

2311 Electronic Fuel Injection Control Valve Circuit Amber2321 Engine Crankshaft Speed/Position - Data Erratic, Intermittant or Incorrect -2322 Engine Camshaft Speed/Position Sensor - Data Erratic, Intermittant or Incorrect -

ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES

Error Code Description Fault Lamp


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Steering

The steering wheel position can be adjusted as required for the mostconvenient operating position. To adjust, pull out adjustment lock andtilt steering wheel up or down as desired; release lever to lockadjustment.

The steering system provides full-time hydraulic power with acontinuous-running pump and a pressurized accumulator. Theaccumulator helps maintain a constant flow of hydraulic power tooperate the steering cylinders.

To steer the front wheels, rotate the steering wheel in the desireddirection to the required radius of turn. The front wheels will turn onlyas the steering wheel is turned and at a rate of turning directlyproportional to steering wheel speed. The front wheels will stop andhold position when the steering wheel is stopped. To return the frontwheels to the straight ahead position or to the opposite direction, turn

the steering wheel in the opposite direction.

WARNINGIn the event of loss of steering pump output pressure, a fully-pressurized accumulator provides a maximum of two lock tolock turns of the front wheels. A red warning light on theinstrument panel illuminates and a buzzer sounds when

steering pressure falls below 83 bar (1200 lbf/in). If thiswarning light illuminates, indicating a loss of steering power,the machine must be stopped immediately and no furtheroperation attempted until the fault is corrected.

The accumulator slowly bleeds down after engine shut-off toprevent accidental steering. However, accumulator pressureshould be dissipated after engine shut-off by turning thesteering wheel in both directions to avoid accidental steering

during bleed down.

Improper steering control unit repair or hose connections

can cause sudden and forceful steering wheel movementwhen engine is started. Keep hands off steering wheel whenstarting engine.

1118

1390


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Transmission

This machine is equipped with an CEC (Commercial ElectronicControl) shift system, to operate the transmission. The CEC shift

system continually monitors the transmission and shift systemelectrical components and warns the operator when a problemdevelops. It also takes action to prevent damage to the transmission,

and provides the serviceman with diagnostic capabilities so thatproblems can be corrected quickly and easily.

WARNINGBefore any welding is done on a machine equipped with aCEC shift system, disconnect battery equalizer groundcables, battery cables from terminal posts (ground cable

first), battery equalizer positive cables and electricalconnections at the ECU to avoid damage to electricalcomponents. Turn off ignition key switch to isolate thebatteries before disconnecting any components.

In addition, CEC provides the following systems designed to protectthe operator and mechanical components:

REVERSE INHIBIT - Prevents gear selection if engine is operating atmore than 20% throttle.

HOIST INTERLOCK PRESSURE SWITCH - The ECU will shift thetransmission from Reverse to Neutral if the body control lever is

moved to the 'Raise' position. When this circuit has been activated,moving the transmission shift lever to Neutral, the re-selecting

Reverse, will engage Reverse gear whilst the body is held in the'Raise' position. This feature is only operational in the normalautomatic driving mode, either power or economy. It is not activatedduring the manual mode.

WARNINGThe standard procedure for raising the body must still be

adhered to.


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BODY UP INTERLOCK - When the body is raised, the CEC systemwill only allow the transmission to operate in First gear. This feature

is only operational in the normal automatic driving mode, eitherpower or economy. It is not activated during the manual mode.

PARKING BRAKE INTERLOCK - If the parking brake is applied

while the transmission is in Neutral, the CEC system will prevent ashift out of Neutral to protect the brake components. If the parkingbrake is applied while the transmission is in gear, the parking brake

interlock will not function and normal shifts will occur.

LOCK-IN-GEAR - The lock-in-gear feature is designed to protect thetransmission from damage should wheel spinning or lockup occurdue to poor traction or panic braking. The ECU will delay making ashift for several seconds and then, if the condition fails to correctitself, locks in gear and prevents any further shifting. The Check

Trans warning light will come on. If this occurs, the ECU must bereset before normal operation may be resumed.

To reset the ECU if the transmission has locked in gear because ofwheel spinning or a panic stop, stop the machine, select 'Neutral',apply the parking brake, and shut down the engine. Wait ten

seconds, then restart the engine. Select 'Reverse', then 'Neutral'.The Check Trans warning light should go 'Off'.

COLD WEATHER STARTS - During cold weather starts, if thetransmission temperature is below -24 C (-10 F) the Check Transwarning light will illuminate and the ECU will prevent the transmissionfrom being shifted out of Neutral. Between -24 C (-10 F) and -7 C

(19 F) the light will go out and the ECU will only permit operation inFirst or Reverse gears. Above -7 C (19 F), normal operation will bepermitted.


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7

3

9

1

2

8

5 4

MANUAL AUTO POWER ECONOMY

6

1

2

3

4

5

D

N

R1

R2

1488

1. Electronic Control Unit (ECU)2. Interface Box3. Gear Shift Selector

4. Mode Selection Switch5. Manual Mode Switch6. Manual Mode Warning Light

7. Check Trans Warning Light8. In-converter Indicator Light9. Digital Data Line

VIEW ON FRONT OFINTERFACE BOX

Description and Operation

1. Electronic Control Unit (ECU) -Contains an electronic

microcomputer. The ECU receives information in the form ofelectronic signals from switches and sensors, processes theinformation, and sends electronic signals to the appropriatesolenoids which control the transmission.

2. Interface Box -Contains fuses and relays.

3. Gear Shift Selector - The shift selector is a remote mounted

lever type. The gear shift selector is connected to the ECU by awiring harness. The shift lever has 6 forward ranges and 2 reverse

ranges, as well as a neutral position.

WARNINGDo not allow the vehicle to coast in Neutral. This practice

can result in severe transmission damage.

The shift selector has a single digit LED display, that during normaloperation will display the gear selected (Not gear attained).Diagnostic information can be displayed on the single digit LED

display by pressing the diagnostic display button. There is a holdoverride button that must be pressed when shifting between R, N

and D. The hold override button is released when desired selectorposition is reached. The selector lever can move freely between Dand the number ranges without pressing the hold override button.

Gear Shift Selector966

1

2

3

4

5

D

N

R

MODE

1

R2


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The transmission upshifts and downshifts automatically betweenfirst range and the highest range selected on the range selector in

direct response to throttle position and transmission output speed.

When Reverse is selected the reverse alarm sounds and the reverselight illuminates at the rear of the vehicle. This feature warns

personnel to the immediate rear of the vehicle that the operator hasshifted to reverse.

When drive 'D' is selected, the transmission automatically upshiftsand downshifts through all six forward ranges as required by loadsand travel speeds. Selecting

Operator Hand Book TR45-60 Tier3

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Transcript of Operator Hand Book TR45-60 Tier3