Operator Hand Book TR45-60 Tier3

Operator Handbook
TR45/60 Tier3
TEREX Equipment Limited Operator Handbook
15503109
OHE881/882
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Operator Handbook
TR45/60 Tier3
TEREX Equipment Limited Operator Handbook Re-Order
15503109
OHE881/882
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
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
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TR45/60 Tier3
TEREX Equipment Limited Operator Handbook - Introduction
Operator Handbook
For further information on the subject matter detailed within this operator handbook,
please refer to Terex Equipment Limited Service Manuals and Product Parts Books.
Alternatively, please contact;
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 prior
permission of Customer Support Department - Terex Equipment Limited.
Please refer to TEREX Specification Sheets or consult Factory Representatives to
ensure that information is current.
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ONLY TRAINED PERSONNEL SHOULD BE

ALLOWED TO OPERATE THIS VEHICLE
The operator is responsible and must be
familiar with the contents of the Operator's
Handbook and any local regulations prior to
operating this vehicle.
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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.
SPARE PARTS STATEMENT

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 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.
EC DECLARATION OF CONFORMITY
MANUFACTURERS NAME AND FULL ADDRESS
TEREX EQUIPMENT LIMITED,
MOTHERWELL,
SCOTLAND,
ML1 5RY
DESCRIPTION OF MACHINERY
DIRECTIVES COMPLIED WITH
MAKE:
MODEL:
87/404/EEC
89/336/EEC
98/37/EEC
2000/14/EC
TEREX
TR45 RIGID TRUCK
TR60 RIGID TRUCK
UNIT SERIAL NO.
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:

can be maintained.
EC DECLARATION OF CONFORMITY
MANUFACTURERS NAME AND FULL ADDRESS
TEREX EQUIPMENT LIMITED,
MOTHERWELL,
SCOTLAND,
ML1 5RY
DESCRIPTION OF MACHINERY
DIRECTIVES COMPLIED WITH
MAKE:
MODEL:
87/404/EEC
89/336/EEC
98/37/EEC
2000/14/EC
TEREX
TR45 RIGID TRUCK
TR60 RIGID TRUCK
UNIT SERIAL NO.
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:

can be maintained.
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
Decals and Instruction Plates
2-4
2-5
2-5
2-6
2-7
2-8
2-8
2-8
2-10
2-10
2-13
2-13
2-14
3. CONTROLS AND OPERATING

Controls and Instruments
Basic Data
Warning Lights
Instruments
Switches
Controls
Heater
Air Conditioner
Operator's Seat Air Suspension
Seat Belt
Machine Controls ..............
Braking ............................
Service Brake ................
Park/Emergency Brake .
Retarder ........................
Engine .............................
Electronic Foot Control ..
Quantum Fuel System ...
Description ....................
Operation.......................
Steering ...........................
Transmission ...................
Description and Operation
General Operation .........
Body Control ...................
Raising the Body ...........
Lowering the Body.........
3-3
3-4
3-4
3-7
3-9
3-12
3-13
3-13
3-14
3-15
3-16
3-16
3-16
3-16
3-17
3-19
3-19
3-19
3-21
3-22
3-26
3-27
3-30
3-35
3-39
3-40
3-40
1-1
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1-2
4. OPERATING THE TRUCK

Pre-Starting Inspection
Component Checks
Suspension Ride Struts
Engine Operation
Starting the Engine
Starting the Engine with
Jumper Cables
Pre-Operating Checks
Brake Function Checks
Driving and Stopping
Stopping the Engine
Parking
4-2
4-3
4-5
4-6
4-7
4-9
4-10
4-10
4-12
4-14
4-16
5. WORKING THE TRUCK

Working the Truck
Loading
Hauling
Dumping
Empty Return
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. MOVING DISABLED TRUCK

Moving Disabled Truck
7-2
8. LUBRICATION AND SERVICING

Safety Precautions
Lubrication and Service Chart
Miscellaneous Servicing
Service Capacities
Recommended Lubricants
8-2
8-3
8-5
8-8
8-12
8-13
9. TECHNICAL DATA
Technical Data - TR45
Technical Data - TR60
9-3
9-8
10. SYMBOL IDENTIFICATION

11. TECHNICAL LITERATURE REQUEST FORM
1-3
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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 alert symbol
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
Intended use of machine

This product and its approved attachments are primarily intended to
be used as described in this manual.
Use of this product in any other way is prohibited and contrary to its
intended 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 to
operate it properly.
Information regarding the machine model, code and chassis serial
number is found on the unit serial number plate on the rear right of
the front frame. The machine model and serial number should
always be referenced in any correspondence with your dealer or
factory.
There is a dealer serving every part of the world where these
products are sold. Your dealer is ready to provide you with any
additional information needed and should be consulted for additional
publications for this machine.
Theft Deterrent Practices
General
The owner/operator should take the following precautions to
discourage 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-vandalism
and
1-6
Introduction
anti-theft devices on the machine.
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
DANGER indicates an imminently hazardous situation which, if

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

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

if not avoided, may result in minor or moderate injury.
CAUTION
CAUTION used without the safety alert symbol indicates an

potentially hazardous situation which, if not avoided, may result in
property damage.
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.
*
Read the AEM Safety Manual and follow the recommended

safety precautions.
Know clearances of all side and overhead obstructions such as

wires, 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 create

on the job. Know proper procedures to follow when a severe rain
or electrical storm strikes.
Never attempt to operate or work on a vehicle when not feeling

physically fit.
Know what safety equipment is required and use it. Such

equipment may be: Hard hat, safety glasses, reflector type vests,
respirators and ear plugs.
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.
Handle fuels and lubricants carefully and clean up spills to

avoid fire and slipping hazards.
Clean any mud, grease or oil from controls, handrails, ladders

and decks. Lash necessary tools securely and remove all loose
items before operating the vehicle. Never rush. Walk, do not run.
Never carry more than one passenger and only in the

passenger seat.
WARNING
The protection offered by the roll over and falling object
protective structure may be impaired if it has been
subjected to any modification or damage. Unauthorized
modification will void certification.
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.
*
The vehicle should be lifted using a spreader bar if possible. Lift

using FOUR slings from the lifting points provided at the bumper
end of the front chassis and at the rear of the body.
Note: Be aware that this vehicle is free to oscillate if not lifted
correctly. If in any doubt contact your dealer for further information.
2054
Vehicle Lifting Instructions
Vehicle Tie Down Precautions

*
The vehicle should be secured at the tie down points located at
the bumper end of the front chassis, the front face of the trailer
chassis and the tow pin at the rear of the trailer chassis.
2055
Vehicle Tie Down Instructions
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).
*
Never use an open flame as a light anywhere on, or around, the

vehicle.
Clean all dirt, oil, grease and other fluids from systems and
components to minimize fire hazards and aid in spotting loose or
leaking lines, fittings etc..
Check the engine compartment for rubbish, oily rags or other

debris that could cause fires before starting the engine.
Dont let greasy, oily rags or similar hazards accumulate in the

cab.
If the vehicle has been operated with an under inflated tyre.

Make sure that the tyre has cooled sufficiently before parking and
leaving the vehicle unattended.
1789
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 checking

fuel, lubricant, coolant and battery fluid levels or when checking for
fluid leaks. Use a flashlight or other safe lighting only.
Shut off engine and use extra caution if engine is hot when
refuelling. Ground the hose spout to prevent sparks when spout is
touched to fuel tank filler tube.
FUEL
Never smoke while checking or adding fuel or other fluids or

handling fluid containers and lines.
Use care and do not stand downwind when adding fuel or other
flammable fluids to tanks and reservoirs to avoid fluids being
blown or splashed onto clothing.
Close fuel tank shut-off valves, if used, before servicing fuel

system.
When preparing vehicles or components for storage, seal and

tape all openings and close containers tightly to seal in all volatile
inhibitor fluids and compounds used.
2-6
1770
Safety Precautions
Follow manufacturers recommendations when handling and

using engine-starting fluids and disposing of spent containers. Do
not puncture or burn empty containers. These fluids are explosive
and highly flammable.
Electrical Hazard Precautions

*
Never smoke or allow open flames or sparks near batteries.
*
Leave battery box open when charging batteries in the vehicle

for adequate ventilation of explosive gas (hydrogen) produced.
Always disconnect batteries before repairing electrical system to

avoid danger of fire-causing sparks. Disconnect battery ground
cable 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 across

battery posts to avoid sparks at battery posts.
Use jumper cables only as recommended. Improper use can

result in battery explosion or unexpected vehicle motion.
Never operate engine starter for more than 30 seconds and

allow two minutes between long cranking periods for cooling. An
overheated starter could cause a fire.
If electric coolant or lubricant heaters are used, be sure to follow

heater manufacturers recommendations for use to avoid electrical
and/or fire hazards.
1771
Mounting and Dismounting

*
Only use steps and hand holds provided to mount or dismount
the vehicle. Do not grasp steering wheel.
*
Always face the access system and maintain at least three

points 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 the

vehicle.
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 perform 'Pre-Starting Inspection' instructions described

on page 4-X to ensure the vehicle is ready for operation.
Always walk around the vehicle to make sure no-one is working on,
underneath or close to the vehicle before starting the engine or
operating the vehicle.
Adjust, secure and latch the seat and fasten the seat belt before
starting the vehicle.
Sound horn before starting the engine or beginning to move the

vehicle; two blasts for forward and three blasts for reverse.
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.
*
Use jumper cables only as recommended. Improper use can

result in battery explosion or unexpected vehicle motion.
Always obey 'Starting the Engine' instructions described on

page 4-7.
DO NOT
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.
Always make sure all gauges, warning/indicator lights and

controls are working properly before operating the vehicle.
Always perform 'Pre-Operating Checks' described on page 4-10

to ensure the vehicle is ready for operating.
1862
Always wear seat belts when operating the vehicle.
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.
*
Do not operate if exposed personnel enter the immediate work

area.
Sound horn before starting engine or beginning to move the

vehicle; two blasts for forward and three blasts for reverse.
Watch for ground crew and other personnel on foot. Sound

horn as a warning before setting the vehicle in motion and when
approaching ground crew.
1774
Be sure the body is fully down before moving the vehicle.
Always try to face or look in the direction the vehicle is

travelling.
Use extreme caution and turn on lights at night or when fog, dust
or similar hazards limit visibility. Do not overdrive your headlights.
Observe instruments frequently. Report any defects or unusual

noises in the vehicle during operation.
Stay in gear when driving downhill. Do not coast with

transmission in neutral. Select the proper gear and maintain safe
speed with the service brakes or/and retarder. Always maintain
safe speeds for haul road operating conditions for maximum
control. Reduce speed before turning.
In the event of a loss of electric power to the gear shift control,

the transmission will automatically lock in a gear range. If this
occurs, stop the vehicle using the service brakes, apply the parking
brake 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 with

other vehicles. Stop in authorized areas only, except in
emergency.
Brake firmly in one application. Do not FAN the pedal. Never

operate the vehicle if a warning light indicates a fault in the braking
system.
Always give loaded vehicles the right-of-way when your vehicle

is empty.
Always watch for holes, soft edges or other hazards when

backing to dump over a spoil bank.
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.
*
*
Always stay in cab when being loaded.

Always lower the body and shut down the vehicle according to
the procedure under 'Stopping The Engine' described on page 414 before leaving the vehicle unattended. If on a grade wheels
should be blocked.
Roading
*
Match speed to road conditions.
*
Yield the right of way when required. Obey the rules of the
road.
Stay as close to the side of the road as possible. Pass other

equipment only when the road is clear and enough room / space to
pass and reserve power is available.
Stop at appropriate intervals to inspect the vehicle and allow the

tyres to cool. Tyre air pressure will rise during operation. Do not
reduce tyre pressure. Excess speed will cause tyres to heat up.
Reduce your travel speed, not tyre pressure.
Use accessory lights and devices at night or in poor visibility.

Carry a flare kit. Do not overdrive your headlights.

*
Do not allow unauthorized personnel to service or maintain this
vehicle. Study this Operators Handbook and the Maintenance
Manual before starting, operating or servicing this vehicle. Always
follow procedures and safety precautions detailed throughout the
Maintenance Manual.
*
Always attach a 'DO NOT OPERATE' or similar warning sign to

the ignition switch or a prominent control before cleaning,
lubricating or servicing the vehicle.
Never allow anyone to work on the vehicle while it is moving.

Make sure there is no one on the vehicle before working on it.
Do not work under or near an unblocked or unsupported body.

Always use the body safety prop. The body safety prop must only
be used when the body is empty.
Do not work under or near any unblocked or unsupported

linkage, part or vehicle.
2-10
1777
9271069
1863
1780
Body Safety Pins
Safety Precautions
Always install the steering lock bar before making adjustments

or servicing the vehicle with the engine running. Refer to 'General'
safety section.
Always shut down the vehicle according to the procedure under

'Stopping The Engine', described on page 4-14, and turn off the
master switch before cleaning, lubricating or servicing the vehicle
except as called for in this Operators Handbook or the
Maintenance Manual.
Always relieve pressure before servicing any pressurised

system. Follow the procedures and safety precautions detailed in
the relevant Maintenance Manual section.
When changing oil in the engine, transmission and hydraulic

systems, or removing hydraulic lines, remember that the oil may be
hot and can cause burns to unprotected skin.
When working on or around exhaust components, remember

that the components may be hot and can cause burns to
unprotected skin.
Always deflate the tyre before attempting to remove any

embedded objects or removing the tyre and rim assembly from the
vehicle.
Always use a self-attaching chuck with a long airline, and, stand

to one side while the tyre is inflating. Refer to Section 160-0050,
WHEEL RIM AND TYRE in the Maintenance Manual.
Do not work under or near an unblocked or unsupported raised

operators cab. Ensure any lifting devices are adequate for the job
which they are intended.
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
Decals and Instruction Plates
Decals and instruction plates fitted to
vehicles may vary from country to
country to suit local needs. These pages
contain a brief description and the
location of the decals and instruction
plates that may appear on your vehicle.
4, 5
1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Tyre Warning
Accumulator Precautions
Accumulator Charging Instructions
Operating On A Grade Instructions
Vehicle Parking Instructions
Acoustic Foam Precautions
Symbol Identification Chart
Radiator Cap Warning
Radiator Fill Instructions
Air Cleaner Information
Vehicle Overall Height
Steering Wheel Lock
Negative Earth
Battery Cable Warning
Ride Strut Pressure Warning
Alternator Precautions
CEC (ATEC) Welding Warning
Engine Instructions
Body Control Lever Positions
Retarder Positions
CEC (ATEC) Switches
Pre-operating Instructions
Acoustic Foam Precautions
Pre-operating Instructions
Hydraulic Oil Decal
Sight Gauge Plate
Hydraulic Oil Pressure Plate
Anti-Syphon Instructions
Instruction Plate
Hydraulic Oil Level
Instruction Decal
Hydraulic Oil Level
Lubrication Chart
Pressure Test Points
Accumulator Charging
Instructions
Accumulator Precautions
Ride Strut Pressure Warning
Machine Serial Plate
2-14
2, 3
8, 9
15
13, 14
11, 12
10
659
15 16 17
13
14
2, 3, 4, 5, 6, 7
13
18
12
11
1
10
25
660
24
14
22, 23
20, 21 19
Safety Precautions
Pictorial Decal Set
O
15335731
Transmission Retarder
(1934)
I.D
kg
TR35
57 760 lb ( 26 200 kg )
TR40
85 800 lb ( 39 000 kg )
TR45
89 100 lb ( 40 500 kg )
TR60
101 200 lb ( 46 000 kg )
TR70
116 850 lb ( 53 000 kg )
TR100
159 500 lb ( 72 500 kg )
15318940
Transmission Retarder
Lever Control (1961)
15335732
15335767
Body Control (1897)
Safety Lift Instruction (1900)
P
15335737
Diagnostic Pressure
Points (1903)
9361787
Battery Earth
(1798)
100%
50%
15335734
50% Front Brake

Reduction (1898)
15335735
Diagnostic Pressure
Points (1901)
15335768
Diagnostic Pressure Points (1905)

TOP
15245918
15335763
Hydraulic Oil Level

(1963)
Diagnostic Pressure
Points (1902)
15335742
Diagnostic Prssure
Points (1899)
15335733
Hydraulic Oil Level

(1962)
Hand Lamp (1964)
P
15335738
Diagnostic Pressure Points (1904)
2-15
Safety Precautions
Pictorial Decal Set
TR35
TR40
TR45
TR60
TR70
TR100
3.68m
4.17m
4.24m
4.45m
4.57m
4.85m
( 12' 8" )
( 13' 8" )
( 13' 11" )
( 14' 7" )
( 15' 0" )
( 15' 11" )
K60
K14
TV
K39
P
C. E. C. 2
V. I. M.
AUTO
K23
K52
(AUX)
F44
(10A)
Vehicle Height (1965)

K23
(AUX)
15303454
K23
K17
K14
K17
R
MANUAL
MANUAL
POWER
K20
K20
ECON
K23
15330961
CEC2 Vehicle Interface Module (1967)
15323142
F45 F44 F43 F42 F41 F40

(5A) (10A) (15A) (10A) (10A) (15A)
K59
F40
15A
K23
F41
5A
K23
F42
5A
F43
15A
K59
F40
15A
K23
F44
15A
TR35
V. I. P. M.
K23
K59
K23
F41
F42
F43
F44
TR70 TR70 TR70 TR70

15A
15A
15A
15A
TR100 TR100 TR100 TR100
20A
20A
20A
20A
K23
K23
F45
15A
F46
15A
K23
K23
15319979
K14
K48
K52
15331024
K25
Power Module (1969)
Power Module (1968)
Vehicle Interface and

Power Module (1966)
Safety Decal Set ISO Standard
15335785
Hydraulic Oil Sight

Gauge (1906)
15334774
Welding Notice, See handbook for

welding procedure (1830)
N
15334772
Nitrogen Filled Tyres, Use nitrogen

only to fill (1886)
2-16
15335864
Backalarm Warning, Operator

must make certain back alarm is
operating properly (1923)
15335749
Crush Hazard, Install support

before servicing (1908)
Safety Precautions
KPH
MPH
KPH
MPH
55
34
55
34
30
17
54
33
10
15
10
34
21
15
1L
15
28
17
20
1L
20
22
14
25
1C
25
15
30
1C
0.3
30
1L
10
5
15335771
Gradeability Chart (1910)
15334764
Read And Understand Operator

Handbook (1878)
15335789
Caution Cab Foam, Do not weld or burn cab

structure unless foam is removed (1921)
15334767
Burn Hazard, allow to cool before

opening (1881)
0
PSI / BAR
N2
15334759
Accumulator Warning, Maintain nitrogen

precharge for proper operation (1875)
15334765
Entanglement Warning, Stop engine

before servicing (1879)
1.
2.
N
15334761
Crush Hazard Warning, Apply park

brake, Shift to neutral (1876)
2-17
Safety Precautions
Blank Page
2-18
Controls and Operating
3 - Controls and Operating
3-1
Blank Page
3-2

CONTROLS AND INSTRUMENTS
1
5 6
7 8
10 11
12 13
14
20
32
31
25 24 23
26
30
22
15
16
19
21
35
33
29
34
18
28
27
17
1477
1. Face Vent/Side Window Demister
21.Ignition and Starter Key Switch
2. Warning Lights
22.Switches
3. Tachometer/Hourmeter
23.Blower Control
4. Engine Water Temperature Gauge
24.Air Conditioner Control
5. Engine Oil Pressure Gauge
25.Heater Control
6. Fuel Gauge
26.Accessory Lamp Socket
7. Warning Lights
27.Accelerator Control
8. Transmission Oil Pressure Gauge
28.Service Brake Control
9. Transmission Oil Temperature Gauge
29.Steering Wheel
10.Speedometer/Odometer
30.Steering Wheel Adjustment Lock
11.Warning Lights
12.Face Vent
31.Headlight Dipper, Direction IndicatoR,

Windscreen Wiper/Washer and Horn Control
13.Park/Emergency Brake Control
32.Radio/Cassette Player
14.Cup Location
33.Foot Rest
15.Windscreen Demister
34.Body Control Lever
16.Side Window Demister
35.Electric Window Switch
17.Document Holder
36.Interior Light (Not Shown). Located above

dash.
18.Fuse Box Cover

19.Transmission Gear Shift Selector
37.Cup Holder (Not Shown). Located on back

wall.
20.Retarder Control
3-3

BASIC DATA
9
10
11
12
15
16
21
13
2
STOP
14
17
18
23
19
20
1628
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. Front Brake Accumulator Pressure (Red) - Illuminates to warn
of low pressure in the front brakesystem accumulator. Stop the
machine if this light illuminates and do not operate until the fault is
corrected.
3-4
22
24
Warning Lights (continued)

10. Rear Brake Accumulator Pressure (Red) - Illuminates to warn
of low pressure in the rear brake system accumulator. Stop the
machine if this light illuminates and do not operate until the fault is
corrected.
11. Low Steering Pressure (Red) - Illuminates when the steering
system oil pressure drops below 83 bar (1200 lbf/in). Stop the
machine when this light illuminates and do not operate until the fault
is corrected.
12. Steering & Braking Tank Low Oil Level (Red) - Illuminates
when the level in the tank falls below the safe operating level. Stop
the machine when this light illuminates and do not operate until the
fault is corrected.
13. Parking Brake (Red) - Illuminates when the parking brake is
applied.
14. Headlight Main Beam (Blue) - Illuminates when headlights are
operated on main beam.
15. Direction Indicator (Green) - Flashes when the indicator lights
are operating.
16. Body-up (Amber) - Illuminates to indicate that the body is NOT
resting on the chassis. Never move the machine until this light goes
OUT.
17. Transmission Oil Temperature (Red) - Illuminates when the
transmission 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 transmission
to the range that will maintain an engine speed as high as possible,
without exceeding the maximum recommendation, to increase oil
circulation and cooling. If the trouble persists, stop the machine and
have the fault corrected.
19. Retarder Indicator (Amber) - Illuminates when the retarder is
applied.
20. In-converter Indicator (Green) - Illuminates when the
transmission is in Torque Converter drive. It goes OUT when Lockup
is engaged.
21. Check Trans (Red) - Illuminates to alert of a fault in the
transmission 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 a
few seconds after the engine is started.
22. Steering Filter Restriction (Amber) - Illuminates when the filter
is 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 is
illuminated.
24. Transmission Overspeed Light - Illuminates when the
transmission ECU senses transmission speed above 2350 rev/min.
3-5

Instruments
1. Tachometer/Hourmeter - Driven from the
engine ECM, the tachometer indicates the engine
speed in revolutions per minute. The needle
shows the variations in engine operating speed.
Never accelerate the engine to speeds indicated
by the red zone on the dial face. A digital
hourmeter is incorporated in the tachometer to
record total hours of engine operation. The
readings can be used for operating and service
records.
2. Engine Water Temperature
Gauge - This gauge should read in the green
zone, after the engine has warmed. If gauge
reads in the red zone, stop the engine until the
fault is corrected.
15
10
RPM x100
20
25
30
STOP
OIL
ENG
PRESS
ENG
TEMP
WATER
1387
3. Engine Oil Pressure Gauge - This gauge

should read in the lower end of the green zone at
normal operating speeds and may fall to the lower
end of the yellow zone at engine idle. Stop the
engine if the needle does not rise above the red
zone until the fault is corrected.
4. Fuel Gauge - Indicates the level in the fuel
tank. 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 Pressure
Gauge - Indicates transmission clutch application
oil pressure. The reading will vary during shifts
and with varying speeds and loads. The needle
should remain in the green zone during normal
operation but might rise into the upper red zone
for short periods under heavy loading. When the
load decreases, the needle should return to the
green zone and may fall momentarily into the
lower red zone. If the needle remains in either of
the extreme zones for extended periods, stop the
machine until the fault is corrected.
6. Transmission Oil Temperature Gauge - This
gauge should read in the green zone during
normal operation. Refer also to 'General
Transmission Operation' on page 3-35 and
'Retarder' section on page 3-18 for variations from
normal.
7. Speedometer/Odometer - Driven by a signal
from the CEC, the speedometer indicates travel
speed in kilometres per hour and miles per hour.
A digital odometer is incorporated in the
speedometer to record the distance travelled by
the vehicle at any given time.
3-6
20
20
10
20
km/h
20
OIL
30
20
MPH
40
50
TRANS
PRESS
7
120
50
TRANS
OIL
1388
140
150
TEMP

Switches
1. Hazard Warning Lights - Press bottom of switch to make turn
indicators flash simultaneously as hazard warning lights. The light in
the switch and direction indicator warning light on the right hand dash
panel will flash. To switch hazard lights off; press the top of the
switch.
2. Position not used.
(0)
50%
HAZARD
Left Hand Panel
1163

5. Front Brake Pressure Reduction (Optional) - Press bottom of
switch to give a 50% reduction in front brake pressure. The lower
front 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 Brake
Pressed at bottom = Transmission
7. Sidelight and Headlight - Press bottom of switch to the first
position to operate side, tail and panel lights. The lights in the other
switches will illuminate. Press switch to the second position to
operate the headlights. To switch lights off; press the top of the
switch.
10
11
12
TEST
1478
Right Hand Panel

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'.
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 the
previous code.
3-7

On machines which have a Low Idle Adjustment feature, this switch
can also be used to increase or decrease (in increments of 25 RPM)
the idle or intermediate speed of the engine.
13

13. Manual Mode Switch - Allows the service technician to change
the operation of the transmission from automatic to manual.
Automatic - Normal operation.
Manual - Service Functions.
14
MANUAL AUTO
POWER ECONOMY
VIEW ON FRONT OF INTERFACE BOX

1479
14. Mode Selection Switch - Allows the service technician to select

between the transmission 'POWER' and 'ECONOMY' shift
schedules.
15. Ignition and Starter Key Switch - The combined switch
operates the ignition and starter motor. The key can only be
withdrawn from position '0'.
0
1
'0' - Ignition switched off. Disconnects the batteries making all

electrical systems inoperative (with the exception of a supply to the
ECM & CEC memory, interior light and to the radio). This position
also cuts off fuel to shut down the engine.
'1' - Turn key clockwise to connect the batteries to the electrical
systems.
1031
15
1397
16
'2' - Ignition switched on, instruments, gauges and warning lights

register as appropriate. All electrical systems are operative. The key
must remain in this position whilst operating the machine.
'3' - Starter motor operates. The key when released will return to
position '2'.
16. Remote Diagnostic Test Point - (Located under the dash panel,
on the steering column mounting bracket). Plug in connector for
diagnostic data reader (DDR).
17
17. Electric Window Switch - Press bottom of switch to lower

window; press top of switch to raise window.
1174
3-8

Controls
Headlight Dipper, Direction Indicator, Windscreen Wiper/Washer
and Horn
1. Headlight Dipper and Flasher: Control downwards
Beam
Neutral Position= Dipped Beam
Control Upwards
= Headlight Flash
= Main
340
341
342
343
2. Direction Indicator:
Control rearwards
= Left Indicators
Control forwards
= Right Indicators
3. Windscreen Wiper/Washer:
Position J
= Not used
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
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 fully
anticlockwise and heated by turning clockwise.
Heater/air conditioner outlets (4) may be adjusted to control air flow
output by opening and closing the control flaps. Air direction can be
adjusted by rotating complete outlet.
Air Conditioner
Keep all windows and vents closed.
Blower control (2) is rotated to select one of three blower speeds.

The air conditioning will not operate if the blower control is not
switched on.
Temperature control (3) adjusts the air conditioner output
temperature. Rotating the control to the right provides maximum
cooling.
Heater/air conditioner outlets (4) may be adjusted to control air flow
output by opening and closing the control flaps. Air direction can be
adjusted by rotating complete outlet.
1105
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 to
a liquid. This puts the compressor unit is under a great deal of strain
trying to compress a liquid instead of a gas and could cause a failure
in the air conditioning unit. The following commissioning procedure
allows the air conditioning unit to achieve normal operating
1389
3-9

parameters.
1. Start the machine and allow it to run until the engine is at a normal
operating 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.
1
5
2
6
1650
Operator's Seat - Air Suspension

The air seat only reacts when the driver sits on the seat. When
unoccupied the seat sinks to the lowest position to allow easier access.
The incorporated suspension block out maintains seat in position for
driving.
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 the
two air cushions in the back of the seat, to suit the exact shape of the
drivers back.
3-10
WARNING
Do not attempt to adjust the seat or seat belt while the
machine is moving. Loss of control may result. Stop the
machine; apply the brakes; then adjust.
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.
1657
Operators Seatbelt
1656
Pasenger Seatbelt
Trainer / Instructor Seat

The trainer / instructor seat has only to be used when operator
training or instruction is being performed or for service personnel
performing service diagnostics.
Note: The trainer / instructor seat is NOT for continuous passenger
use.
3-11
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.
251
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.
Park/Emergency Brake
Pushing the control in will apply the spring operated parking brakes
within the rear brake assemblies and the service brakes at all
wheels. The parking brake warning light on the instrument panel will
illuminate when the control is pushed in. To release the brakes; turn
the control clockwise.
The Park/Emergency Brake Control should only be used to stop the
machine in an emergency, or, for applying the parking brake once
the machine has been stopped. For normal braking the service brake
pedal should be employed.
WARNING
Always apply the parking brake before leaving the operator's
seat.
3-12
1106

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 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.
1
2
3
4
5
D
N
R1
R2
2
1480
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 be
employed when using the retarder control. Pressed at top = Disc
Brake, Pressed at bottom = Transmission. Machines which do not
have a transmission retarder fitted do not have the selection switch
fitted.
The operator should select the correct gear range to match the site
conditions. Application of the retarder gives the transmission
enhanced retardation through 6th and 5th gears until 4th gear is
attained.
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.
WARNING
Do not use the retarder
for parking the vehicle.
Only use the parkingemergency brake
control for this purpose.
3-13
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
the gear range selected should be high enough to keep the engine
operating at governed speed with the throttle closed (operator's foot
off the accelerator pedal). This will ensure maximum oil circulation
and cooling. If the rate of descent is too slow, the transmission
should be upshifted to the next highest gear range. If the rate of
descent is too fast, the gear range selected is too high and the
operator must slow the machine by using the service brakes, then
downshift into a lower gear range which will allow a safe descent and
efficient retarder operation.
Oil Temperature - Disc Brake

The disc brake hydraulic temperature warning light on the instrument
panel will illuminate and an electric horn will sound if the oil flowing
through the disc brake assemblies overheats. If alarm is activated,
reduce downgrade travel speed. If the trouble persists, stop the
machine and have the fault corrected.
Oil Temperature - Transmission
During normal operation the transmission oil temperature gauge
should read in the green zone. However, during transmission
retarder operation oil temperature can enter the yellow 'RETARDER
ON' zone but should not enter the red zone. Do not allow the
temperature to stay at or near the top of the yellow zone for more
than 3 minutes. Reduce downgrade travel speed to avoid the oil
overheating and possible damage to the transmission.
3-14

Engine
Electronic Foot Pedal
The electronic foot pedal provides an electronic signal to the engine's
fuel control system in proportion to the degree of pedal actuation.
Note: The electronic controlled engine will override the electronic
foot 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.
255
QUANTUM Electronic Fuel System

This machine is equipped with the Quantum Electronic Fuel System,
an electronic engine control system, which continually monitors the
engine and warns the operator when a problem develops. The
system also takes action to prevent damage to the engine and,
provides the serviceman with diagnostic capabilities so that problems
can be corrected quickly and easily.
WARNING
Before any welding is done on a machine equipped with the
Quantum Electronic Fuel System, disconnect the following in
this 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) and
ECM sensor harness connector (30 pin LHS). Turn off
ignition key switch to isolate the batteries before
disconnecting any components.
After welding connect all of the above in the reverse order.
3-15
3
STOP
6
7
TEST
9
1,2
4
1 - Electronic Control Module (ECM)

2 - Programmable Read Only Memory (PROM)
3 - Quantum Fuel System Injectors
4 - Electronic Foot Pedal

5 - 'Stop' Light
6 - 'Warning' Light
7 - 'Fluid' Light
8 - Diagnostic Test Points
9 - Diagnostic Switches
1486
QUANTUM Electronic Fuel System - Description

1. Electronic Control Module (ECM) - Receives electronic inputs from the driver as well as
from sensors that provide information electronically, such as oil pressure and temperature and
intake manifold pressure. This information is used to control both the quantity of fuel injected
and injection timing.
2. Programmable Read Only Memory (PROM) - Located in the ECM and encoded with the
operating software. Additional information is programmed into the EEPROM. This information
controls the horsepower rating, torque curve, maximum engine speed and engine protection
devices. The ECM processes this information and sends electronic signals to the Electronic
Fuel 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 beginning
of injection timing is determined by the ECM. The ECM sends a command pulse which
activates 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 they
will burn out. Before removing injectors, the fuel passages must be blown out to prevent fuel
flow from entering the cylinder head.
3-16

QUANTUM Electronic Fuel System - Operation
When the 'Stop' light on the dash panel illuminates, the computer has
detected a major malfunction in the engine that requires immediate
attention. It is the operators responsibility to shut down the engine to
avoid serious damage.
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 is
initiated. The engine power and speed will be gradually reduced
depending 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 serious
damage.
The engine should not be restarted after it has been shut down after
activation of the engine protection derate system unless the problem
has been diagnosed and corrected.
Conditions that will cause the amber 'Fluid' light to come on are; Low
coolant level, High coolant temperature, Idle validation/throttle pedal
switch mismatch, High intake manifold temperature, Low oil pressure
and High fuel rail pressure.
Whenever the 'Stop', 'Warning' or 'Fluid' light comes on, the Electronic
Fuel 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 changing
engine condition.
A special diagnostic data reader (INSITE) is available that can be
plugged into the engine computer memory to extract information related
to the cause of the problem. Once the malfunction has been corrected,
the 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 can
only be viewed using the data reader. The fault code recorded in the
ECM memory will remain until it is erased by a technician.
The operator can check for active faults by turning the ignition key
switch to the 'OFF' position, switching the diagnostic switch 'ON' and
then turning the ignition key switch to position '1'. If no active fault
codes are recorded, all three ('Stop', 'Warning' & 'Fluid') lights will come
on and stay on. If active codes are recorded, all three lights will come
on momentarily. The yellow ('Warning') and red ('Stop') lights will begin
to flash the code of the recorded fault. The fault codes flash in the
following sequence: the yellow light flashes once, then there is a pause
where both lights are off. Then the numbers of the recorded fault code
flash in red. There is a pause between each number. When the number
is 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 code
235. The number will repeat in the same sequence until the system is
advanced to the next active fault code or the diagnostic switch is
switched to the 'OFF' position. Refer to 'Electronic Fuel System
Diagnostic Codes' table for fault code descriptions.
3-17
ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES

Error Code
111
112
113
114
115
116
117
118
119
121
122
123
131
132
135
141
143
144
145
146
151
153
154
155
187
195
196
197
221
222
223
224
227
231
232
233
234
235
237
238
254
259
261
263
265
271
272
285
286
316
318
319
322
323
324
325
331
332
342
343
346
351
352
386
415
418
422
423
426
427
431
432
441
3-18
Description
ECM Hardware Internal Failure - Mission disabling
Timing Actuator - Mechanically stuck
Timing Actuator - Component shorted high
Timing Actuator - Component shorted low
Engine Speed Sensor - Both signals lost
Fuel Timing Pressure Sensor - Component shorted high
Fuel Timing Pressure Sensor - Component shorted low
Fuel Pump Pressure Sensor - Component shorted high
Fuel Pump Pressure Sensor - Component shorted low
Engine Speed Sensor - One signal lost
Intake Manifold 1 - Component high voltage or shorted high
Intake Manifold 1 - Component low voltage or shorted low
Throttle Position Sensor - Component shorted high
Throttle Position Sensor - Component 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
Engine Coolent Temperature Sensor - Data moderately above normal range
Engine Coolant Temperature Sensor - Data excessively above normal range
Intake Manifold 1 Temperature Sensor - Component shorted high
Intake Manifold 1 Temperature Sensor - Component shorted low
Intake Manifold 1 Temperature Sensor - Data above normal range
Sensor Supply 2 Circuit - Component Low Voltage or shorted low
Coolent Level Sensor Circuit 1 - Component High Voltage or shorted high
Coolent Level Sensor Circuit 1 - Component Low Voltage or shorted low
Coolent Level Sensor Circuit 1 - Data below normal range, moderate severity
Ambient Air Pressure Sensor - Component shorted high
Ambient Air Pressure Sensor - Component shorted low
Engine Oil Burn Valve Solenoid - Low Voltage or shorted low
Engine Oil Burn Valve Solenoid - High Voltage orshorted high
Sensor Supply 2 Circuit - Component High Voltage or shorted high
Coolant Pressure Sensor - Component shorted high
Coolant Pressure Sensor - Component shorted low
Coolant Pressure, Engine Protection - Low coolant pressure
Engine Speed - Data above normal range
Engine Coolant Level - Data below normal range
External Speed Input (Multiple Unit Synchronization) - Data Incorrect
Fuel Shutoff Value - Component shorted low
Fuel Shutoff Solenoid - Fuel shutoff valve stuck open
Fuel Temperature, Engine Protection - Fuel temperature high
Engine Fuel Temperature Sensor 1 Circuit - Component High Voltage or shorted high
Engine Fuel Temperature Sensor 1 Circuit - Component Low Voltage or shorted low
Fuel Pump Pressurizing Assembly 1 Circuit Component Low Voltage or shorted low
Fuel Pump Pressurizing Assembly 1 Circuit Component High Voltage or shorted high
SAE J1939 Multiplexing PGN Timeout Error - abnormal update rate
SAE J1939 Multiplexing Configuration Error - Out of calibration
Fuel Pump Actuator - Component shorted high or low
Fuel Pump Flow - Mismatch between estimated and desired pressures
Real Time Clock Power Interrupt - Data Erratic, Intermmitant or Incorrect
Injector Solenoid Driver Cylinder 1 Circuit - Current below normal or open circuit
ECM Not Calibrated - ECM software mission disabling failure
ECM Hardware Failure - Bad Intelligent Device or Component
ECM Software - Read/write, checksum error - Non mission disabling
Injector Power Supply - Bad Intelligent Device or Component
Oil Pressure Sensor - Data indicates very low oil pressure
Water in Fuel Indicator - Data Valid but only slightly above operating range
Engine Coolant Level Sensor Signals - Data invalid
Fuel Timing Pressure Sensor - In-range failure
SAE J1939 Datalink - Cannot transmit
SAE J1939 Not Fast Enough
Throttle Position Idle Validation Switch - Invalid
Throttle Position Idle Validation Switch - Switch position and throttle percent mismatch
Battery Voltage, Unswitched - Data below normal engine range (moderately severe)
Fault Lamp
Red
Red
Yellow
Yellow
Red
Red
Red
Yellow
Yellow
Yellow
Amber
Amber
Red
Red
Amber
Amber
Amber
Amber
Amber
Amber
Red
Amber
Amber
Red
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Yellow
Yellow
Amber
Red
Red
Amber
Amber
Red
Red
Amber
Amber
Amber
Amber
Amber
Amber
Amber
Yellow
Yellow
Maint
Amber
Amber
Amber
Amber
Amber
Amber
Red
Amber
Yellow
Amber
Amber
Amber
Red
Maint
Yellow
Yellow
Yellow
Yellow
Amber
Amber
ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES

Error Code Description
442
449
451
452
455
467
468
471
472
473
487
488
489
511
514
524
527
529
551
546
547
553
554
555
559
611
649
689
719
729
731
753
777
1117
1357
1363
1376
1387
1597
1845
1846
1852
1891
1911
2185
2186
2215
2261
2262
2265
2266
2311
2321
2322
Battery Voltage, Unswitched - Data above normal engine range (moderately severe)
Injector Metering Line 1 Pressure
Fuel Pressure Sensor - Component shorted high
Fuel Pressure Sensor - Component shorted low
Fuel Control Valve - Component shorted high or open
Timing Fuelling Flow - Mismatch between estimated and desired timing
Fuelling Rail Flow - Mismatch between estimated and desired rail pressure
Engine Oil Level Low - Maintenance
Engine Oil Level #2 Low - Maintenance
Engine Oil Level #2 Low - Warning
Start Assit Device - Canister empty (Ether injection)
Intake Manifiold 1 Temperature - Data Valid but only slightly above
operating range (moderately severe)
Transmission Output Shaft Speed - Data Valid but only slightly below
operating range (moderetely severe)
Fuel Control Valve - Component - shorted low
Fuel Control Valve - Actuator mechanically stuck open
Alternate Droop Switch Fault
Auxiliary Input/Output #2 Circuit - Shorted high
Auxiliary Input/Output #3 Circuit - Shorted high
Idle Validation Circuit - No voltage detected on both off-idle and idle pins
Fuel Delivery Pressure Sensing Circuit- Component High Voltage or
shorted high
Fuel Delivery Pressure Sensing Circuit - Component Low Voltage or
shorted low
Engine Fuelling Pressure Exceeded - Data above normal range
Fuel Pressure Sensor - In-range failure
Blowby Pressure, Engine Protection - Blowby pressure high
Injector Metering Line 1 Pressure - Data Valid but only slightly below
Engine Hot Shutdown
Change Lubricating Oil and Filter
Engine Crankshaft Speed/Position - Data Erratic, Intermittant or Incorrect
Blowby Pressure Sensor - Component shorted high
Blowby Pressure Sensor - Component shorted low
Engine Speed/Position Camshaft and Crankshaft MisalignmentMechanical system not responding or out of adjustment
Engine Speed Sensor - Engine speed signals do not match
Turbocharger #1 Turbibe Inlet Temperature High - Warning level
Power Lost with Ignition On - Data Erratic, Intermittant or Incorrect
Engine Oil Level Remote Reservoir - Data Valid but only slightly below
Intake Manifold 1 Pressure - Data Valid but only slightly below
operating range (least severe level)
Engine Camshaft Speed/Position Sensor - Data Erratic, Intermittant or Incorrect
SAE J1939 Engine Commanded Shutdown
Engine Control Module Critical Internal Failure - Bad Intelligent Device
or Component
Water in Fuel Injector Sensor Circuit - Component High Voltage or
shorted high
Water in Fuel Injector Sensor Circuit - Component Low Voltage or
shorted low
Water in Fuel Indicator - Data Valid but only slightly above
Engine Oil Change Interval
Injector Metering Rail 1 Pressure - Data Valid but above normal
operating range (most severe level)
Fuel Pump Delivery Pressure - Data Valid but only slightly below
Fuel Pump Delivery Pressure - Data Valid but above operating range
(least severe level)
Fuel Pump Delivery Pressure - Data Valid but below operating range
(least severe level)
Electric Lift Pump for Engine Fuel Supply Circuit - Component High Voltage or
shorted high
Electric Lift Pump for Engine Fuel Supply Circuit - Component Low Voltage or
shorted low
Electronic Fuel Injection Control Valve Circuit
Engine Crankshaft Speed/Position - Data Erratic, Intermittant or Incorrect
Engine Camshaft Speed/Position Sensor - Data Erratic, Intermittant or Incorrect
Fault Lamp
Amber
Red
Amber
Amber
Red
Yellow
Yellow
Maint
Maint
Yellow
Amber
Amber
Red
Red
Yellow
Yellow
Yellow
Red
Amber
Amber
Red
Yellow
Amber
Amber
Amber
Yellow
Yellow
Amber
Off
Yellow
None
Amber
Maint
Maint
Maint
Maint
Maint
Amber
Amber
Amber
Maint
Maint
Amber
Maint
Maint
Amber
Amber
Amber
-
3-19
Steering
The steering wheel position can be adjusted as required for the most
convenient operating position. To adjust, pull out adjustment lock and
tilt steering wheel up or down as desired; release lever to lock
adjustment.
The steering system provides full-time hydraulic power with a
continuous-running pump and a pressurized accumulator. The
accumulator helps maintain a constant flow of hydraulic power to
operate the steering cylinders.
To steer the front wheels, rotate the steering wheel in the desired
direction to the required radius of turn. The front wheels will turn only
as the steering wheel is turned and at a rate of turning directly
proportional to steering wheel speed. The front wheels will stop and
hold position when the steering wheel is stopped. To return the front
wheels to the straight ahead position or to the opposite direction, turn
the steering wheel in the opposite direction.
WARNING
In the event of 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 and a buzzer sounds when
steering pressure falls below 83 bar (1200 lbf/in). If this
warning light illuminates, indicating a loss of steering power,
the machine must be stopped immediately and no further
operation attempted until the fault is corrected.
The accumulator slowly bleeds down after engine shut-off to
prevent accidental steering. However, accumulator pressure
should be dissipated after engine shut-off by turning the
steering 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 movement
when engine is started. Keep hands off steering wheel when
starting engine.
3-20
1118
1390

Transmission
This machine is equipped with an CEC (Commercial Electronic
Control) shift system, to operate the transmission. The CEC shift
system continually monitors the transmission and shift system
electrical components and warns the operator when a problem
develops. It also takes action to prevent damage to the transmission,
and provides the serviceman with diagnostic capabilities so that
problems can be corrected quickly and easily.
WARNING
Before any welding is done on a machine equipped with a
CEC shift system, disconnect battery equalizer ground
cables, battery cables from terminal posts (ground cable
first), battery equalizer positive cables and electrical
connections at the ECU to avoid damage to electrical
components. Turn off ignition key switch to isolate the
batteries before disconnecting any components.
In addition, CEC provides the following systems designed to protect
the operator and mechanical components:
REVERSE INHIBIT - Prevents gear selection if engine is operating at
more than 20% throttle.
HOIST INTERLOCK PRESSURE SWITCH - The ECU will shift the
transmission 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 normal
automatic driving mode, either power or economy. It is not activated
during the manual mode.
WARNING
The standard procedure for raising the body must still be
adhered to.
3-21

BODY UP INTERLOCK - When the body is raised, the CEC system
will only allow the transmission to operate in First gear. This feature
is only operational in the normal automatic driving mode, either
power 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 a
shift out of Neutral to protect the brake components. If the parking
brake 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 the
transmission from damage should wheel spinning or lockup occur
due to poor traction or panic braking. The ECU will delay making a
shift for several seconds and then, if the condition fails to correct
itself, locks in gear and prevents any further shifting. The Check
Trans warning light will come on. If this occurs, the ECU must be
reset before normal operation may be resumed.
To reset the ECU if the transmission has locked in gear because of
wheel 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 the
transmission temperature is below -24 C (-10 F) the Check Trans
warning light will illuminate and the ECU will prevent the transmission
from 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 in
First or Reverse gears. Above -7 C (19 F), normal operation will be
permitted.
3-22
1
2
3
4
5
D
N
R1
R2
VIEW ON FRONT OF
INTERFACE BOX
5 6 4
1
MANUAL AUTO
POWER ECONOMY
2
1. Electronic Control Unit (ECU)
2. Interface Box
3. Gear Shift Selector
4. Mode Selection Switch

5. Manual Mode Switch
6. Manual Mode Warning Light
7. Check Trans Warning Light

8. In-converter Indicator Light
9. Digital Data Line
1488
Description and Operation

1. Electronic Control Unit (ECU) - Contains an electronic
microcomputer. The ECU receives information in the form of
electronic signals from switches and sensors, processes the
information, and sends electronic signals to the appropriate
solenoids 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 a
wiring harness. The shift lever has 6 forward ranges and 2 reverse
ranges, as well as a neutral position.
1
MODE
2
3
4
WARNING
Do not allow the vehicle to coast in Neutral. This practice
can result in severe transmission damage.
5
D
N
R1
R2
The shift selector has a single digit LED display, that during normal
operation 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 hold
override button that must be pressed when shifting between R, N
and D. The hold override button is released when desired selector
position is reached. The selector lever can move freely between D
and the number ranges without pressing the hold override button.
966
Gear Shift Selector
3-23

The transmission upshifts and downshifts automatically between
first 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 reverse
light illuminates at the rear of the vehicle. This feature warns
personnel to the immediate rear of the vehicle that the operator has
shifted to reverse.
1
MODE
2
3
4
5
D
When drive 'D' is selected, the transmission automatically upshifts

and downshifts through all six forward ranges as required by loads
and travel speeds. Selecting a lower range (4th, 3rd etc.) limits the
highest range to which the transmission will automatically upshift.
If a lower range is selected while moving forward, the transmission
automatically downshifts sequential to the selected lower range at
maximum controlled engine speeds. Downshifts will not occur until
vehicle is slowed by use of the service brakes and/or retarder.
When shifting from neutral to start from a standstill, or to reverse
direction, decelerate the engine to idle speed. To move forward,
select drive 'D' and accelerate the engine to the vehicle load and
speed requirements. The transmission will automatically upshift from
1st through 6th ranges as travel speed increases.
With the throttle fully depressed, and the mode selection switch in
the Power position, the transmission upshifts to the next higher range
when the engine attains maximum rated speed, since maximum
power train output is needed under this condition. At lower throttle
settings where minimum power train performance is required, the
transmission will upshift to the next higher range at less than
maximum rated engine speed.
Upgrades or soft spots might slow travel speed, even at full throttle,
requiring transmission downshifts to maintain maximum powertrain
performance. When this occurs, the transmission downshifts
automatically.
Shift the transmission to the next lowest range if transmission
'Hunting' or 'Shift Cycling' occurs.
When temporarily stopped, such as for yielding the right-of-way to a
loaded vehicle, the transmission can be left in the selected range and
the vehicle held stationary with the service brakes.
However, when stopped for a more extended period with the engine
left running, shift the transmission to neutral to avoid unnecessary
heat buildup and apply the parking brake.
WARNING
Always select Neutral and apply the parking brake before
leaving the operators seat.
3-24
N
R1
R2
966
Gear Shift Selector

4. Mode Selection Switch - Gives the option to select between
transmission 'POWER' and 'ECONOMY' shift schedules. The
transmission must be in Neutral before the switch will function.
The transmission torque converter is equipped with a lockup clutch
which, when engaged by the ECU, locks the converter pump and
turbine together as a single unit and allows power to be transmitted
mechanically from the engine directly to the transmission gearing on
a 1 to 1 ratio. When the lockup clutch is disengaged, the torque
converter acts as a fluid coupling, multiplying torque when engine
speed is significantly higher than transmission output shaft speed.
MANUAL AUTO
POWER ECONOMY
1489
When the Mode Selection Switch is in the 'POWER' position, the

ECU controls operation of the lockup clutch according to signals
received by the throttle position sensor (giving engine speed as a
percent of throttle), the transmission output shaft speed sensor, and
range selector. The ECU may delay application of the lockup clutch
and allow torque multiplication by the torque converter to take place
until a balance is achieved between engine speed and transmission
output shaft speed before activating the lockup clutch.
Power versus Economy Mode
The POWER mode is designed for applications involving heavy
loads and hilly duty cycles where performance rather than fuel
economy is of prime importance.
5
The ECONOMY mode is designed for applications involving lighter

loads and level duty cycles or where fuel economy is more important
than performance.
In the ECONOMY mode, the ECU controls operation of the lockup
clutch with a timed, preprogrammed schedule where in Second
through Sixth gears the
lockup clutch is disengaged only long enough to allow the torque
converters fluid coupling to absorb shift shock. Otherwise, the lockup
clutch is engaged and no torque multiplication takes place in Second
through Sixth gears.
MANUAL AUTO
POWER ECONOMY
1490
5. Manual Mode Switch - The manual mode facility is designed as a

Service Technician facility to allow stall checks and clutch pressure
checks to be implemented by Service Personnel, and permit
movement of the vehicle, if necessary, to a repair area. With the
manual mode switch in the 'On' position, the body up interlock and
hoist interlock pressure switch mechanisms are disengaged.
3-25
WARNING
This allows unauthorised selection of reverse or any forward
gear with the body raised, constituting a safety hazard.
Operators must not use the manual mode facility when
working the vehicle! It is recommended that the mode
selection key is removed from the unit and retained in a safe
place until required by Service personnel.
Note: The manual mode can only be used if the mode selection
switch is in the Power position and the transmission is in neutral.
WARNING
Do not operate engine for more than 30 seconds at full
throttle with transmission in gear and output stalled as this
will result in severe overheat damage to the transmission.
WARNING
The manual mode is not intended to be used for normal
operations. The machine should only be driven at very low
speeds in first or reverse gears if the manual mode is
activated, or damage to the transmission may result.
6. Manual Mode Warning Light - This light is located on the front
face of the CEC2 interface box. The Manual Mode Warning Light
illuminates to alert the operator when the transmission has been
switched to operate in the manual mode. The light should be 'Off'
during normal operation.
7. Check Trans Warning Light - Illuminates to alert of a minor fault
in the transmission shift system or abnormal transmission
temperature. The warning light will come 'On' when the ignition
keyswitch is turned to position '1' to provide a bulb and system check
and should go 'Off' a few seconds after the engine is started and the
transmission oil pressure rises.
The check trans warning light will come 'On' during operation if the
ECU has detected a minor fault in an electrical component or
abnormal transmission oil temperature. If transmission oil
temperature is too high, stop the machine, select Neutral (N), and
increase engine speed to allow a greater flow of oil to the oil cooler
until oil temperature drops to normal operating range. In most cases,
a minor fault triggering the check trans warning light will not prevent
normal operation from continuing but, depending on the nature of the
problem, the ECU could take action to protect the transmission from
damage, such as preventing operation in high gear ranges. If the
check trans warning light comes 'On', have the problem diagnosed
and corrected at the earliest opportunity.
3-26
1
2
3
4
5
D
N
R1
R2
1481

8. In-convertor Indicator Light - Illuminates when the transmission
is in torque converter drive. It goes 'Off' when Lockup is engaged. In
order to avoid unnecessary waste of fuel, if traffic or other road
conditions permit, the operator should modify throttle position, or
gear held to achieve a steady road speed with
the torque converter lockup engaged (Indicator Light 'Off'). The
Lockup relay in the interface box is also activated by the 20 bar (290
psi) pressure switch on the foot brake pedal. When this switch is
activated the converter in light will be illuminated due to the
transmission dropping out of converter lock up, avoiding engine stall.
10
1487
9. Digital Data Line - Located in the right hand side of the

transmission control tower. Plug in connector for diagnostic data
reader (DDR).
10. Transmission Overspeed Light - Illuminates when the
transmission ECU senses transmission speed above 2350 rev/min.
GENERAL TRANSMISSION OPERATION
Watch for wide deviations from normal readings on the transmission
oil temperature gauge during machine operation. If the transmission
oil temperature gauge, on vehicles which do not have a transmission
retarder fitted, shows oil temperature consistently rising above the
green zone (43 - 135 C; 100 - 275 F) under normal operating
conditions; check for external causes. If none are evident shift to
Neutral (N) and operate the engine at 1 200 - 1 500 rev/min. If the
transmission oil temperature does not decrease into the green zone
within 2 or 3 minutes, the cause of the overheating should be
corrected before the machine is operated further. Watch the oil
temperature gauge when operating on upgrades, also. If the oil
temperature goes into the red zone (135 - 176 C; 275 - 350 F),
select the range which will limit upshifts to the highest range in which
the transmission will operate within the normal temperature range. If
upshifting must be consistently limited to ranges lower than normal
for the loads and the grades encountered to prevent overheating the
transmission oil, the causes should be determined and corrected. On
vehicles fitted with a transmission retarder, it is permissible to
operate with the gauge showing in the yellow zone, during operation
of the transmission retarder.
3-27
Retrieving Diagnostic Codes

Diagnostic fault codes can be retrieved from the CEC2 system using
the gear shift selector or by plugging in the diagnostic data reader
(DDR). To obtain diagnostic codes using the gear shift selector:
4
- Check transmission warning light on dash will illuminate when ECU

detects a fault.
- Stop truck and select 'Neutral'.
Clearing Diagnostic Codes

- To clear active codes, press and hold mode button (3) for 3 to 5
seconds.
- To clear inactive codes, press and hold mode button (3) for 8 to 10
seconds.
To exit diagnostic mode, press diagnostic button (1). Refer to table
for diagnostic code description.
3-28
N
R1
R2
- Press diagnostic button (1) on gear shift selector. Display (2) on

gear shift selector will flash one digit at a time.
- Active codes are indicated by illumination of the mode light (4).
- To advance to the next code, press the mode button (3). Up to five
codes can be stored.
2
3
- Display starts with code position D1, D2, etc, followed by the two
digit main code, then the two digit subcode.
1
MODE
1580
CEC2 DIAGNOSTIC CODES

Main Code Sub Code
Description
13
12
ECU input voltage low
13
23
ECU input voltage high
21
12
Throttle sensor failed low
21
23
Throttle sensor failed high
22
14
Engine speed sensor
22
15
Turbine speed sensor
22
16
Output speed sensor
23
12
Primary shift selector
23
12
Primary shift selector mode function
23
14
Secondary shift selector
23
15
Secondary shift selector mode function
23
16
Shift selector display line fault
24
12
Sump fluid temperature cold
24
23
Sump fluid temperature hot
25
11
Output speed sensor, zero speed, 1st
25
22
Output speed sensor, zero speed, 2nd
25
33
Output speed sensor, zero speed, 3rd
25
44
Output speed sensor, zero speed, 4th
25
55
25
66
25
77
25
88
26
00
Throttle source not detected
33
12
Sump fluid temperature sensor failed low
33
23
Sump fluid temperature sensor failed high
34
12
Factory calibration compatibility number wrong
34
13
Factory calibration fault
34
14
Power off fault
36
00
Hardware/software not compatible
45
12
General solenoid failure - F
45
13
General solenoid failure - K
45
14
General solenoid failure - B
45
15
General solenoid failure - G
45
16
General solenoid failure - E
45
21
General solenoid failure - H/J
45
22
General solenoid failure - A
45
23
General solenoid failure - D
45
24
General solenoid failure - I
45
26
General solenoid failure - C
46
21
High-side overcurrent, H/J solenoid
46
26
High-side overcurrent, C, D, E solenoid
46
27
High-side overcurrent, A, B, F, G, I, K solenoid
56
11
Range verification ratio test, 1st
56
22
Range verification ratio test, 2nd
56
33
Range verification ratio test, 3rd
56
44
Range verification ratio test, 4th
56
55
56
66
56
77
Range verification ratio test, R1 or 7th
56
88
Range verification ratio test, R2 or 8th
65
00
Engine rating too high
66
00
Serial communications interface
69
27
ECU, inoperative A, B, F, G, I, K solenoid
69
28
ECU, inoperative H/J solenoid
69
29
ECU, inoperative C, D, E solenoid
69
33
ECU, COP fault
69
34
ECU, EEPROM fault
69
35
ECU, EEPROM fault
69
42
SPI output failure
69
43
SPI input failure
34
15
Diagnostic queue fault
34
16
Real time fault
34
17
Customer modifiable constants fault
35
00
Power interruption
35
16
Real time write interruption
Check Trans Light

Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
No
Yes
3-29

Body Control
The lever to the left of the operators seat controls the hydraulic
valve which operates the body hoist cylinders. The four operating
positions of the lever from front to rear are as follows:
'LOWER' - This position provides hydraulic force to power-down the
body. It is needed when the body cannot be started downward from
the fully raised position by gravity. When the body starts lowering by
gravity, the lever should be moved to the 'FLOAT' position.
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
3-30
Raising the Body

Before raising the body, allow the engine to slow to idle, make sure
the rear wheels are on firm level ground, shift the transmission to
Neutral and hold the machine stationary by applying the brakes with
the Parking-Emergency brake control.
Move the body control lever all the way back to the 'RAISE' position
and accelerate the engine. The body can be stopped at any point by
moving the lever to 'HOLD'. Decelerate the engine as the last stages
of the body hoists begin to extend to slow the raising speed as the
hoists approach their maximum extensions.
When the body has been raised to the desired height, move the
control lever to the 'HOLD' position until the body is to be lowered.
Lowering the Body
To lower the body, move the control lever to the 'FLOAT' position to
allow the body's weight to lower it to the frame. Body descent can be
stopped at any position by moving the lever back to the 'HOLD'
position. If the body does not begin to lower by its own weight, such
as after dumping downgrade, move the control lever all the way
forward to the 'LOWER' position and power the body downward until
it begins lowering by gravity. Then move the lever to 'FLOAT' to allow
the body to lower the rest of the way to the chassis.
Make sure that the body is completely lowered and the control lever
is in 'FLOAT' before releasing the brakes and moving the machine.
3-31
Blank Page
3-32
Operating the Truck
4 - Operating the Truck
4-1
Operating the Truck
Blank Page
4-2
Operating the Truck

OPERATING THE TRUCK
Pre-Starting Inspection
* Before the engine is started
ensure the machine is ready for
operation.
* The machine should be in a
level position to permit
accurate checking of fluid
quantities in the engine and
other components.
* Make sure parking brake is
applied and block wheels
securely to prevent accidental
movement of the machine
while checking component
levels.
* Test all lights, warning
signals, controls and
instruments for proper
operation.
RADIATOR AND COOLING

LINES
Check for leaks.
ENGINE
Check oil level. Check for
leaks.
CAB, PLATFORM AND

STEPS
Check for cleanliness. Check
seat belts.
FRONT RIDE CYLINDERS

Check for debris, leaks and
damage. Check height.
BRAKE ACCUMULATORS
Check for leaks.
WHEELS AND TYRES

Check condition, inflation,
nuts and for damaged rims.
TRANSMISSION
Check oil level. Check
for leaks.
RADIATOR HEADER TANK

Check coolant level.
STEERING ACCUMULATOR
Check for leaks.
STEERING AND
BRAKING TANK
leaks.
BODY AND DISC
BRAKE COOLING TANK
leaks.
WHEEL PLANETARIES
Check for leaks.
DISC BRAKE ASSEMBLIES
Check for leaks.
STEERING CYLINDERS
damage. Check lines
for wear and leaks.
FUEL TANK
Check fuel level. Ensure fuel
tank is full. Check that tank is
securely mounted.
BODY CYLINDERS
damage. Check lines for
wear and leaks.
DIFFERENTIAL
Check for leaks.
REAR RIDE CYLINDERS
Check for debris leaks and
damage. Check height.
1492
* Walk around the machine and

carry out the Inspections and
Component Checks described
in the drawing opposite and on
the following pages.
4-3
Operating the Truck

Component Checks
1. Engine - With the engine off, check oil level. The oil level should
be between the lower and upper marks on the dipstick. Add oil if low.
259
037
2. Fuel Filters - Drain sediment and water from sump until fuel runs
clear.
3. Fuel Pre-Filter - Drain sediment and water from filter.
PENDING IMAGE
1864
640
038
041
4. Radiator Header Tank - Check coolant level. Add if low.
WARNING
Press button in centre of cap to bleed pressure before
removing cap completely. Fill to bottom of filler neck.
5. Air Cleaner Vacuator Valve(s) - Check for proper operation.
Clean if required.
6. Tyres - Carefully inspect all tyres for cuts, bruises, or other

damage and proper inflation for the loads to be carried. Inflate all
tyres to the recommended pressure while cold.
4-4
Operating the Truck

7. Fuel Level Gauge - Check fuel level. Tank should be filled at end
of each shift to prevent condensation.
641
8. Body and Disc Brake Cooling Tank - Cold Oil Level - The
bottom sight gauge should show full. Add fluid, if low.
642
643
263
10
472
11
9. Steering and Braking 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.
10. Transmission - Cold Oil Level - This check is made only to

determine if the transmission contains sufficient oil for safe starting.
Make sure there is some oil showing on the sight gauge before
starting the engine. Add oil if low.
11. 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.
4-5
Operating the Truck

Suspension Ride Struts
Suspension ride struts are oiled and charged with nitrogen to ensure optimum ride comfort.
However, ride struts may have been lowered during transportation of the machine. These
struts must be correctly set prior to operating the machine.
The ride struts contain a mixture of nitrogen and oil, so when the struts are lowered, some oil
will be lost along with the nitrogen. Although only a small amount of oil may be lost, this will
still affect the final ride height, so it is important that ride struts contain the correct volume of
oil.
To recharge the ride struts, nitrogen pressures are given in the table below. These pressures
are dependant on oil levels being correct, refer to Section 180, SUSPENSION SYSTEM in
the Maintenance Manual. Use suitable lifting equipment to fully extend ride struts and charge
with nitrogen.
Note: The heights given are intended as reference only, cylinders should always be set
according to pressure. Refer to Section 180, SUSPENSION SYSTEM in the Maintenance
Manual for full details.
Truck
Front Ride Struts - bar (lbf/in2)
Height - mm (in)
Rear Ride Struts - bar (lbf/in2)
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
Operating the Truck

Engine Operation
Note: The electronic controlled engine will override the electronic foot
pedal position until the engine is warmed up to the correct operating
temperature. The engine MUST be started with foot 'OFF' the electronic
foot pedal.
Do not place engine under FULL LOAD at FULL SPEED
IMMEDIATELY after starting. ALWAYS allow the engine to fully
circulate lubricant and warm up gradually before operating at full speed
and full load.
Operate engine at top rated speed when maximum power is needed for
the load.
NEVER idle the engine more than 5 minutes at a time; shut it off.
If any gauge operates outwith its normal operating range or a warning
light illuminates, shut engine down immediately and report to service or
maintenance personnel.
If the 'Stop', 'Warning' and/or 'Fluid' warning lights illuminate, during
operation of the machine, take effective action to stop the engine and
correct the fault, as described under 'Electronic Fuel System Operation, in
Section 3 of this handbook.
WARNING
Never start the engine indoors unless proper exhaust
ventilation is provided to remove deadly exhaust gases. Once
the engine is running, move the machine outdoors as soon as
possible. Exhaust gases are hazardous and can cause
unconsciousness and death.
Operating the engine beyond high idle speed can cause severe
engine damage. The engine speed must not exceed 2 400 rev/
min under any circumstances. When descending a steep grade,
use a combination of transmission gears, retarder and service
brakes to control the vehicle and engine speed.
4-7
Operating the Truck

Starting the Engine
Attention to the warning lights and instruments when starting the
engine, and operating, will help the operator monitor the machine
systems and components.
1. Make sure the park-emergency brake control is in the 'PARK'
position.
1106
2. Insert switch key and turn clockwise to position '1'.
0
1
1044
052
3. Make sure the body control lever is in the 'FLOAT' position.
4. Make sure the transmission shift selector is in the 'NEUTRAL'

position.
1
MODE
2
3
4
5
D
N
R1
R2
1485
314
5. Press horn control to sound horn.

Note: Always sound horn before starting engine or operating any
control.
6. Turn key switch to position '2' to switch on the ignition. Press

warning light test switch to test operation of warning lights.
0
1
2
1045
4-8
Operating the Truck

7. Turn key further clockwise against spring pressure to position '3' to
crank the engine. Release the key as soon as the engine starts firing.
0
1
2
Note: Never crank the engine more than 30 seconds continuously.

Allow starter(s) at least 2 minutes cooling time between cranking
periods to avoid overheating.
1175
8. Check the engine oil pressure gauge. Within 10 to 15 seconds at

engine idle, the gauge needle should rise into the yellow zone. If the
needle does not rise within 15 seconds, shut off the engine and do
not operate until the fault is identified and corrected.
15
10
RPM x100
20
20
10
20
30
20
MPH
20
km/h
20
40
25
0
30
50
1392
9. Observe the engine water temperature gauge. After a few minutes

running time at moderate load and varying speed, the gauge needle
should be in the green zone. If the needle moves into the red zone,
the engine is over heated and should be shut down immediately.
15
10
RPM x100
20
20
10
5
0
30
30
20
MPH
20
km/h
20
40
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.
20
25
STOP
1115
10
4-9
Operating the Truck

Starting the Engine with Jumper Cables
WARNING
Hazardous hydrogen gas and sulphuric acid. Check for
required voltage and polarity connections to discharged
batteries. Excessive booster voltage and/or incorrect jumper
cable connections, open flame, lighted cigar, or other ignition
source can cause battery explosion/fire. Keep all sources of
ignition away from batteries. Do not lean over batteries, and
wear eye protection at all times to prevent personal injury.
Do not jump start a vehicle by using arc welding equipment.
Currents and voltages are dangerously high and cannot be
sufficiently reduced to make the method safe.
Note: Be sure machines are not touching each other. Use cables
that are equal to cable size on the machine, for example (1/0) or (2/
0).
If jumper cables are used to start an engine, be sure to follow this
procedure:
Connect one end of a jumper cable, usually coloured red, to the
discharged battery 'POSITIVE' (+) post. Connect the other end of the
same cable to the 'POSITIVE' (+) post on the booster or charged
battery.
Connect one end of the second cable, usually coloured black, to the
'NEGATIVE' (-) post of the booster battery. Connect the other end of
the 'NEGATIVE' (-) cable to machine frame for grounding so that if a
spark occurs, it is away from battery fumes (explosive hydrogen).
Check for cause of failure on the dead battery.
4-10
Operating the Truck

Pre-Operating Checks
Make sure all cab glass, mirrors and lights are clean. Test all controls
to ensure they are functioning properly. Select 'REVERSE'
momentarily on the transmission shift selector to make sure the
reverse alarm sounds.
1. Transmission - Hot Oil Level - The parking brake must be

applied and the road wheels securely blocked while carrying out this
check. With the engine idling, transmission in 'NEUTRAL' and at
normal operating temperature, the top of the oil column should be
visible in the sight gauge. Add oil if low. If the top of the column is
above the sight gauge, the transmission is overfull and oil should be
drained.
263
647
648
2. Body and Rear Brake Cooling 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
Operating the Truck

BRAKE FUNCTION CHECKS
In addition to the above checks, the following brake function checks
can be carried out to determine if both the service and emergency
brake systems are functional before operating the machine.
WARNING
Make sure the area around the machine is clear of personnel
and obstructions before carrying out these checks.
If the machine moves during these checks, stop the machine,
apply the parking brake and do not operate until the fault is
corrected.
Note: The following checks are NOT intended to measure maximum
brake holding ability. If NEW brake pads are fitted, they MUST be
burnished as per the manufacturers recommendations before
carrying out the checks.
Service Brake Holding Ability Check
Depress the service brake pedal and select 1st gear on the
transmission shift selector. Pull the park/emergency brake control out
to release the brakes. Depress accelerator control and accelerate
engine to 1 350 rev/min. The machine should not move. Decelerate
engine, shift transmission to 'NEUTRAL' and apply the parking brake
before releasing the service brake.
Emergency Brake Holding Ability Check
Depress the service brake pedal, release the park/emergency
brakes, select first gear, apply the park/emergency brakes and
release the service brake pedal. Depress accelerator control and
accelerate engine to 1 350 rev/min. The
machine should not move. Decelerate engine and shift transmission to
'NEUTRAL'.
Note: Brake holding effort required to hold a machine static at a
specific engine speed, can vary from machine to machine due to
differences in engine performance, powertrain efficiency, etc., as well
as differences in brake holding ability.
Note: As an indication of system deterioration, the engine speed at
which point the machine moved, with the service or emergency
brakes applied, can be compared against the engine speed your
machine was able to hold to on a previous check.
4-12
Operating the Truck

Driving and Stopping
Before driving off observe all instruments and warning lights. All
instruments should operate in their normal range and all warning lights
should be out except possibly the Direction Indicator and Headlight
Main Beam warning lights.
Make sure the area around the machine is clear of personnel and
obstructions before driving off.
In the first few minutes of travel, check carefully for the required
steering, braking, engine and transmission power response for
maximum operating safety.
1. Make sure the body is fully down and body control lever is in the
'FLOAT' position.
052
273
2. Apply the service brake and release the parking brake.
3. Select the driving direction and the required range.

1
MODE
2
3
4
5
D
N
R1
R2
1484
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
Operating the Truck

6. To stop the machine release the accelerator and depress the
service brake pedal. Release the service brake as the machine slows
until, when stopped, the pedal is depressed just enough to hold the
machine stationary.
276
277
1106
1106
7. When the machine has stopped, shift the transmission to Neutral,

apply the parking brake and release the service brake.
8. If the service brake does not stop the machine. Apply the parking emergency brake. This should only be applied to stop the machine in
an emergency.
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.
Stopping the Engine

1. Make sure the parking-emergency brake control is in the 'PARK'
position.
2. Make sure the transmission is in 'NEUTRAL'.

1
MODE
2
3
4
5
D
N
R1
R2
1485
4-14
Operating the Truck
3. Allow the engine to idle 3 - 5 minutes after a full load operation

before shutting it off. This allows the engine to cool gradually and
uniformly.
278
4. To stop the engine, turn the ignition key switch to position '1'.
1
2
1034
1109
052
281
5. Turn the steering wheel in both directions to dissipate the pressure

in the steering accumulator to prevent accidental steering during
bleed down.
6. Make sure the body control lever is in the 'FLOAT' position.
7. Turn the ignition key switch to the 'OFF' position ('0').
4-15
Operating the Truck

Parking
When parking the machine overnight, or for an extended
period, the following procedure in addition to that given in
'Stopping the Engine' will help maintain it in good condition
for subsequent use:
1. Fill the fuel tank completely, to prevent condensation. If

security kit is supplied, keep it locked.
641
651
2. Always park the machine on level ground where possible.

If the machine must be parked on a grade, position the
machine at right angles to the grade and block the wheels
securely.
3. If below freezing temperatures are expected, make sure

the cooling system has sufficient antifreeze to prevent the
coolant freezing. If antifreeze cannot be added to the cooling
system, drain the cooling system completely.
Check all tyres, hoses, wiring, tubing and fittings for cuts, ply
separation, abrasion, fraying, or other damage or
deterioration. Inspect for structural damage to the cab, body
and chassis. Attach warning signs to the steering wheel or to
a control to alert others if lubricant has been drained,
batteries removed etc..
4-16
Working the Truck
5 - Working the Truck
5-1
Working the Truck
Blank Page
5-2
Working the Truck
WORKING THE TRUCK

Off-highway trucks are used on a variety of hauling jobs, from mine
overburden removal to dam building. Every truck operation,
regardless of the type of job, can be divided into four phases;
loading, hauling, dumping and the empty return.
Note: After coming to a stop for loading or unloading the truck, the
Parking-Emergency Brake control can be pushed in to hold the
brakes in the applied position as though the foot brake is depressed.
1106
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.
Holding Truck Stationary
90
2039
Minimize Bucket Swing
2040
Semicircular Loading
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
Working the Truck

A cleanup dozer or small loader is often working in conjunction with
the main loading machine to keep the area clear of bucket spillage
for maximum efficiency of the loading operation. The truck operator
must always be alert to the position of the cleanup machine when
entering the loading area to avoid congestion, and for maximum
safety.
2041
Stay Two Lengths Behind
The following precautions should be observed when approaching the

loading area and while being loaded Avoid rocks and other shovel spillage that can needlessly damage
tyres or other truck components. Allow the cleanup machine
sufficient time to
clear up such debris.
Do not move the truck into loading position with the shovel bucket
swinging overhead. Large rocks that might fall from the bucket can
be dangerous to both the truck and operator.
2042
Loading Both Sides
2043
Watch Other Trucks
Keep your head and arms inside the cab during loading to avoid
the danger of falling rocks or other shovel spillage.
When the loader operator signals that the truck is loaded, sound
two blasts on the horn, release the brakes and shift the
transmission to drive (D). Move out of the loading area and onto the
haul road with the least possible delay to allow any waiting truck to
move into the loading position as soon as possible.
5-4
Working the Truck
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.
2044
Load Downwind
2045
Watch Cleanup Machine
20
10
0
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.
2046
20
30
20
MPH
20
km/h
20
40
50
Maintain Safe Speed
Be sure to reduce speed and come to a full stop, as required, at

intersections, rail-roads, public highways etc.. Where a 'FLAGMAN' is
stationed to direct traffic, always stay alert and follow his directions.
5-5
Working the Truck

Dumping
The dumping operation usually depends upon the type of material
being hauled. For instance, overburden and other waste material is
usually dumped over a spoil bank or piled into large mounds. The
dumping on a job of this type might be controlled by a dump
'SPOTTER', 'FLAGMAN' or 'BANKSMAN' or second person who
directs the truck to its dumping area. The 'SPOTTER' is needed due
to the limited rear visibility the operator has with a loaded truck of this
size. While backing to dump, the operator must watch the
'SPOTTER' at all times and follow his direction. Under no
circumstances should the operator leave his seat to gain better
visibility while backing. Always remain seated to maintain maximum
machine control.
TWO MINIMUM
2047
Safety First
2048
Avoid Obstacles
2049
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
Working the Truck
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.
2050
Never Leave Seat
2051
Watch Inside Duals
2052
Keep Wheels Level
2053
Don't Jump Dump
052
Make Sure Body is Fully Down
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
Working the Truck
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
Moving a Disabled Truck
7 - Moving a Disabled Truck
7-1
Blank Page
7-2

MOVING DISABLED TRUCK
Any unusual power train noises noted while operating the truck
should be reported to those responsible for maintenance. Should the
power train, hydraulic or electrical systems fail, the machine should
be stopped and shut down immediately until suitable repairs can be
made. If the failure is in the power train and the truck must be moved
to a service area or workshop to make required repairs, remove the
drive flange covers from the drive wheels and pull the axle shafts and
final drive planetary sun gears from the planetary assemblies. This
will prevent any possible additional damage, which may be caused
by the drive wheels turning the power train as the machine is towed.
Replace the covers on the drive wheels to retain lubricant and
prevent entry of dirt.
If possible, start the engine to provide the required hydraulic
pressure for steering and braking. Never allow riders on a machine
being towed without sufficient hydraulic pressure for safe steering
and braking.
If the nature of the trouble prevents engine operation, repairs must
be made on the site of the breakdown, or special arrangements
made for towing the machine safely to the repair area without
steering and braking power.
If the parking brake must be released, but the engine cannot be
operated to provide the required hydraulic power needed to release
the brake, refer to the machine service manual Section 165-0030, for
parking brake release with auxiliary hydraulic power source. See
WARNING on previous page.
Connect a suitable towing bar to one of the lugs on the front bumper
of the disabled machine and reverse another machine, in a straight
and in-line manoeuvre, towards the disabled machine. Connect the
opposite end of the towing bar to the towing point on the rear axle of
the recovery machine and ensure that it is securely locked.
Note: An alternative method of towing a disabled machine is by
connecting an A-Frame arrangement to the lugs on the front bumper
of the disabled machine and the towing point of the recovery
machine.
To prevent possible damage to the transmission, the towing speed
should never exceed 10 km/h (6.2 mile/h) and the distance towed
should not be longer than 10 km (6.2 miles).
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 - Lubrication and Servicing
8-1
Blank Page
8-2

SAFETY PRECAUTIONS
Do not allow unauthorized personnel to service or maintain this
machine. Study the Operators Handbook and Maintenance Manual
before starting, operating or servicing this machine. Always follow
procedures and safety precautions detailed in the Maintenance
Manual.
TY L
FE UA
SA AN
M
Always attach a 'DO NOT OPERATE' or similar warning sign to

ignition switch or a control before cleaning, lubricating or servicing
the machine.
Never allow anyone to work on the machine while it is moving. Make
sure no one is on the machine before working on it.
1767
Do not work under or near unblocked or unsupported body. Always

use the body safety prop. Body prop must only be used when the
body is empty.
Do not work under or near any unblocked or unsupported linkage,
part or machine.
D O N OT
OPE RATE
Always shut down machine according to the procedure under

'Stopping The Engine', described on page 4-14. Turn off the master
switch before cleaning, lubricating or servicing the machine except as
called for in this Handbook or Maintenance Manual.
Always install steering lock bar before adjusting or servicing the
machine with the engine running. Refer to 'General' safety section on
page 2-4.
1775
Always relieve pressure before servicing any pressurized system.

Follow the procedures and safety precautions detailed in the relevant
Maintenance Manual section.
When changing oil in the engine, transmission and hydraulic
systems, or removing hydraulic lines, remember that the oil may be
hot and can cause burns to unprotected skin.
When working on or around exhaust components, remember that the
components may be hot and can cause burns to unprotected skin.
Always deflate tyre before attempting to remove any embedded
objects or removing the tyre and rim assembly from the machine.
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.
1781
WARNING
Injection Hazard.
Escaping fluid under pressure
can penetrate skin, causing
serious injury.
Relieve pressure before

disconnecting hydraulic lines.
Keep away from leaks and pin
holes. Use a piece of
cardboard or paper to search
for leaks. Do not use hand.
Fluid injected into the skin must be
surgically removed within a few
hours by a doctor familiar with
this type of injury or gangrene
will result.
15333273
8-3

LUBRICATION AND SERVICING
Lubrication is an essential part of preventive maintenance. It is
important that the instructions regarding types of lubricants and the
frequency of their application be followed to prolong the useful life of
the machine. Periodic lubrication of moving parts reduces to a
minimum the possibility of mechanical failures.
Thoroughly clean all fittings, caps, plugs etc., to prevent dirt from
entering the system while servicing.
Lubricants must be at operating temperature when draining.
Do not operate any system unless oil level is within the operating
range as indicated on oil level dip stick, sight gauge or level plug.
Small circles on the following illustrations represent points at which
lubrication or servicing must take place, at the intervals indicated on
the left-hand side of the lubrication chart.
The numbered circles on the illustrations contain reference numbers
which correspond to the 'Ref. Points' column of the chart.
All change and service periods are recommendations based on
average operating conditions. Lubricants showing evidence of
excessive heat, oxidation or dirt should be changed more frequently
to prevent these conditions. Lubricant change and service periods
must be established on the basis of individual job conditions.
8-4
27
16 21 5
6 29 23
8 26 10
28
21
22
22 24 26 8 10 28 11 28 20
19
12
4 20 2
21
25
15
13
18
14
25 18 17
14
LUBRICATION AND SERVICE CHART

Interval Ref.
Hours Points Identification
10
1
2
3
4
5
6
7
8&9
-
50
No. of
Points Lubricant Service/Quantities
29
Engine Fuel Pre-Filter
Check oil level. Add if low.

Check coolant level. Add if low.
Check W/Light. Replace element if reqd.
Check indicator. Replace element if reqd.
Drain water and sediment.
Visually inspect for debris and damage.
Visually inspect all belts.
Visually inspect heights.
Check. Replace element if reqd.
Check for proper operation.
Check condition. Check pressures when
tyres are cold.
Check for proper operation.
Check for leaks and worn/damaged parts.
Repair/replace as required.
Drain water and sediment
Front Ride Cylinders
Lube.
EP, NLGI 20 Strokes
9
10
28
11
12
13
14
15
Rear Ride Cylinder Spherical Bushings

Steering Cylinders
Steering Linkage
Steering Pivot Pin
A-Frame Nose Spherical Bushing
Banjo Stabilizer Spherical Bushings
Body Hinge Pins
Body Hoist Bushings
Lube.
Lube.
Lube.
Lube.
Lube.
Lube.
Lube.
Lube.
4
4
4
2
1
2
2
4
EP,
EP,
EP,
EP,
EP,
EP,
EP,
EP,
Engine
Transmission
Main Hydraulic Tank
Steering Hydraulic Tank
Radiator Header Tank
Steering Filter
Rear Disc Brake Filter(s)
Fuel Filter/Water Separator
Cooling Fan
Drive Belts
Front and Rear Ride Cylinders
Air Cleaner Restriction W/Light
Air Cleaner Vacuator Valve(s)
Tyres
Service Instructions
Controls, Instruments and W/Lights

General Inspection
1
1
1
1
1
1
2
1
4
1
6
EO
EO
HO
HO
Antifreeze
-
NLGI
NLGI
NLGI
NLGI
NLGI
NLGI
NLGI
NLGI
As Required
As Required
As Required
As Required
See Page 8-7 / 8
See Page 8-7
See Page 8-7
See Page 8-7
Serv man 180-0050
Serv man 160-0050
See Note A
See Note A
See Note A
See Note A
See Note A
See Note A
See Note A
See Note A
8-5

LUBRICATION AND SERVICE CHART (CONTINUED)
Interval Ref.
Hours Points Identification
250
No. of
Points Lubricant Service/Quantities
Service Instructions
1
7
16
17
18
-
Engine
Engine Oil Filters
Engine Fuel Filters
Engine Coolant Additive
Engine Coolant Filter(s)
Engine Crankcase Breather
Engine Cooling Fan
Engine Power Takeoff
Differential
Wheel Planetaries
Differential Breather
Transmission Breather
Alternator Drive Belt
Accessory Drive Belts (if fitted)
Front Brake Pads
Drain and refill.

Replace filters.
Replace filters.
Check DCA concentration and replenish.
Replace filter(s) if required.
Clean.
Check condition.
Clean.
Clean.
Check belt tension. Adjust if required.
Check belt tension. Adjust if required.
Check wear. Replace as required.
1
2
1
1
1
1
2
1
1
1
2
EO
DCA4
EPL
EPL
EPL
-
29
Engine Fuel Pre-Filter
Replace filter.
19
20
21
22
23
-
Fuel Tank
Air Cleaner(s)
Accumulators
Driveline Universal Joints
Driveline Slip Joints
Steering Column Universal Joints
Hydraulic & Steering Tank Breather
Clean filler neck screen and cap.

Clean primary tubes and inlet screens.
Check nitrogen pressures.
Lube (if grease nipple fitted).
Lube (if grease nipple fitted).
Lube.
Clean.
3
3
1
*EP, NLGI
*EP, NLGI
*EP, NLGI
-
1 000
6
2
-
Hydraulic System Pressure Checks

Main Hydraulic Filter
Rear Disc Brake Filter(s)
Transmission
Transmission Oil Filter
Check pressures at check points.

Replace elements.
Replace element(s).
Drain and refill.
Replace element.
2
1
1
EO
-
1 500
16
17
18
-
Engine Crankcase Breather

Differential
Wheel Planetaries
Fan Idler Pivot Arm
Clean/Replace
Drain and refill
Drain and refill
Drain and refill
Lube
1
1
1
2
1
EPL
EPL
EPL
EP, NLGI
2 000
3
4
19
25
Main Hydraulic Tank

Main Hydraulic Tank Suction Screens
Steering Tank
Steering Filter
Steering Tank Suction Screen
Fuel Tank
Rear Brake Packs
Drain and refill

Remove and clean
Drain and refill
Replace element
Remove and clean
Drain and refill
Drain and refill
1
2
1
1
1
1
2
HO
HO
Diesel
HO
4 000
27
-
Cooling System
Air Conditiong Compressor
Drain, flush and refill

Drain, flush and refill
1
1
Antifreeze See Page 8-9

PAG Oil See Page 8-8 / 9
5 000
26
Front Wheel Bearings
Repack
*EP, NLGI *
500
Lube Note A
Note -
Lubricate slowly until excess lube is seen.
*-
Fill compartment one half full.
EO -
Engine Oil. Refer to chart under 'Recommended

Lubricants'.
EPL -
Extreme Pressure Gear Lubricant meeting

specification MIL-L-2105C.
HO -
Serv man 110-0030
See Note A
See Note A
See Note A
See Page 8-7
See Page 8-7
See Page 8-7
See Page 8-8 / 9
Ref Engine Manual
See Page 8-8 / 9
See Page 8-8 / 9
See Page 8-8 / 9
See Note A
See Page 8-8 / 9
See Page 8-8 / 9
See Page 8-7
See Page 8-9
-
Hydraulic Transmission Oil meeting

Specification EMS19058 Refer to chart under
'Recommended Lubricants'.
EP, NLGI - Extreme Pressure Lithium No. 2 Grease.

Refer to chart under 'Recommended
Lubricants'.
*EP, NLGI - Extreme Pressure Lithium No. 2 Grease
(without 'Molybdenum'). Refer to chart Under
'Recommended Lubricants'.
PAG Oil -
8-6
See Page 8-8 / 9

Serv man 110-0030
Serv man 110-0030
See Page 8-7 / 8
See Page 8-7 / 8
Ref Engine Manual
See Page 8-7
See Page 8-7
See Page 8-7
See Page 8-7
Polyalklene Glycol (PAG) Compressor

Lubricating Oil - Low Viscosity (ISO46).

MISCELLANEOUS SERVICING
Engine Fuel Pre-filter - Replace fuel pre-filter.
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.
Windscreen Wipers and Washers - Inspect wiper blades and

replace if damaged. Top up washer reservoir.
Wheel Rim Nuts - After first 10 hours of operation re-torque
nuts to 690 Nm (510 lbf ft). Check torque every 50 hours
(weekly) thereafter.
EVERY 10 HOURS OF OPERATION
Walk Around Inspection - Inspect the machine as described
in Section 4.
Engine - Visually check engine for damage, loose or frayed
belts and listen for any unusual noises.
idler arm, therefore, there is no need to check or adjust belt

tension.
Drive Belts - Visually check the belts and replace if they are
cracked or frayed. Adjust belts that have a glazed or shiny
surface which indicates belt slippage. Correctly installed and
tensioned belts will show even pulley and belt wear. Refer to
Section 110-0030, ENGINE AND MOUNTING, in the
Maintenance Manual for drive belt tension and adjustment of
new and used drive belts.
Front Brakes - Check pads and discs for wear and replace
where necessary.
Note: This service interval applies to normal driving. Check more
frequently under more severe conditions. Thickness of pad
friction material should never be allowed to wear below 3 mm
(0.12 in).
Engine Air Cleaner(s) - Check air cleaner piping, hoses and

clamps. Change air cleaner element only when air cleaner flow
restriction warning light illuminates. Service vacuator valves
daily. Inspect and remove any obstructions from the vacuator
valve lips. Valve lips should be open and pliable with engine
EVERY 1 000 HOURS OF OPERATION
stopped.
Hydraulic System Pressure Checks - Check all steering, body
Note: Service air cleaner(s) more often under extremely dusty
and braking system pressures.
operating conditions.
Note: Instructions for checking pressure, and locations of
pressure check points, are contained in the relevant service
Radiator Header Tank - Check coolant level and add if low.
manual section. If the pressures are outwith the specified
Fill radiator header tank with coolant until coolant reaches the
bottom of the filler neck and holds at that level.
settings then components in the relevant system should be
inspected, repaired or replaced to ensure the correct operation
Note: Any time a significant amount of coolant is added, the
of the system. All safety instructions in the relevant sections
DCA4 concentration MUST be checked. If the concentration is
low, engine damage will result. Conversely, over-inhibiting
should be strictly adhered to.
antifreeze solutions can cause silicate dropout. Refer to
Main Hydraulic Filter - Clean filter housing and install new
Section 210-0010, COOLING SYSTEM, in the Maintenance
Manual.
element.
Steering, Braking and Body Hoist Systems - Check for
correct operation of all systems before operating the truck.
Rear Disc Brake Filter(s) - Replace filter element(s) when

indicator sight gauge shows replacement is necessary, or after 1
000 hours of operation, whichever comes first.
Steering Filter - Check steering filter restriction warning light

with the truck empty, brakes released, oil at normal operating
temperature, engine operating at
EVERY 2 000 HOURS OF OPERATION
1 500 rev/min and while turning the steering wheel at one turn/
Steering Filter - Clean filter housing and install new element
sec. If the warning light illuminates, the filter element should be
when indicated, or after 2 000 hours of operation, whichever
replaced.
comes first.
Rear Disc Brake Filter(s) Replace element(s) when indicator shows oil at the replace
element level.
ENGINES AND TRANSMISSIONS
All information contained in the 'LUBRICATION AND SERVICE
CHART' was extracted from the relevant manufacturers
AFTER FIRST 150 HOURS OF OPERATING NEW OR
'Operation and Maintenance Manual', and was correct at time of
REBUILT COMPONENTS
publication. User should ensure that information contained in this
Transmission - Drain oil, replace filters and refill.
chart reflects the information shown in the relevant
manufacturers 'Operation and Maintenance Manual' supplied
Differential - Drain oil and refill.
with the truck. Maintenance procedures should be carried out in
Planetaries - Drain oil and refill.
conjunction with any additional procedures contained in the
relevant manufacturers 'Operation and Maintenance Manual', at
the intervals specified.
EVERY 250 HOURS OF OPERATION
Oil Can Points - Oil accelerator linkage, hinges, and other
working parts with engine oil.
Coolant Additive - Check and replenish DCA4 concentration
as described in Section 210-0000, COOLING SYSTEM, in the
Maintenance Manual.
Coolant Filter(s) - Replace coolant filter(s) if required. When
testing the DCA4 concentration, depending on the level of
DCA4, the coolant filter(s) may not necessarily have to be
changed. Refer to Section 210-0010, COOLING SYSTEM, in
the Maintenance Manual.
8-7
SERVICE CAPACITIES
Service Capacities
Ref.
Points Identification
1
2
3
4
27
19
8
9
16
17
18
-
Engine Crankcase and Filters

Transmission and Filters
Main Hydraulic Tank
Main Hydraulic System
Steering Hydraulic Tank
Steering Hydraulic System
Cooling System
Fuel Tank
Front Ride Cylinders (Each)
Rear Ride Cylinders (Each)
Differential
Wheel Planetaries (Total)
Air Conditioning Compressor
TR45
TR60
Lubricant
litres
US gal
litres
US gal
EO
EO
HO
HO
HO
HO
Coolant
Diesel
HO
HO
EPL
EPL
EPL
PAG Oil
55
68
216
258
61
85
126
606
14
17
2
60
66
0.135
14.5
18
57
68
16
22.5
33.3
160
3.7
4.5
0.53
15.8
17.4
0.036
55
85
216
258
61
72
136
606
14
17
2
52
43
0.135
14.5
22.5
57
68
16
19
35.9
160
3.7
4.5
0.53
13.7
11.4
0.036
Note: Capacities given are approximate. Work to dipstick, sight gauges or level plugs.
Use table in conjunction with 'Recommended Lubricants' table.
AIR CONDITIONING RE-START PROCEDURE

If the machine has been idle for an extended period of time (2 weeks), the refrigerant in the air conditioning unit converts from a gas
to a liquid. This puts the compressor unit is under a great deal of strain trying to compress a liquid instead of a gas and could cause
a failure in the air conditioning unit. The following commissioning procedure allows the air conditioning unit to achieve normal
operating parameters.
1.
2.
3.
4.
5.
Start the machine and allow it to run until the engine is at a normal operating temperature of 80C (176F)
Turn the blower control to setting 1.
Turn on the air conditioning unit on for 5 seconds then off for 5 seconds.
Repeatedly switch the air conditioning on and off for at least 1 minute. This should be at least 12 repetitions.
Commissioning the air conditioning unit is complete and ready for use.
8-8
RECOMMENDED LUBRICANTS
COMPONENT
LUBRICANT
Engine
Engine oil with 1.00% sulphated ash is recommended.

Sulphated ash must not exceed 1.85% limit.
API code CH-4, ACEA-E5. See Note 2*
Ambient Temp
0 C and above
-10 C and above
-25 to 35 C
Allison C-4 Type Specification; Refer to

www.allisontransmission.com for a complete
list of C-4 approved oils. See Note 3*
Ambient Temp
-35C
-30C
-28C
-20C
-15C
0C
10C
Transmission
VISCOSITY (See Note 1*)

Recommendation
SAE 20W-40
SAE 15W-40
SAE 10W-30
Recommendation
SAE 0W-30 or TranSynd RD
SAE 0W-20 (Arctic)

DEXRON-III
SAE 10W
SAE 15W-40
SAE 30
SAE 40
Cooling System
Heavy Duty Coolant. Refer to Section 210-0010,

COOLING SYSTEM, in the Service Manual.
Fuel Tank
Diesel Fuel Oil with maximum sulphur 0.5%.
DIN EN590
Differential
Planetary Gears
Power Takeoff
Multipurpose Extreme Pressure type gear oil meeting

MIL-L-2105C Specifications (No Zinc Additive).
See Note 4*.
SAE 80W-90
at ambient temperatures of -18 to 32 C
Grease Fittings
Multipurpose Extreme Pressure Lithium Grease (which

may or may not contain 'Molybdenum'), with a typical
melting point of 190 C.
No. 2 Consistency
Drivelines
Steering Column
Wheel Bearings
Multipurpose Extreme Pressure Lithium Grease (without No. 2 Consistency

'Molybdenum'), with a typical melting point of 190 C.
Air Conditioning
Compressor
Polyalklene Glycol (PAG)

Compressor Lubricating Oil - Low Viscosity
ISO46
SP 10
Ride Cylinders
(Nitrogen/Oil)
Hydraulic oil meeting MIL-L-2104B Specification.
SAE 10W
Hydraulic System
Hydraulic Transmission Oil meeting Specification

EMS19058. See Note 5.
SAE 10W
at ambient temperatures of -18 to 32 C
SAE 30W
at ambient temps of 32 C and above
Note 1 - Consult your lubricant supplier for the correct viscosity of lubricant to use when ambient temperatures are
consistently above or below those listed.
Note 2 - Cummins Engine Co. do not recommend any specific brand of engine oil but the use of oils that meet API categories.
Cummins recommend use of only the multi-graded viscosity oils shown for the various ambient temperatures listed.
Note 3 - Operation below the minimum temperatures listed for the oil used without proper preheat or warm-up results in
greatly reduced transmission life. If auxiliary heating is available, preheat the oil to the minimum temperature limit. If not
available, run the engine at part throttle with the transmission in neutral to raise the fluid temperature.
Note 4 - If rear axle has limited slip differential, an EP oil with limited slip additives should be used because using standard
SAE 90 oil may result in very loud noise and jerking of the wheels when driving slowly round sharp corners.
Note 5 - Typical SAE 10W oils complying with Specification EMS19058 are:
KUWAIT TO4
TEXACO TEXTRAN
TOTAL TRANSMISSION AC
SHELL DONAX TC
MOBILTRANS HD
BP AUTRAN 4
ESSO TORQUE FLUID
CASTROL TFC
Other lubricant suppliers may have comparable products and should be consulted for confirmation.
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
100 113 200 375
45
93
190
8-9

TYRE PRESSURES
Tyre pressures on this pages apply to the truck serial number range specified only, Gross Vehicle Weight (G.V.W.) and axle
weights may vary between truck derivatives. Tyre pressure should be recalculated if not shown for a particular truck. Contact
TEREX for assistance.
The tyre inflation pressures listed are manufacturers recommendations for G.V.W. travelling at maximum speed. TEREX Advise
that operators check tyre inflation pressures with tyre manufactures to ensure correct setting for each particular application.
MANUFACTURE
TR35
877
BRIDGESTONE
BRIDGESTONE
MICHELIN
ALTURA
ALTURA
18.00-R25
18.00-R25
18.00-R25
18.00-R25
18.00-R25
VMTP
7.4
VMTS
7.4
XHD1-A4
6.2
GRIPMASTER ND 7.0
GRIPMASTER XL 7.0
108
108
90
102
102
7.7
7.7
6.2
7.0
7.0
111
111
90
102
102
TR45
881
BRIDGESTONE
BRIDGESTONE
MICHELIN
BELSHINA
21.00-R35
21.00-R35
21.00-R35
21.00-35
VMTP
VELS
XDT-A4
BEL51-A
7.7
7.7
5.5
5.8
111
111
80
84
7.2
7.2
5.2
5.8
105
105
75
84
TR60
882
BRIDGESTONE
BRIDGESTONE
MICHELIN
BELSHINA
24.00-R35
24.00-R35
24.00-R35
24.00-35
VMTP
VRLS
XDT-A4
FBEL-150
6.5
6.5
5.5
5.5
94
94
80
80
6.3
6.3
5.5
5.5
91
91
80
80
TR70
913
BRIDGESTONE
BRIDGESTONE
MICHELIN
24.00-R35
24.00-R35
24.00-R35
VMTP
VRLS
XDT-A4
7.9
7.9
7.2
114
114
105
7.9
7.9
6.9
114
114
100
TR100
783
BRIDGESTONE
BRIDGESTONE
MICHELIN
PACETRONIC
BELSHINA
27.00-R49
27.00-R49
27.00-R49
27.00-49
27.00-49
VMTP
VRLS
XDT-A4
E4D
FBEL-150
7.0
7.0
6.6
6.6
6.4
102
102
95
95
93
6.8
6.8
6.6
6.6
6.4
98
98
95
95
93
TR100DD
883
BRIDGESTONE
BRIDGESTONE
MICHELIN
PACETRONIC
27.00-R49
27.00-R49
27.00-R49
27.00-49
VMTP
VRLS
XDT-A4
E4D
7.0
7.0
6.6
6.6
102
102
95
95
6.8
6.8
6.6
6.6
98
98
95
95
8-10
SIZE PATTERN
TYRE INFATION PRESSURE

FRONT
REAR
BAR
lb/in2
BAR
lb/in2
MODEL
Technical Data
9 - Technical Data
9-1
Technical Data
Blank Page
9-2
Technical Data
TECHNICAL DATA TR45
4 060
(13-4)
Max 1 195
Body (3-11)
Depth
3 800
(12-6)
3 530
(11-7)
810 450
(2-8) (1-6)
1 520
(5-0)
2 710 (8-11)
4 000 (13-1)
4 240 (13-11)
Optional
Spillguard
Vehicle Clearance Diameter (SAE) 21m (69ft)

7 645
(25-1)
7 417
(23-4)
5 485
(18-0)
4 700
(15-5)
4 630 (15-2)
4 370 (14-4)
430
(1-5)
58
4 520
(14-10)
4 245
(13-11)
3 855
(12-8)
4 135
(13-7)
15
585
(1-11)
1689
2 665 (8-10)
3 325 (10-11)
3 965 (13-0)
ENGINE
Make/Model ...................................................
Type ..............................................................
Gross Power at 2 000 rev/min .......................
Net Power at 2 000 rev/min ...........................
3 425
(11-3)
585 (1-11)
2 350 (7-9)
3 940 (12-11)
8 700 (28-7)
2 410 (7-11)
Cummins QSK19-C525
4 Cycle, Turbocharged/
Low Temperature aftercooled.
Electronic Management.
392 kW (525 hp, 532 PS)
370 kW (495 hp, 502 PS)
Note: Power ratings to SAE J1995 Jun 90. Engine emission meets Tier 3
USA EPA/CARB MOH 40 CFR 89 and proposed EU non-road mobile
machinery directive.
Maximum Torque ..........................................
Number of Cylinders/Configuration ...............
Bore x Stroke .................................................
Total Displacement .......................................
Starting ..........................................................
Maximum Speed, Full Load...........................
Maximum Speed, No Load ............................
Idle Speed .....................................................
Safe Operating Angle ....................................
2 407 Nm (1 775 lbf ft)

at 1 300 rev/min
6, in line
159 x 159 mm (6.25 x 6.25 in)
18.9 litres (1 150 in)

Electric
2 000 rev/min
2 244 rev/min
700/750 rev/min
30/60% Grade
9-3
Technical Data
TRANSMISSION
Make/Model ................................................... Allison M5610AR
automatic electronic control with soft shift feature. Remote mounted in
the frame. Integral torque converter and planetary gearing. Six speeds
forward, two reverse. Automatic converter lockup action in all speed
ranges. Downshift inhibitor. Intregal hydraulic retarder.
DRIVE AXLE
Heavy duty axle with single reduction spiral bevel gear differential, full
floating axle shafts, and planetary reduction at each wheel.
Ratios:
Standard Optional
Differential .......................... 3.15:1
3.73:1
Planetary ............................ 5.66:1
5.66:1
Total Reduction ................ 17.83:1 21.11:1
Speeds With Standard Differential
Forward
Gear
1
2
3
Ratio
4.00
2.68
2.01
km/h
11.3
16.8
22.4
mile/h
7.0
10.5
13.9
Reverse
Gear
1
2
Ratio
5.12
3.46
km/h
7.1
12.9
mile/h
4.4
8.0
4
1.35
33.4
20.7
5
1.00
45.2
28.0
6
0.67
65.0
40.4
SUSPENSION
Front: King pin strut type independent front wheel suspension by selfcontained, variable rate, nitrogen/oil cylinders.
Rear: Variable rate nitrogen/oil cylinders with A-frame linkage and
lateral stabilizer bar.
Maximum Strut Stroke
Front .................................. 251 mm (9.9 in)
Rear ................................... 182 mm (7.2 in)
Maximum Rear Axle Oscillation 6.5 Degrees
WHEELS AND TYRES
Wheel Rim Width .................................. 13 in
Wheel Rim Width(Optional) ................... 15 in
Standard Tyres (Front & Rear)18.00 R 33** Radial
Optional Tyres (Front & Rear) 21.00 R 35** Radial
Note: It is recommended that for tyres both listed and unlisted, the user
should consult the tyre manufacturer and evaluate all job conditions in
order to make the proper selection.
9-4
Technical Data
BRAKES
SERVICE
All hydraulic brake system. Transmission mounted pressure
compensating pump provides hydraulic pressure for brakesand
steering. Independent circuits front and rear. Each circuit incorporates
a nitrogen accumulator which stores energy to provide consistent
braking response.
Front Brake Circuit Pressure159 bar (2 300 lbf/in)
Rear Brake Circuit Pressure52 bar (750 lbf/in)
Accumulators:
Nitrogen Precharge Pressure55 bar (800 lbf/in)
Front:
Type ............................................................
Disc Diameter .............................................
Pad Area, Total ...........................................
Dry Disc with 1

calliper per wheel
660 mm (25.5 in)
1 395 cm (216 in)
Rear:
Type ........................................... Oil cooled, multiple friction discs
(14 total),completely sealed from dirt and water.
Braking Surface, ................................. Total 38 310 cm (5 938 in)
Cooling Flow, ..................................... Max. 553 litres/min (146 US
gal/min)
PARKING
Application of rear brakes by springs in brake disc pack. Hydraulically
released.
Hold-off Pressure .......................................... 83 bar (1 200 lbf/in)
RETARDATION
Modulated lever control of rear disc pack.
Retarder Actuation Pressure .........................
up to 33 bar (480 lbf/in)
EMERGENCY
Push button solenoid control applies service and parking brakes.
Automatically applies when engine is switched off. Parking brake
applies should system pressure fall below a predetermined level.
Brakes conform to ISO 3450, SAE J1473 OCT 90.
9-5
Technical Data
STEERING SYSTEM
Independent hydrostatic steering with closed-centre steering valve,
accumulator and pressure compensating piston pump.
Accumulator provides uniform steering regardless of engine speed. In
the event of loss of engine power it provides steering of approximately
two lock-to-lock turns. A low pressure indicator light warns of system
pressure below 83 bar (1 200 lbf/in). Steering meets ISO 5010, SAE
J53.
System Pressure ...........................................
Relief Pressure ..............................................
Steering Cylinders .........................................
Accumulator:
Oil Capacity ................................................
Nitrogen Precharge Pressure .....................
Steering Angle (Left and Right) .....................
Pump:
Type ............................................................
Capacity at 2 100 rev/min ...........................
159 bar (2 300 lbf/in)

207 bar (3 000 lbf/in)
Double Acting,
Single Stage
14.0 litres (3.70 US gal)
55 bar (800 lbf/in)

39
Piston
1.4 litres/s (22 US gal/min)
BODY HYDRAULICS
Two body hoist cylinders are mounted between the frame rails.
Cylinders are two-stage with power down in the second stage.
System Relief Pressure .................................
Pump:
Type ............................................................
190 bar (2 750 lbf/in)
Control Valve ................................................
Servo Controlled,
Open Centre
13 Seconds
9 Seconds
Body Raise Time ...........................................

Body Lower Time ..........................................
Gear
227 litres/min (60 US gal/
min)
ELECTRICAL
Type ..............................................................
24 Volt, Negative
Ground
Battery
Two, 12 Volt, 165 Ah each, Maintenance Free
Accessories ................................................... 24 Volt
Alternator ....................................................... 70 Amp
Starter ............................................................ 8.9 kW
BODY
Longitudinal 'V' type floor with integral transverse box-section
stiffeners. The body is exhaust heated and rests on resilient impact
absorption pads.
Body wear surfaces are high hardness (360-440 BHN) abrasion
resistant steel. Yield strength of plates 1 000 MPa (145 000 lbf/in).
9-6
Technical Data
Plate Thicknesses:
Floor ...........................................................
Side ............................................................
Front, lower .................................................
19 mm (0.75 in)
10 mm (0.39 in)
10 mm (0.39 in)
ROPS Cabguard SAE J1040 Feb 86. ISO 3471

Volumes:
Struck (SAE) ...............................................
Heaped 2:1 (SAE) .......................................
SERVICE CAPACITIES
Engine Crankcase and Filters .......................
Transmission and Filters ...............................
Cooling System .............................................
Fuel Tank ......................................................
Steering Hydraulic Tank ................................
Steering System ............................................
gal)
Body and Brake Cooling Tank ......................
Body and Brake Cooling System ..................
Planetaries (Total) .........................................
Differential .....................................................
Front Ride Strut (Each) ..................................
Rear Ride Strut (Each) ..................................
Power Takeoff ...............................................
Air Conditioning Compressor ........................
TYPICAL NOISE LEVELS
Operator Ear (ISO 6394) ................................
19.6 m (25.6 yd)

26.0 m (34.0 yd)
55 litres (14.5 US gal)
68 litres (18 US gal)


85 litres (22.5 US

0.135 litres (0.036 US gal)
80 dbA
*Exterior Sound Rating (ISO 6395) ................ 88 dbA

* - The above result is for the mode giving the highest exterior sound
level when measured and operated as per the prescribed procedures
of the standard. Results shown are for the vehicle in base
configuration.
Note: Noise Level Exposure to the operator and bystander personnel
may be higher depending upon proximity to buildings, rock piles,
machinery etc.. The actual job site Noise Level Exposure must be
measured and applicable regulations complied with in respect to
Employee Hearing Protection.
9-7
Technical Data
VEHICLE WEIGHTS (MASS)

kg
lb
Chassis, with hoists
27 835
61 365
Body, standard
9 300
20 500
Net Weight
37 135
81 870
PAYLOAD, maximum
40 825
90 000
Maximum Gross Weight*
77 960
171 870
FOR UNIT EQUIPPED WITH OPTIONAL BODY LINER PLATES:
27 835
61 365
Body, heavy duty
10 800
23 810
Net Weight
38 635
85 175
PAYLOAD, maximum
39 325
86 700
77 960
171 870
* Maximum permissible gross vehicle weight with options, attachments,
full fuel tank and payload.
WEIGHT DISTRIBUTION
Front Axle
Rear Axle
Empty %
48
52
Loaded %
34
66
9-8
Technical Data
TR60 Technical Data

On Following Page
9-9
Technical Data
TECHNICAL DATA TR60
4 470
(14-8)
Max 1 425
Body (4-8)
Depth
4 270
(14-0)
3 950
(12-11)
950 600
(3-1) (2-0)
1 380
(4-6)
2 900 (9-6)
4 450 (14-7)
Optional
Spillguard
Vehicle Clearance Diameter (SAE) 21 m (68-10)

8 050
(26-5)
7 750
(25-5)
6 000
(19-8)
5 050
(16-7)
4 980 (16-4)
4 630 (15-2)
500
(1-8)
58
4 820
(15-10)
4 440
(14-7)
3 970
(13-0)
15
660
(2-2)
2 580 (8-5)
3 320 (10-11)
3 680
(12-1)
580 (1-11)
2 360 (7-9)
4 170 (13-8)
2 600 (8-6)
9 130 (29-11)
4 060 (13-4)
1690
ENGINE
Make/Model ...................................................
Type ..............................................................
Gross Power at 1500 through 2 000 rev/min .
Net Power at 1500 through 2 000 rev/min .....
Dimensions in mm (ft-in)
Cummins QSK19-C700
4 Cycle, Turbocharged/
Low Temperature aftercooled.
Electronic Management.
522 kW (700 hp, 710 PS)
462 kW (620 hp, 628 PS)
Note: Power ratings to SAE J1995 Jun 90. Engine emission meets Tier III USA
EPA/CARB MOH 40 CFR 89 and proposed EU non-road mobile machinery
directive.
Maximum Torque ..........................................
Number of Cylinders/Configuration ...............
Bore x Stroke .................................................
Total Displacement .......................................
Starting ..........................................................
Maximum Speed, Full Load...........................
Maximum Speed, No Load ............................
Idle Speed .....................................................
Safe Operating Angle ....................................
9-10
2 983 Nm (2 200 lbf ft)

at 1 300 through 1500 rev/min
6, in line
159 x 159 mm (6.25 x 6.25 in)
18.9 litres (1 150 in)

Electric
2 000 rev/min
2 350 rev/min
Self Adjusting
30/60% Grade
Technical Data
TRANSMISSION
Make/Model ................................................... Allison M6610AR
automatic electronic control with soft shift feature. Remote mounted in
the frame. Integral TC 682 torque converter and planetary gearing. Six
speeds forward, two reverse. Automatic converter lockup action in all
speed ranges. With body up, gear range is limited to 1st forward only.
Downshift inhibitor. Intregal hydraulic retarder.
DRIVE AXLE
Heavy duty axle with single reduction spiral bevel gear differential, full
floating axle shafts, and planetary reduction at each wheel.
Ratios:
Differential .......................... 3.73:1
Planetary ............................ 5.80:1
Total Reduction ................ 21.63:1
Speeds With 24.00 R 35 Tyres
Forward
Gear
1
2
3
Ratio
4.00
2.68
2.01
km/h
9.5
14.2
18.9
mile/h
5.9
8.8
11.8
Reverse
Gear
1
2
Ratio
5.12
3.46
km/h
7.4
11.0
mile/h
4.6
6.8
4
1.35
28.2
17.5
5
1.00
38.1
23.7
6
0.67
57.0
35.5
SUSPENSION
Front: King pin strut type independent front wheel suspension by selfcontained, variable rate, nitrogen/oil cylinders.
Rear: Variable rate nitrogen/oil cylinders with A-frame linkage and lateral
stabilizer bar.
Maximum Strut Stroke
Front .................................. 251 mm (9.9 in)
Rear ................................... 182 mm (7.2 in)
Maximum Rear Axle Oscillation 6.5 Degrees
WHEELS AND TYRES
Wheel Rim Width .................................. 17 in
Standard Tyres (Front & Rear)24.00 R 35** Radial
Note: It is recommended that for tyres both listed and unlisted, the user
should consult the tyre manufacturer and evaluate all job conditions in order
to make the proper selection.
9-11
Technical Data
BRAKES
SERVICE
All hydraulic brake system. Transmission mounted pressure
compensating pump provides hydraulic pressure for brakesand steering.
Independent circuits front and rear. Each circuit incorporates a nitrogen
accumulator which stores energy to provide consistent braking
response.
Front Brake Circuit Pressure .........................
Rear Brake Circuit Pressure ..........................
Accumulators:
55 bar (800 lbf/in)
Front:
Type ....... Dry Disc with 1 calliper per wheel
Disc Diameter .............................................
Pad Area, Total ...........................................
710 mm (28 in)

1 395 cm (216 in)
Rear:
Type ............................................................
Braking Surface, Total ................................
159 bar (2 300 lbf/in)

52 bar (750 lbf/in)
Oil cooled, multiple

friction discs (14 total
completely sealed
from dirt and water.
l47 151 cm (7 308 in)
PARKING
Application of rear brakes by springs in brake disc pack. Hydraulically
released.
Hold-off Pressure .......................................... 83 bar (1 200 lbf/in)
RETARDATION
Modulated lever control of rear disc pack. .....
Retarder Actuation Pressure .........................
510 kW (685 hp)

up to 33 bar (480 lbf/in)
EMERGENCY
Push button solenoid control applies service and parking brakes.
Automatically applies when engine is switched off. Parking brake
applies should system pressure fall below a predetermined level.
Brakes conform to ISO 3450, SAE J1473 OCT 90.
9-12
Technical Data
STEERING SYSTEM
Independent hydrostatic steering with closed-centre steering valve,
accumulator and pressure compensating piston pump.
Accumulator provides uniform steering regardless of engine speed. In
the event of loss of engine power it provides steering of approximately
two lock-to-lock turns. A low pressure indicator light warns of system
pressure below 83 bar (1 200 lbf/in). Steering meets ISO 5010, SAE
J53.
System Pressure ...........................................
Relief Pressure ..............................................
Steering CylindersDouble Acting, Single Stage
Accumulator:
Oil Capacity ................................................
Steering Angle (Left and Right) .....................
Pump:
Type ............................................................
159 bar (2 300 lbf/in)

207 bar (3 000 lbf/in)
14.0 litres (3.70US gal)
55 bar (800 lbf/in)

39
Piston
1.4 litres/s (22 US gal/
min)
BODY HYDRAULICS
Two body hoist cylinders are mounted between the frame rails.
Cylinders are two-stage with power down in the second stage.
System Relief Pressure .................................
Pump:
Type ............................................................
gal/min)
Control Valve ................................................
190 bar (2 750 lbf/in)
Body Raise Time ...........................................

Body Lower Time ..........................................
13 Seconds
9 Seconds
Gear
227 litres/min (60 US
Servo Controlled, Open
Centre
ELECTRICAL
Type .............................................................. 24 Volt, Negative
Ground
BatteryTwo, 12 Volt, 165 Ah each, Maintenance Free
Accessories ................................................... 24 Volt
Alternator ....................................................... 70 Amp
Starter ............................................................ 8.9 kW
BODY
Longitudinal 'V' type floor with integral transverse box-section
stiffeners. The body is exhaust heated and rests on resilient impact
absorption pads.
Body wear surfaces are high hardness (360-440 BHN) abrasion
resistant steel. Yield strength of plates 1 000 MPa (145 000 lbf/in).
9-13
Technical Data
Plate Thicknesses:
Floor .................................. 19 mm (0.75 in)
Side ................................... 10 mm (0.39 in)
Front, lower ........................ 10 mm (0.39 in)
ROPS Cabguard SAE J1040 Feb 86. ISO 3471
Volumes:
Struck (SAE) ......................... 26 m (34 yd)
Heaped 2:1 (SAE) ................. 35 m (46 yd)
SERVICE CAPACITIES
Engine Crankcase and Filters .......................
Transmission and Filters ...............................
Cooling System .............................................
Fuel Tank ......................................................
Steering Hydraulic Tank ................................
Steering System ............................................
Body and Brake Cooling Tank ......................
Body and Brake Cooling System ..................
Planetaries (Total) .........................................
Differential .....................................................
Front Ride Strut (Each) ..................................
Rear Ride Strut (Each) ..................................
Power Takeoff ...............................................
Air Conditioning Compressor ........................
US gal)

0.135 litres (0.036
TYPICAL NOISE LEVELS

Operator Ear (ISO 6394) ................................
79 dbA
*Exterior Sound Rating (ISO 6395)................
89 dbA
* - The above result is for the mode giving the highest exterior sound
level when measured and operated as per the prescribed procedures
of the standard. Results shown are for the vehicle in base
configuration.
Note: Noise Level Exposure to the operator and bystander personnel
may be higher depending upon proximity to buildings, rock piles,
machinery etc.. The actual job site Noise Level Exposure must be
measured and applicable regulations complied with in respect to
Employee Hearing Protection.
9-14
Technical Data
Vehicle Weights (Mass)

kg
lb

30 600
67 460
Body, standard
10 650
23 480
Net Weight
41 250
90 940
PAYLOAD, maximum
54 430
120 000
95 680
210 940
FOR UNIT EQUIPPED WITH OPTIONAL HARD ROCK
BODY:
30 600
67 460
Body, with wear plates
13 200
29 100
Net Weight
43 800
96 560
PAYLOAD, maximum
51 880
114 380
95 680
210 940
* Maximum permissable gross vehicle weight with options,
attachments, full tank and payload.
WEIGHT DISTRIBUTION
Front Axle
Rear Axle
Empty %
48
52
Loaded %
34
66
9-15
Technical Data
Blank Page
9-16
Symbol Identification
10 - Symbol Identification
10-1
Blank Page
10-2
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
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
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
NOTES
10-6
NOTES
10-7
NOTES
10-8
11 - Technical Literature
Request Form
11-1
Blank Page
11-2
NEW TRUCK DELIVERY

TECHNICAL LITERATURE REQUEST FORM
Please complete this form if you require complimentary technical literature for your new truck.
-Veuillez remplir ce formulaire si vous avez besoin d'une documentation technique complmentaire pour votrenouveau tombereau.
-Bitte fllen Sie dieses Formular aus, wenn Sie ergnzende technische Dokumentation fr Ihren neuen Muldenkipper bentigen.
-Por favor, rellene esta hoja si desea recibir publicaciones tcnicas adicionales para su nuevo dmper.
Check the appropriate boxes
-Cochez les cases appropries x

-Kreuzen Sie die betreffenden
x
-Marque las casillas correspondintes
and enter the correct truck serial number

et entrez le numro de srie de tombereau correct.
Kstchen an und tragen Sie die korrekte Seriennummer des Muldenkippers ein.
x
e indique el nmero de serie del dmper.
You will receive 1 (one) hard copy of the requested literature per truck, FREE OF CHARGE.
-Vous recevrez 1 (une) copie papier de la documentation rclame par tombereau, GRATUITEMENT.
-Sie erhalten je Muldenkipper 1 (ein) Hardcopy-Exemplar der angeforderten technischen Dokumentation, KOSTENLOS.
-Recibir 1 (un) ejemplar impreso de la publicacin solicitada por cada dmper, SIN CARGO.
SERIAL NUMBER
TEREX PARTS
BOOK
TEREX
MAINTENENCE
MANUAL
TEREX
OPERATORS
MANUAL
If you require additional copies of technical literature, please order via;

-Si vous avez besoin d'exemplaires supplmentaires de la documentation technique, veuillez commander via;
-Sollten Sie weitere Exemplare der technischen Dokumentation bentigen, bestellen Sie diese bitte bei:
-Si necesita copias adicionales de las publicaciones tcnicas, solictelas a:

Quote correct 8 digit reference number. Refer to Technical Literature CD-ROM or http://constructionsupport.terex.com for
details.
-Indiquez un numro de rfrence 8 chiffres correct. Reportez-vous au CD-ROM/ http:constructionsupport.terex.com de la documen
tation technique pour plus de dtails.
-Geben Sie die korrekte achtstellige Referenznummer an. Weitere Einzelheiten knnen Sie der CD-ROM/
http:constructionsupport.terex.commit der technischen Dokumentation entnehmen.
-Indique correctamente el nmero de referencia de 8 cifras. Para ms informacin, vase el CD-ROM/
http:constructionsupport.terex.com correspondiente a las publicaciones tcnicas.
Delivery Address | Adresse livraison | Lieferadresse | Direccin de entrega
Contact Name ________________________________________________________________________

Company
________________________________________________________________________
Address
________________________________________________________________________
________________________________________________________________________
City
________________________________________________________________________
ZIP/Postal Code _______________________________________________________________________
Country
________________________________________________________________________
Telephone
________________________________________________________________________
Fax Number
________________________________________________________________________
To place your order
To place your order | Pour passer votre commande | Fr Ihre Bestellung | Solicite su pedido al nmero:
FAX; +44 (0) 1698 503210

Or alternatively post to
| Ou retournez par courrier | Oder bestellen Sie per Post bei | O alternativamente envelo por correo a:
Terex Equipment Ltd

Motherwell
ML1 5RY
Scotland
This order form must be returned within 60 days of delivery of your new Terex truck, To qualify for your free complimentary
technical literature. Please allow 28 days for deliver.
-Ce formulaire de commande doit tre retourn dans les 60 jours de livraison de votre nouveau tombereau Terex pour obtenir votre documen
tation technique complmentaire gratuite. Veuillez compter 28 jours avant de recevoir la documentation que vous avez commande.
-Dieses Bestellformular innerhalb von 60 Tagen nach der Lieferung Ihres neuen Terex-Muldenkippers zurcksenden, damit Sie Ihre
kostenlose ergnzende technische Dokumentation erhalten. Es kann bis zu 28 Tage dauern, bis Sie die Lieferung der von Ihnen bestellten
Dokumentation erhalten.
-Devuelva esta hoja en el plazo de 60 das tras la entrega de su nuevo dmper Terex para tener derecho a recibir publicaciones tcnicas
adicionales sin cargo. Las publicaciones solicitadas se reciben en un plazo aproximado de 28 das.
11-3
Blank Page
11-4

Operator Hand Book TR45-60 Tier3

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Operator Handbook

TEREX Equipment Limited Operator Handbook

TEREX Equipment Limited Operator Handbook Re-Order

This controlled document is the original instruction and

TEREX Equipment Limited Operator Handbook - Introduction

ONLY TRAINED PERSONNEL SHOULD BE

SPARE PARTS STATEMENT

DIRECTIVES COMPLIED WITH

UNIT SERIAL NO.

SPARE PARTS STATEMENT

DIRECTIVES COMPLIED WITH

UNIT SERIAL NO.

SPARE PARTS STATEMENT

3. CONTROLS AND OPERATING

4. OPERATING THE TRUCK

5. WORKING THE TRUCK

7. MOVING DISABLED TRUCK

8. LUBRICATION AND SERVICING

10. SYMBOL IDENTIFICATION

Safety alert symbol

Intended use of machine

DANGER indicates an imminently hazardous situation which, if

WARNING indicates an potentially hazardous situation which,

CAUTION indicates an potentially hazardous situation which,

CAUTION used without the safety alert symbol indicates an

Read the AEM Safety Manual and follow the recommended

Know clearances of all side and overhead obstructions such as

Be especially aware of overhead power lines.

Be aware of operating hazards that weather changes can create

Never attempt to operate or work on a vehicle when not feeling

Know what safety equipment is required and use it. Such

Handle fuels and lubricants carefully and clean up spills to

Clean any mud, grease or oil from controls, handrails, ladders

Never carry more than one passenger and only in the

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

Vehicle Lifting Instructions

Vehicle Tie Down Precautions

Vehicle Tie Down Instructions

Never use an open flame as a light anywhere on, or around, the

Check the engine compartment for rubbish, oily rags or other

Dont let greasy, oily rags or similar hazards accumulate in the

If the vehicle has been operated with an under inflated tyre.

Flammable Fluid Precautions

Never use an open flame (match, lighter etc.) when checking

Never smoke while checking or adding fuel or other fluids or

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

When preparing vehicles or components for storage, seal and

Follow manufacturers recommendations when handling and

Electrical Hazard Precautions

Leave battery box open when charging batteries in the vehicle

Always disconnect batteries before repairing electrical system to

Always disconnect batteries & alternator leads before carrying

Never check battery charge by placing metal objects across

Use jumper cables only as recommended. Improper use can

Never operate engine starter for more than 30 seconds and

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

Mounting and Dismounting

Always face the access system and maintain at least three

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