Terex TA35 Operation, Safety, Maintenance Manual
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Terex TA35 Operation, Safety, Maintenance Manual

Terex TA35 Operation, Safety, Maintenance Manual

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TA35/TA40
Operation - Safety - Maintenance
Courtesy of Machine.Market

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Summary of Contents for Terex TA35

  • Page 1 TA35/TA40 Operation - Safety - Maintenance Courtesy of Machine.Market...
  • Page 2 WHEN RE-ORDERING THIS HANDBOOK, SPECIFY - PART NUMBER 15275590 TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED MOTHERWELL, SCOTLAND ML1 5RY Ref No. OHE 836/820 June 2005 Courtesy of Machine.Market...
  • Page 3 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. Courtesy of Machine.Market...
  • Page 4 Courtesy of Machine.Market...
  • Page 5 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 lead compounds, chemicals known to the State of California to cause cancer...
  • Page 6 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.
  • Page 7 ML1 5RY DESCRIPTION OF MACHINERY DIRECTIVES COMPLIED WITH MAKE: TEREX 87/404/EEC 97/23/EC MODEL: TA35 ARTICULATED TRUCK 89/336/EEC TA40 ARTICULATED TRUCK 98/37/EEC 2000/14/EC UNIT SERIAL NO. DATE OF MANUFACTURE: INSPECTOR: THE ABOVE MACHINERY, TAKING INTO ACCOUNT THE STATE OF THE ART, COMPLIES WITH, OR IS DESIGNED AND CONSTRUCTED AS FAR AS POSSIBLE TO COMPLY WITH, THE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS OF THE MACHINERY DIRECTIVE.
  • Page 8 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.
  • Page 9 ML1 5RY DESCRIPTION OF MACHINERY DIRECTIVES COMPLIED WITH MAKE: TEREX 87/404/EEC 97/23/EC MODEL: TA35 ARTICULATED TRUCK 89/336/EEC TA40 ARTICULATED TRUCK 98/37/EEC 2000/14/EC UNIT SERIAL NO. DATE OF MANUFACTURE: INSPECTOR: THE ABOVE MACHINERY, TAKING INTO ACCOUNT THE STATE OF THE ART, COMPLIES WITH, OR IS DESIGNED AND CONSTRUCTED AS FAR AS POSSIBLE TO COMPLY WITH, THE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS OF THE MACHINERY DIRECTIVE.
  • Page 10 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.

  • Page 11: Table Of Contents

    Jumper Cables ....... 4-9 Warning Lights ....... 3-4 9. TECHNICAL DATA Pre-Operating Checks ..... 4-10 Instruments ........3-6 Technical Data - TA35 ...... 9-3 Brake Function Checks ....4-11 Switches ......... 3-8 Technical Data - TA40 ...... 9-8 Driving and Stopping ....... 4-13 Controls ........

  • Page 12: 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 TA35 and TA40 Articulated Trucks. Look for this symbol to point out important safety precautions. It means:...
  • Page 13 WARNING These vehicles are equipped with cylinders containing compressed nitrogen gas. Transportation of these vehicles 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.

  • Page 14: Machine Identification

    Machine Identification While reading this handbook you will notice references to controls and equipment which may not be found on all vehicles. It is important that you know your vehicle and its equipment and how to operate it properly. Information regarding the vehicle model, code and chassis serial number is found on the unit serial number plate on the rear right of the...

  • Page 15: Theft Deterrent Practices

    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 vehicle is stolen, or to reduce vandalism. Actions to Discourage Theft and Vandalism Remove all keys any time the vehicle is left unattended. At night lock all doors and attach, secure or lock all anti-vandalism and anti-theft devices on the vehicle.
  • Page 16 Actions to Aid in Recovery of Stolen Vehicles 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 Operator’s Handbook, photographs, and advertising, to familiarize him with the appearance of the vehicle.
  • Page 17 2 - Safety Precautions Courtesy of Machine.Market...

  • Page 18: Safety Precautions General

    SAFETY PRECAUTIONS General Read this Operator’s Handbook and learn the operating characteristics and limitations of the vehicle. Know what operating clearances the vehicle requires. Read the CIMA Safety Manual and follow the recommended safety precautions. Know clearances of all side and overhead obstructions such as wires, bridges, etc., for operating safely.

  • Page 19: Articulation And Oscillation Locks

    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...

  • Page 20: Vehicle Lifting Precautions

    Vehicle Lifting Precautions Prior to lifting, the vehicle should be parked on a level surface, wheels blocked, steering lock bar connected, oscillation lock pin inserted 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.

  • Page 21: Preventing Fire Hazards

    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 machine). 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..
  • Page 22 Shut off engine and use extra caution if engine is hot when refuelling. Ground the hose spout to prevent sparks when spout is touched to fuel tank filler tube. Never smoke while checking or adding fuel or other fluids or handling fluid containers and lines.

  • Page 23: Mounting And Dismounting

    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 cranking periods for cooling.

  • Page 24: Pre-Starting

    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 4-2 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.

  • Page 25: Operating

    Operating Ensure all cab glass, mirrors and light lenses are clean during vehicle operation for maximum visibility. 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 vehicle.
  • Page 26 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 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 and/ or retarder.

  • Page 27: Roading

    Always stay in cab when being loaded. Always lower the body and shut down the vehicle according to the procedure under 'Stopping The Engine' described on page 4-14 before leaving the vehicle unattended. If on a grade wheels should be blocked. Roading Match speed to road conditions.

  • Page 28: Lubrication And Servicing

    Lubrication and Servicing Do not allow unauthorized personnel to service or maintain this vehicle. Study the Operator’s Handbook and 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 ignition switch or a prominent control before cleaning, lubricating or servicing the vehicle.
  • Page 29 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 vehicle. Always use a self-attaching chuck with a long airline and stand to one side while the tyre is inflating.

  • Page 30: Wheels And Tyres

    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.

  • Page 31: Avoid Tyre Explosion Hazard

    Avoid Tyre Explosion Hazard AT LEAST AT LEAST 460 m (1 500 ft) 15 m (50 ft) WARNING Whenever a vehicle’s tyre(s) is (are) exposed to excessive heat such as a machine fire or extremely hot brakes, the hazard of a subsequent violent tyre explosion must be recognized.

  • Page 32: Decals And Instruction Plates

    Decals and Instruction Plates Decals and instruction plates fitted to vehicles may vary from country to country to suit local needs. These pages contain a brief description and the location of the decals and instruction plates that may appear on your vehicle. 1.
  • Page 33 19. Cigar Lighter 24 V 20. Transmission Shift Control 21. Park/Emergency Brake Control 22. Differential Lock Precautions 23. Document Holder 24. Hydraulic Control Lever 25. Hand Lamp 26. Back Alarm 27. Pre-operating Instructions 28. Hydraulic Oil Recommendations 29. Remote Lube and Pressure Points 30.
  • Page 34 2-18 Courtesy of Machine.Market...

  • Page 35: Controls And Operating

    3 - Controls and Operating Courtesy of Machine.Market...
  • Page 36 28 27 1457 Courtesy of Machine.Market...

  • Page 37: Controls And Instruments

    CONTROLS AND INSTRUMENTS 20. Blower Control 1. Side Window Demister 21. Retarder Switch (TA35 only) 2. Windscreen Demister 22. Body Control Lever 3. Face Vent 23. Accelerator Control 4. Warning Lights 24. Service Brake Control 5. Tachometer/Hourmeter 25. Recirculation Vents 6.

  • Page 38: Basic Data

    BASIC DATA Warning Lights 1. Engine Stop Light (Red) - When the 'Stop Engine' light comes on, the computer has detected a major STOP malfunction in the engine that requires STOP immediate attention. It is the operators responsibility to shut down the engine to avoid serious damage.
  • Page 39 9. Transmission Stop Warning Light (Red) - Illuminates for 2 seconds when the ignition is turned on and should go out when the engine starts. Illuminates to indicate any of the following conditions: High retarder temperature High transmission sump temperature Engine overspeed If light illuminates, stop the engine and investigate the cause.

  • Page 40: Instruments

    Instruments 1. Tachometer/Hourmeter - Driven from the alternator, the tachometer indicates the number of engine crankshaft revolutions per minute. The needle shows the variations in engine operating speed. Never accelerate the engine to speeds indicated by the red RPM x100 zone on the dial face.
  • Page 41 4. Fuel Level Gauge - Indicates the level in the fuel tank. Capacity 463 litres (122 US gal). Fill the tank before parking the vehicle overnight to minimize condensation in the tank. Avoid a dry tank condition which requires bleeding the fuel system.

  • Page 42: Switches

    Switches 1. Hazard Warning Light - Press bottom of switch to make turn indicators flash simultaneously as hazard warning lights. The direction indicator warning light, on the instrument panel will flash. To switch hazard lights off; press the top of the switch.
  • Page 43 High Coolant Temperature Low Oil Pressure High Oil Temperature 13. Retarder Switch (TA35) - Pressing the bottom of the switch will request and engage the transmission retarder, provided the transmission is in 'lockup'. To disengage retarder; press the top of the switch.
  • Page 44 14. Diagnostic Test Point - (Located under the dash panel, adjacent to the fuse banks). Plug in connector for diagnostic data reader (DDR). 1014 15. Ignition and Starter Key Switch - The combined switch operates the ignition and starter motor. '0' - Ignition switched off.

  • Page 45: Controls

    Controls Headlight Dipper, Direction Indicator, Windscreen Wiper/ Washer and Horn 1. Headlight Dipper and Flasher: Control downwards = Main Beam Neutral Position = Dipped Beam Control Upwards = Headlight Flash 2. Direction Indicator: Control rearwards = Left Indicators Control forwards = Right Indicators 3.

  • Page 46: Heater

    Heater Blower control (1) is rotated to select one of three blower speeds. Temperature control (3) 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.

  • Page 47: Operator's Seat

    Operator's Seat - Air Suspension (Grammer) The air seat only reacts when the driver sits on the seat. When unoccupied, the seat sinks to the lowest position to allow easier access. The following is the list of controls to adjust the seat: 1.
  • Page 48 Operator's Seat - Operation To achieve the most comfortable driving position, adjust the seat as follows; 1. Sit in seat. 2. Pull up and release height and weight adjustment (1) handle - this will reset the seat to the predetermined height setting - 'bounce' lightly until a 'click' is heard, the seat position in now engaged properly.
  • Page 49 Seat Belt Retractable seat belts are installed on both the operators seat and jump seat. The seat belts require no external adjustment and allow freedom of movement for proper manipulation of all controls. Note: Passenger seat belt has a release button mounted on the under side of the seat belt barrel.

  • Page 50: Machine Controls

    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 Parking-Emergency Brake Control. A 'Brake System Balance' warning light, 'Front Brake System' warning light and a 'Rear Brake System' warning light are located on the instrument panel.
  • Page 51 This switch is used to request the next highest gear. If the rate of descent is too fast, the service brakes should be transmission retarder on TA35 applied and the transmission shifted into a lower gear which will allow a safe descent machines.
  • Page 52 If the vehicle is approaching an overspeed condition, the transmission performs an upshift at an engine speed of 2 500 rev/min to the next highest gear to decrease the engine speed, whether in manual or automatic mode. If 6th gear is already selected, the retarder is automatically engaged at 2600 rev/min to decrease the engine speed irrespective of the accelerator position.
  • Page 53 STOP 1 - Electronic Control Module (ECM) 6 - Check Engine Light 2 - Programmable Read Only Memory (PROM) 7 - Stop Engine Light 3 - Electronic Unit Injectors (EUI) 8 - Diagnostic Request/Stop 4 - Batteries Engine Override Switch 5 - Electronic Foot Pedal 9 - Diagnostic Test Point 1139...
  • Page 54 DDEC III & IV Description 1. Electronic Control Module (ECM) - Receives electronic inputs from the driver as well as from mounted 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.
  • Page 55 DDEC III & IV Operation The DDEC system operates from a 24 volt supply. However, in the event of a loss of power supply, the system will operate at reduced voltage. At reduced voltage the electronic control system will detect a malfunction and the check engine light on the dash panel will illuminate.
  • Page 56 Note: The ECM will record the number of times the override is activated after the fault occurs. Available Torque is the actual torque available from the engine WARNINGS when the fault occurred based on the actual rev/min when the fault occurred. The operator of a DDEC- The engine should not be restarted after it has been shut down after activation of equipped vehicle must not...
  • Page 57 DDEC IV DIAGNOSTIC CODES DDEC Code # (Flashed) DDEC Description Fram checksum incorrect Clock module abnormal rate Clock module fault/failure Incompatible calibration version External failed RAM Internal failed RAM Entered boot via switches VSG sensor voltage low VSG switch system not responding VSG sensor high Coolant level sensor input voltage low Add coolant level sensor input voltage low...
  • Page 58 DDEC IV DIAGNOSTIC CODES DDEC Code # (Flashed) DDEC Description Oxygen content circuit input voltage low Reserved for 'No Codes' Auxiliary shutdown #1 active Auxiliary shutdown #2 active Ambient air temperature sensor input voltage high (Release 2.00 or later only) Air temperature sensor input voltage high Intake manifold temperature sensor input voltage high Ambient air temperature circuit failed low (Release 2.00 or later...
  • Page 59 DDEC IV DIAGNOSTIC CODES DDEC Code # (Flashed) DDEC Description High range fuel pressure sensor input voltage high Fuel restriction sensor input voltage high Fuel pressure sensor input voltage low High range fuel pressure sensor input voltage low Fuel restriction sensor input voltage low Too many SRS (missing TRS) Too few SRS (missing SRS) Coolant level low...
  • Page 60 DDEC IV DIAGNOSTIC CODES DDEC Code # (Flashed) DDEC Description Out of calibration Vehicle speed sensor fault J1939 data link fault Proprietary datad link fault (Master) Proprietary datad link fault (Receiver) J1587 data link fault J1922 data link fault Torque overload Injector xxx response time long Aux.
  • Page 61 DDEC IV DIAGNOSTIC CODES DDEC Code # (Flashed) DDEC Description PWM #2 short to battery (+) PWM #2 open circuit PWM #3 short to battery (+) PWM #3 open circuit PWM #4 short to battery (+) PWM #4 open circuit PWM #1 above normal range PWM #1 below normal range PWM #2 above normal range...
  • Page 62 DDEC IV DIAGNOSTIC CODES DDEC Code # (Flashed) DDEC Description Coolant pressure sensor input voltage low Air inlet pressure sensor input voltage high Air inlet pressure sensor input voltage low High range coolant pressure sensor input voltage high High range coolant pressure sensor input voltage low TPS idle validation circuit fault (short to ground) TPS idle validation circuit fault (open circuit) Injector xxx response time short...
  • Page 63 DDEC IV DIAGNOSTIC CODES DDEC Code # (Flashed) DDEC Description Oil level sensor input voltage high Crankcase pressure sensor input voltage high Injection control pressure circuit voltage high Exhaust temperature sensor input voltage high Timing actuator (dual fuel) input voltage low Oil level sensor input voltage low Crankcase pressure sensor input voltage low Injection control pressure circuit voltage low...
  • Page 64 Steering The steering wheel position can be adjusted as required for the most convenient operating position. To adjust, pull out adjustment lock and tilt steering wheel up or down as desired; release lever to lock adjustment. To steer the machine, rotate the steering wheel in the desired direction to the required radius of turn.
  • Page 65 EST-37 Automatic Shift Transmission WARNING The EST-37 transmission is equipped with an electronic control unit (ECU) Before any welding is done on a which continually monitors the transmission and shift system electrical machine equipped with an components and warns the operator when a problem develops. It also takes EST-37 shift system, disconnect action to prevent damage to the transmission, and provides the serviceman battery earth cable, battery...
  • Page 66 VTS-3 Shift Controller - Operation: The shift controller has 3 positions the lever can rest in, Forward, Neutral (N) and Reverse. Within each of these positions, the gear can be changed by pushing the lever to the right (+) to upshift or to the left (-) to downshift.
  • Page 67 When shifting from 'NEUTRAL' to start from a standstill, or to reverse direction, decelerate the engine to idle speed before selecting the proper gear. When 'REVERSE' is selected, the 'Reverse Alarm' sounds and the 'Reverse Light' illuminates to warn personnel to the rear of the machine that reverse gear has been selected.
  • Page 68 A dashboard display is provided which indicates gear selected and driving direction as follows: Manual Mode - When driving with shift selector in manual range, the bars only are shown in position 1, and, driving direction and gear selected are indicated in positions 2 and 3.
  • Page 69 Note: In cold weather, the transmission oil should be warmed up by running the engine at idle speed with the gear selector in neutral, since the system will not operate satisfactorily if the oil is too cold. When temporarily stopped, such as for yielding the right-of-way to a loaded machine, the transmission can be left in gear and the machine held stationary with the service brakes.
  • Page 70 DESCRIPTION OF FAULT CODES ERGOCONTROL Code Operator Action Mode Meaning Service Action Stop and investigate Direction signal: no operation Electrical problem on TCU input Check cables from gear Range signal: normal from gear selector selector to TCU Drive truck to Substitute mode (controlled Electrical problem on analog TCU Check cables to load sensor/...
  • Page 71 DESCRIPTION OF FAULT CODES ERGOCONTROL Code Operator Action Mode Meaning Service Action Stop and investigate Limp home Electrical problem on transmission Check cables to transmission solenoids control valve Stop and investigate Limp home Electrical problem on transmission Check cables to transmission solenoids control valve Drive truck to...
  • Page 72 DESCRIPTION OF FAULT CODES ERGOCONTROL Code Operator Action Mode Meaning Service Action Drive truck to No converter lockup clutch, Electrical problem on peripheral Check cables to converter next service difflock, retarder solenoids. lockup clutch, difflock, retarder Stop and investigate Limp home Mechanical or hydraulic problem in Check transmission pressure, clutches or faulty speed reading...
  • Page 73 DESCRIPTION OF FAULT CODES ERGOCONTROL Code Operator Action Mode Meaning Service Action Stop F1-F5: No operation General fault (F6) Start AEB, else replace Abbreviations: TCU = Transmission Control Unit TC = Torque Converter AEB = Self Calibration Clutches Operator Warning Codes Code Meaning Action...
  • Page 74 Differential Lock The differential lock switch engages the differential locks in both the transmission drop-box differential and the centre axle thru-drive differential for improved traction when operating in soft or slippery conditions. The amber 'Differential Lock' switch illuminates to alert the operator when the differential locks are requested.
  • Page 75 Body Control This lever operates the body hoist cylinders. The four operating positions of the lever are - Raise - Pushing the lever back and holding it in this position will raise the body. When released, the lever will spring back to the 'HOLD' position. Hold - This position stops and holds the body at any desired height.
  • Page 76 3-42 Courtesy of Machine.Market...
  • Page 77 4 - Ope ra t ing T he Truc k Courtesy of Machine.Market...

  • Page 78: Operating The Truck Pre-Starting Inspection

    OPERATING THE TRUCK ENGINE DIFFERENTIAL Pre-Starting Inspection Check oil level. Check for leaks. Check for leaks * Before the engine is started ensure SHOCK ABSORBERS BRAKE COOLANT TANK (TA40 only) the vehicle is ready for operation. Check for debris, leaks and Check oil level.

  • Page 79: Component Checks

    COLD FILL LEVEL MINIMUM - ENGINE OFF 1468 152mm (6") Min LEVEL BAND - ENGINE COLD FILL RUNNING LEVEL MINIMUM - ENGINE RUNNING 1572 2. Engine - With engine off, check 3. Radiator Top Tank - Check Component Checks engine oil level. The oil level should Coolant Level.
  • Page 80 4. Engine Air Cleaner Dust Valve - Check for plugged dust cap valve. Unplug valve and clean air cleaner dust cup if required. 1469 5. Hydraulic Filter - Check filter indicator and have filter element replaced if necessary. 1470 6. Tyres - Carefully inspect all tyres for cuts, bruises, or other damage, and, proper inflation for the loads to be carried.
  • Page 81 7. Hydraulic Tank - Oil Level Check - Operate the body hoist cylinders to their fully-extended positions to charge cylinders and lines then lower the body. With the engine off, the sight gauge should show half full. Add oil if low. 1471 8.

  • Page 82: Engine Operation

    Engine Operation Note: The engine MUST be started with foot 'OFF' the electronic foot pedal. Operate engine at top rated speed when maximum power is needed for the load. NEVER idle the engine for more than 5 minutes at a time; shut it off. If 'Check Engine' light and/or 'Stop Engine' light illuminate during operation of the vehicle, take effective action to stop the engine and correct the fault, as described under 'DDEC Operation', in Section 3 of this handbook.

  • Page 83: Starting The Engine

    Starting the Engine Attention to the warning lights and instruments when starting the engine, and operating, will help the operator monitor the vehicle systems and components. 1. Make sure park-emergency brake control is in the 'PARK' position. 1461 1233 2. Turn master switch to 'ON' position. 3.
  • Page 84 7. Turn key farther clockwise, against spring pressure, to position '2' to crank engine; release key as soon as engine starts firing. Note: Engine MUST be started with foot 'OFF' the accelerator pedal. Note: Never crank the engine more than 30 seconds continuously. Allow starter at least 2 minutes cooling time between cranking periods to avoid overheating.
  • Page 85 Starting the Engine with Jumper Cables WARNINGS 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.

  • Page 86: Pre-Operating Checks

    Pre-Operating Checks Make sure all cab glass, mirrors and lights are clean. Test all controls to ensure they are functioning properly. Move transmission gear shift control momentarily to 'REVERSE' to make sure the reverse alarm sounds. 1. Transmission - Hot Oil Level - Apply the parking brake, select neutral gear and start the engine.

  • Page 87: Brake Function Checks

    BRAKE FUNCTION CHECKS In addition to the 'Pre-Operating 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 vehicle. WARNING Make sure the area around the vehicle is clear of personnel and obstructions before carrying out these checks.
  • Page 88 Note: Brake holding effort required to hold a machine static at a specific rev/min, can vary from machine to machine due to differences in engine performance, powertrain effeciencies, etc., as well as differences in brake holding ability. Note: As an indication of system deterioration, the engine rev/min at which point the machine moved, with the service or emergency brakes applied, can be compared against the engine rev/min your specific machine was able to hold to on a previous check.

  • Page 89: Driving And Stopping

    Driving and Stopping Before driving off observe all instruments and warning lights. All instruments should operate in their normal range and all warning lights should be out except possibly the Direction Indicator, Headlight Mainbeam and Differential Lock warning lights. Make sure the area around the vehicle is clear of personnel and obstructions before driving off.
  • Page 90 4. Sound horn; two blasts for forward and three blasts for reverse. 5. Release the service brake, apply the accelerator and move off. Shift up a gear as speed and conditions allow. Shift down a gear, only after the top speed of the next lower gear has been reached.

  • Page 91: Stopping The Engine

    Stopping the Engine 1. Make sure parking-emergency brake control is in the 'PARK' position. 2. Make sure the transmission is in 'NEUTRAL'. 3. Allow the engine to run between idle and 1 000 rev/min with no load for 4 or 5 1461 minutes.
  • Page 92 Parking When parking the machine overnight, or for an extended period, the following RPM x100 procedure in addition to that given in 'Stopping the Engine' will help maintain it in good condition for subsequent use: 1. Fill the fuel tank completely before parking the machine overnight, or for extended periods, to prevent condensation.
  • Page 93 5 - Work ing t he Truc k Courtesy of Machine.Market...

  • Page 94: Working The Truck

    WORKING THE TRUCK Off-highway articulated trucks are used on a variety of hauling jobs, from sand and gravel pits to road construction and mining. Every truck operation, regardless of the type of job, can be divided into four phases; loading, hauling, dumping and the empty return.
  • Page 95 For maximum material movement, the truck operator must help the loading machine operator keep loading time to a minimum. The shorter the distance the loading unit bucket must travel between the cut, or stockpile and the truck body, the more passes it can make in a given period of time and the quicker the truck can be loaded.
  • Page 96 For fastest, most accurate loading, when being loaded by a front end loader, the truck operator should stop 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.
  • Page 97 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 or encountering extremely soft or slippery conditions, stop the machine and engage the differential locks.
  • Page 98 Dumping When dumping the operator should steer the vehicle ensuring that it is straight and with the load on level ground. 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.
  • Page 99 Before raising the body, make sure that the rear wheels are on firm level ground. If one wheel is higher than the other, a twisting strain is imposed upon the body hinge pins, hoists and chassis. Stop the 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.
  • Page 100 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 gear before releasing the brakes and moving away from the dump site. WARNING Do NOT drive the truck with the body up. No articulated truck is stable in this condition and, apart from the risk of a rear-end topple, there can Make Sure Body is Fully Down be severe danger from contacting overhead electric cables, trees, or...

  • Page 101: 6 - Roa Ding

    6 - Roa ding Courtesy of Machine.Market...

  • Page 102: General

    ROADING Note: Make sure the body control WARNING lever is in the 'FLOAT' position. These machines are equipped with cylinders containing compressed Failure to comply to this could nitrogen gas. Transportation of these machines by any method may result in overheating the hydraulic require a special permit from the appropriate authority of the country oil and failure of the hydraulic involved.
  • Page 103 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.

  • Page 104: In Case Of Trouble

    In Case of Trouble If trouble develops on route, move the vehicle 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.

  • Page 105: 7 - M Oving Disa Ble D Truc K

    7 - M oving Disa ble d Truc k Courtesy of Machine.Market...
  • Page 106 MOVING DISABLED TRUCK WARNINGS Any unusual power train noises noted while operating the truck should be reported to those responsible for maintenance. Should the power train, hydraulic Disconnecting transmission or electrical systems fail, the vehicle should be stopped and shut down from engine will prevent the steering pump from operating, immediately until suitable repairs can be made.
  • Page 107 Block all wheels securely. Turn the hex-head on the parking brake actuator anticlockwise until the brake pads are free from the disc. When the hydraulic WARNINGS system is repaired, return the actuator to its original position by turning the hex- head fully clockwise.
  • Page 108 Courtesy of Machine.Market...

  • Page 109: Lubrication And Servicing

    8 - Lubrication and Servicing Courtesy of Machine.Market...
  • Page 110 SAFETY PRECAUTIONS Do not allow unauthorized personnel to service or maintain this machine. Study the Operator’s Handbook and Maintenance Manual before starting, operating or servicing this machine. Always follow procedures and safety precautions detailed in the Maintenance Manual. Always attach a 'DO NOT OPERATE' or similar warning sign to ignition switch or a control before cleaning, lubricating or servicing the machine.
  • Page 111 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.
  • Page 112 8 25 9 15 11 29 31 30 37 36 7 16 32 27 1661 Courtesy of Machine.Market...

  • Page 113: Lubrication And Service Chart

    Lube. EP, NLGI See Note 1 Wheel Rim Nuts (TA40) Check torque. 540 Nm (400 lb ft) Wheel Rim Nuts (TA35) Check torque. 730 Nm (540 lb ft) Cab Ventilation Filter Inspect and clean if required. Drive Belts Check tension. Adjust if required.
  • Page 114 Check end float. Adjust if required. Parking Brake Slack Adjuster Lube Parking Brake Pads Check wear. Replace/adjust if required. Service Brake Pads (TA35) Check wear. Replace if required Fuel Cooler Clean and inspect cooler fins. See Note 6 Charge Air Cooler Clean and inspect cooler fins.
  • Page 115 LUBRICATION AND SERVICE CHART (Continued) Interval Ref. No. of Service Hours Points Identification Service Instructions Points Lubricant Quantities Engine Steam clean Radiator and Cooling System Drain, flush and refill. Coolant See Page 13 21/22 Drivelines (Low Maintenance) Check for leaks and damage. See Page 12 Articulation Pivot Nut Check torque...

  • Page 116: Miscellaneous Servicing Information

    Wheel Rim Nuts (TA40) - After first 10 hours of operation re-torque nuts to 540 Nm (400 lb ft). Check torque every 50 hours (weekly) thereafter. Wheel Rim Nuts (TA35) - After first 10 hours of operation re-torque nuts to 730 Nm (540 lb ft). Check torque every 50 hours (weekly) thereafter.
  • Page 117 1. Dot Marks - Before starting up after a major shut down period the oil level should be up to the top dot mark (Cold level). 2. Dash Marks - Upon shutting down the engine at low idling (wait 1 to 2 minutes) the oil level should be up to, but not over, the top dash mark (Hot level).
  • Page 118 Examine the vehicle, particularly the chassis, for cracks or broken welds. Repair where necessary. Service Brakes (TA35) - Check pads and discs for wear and replace where necessary. Test for proper function. Note: This service interval applies to normal driving. Check the pads more frequently under more severe conditions.
  • Page 119 Brake Coolant Tank (TA40 only) - Drain oil, replace filter and breather. Refill brake coolant tank. Replace tank breather. Axles (TA35) - Drain lubricant and refill to level plug. Note: When refilling centre axle ensure that 3rd differential unit is primed with 1 litre (1.75 UK pints) of oil before filling drive head.
  • Page 120 EVERY 2 000 HOURS Drivelines - Visually check Low Maintenance drivelines for leaking or damaged seals. Note: Low Maintenance drivelines can be identified by having plugs fitted to the spiders, not grease nipples. Axles (TA40) - Drain lubricant and refill to level plugs. Note: When refilling centre axle ensure that 3rd differential unit is primed with 1 litre (1.75 UK pints) of oil before filling drive head.

  • Page 121: Recommended Lubricants

    Planetaries - TA40 Extreme Pressure 8.5 litre each MIL-L-2105 D GL-5 80W-90 LS Gear Lubricant (2.2 US gal) (See Note 3) Differentials - TA35 Extreme Pressure 31 litre each MIL-L-2105 D GL-5 80W-90 LS (Front,Centre,Rear) Gear Lubricant (8.2 US gal) (See Note 3)
  • Page 122 RECOMMENDED LUBRICANTS - continued COMPONENT LUBRICANT *CAPACITY SPECIFICATIONS API CODE SAE GRADE Fuel Tank Diesel Fuel Oil with 463 litre DIN EN590 max. sulphur 0.5% (122 US gal) Grease Nipples** Extreme Pressure No.2 Lithium Grease Consistency Driveshaft through Extreme Pressure 1.50 litre MIL-L-2105 D GL-5...
  • Page 123 Recommended Lubricants notes LUBRICANT GRADE SELECTION GUIDE AT AMBIENT (START-UP) Capacities given are approximate, TEMPERATURE work to dipstick, sight gauges or level plugs. HYDRAULIC OIL ** Refer to the 'Recommended Lubricants Table' for the different MIL-SPEC applications. DO NOT use on the CODE Articulation or Oscillation bearings.
  • Page 124 8-16 Courtesy of Machine.Market...

  • Page 125: Technical Data

    9 - Technical Data Courtesy of Machine.Market...
  • Page 126 1 280 Body 3 220 (4-2) Depth ( 10-7 ) 3 000 (9-10) Vehicle Clearance 45˚ Turning Diameter 19.5m (64ft) 6 500 (21-4) 65˚ 3 720 (12-2) 5 673 (18-5) 5 373 (17-5) 3 620 (11-7) 25˚ 2 860 3 340 (9-4) (10-11) 2 170...

  • Page 127: Technical Data -Ta35

    TECHNICAL DATA -TA35 Pressures: ENGINE Main ........16 + 2 bar (232 + 30 lbf/in²) Lockup (Wk) ..... 14 ± 1 bar (190 + 15 lbf/in²) Make/Model ........Detroit Diesel Series 60 Converter 'IN' ..7.6 bar (110 lbf/in²) at 2 300 rev/min Type ..
  • Page 128 AXLES suspension linkages are rubber-bushed and maintenance-free. Three axles in permanent all-wheel drive with differential coupling between each axle to prevent driveline wind-up. Heavy duty axles with fully-floating axle shafts and outboard Axle Vertical Travel ......± 115 mm (± 4.5 in) Axle Oscillation ............
  • Page 129 Steering WHEELS AND TYRES Hydrostatic power steering by two double-acting, Wheels ..Five-piece Earthmover rims with 23 Stud Fixing cushioned steering cylinders. Actuating pressure for Size: steering operation is supplied by the main hydraulic gear Standard ....... 25 x 22.00 in for 26.5 R25** tyres pump.
  • Page 130 Typical Noise Levels BODY All welded construction, fabricated from high hardness Operator Ear (ISO 6394) ..........80dbA (min. 360 BHN) 1 000 MPa (145 000 lbf/in²) yield strength steel. 25° tail chute angle provides good load *Exterior Sound Rating (ISO 6395) ......112 dbA retention without tailgate.
  • Page 131 VEHICLE WEIGHTS Standard Vehicle Net Distribution Front Axle 13 600 29 985 Centre Axle 7 400 15 315 Rear Axle 7 100 15 650 Net Weight 28 100 61 950 Payload 32 000 70 545 Gross Distribution Front Axle 17 700 39 020 Centre Axle 21 350...
  • Page 132 Courtesy of Machine.Market...
  • Page 133 TA40 Technical Data On Following Page Courtesy of Machine.Market...
  • Page 134 1 450 Body 3 220 (4-9) Depth ( 10-7 ) 3 020 (9-11) Vehicle Clearance 45˚ Turning Diameter 19.5m (64ft) 6 500 (21-4) 65˚ 3 720 (12-2) 5 700 (18-8) 5 370 (17-7) 3 670 (12-0) 25˚ 3 100 3 450 (10-2) (11-4) 2 240...

  • Page 135: Technical Data - Ta40

    TECHNICAL DATA - TA40 Pressures: ENGINE Main ........16 + 2 bar (232 + 30 lbf/in²) Lockup (Wk) ..... 14 ± 1 bar (190 + 15 lbf/in²) Make/Model ........Detroit Diesel Series 60 Converter 'IN' ..7.6 bar (110 lbf/in²) at 2 300 rev/min Type .....
  • Page 136 AXLES rear suspension linkages are rubber-bushed and Three axles in permanent all-wheel drive with differential maintenance-free. coupling between each axle to prevent driveline wind-up. Heavy duty axles with fully-floating axle shafts and Axle Vertical Travel ......± 115 mm (± 4.5 in) Axle Oscillation ............
  • Page 137 WHEELS AND TYRES Pump capacity (at 2258 rpm) ....... 7.03 litre/s (111 US gal/min) Wheels ..Five-piece Earthmover rims with 23 Stud Fixing Size: Steering Standard ....... 25 x 25.00 in for 29.5 R25** tyres Hydrostatic power steering by two double-acting, Tyres: cushioned steering cylinders.
  • Page 138 ELECTRICAL SYSTEM Differential - Dana (Centre) ....38 litres (10 US gal) Differential - Dana (Rear) ....31.5 litres (8.3 US gal) Type ..........24 volt, Negative Ground. Planetaries - Dana ......8.5 litres (2.2 US gal) Battery ..Two, 12 Volt, 175 Ah each, Maintenance Free Driveshaft Bearings ......
  • Page 139 VEHICLE WEIGHTS Standard Vehicle Net Distribution Front Axle 15 275 33 675 Centre Axle 7 750 17 085 Rear Axle 7 705 16 985 Net Weight 30 730 67 745 Payload 36 500 80 470 Gross Distribution Front Axle 20 170 44 465 Centre Axle 23 530...
  • Page 140 9-16 Courtesy of Machine.Market...
  • Page 141 1 0 - Sym bol I de nt ific a t ion Courtesy of Machine.Market...

  • Page 142: Symbol Identification

    SYMBOL IDENTIFICATION These pages explain the meaning of symbols that may appear on your machine. Basic Switch Warning 'Off' Hourmeter Lock Symbol Pressurised Negative Fast Basic Compartment Ground Engine Master Ammeter Slow Engine Switch Starter Switch Circuit Lock Engine 'On' Breaker Rev/Min 10-2...
  • Page 143 Engine 'Off' Basic Transmission Minimum Transmission Convertor Lockup Emergency Transmission Maximum Engine Pressure Shut Off High Engine Transmission Air Filter Basic Hydraulic Pressure Restriction Oil Symbol Engine Transmission Starter Hydraulic Pressure Temperature Pressure Filter Engine Transmission Oil level Hydraulic Oil Filter Oil Filter Filter Pressure...
  • Page 144 Heating Light Flood Horn Hydraulic Coolant Fuel Gauge Light Low Windshield Temperature Beam Wiper Fill tube Coolant 'cold' Fuel Filter Light High Windshield Beam Defroster Coolant 'Hot' Fuel Instrument Windshield Shut-Off Panel light Washer Cooling Basic Lamp Test Blower Fan Lights Symbol 10-4...
  • Page 145 Heater Parking Low Steering Body 'Hold' Brake Pressure Brake Oil High Speed Body Conditioner Temperature or Level 'Lower' Inside Turn Left Low Speed Body or Level Float' Circulation Outside Turn Right Body Up Dumpertruck 'Retarder' Parking Brake Tilt Steering Body 'Raise' Neutral 10-5 Courtesy of Machine.Market...
  • Page 146 Lift Point Clutch Bowl Engine STOP 'Disengaed' Suspension Stop Brake Trans. Do Not Lift Applied Maintenance Over speed Clutch Engaged Forward Brake Applied Transmission Clutch Convertor Disengaged Reverse Water in Brake air Fuel Pressure Clutch Wait to Engine 'Engaged' Start Check 10-6 Courtesy of Machine.Market...
  • Page 147 Notes 10-7 Courtesy of Machine.Market...
  • Page 148 NOTES 10-8 Courtesy of Machine.Market...
  • Page 149 NOTES 10-9 Courtesy of Machine.Market...
  • Page 150 NOTES 10-10 Courtesy of Machine.Market...

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