Terex TA9P Tier 4 Final Operation Manual
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Terex TA9P Tier 4 Final Operation Manual

Terex TA9P Tier 4 Final Operation Manual

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SITE DUMPER
Operations Manual
TA9, TA9P, TA9S
TA9SP & TA10P
Issue Date:
Language:
Revision No.:
Reference No.:
Original Instructions
Tier 4
Final
1 March 2016
English
1.4
1501

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Summary of Contents for Terex TA9P Tier 4 Final

  • Page 1 TA9, TA9P, TA9S TA9SP & TA10P Tier 4 Final SITE DUMPER Operations Manual Issue Date: 1 March 2016 Language: English Revision No.: Reference No.: 1501 Original Instructions...
  • Page 2 Terex Construction Central Boulevard Prologis Park Coventry CV6 4BX England +44 (0)24 7633 9400 +44 (0)24 7633 9500 Email:sales@terex.com www.terex.com Serial Number Year of Construction Date of Delivery Dealer Stamp Notice...
  • Page 3 Record of Revisions Record of Revisions Revision Number Reason for Change Date Original Issue 1-May-2015 Technical Data Section Revised 1-November-2015 Revised Weights Added 1-January-2016 TA 9P, 10 &10P version added also “Stop-Start”* option 1-February-2016 TA9S and TA9SP Swivel Skip Version Added 1-March-2016 * The “Stop-Start”...
  • Page 4 Record of Revisions Intentionally Left Blank 1-March-2016 United Kingdom Operations Manual Page 2 -2 TA9 & TA10 Tier 4 Final...

  • Page 5: Table Of Contents

    Table of Contents Table of Contents Introduction Important Information ..............1.1 Safety Alert System ..............1.1 Intended Use ................1.1 Operations Manual ..............1.1 Identification Plate ..............1.2 Warranty Registration ..............1.3 Warranty ..................1.3 Service and Replacement Parts Enquiries ......... 1.3 Official Documents European Community Only ......
  • Page 6 Table of Contents Safety Sign Location - ANSI ..........2.16 Technical Data Dimensions .................3.1 TA 9, TA9P & TA10P .............3.1 Dimensions ..................3.2 TA9S & TA9SP ...............3.2 Turning Circle ................3.3 Data ....................3.4 Noise Emissions .................3.6 Vibration Levels ................3.6 Description TA 9, TA9P & TA10P Dumper .............4.1 TA9S &...
  • Page 7 Table of Contents 4.17 Gear Selector Lever “Synchro-Shuttle” Machines ....4.19 4.18 Gear Change - “Power Shift” Machines ........4.20 4.19 Parking Brake ................4.21 4.20 Skip Control Lever ..............4.22 4.21 Tow Hitch ................. 4.22 4.22 12v Accessory Socket ............... 4.23 Transportation Transporting by Rail ..............
  • Page 8 Table of Contents To Return the Skip to the Ahead (Travelling) Position ..7.12 7.11 Parking the Machine After Use ..........7.12 Emergency Operating Procedures Running Out of Fuel on a Slope ..........8.1 To Lower the Skip with the Engine “Dead” ........8.1 “Jump Starting”...
  • Page 9 Table of Contents Gearbox ................9.21 Transfer Box ................ 9.21 Axles ..................9.21 Brake Reservoir ..............9.22 Hydraulic System ..............9.22 Engine Coolant ..............9.22 Fuel System ................. 9.22 Grease ................. 9.22 9.21 Fluid Capacities ................ 9.22 10. Troubleshooting 10.1 General Troubleshooting ............10.1 Engine will not start ..............
  • Page 10 Table of Contents Intentionally Left Blank 1-March 2016 United Kingdom Operations Manual Page -6 TA9 Tier 4 Final...

  • Page 11: Introduction Important Information

    Introduction Important Information TEREX appreciates your choice of our product for your application. Our number one priority is user safety which is best achieved by our joint efforts. We feel you can make a major contribution to safety if, you as the machines user: •...

  • Page 12: Identification Plate

    Introduction 1 Any person who intends to use this equipment must read this operations manual carefully before operating the machine. Make sure this operations manual is kept with the machine at all times and is in good condition - replace the manual immediately if it becomes dirty, damaged or has been lost. The manual holder is located in the back of the seat (Figure 1.1) and is lockable.

  • Page 13: Warranty Registration

    Model Year Bar Code Warranty Registration Your dealer will have registered you as the owner with Terex at the time of sale. Should you have any queries please consult your dealer in the first instance. Warranty Full terms and conditions of the machines warranty will be found in the warranty certificate included in or accompanying this manual.

  • Page 14: Official Documents European Community Only

    Introduction 1 Official Documents European Community Only CE mark The Machinery Safety directive is intended to harmonise all the machinery safety regulations throughout the community so that there will be no technical barriers to trade. Compliance with the essential safety requirements of the EEC directives 2006/42/EC (machinery), 2000/14/EC (Noise) and 2004/108/EC, permits companies to CE mark their products.
  • Page 15 Commercial Name: Same as Model /Type Terex GB Limited hereby declares that the above piece of machinery is in conformity with the relevant provisions of the Machinery Directive 2006/42/ EC Terex GB Limited hereby declares that the above piece of machinery is in conformity with the provisions of the following other EC-directives: Noise - Equipment Used Outdoors (2000/14/EC), Emissions - Non-Road Engines (97/68/EC) and Electromagnetic Compatibility (2004/108/EC).

  • Page 16: California Proposition

    • For any product modifications to your machine. • To report an accident involving Terex equipment. • Product applications and safety. • Standards and regulations compliance. • To report change of ownership or ownership details (if not reported to a Terex dealer). 1-March-2016 United Kingdom Operations Manual Page 1 - 6 TA9 &...

  • Page 17: Transfer Of Machine Ownership

    1.13 Transfer of Machine ownership If you sell or otherwise dispose of your machine you must tell your dealer or otherwise Terex.:- • The name and address of the new owner • The model and VIN number of the machine •...
  • Page 18 Introduction 1 Intentionally Left Blank 1-March-2016 United Kingdom Operations Manual Page 1 - 8 TA9 & TA10 Tier 4 Final...

  • Page 19: Safety

    Safety 2 Safety This manual is designed as a guide to the Machines Controls, Operation and Maintenance. IT IS NOT A TRAINING MANUAL Safety Alert System The Safety Alert Symbol is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death ANSI Hazard Classification System Only Applicable to ANSI Safety Signs)

  • Page 20: Personal Protective Equipment (Ppe)

    Safety 2 Property Damage NOTICE NOTICE - (Used without a safety alert symbol and white italic letters on a blue background) Is used to address practices not related to personal injury Procedure PROCEDURE PROCEDURE - (Used without a safety alert symbol and black letters on a green background). This indicates a procedure that must be followed step by step for safe operation.
  • Page 21 Safety 2 The following symbols indicate the personal protective equipment that must be worn when site conditions dictate. Protective Protective Face Shield A face shield Gloves gloves must must be worn be worn when when necessary to conditions prevent injury dictate to from sharp prevent eye or...

  • Page 22: General Safety Information

    Safety 2 The following symbols indicate the personal protective equipment that must be used when site conditions dictate when performing maintenance on the machine. Protective Protective Protective Protective Clothing clothing must Gloves gloves must be worn when be worn when conditions conditions dictate.
  • Page 23 Safety 2 • The exhaust gets extremely hot. Do not place anything on top of it and keep all combustible materials clear. Do not attempt any maintenance on a hot engine. • Be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions.

  • Page 24: Seat Belt

    Safety 2 • Keep floor plates and steps free from dirt, oil, snow, ice etc. • Check seat belts daily. YOU MUST ALWAYS WEAR A SEAT BELT WHEN OPERATING THE MACHINE. • Do not remove the radiator cap when the engine is hot. Do not add coolant to a hot engine. •...

  • Page 25: Lockout And Tag Out

    Safety 2 Do NOT use the ROPS as an attachment point for towing or pulling equipment. Lockout and Tag Out To prevent unauthorised starting of the machine, before any maintenance you must always:- • Apply parking brake. • Place transmission in Neutral •...

  • Page 26: Fires

    Safety 2 Never 'jump start' a machine with a frozen battery. To help prevent freezing, keep the battery fully charged. Do Not Use a Machine with Frozen Battery Electrolyte 2.11 Fires Using water to extinguish an oil fire could spread the fire or give you a shock from an electrical fire.

  • Page 27: First Aid - Oil

    Safety 2 • Use special hand cleansers to help clean dirty hands. • Never use petrol, diesel fuel or kerosene. • Avoid skin contact with oil soaked clothing. • Do not keep oily rags in pockets. • Wash dirty clothing before reuse. •...

  • Page 28: Maximum Gradient

    Safety 2 Maximum Gradient The maximum gradient - X - (Figure 2.2) permissible for this machine is 20% (11º, 1 in 5) Do not attempt to exceed the machines gradient capabilities. It should be noted that adverse ground conditions will limit the machine’s gradient capabilities. OV00404 Figure 2.2 - Maximum Gradient (3) Crossing a Slope...

  • Page 29: Overturning

    Safety 2 especially at an angle etc. The driveways must also avoid any other possible dangers e.g. overhead cables, work areas etc. The operator must make sure the machine is driven correctly at all times especially with regards to speed, overloading, only using the machine for the intended task, not driving dumpers with a lift-skip in the raised position etc.

  • Page 30: Safety Sign Symbols

    Safety 2 Safety Sign Symbols Table 2.1 - Description of Safety Symbols HAZARD AVOIDANCE DESCRIPTION Hazard: Attention, safety involved Avoidance: Read and understand operator’s manual before using the equipment Hazard: Attention, safety involved Avoidance: Remove start key and isolate battery before maintaining the machine Hazard: Fall/Crush Avoidance: Do not carry passengers or allow people to ride on the machine...
  • Page 31 Safety 2 HAZARD AVOIDANCE DESCRIPTION Hazard: Entanglement Avoidance: Keep away from fan and belt.Turn off engine and remove key before servicing. Hazard: Crushing Avoidance: Stay clear of machine Hazard: Machine Instability. Avoidance: Read operators manual Hazard: Crush during Roll Over Avoidance: Always wear a seat belt when operating the machine Hazard: Crush Zone...

  • Page 32: Safety Sign Location - Iso

    Safety 2 Safety Sign Location - ISO Figure 3-4 - Safety Sign Location - ISO COV00631A 1-March-2016 United Kingdom Operations Manual Page 2 - 14 TA9 & TA10 Tier 4 Final...
  • Page 33 Safety 2 Table 2 .2 - Safety Signs - ISO Item Decal Description Remarks Safety - Read Instruction Book Safety - Remove Start Key Before Maintenance Safety - Fall Hazard - No Passengers Safety - Gradient Hazard Safety - Tip Over Hazard Safety - High Pressure Oil Leaks Information - Dashboard Symbols Information - Auto Stop/Start Decal...
  • Page 34 Safety 2 Intentionally Left Blank 1-March-2016 United Kingdom Operations Manual Page 2 - 16 TA9 & TA10 Tier 4 Final...

  • Page 35: Technical Data Dimensions

    Technical Data 3 Technical Data Dimensions (1) TA9, TA9P & TA10P COV00523 Figure 3.1 - Dimensions Table 3.1 - Dimensions Dimensions mm (in) Model Overall Operating Width Mass 3668 3416 2450 4489 1202 2728 2502 4995Kg* (144.4) (134.4) (96.4) (176.7) (21.2) (47.3) (32.0)

  • Page 36: (1) Ta9S &Ta9Sp

    Technical Data 3 Dimensions (1) TA9S &TA9SP COV00694 Figure 3.2 - Dimensions Table 3.2 - Dimensions Dimensions mm (in) Model Overall Operating Width Mass TA9S 3668 3416 2540 4666 989.5 3747 2380 5335 Kg* (144.4) (134.4) (96.4) (18.37) (21.2) (38.30) (38.95) (147.5) (93.7)

  • Page 37: Turning Circle

    Technical Data 3 Turning Circle COV00007 Figure 3.3 - Turning Circle Table 3.3 - Turning Circle Turning Circle - mm (in) TA9 &9P TA9S & 9SP TA10P 11988 (472.0) 11632 (457.9 12022 (473.3) Operations Manual United Kingdom 1-March-2016 TA9 & TA10 Tier 4 Final Page 3 - 3...

  • Page 38: Data

    Technical Data 3 Data Table 3.4 - Data Data TA 9, TA9S, TA9P, TA9SP & TA10P Engine Manufacturer/Model ECOMAX Tier 4 Final Capacity 4.4 Litre Rated Power 55kW at 2200 rpm Maximum Torque 400Nm at 1400 rpm Oil Capacity Minimum 11.5 Litres (30 US Gal.) - Maximum 14.0Litres (3.6 US Gal.) Cooling System Capacity 24 Litres (36.3 US Gal.) TA 9 &...
  • Page 39 Technical Data 3 Table 3.4 - Data (Continued) Data TA9,TA9S, TA9P, TA9SP & TA10P Electrical System Type 12v Negative Earth Alternator Belt Driven Output 95 Amps Battery Varta Silver830 - 100AH Braking System Primary Hydraulic Multi Plate In-board Wet Disc Parking Mechanical (Disc on output shaft of transmission) Brake Reservoir...

  • Page 40: Noise Emissions

    Technical Data 3 Noise Emissions Table 3.5 - Noise Emissions Declared Single-Number Noise Emission Model Values to ISO 4871 A- rated sound pressure level at A - rated sound power of machine operator station LpAd LWAd TA9 & TA9S 84 dB 101dB TA9P &...

  • Page 41: Description Ta9, Ta9P & Ta10P Dumper

    Description 4 Description TA9, TA9P & TA10P Dumper COV00547 Figure 4.1 - TA9 Dumper The TA9 machine is illustrated; the TA10P has a wider skip. Operations Manual United Kingdom 1-March 2016 TA9 & TA10 Tier 4 Final Page 4 - 1...

  • Page 42: Ta9S & Ta9Sp Dumper

    Description 4 TA9S & TA9SP Dumper COV00700 Figure 4.1A - TA9S Dumper Description This range of 4 wheel drive site dumpers have been designed to provide the greatest degree of component standardisation possible, thus providing the user with simplified servicing requirements.

  • Page 43: Chassis

    Description 4 Chassis The chassis is of the two part articulating type having a centre pivot which articulates in both vertical and horizontal planes. Front and rear axles are bolted directly to the chassis. Steering Steering of the dumper is by an ‘Orbitrol’ hydrostatic steering unit, that powers a single hydraulic cylinder connecting the front and rear chassis units.The steering unit is operated by a conventional steering wheel.

  • Page 44: Raised Skip

    Description 4 Raised Skip As a safety aid when working on the machine a support is provided to lock the skip in the raised position when performing maintenance or repairs on the machine This prevents the skip from lowering accidentally and causing injury. Do not reach or work under a raised skip without the support fitted.

  • Page 45: Battery Isolator

    Description 4 The skip can be elevated at varying speeds dependent on engine speed, and it can be stopped at any intermediate point for discharging of partial loads. Battery Isolator The battery isolator, Figure 4.3. is both a maintenance aid and an anti-theft and vandalism device.

  • Page 46: Circuit Breaker

    Description 4 Circuit Breakers These components are fitted on the dash box; Figure 4.4 refers. COV00568 Figure 4.4. - Circuit Breakers Circuit Breakers The circuit breakers are located on the right hand side of the dash box. A 20 amp circuit breaker is fitted protecting the engine electrical system.

  • Page 47: Control Panel And Switch Functions

    Description 4 4.10 Control Panel and Switch Functions COV00573A Figure 4.5 Control Panel - Synchro-Shuttle Machines Switch - Hazard Warning Lights (When fitted) Multifunction LCD Display Instruction - Seat Interlock Instruction - Direction Indicator Switch (When Fitted) Instruction - Start Key Switch Switch - Highway Lighting (When Fitted) Button - Horn Instruction - Gear Change Lever...
  • Page 48 Description 4 COV00573B Figure 4.6 Control Panel - Power Shift Machines Switch - Hazard Warning Lights (When fitted) Multifunction LCD Display Instruction - Seat Interlock Instruction - Direction Indicator Switch (When Fitted) Instruction - Start Key Switch Switch - Highway Lighting (When Fitted) Button - Horn Instruction - Forward/Reverse Switch COV00648...

  • Page 49: Multifunction Lcd Display

    Engine Temperature - Displays current engine coolant temperature. LCD Display - Machine Hours Run / Engine Fault Codes LCD Display - Tachometer (Engine Speed) / Engine Fault Codes Should a fault code be displayed refer to Terex Service. Operations Manual United Kingdom 1-March 2016 TA9 &...

  • Page 50: Warning Lights

    Description 4 Warning Lights km/h COV00567 Figure 4.8 - Multi Function LCD Display Warning Lights The LCD display contains the warning lights listed in table 4.1. Some may not be applicable to certain machines. Table 4.1 - LCD Display Warning Light Symbol Description Symbol Name Description...
  • Page 51 Description 4 Table 4.1 - Continued Warning Light - This warning light comes on when the engine Engine Oil Pressure oil pressure is too low. If the light comes on when the machine is working stop the engine and investigate the fault. Warning Light - The battery charge warning light should only Battery Charge...

  • Page 52: Control Panel Symbols

    Description 4 Control Panel Symbols Table 4.2 - Control Panel Symbol Description Symbol Name Description Instruction - Engine This symbol indicates that the operator must be Starting seated before the engine will start. Instruction - Direction When fitted, this instruction informs the Indicator Switch Operator in which direction to move the switch in order to operate the LEFT and RIGHT...

  • Page 53: Switch Operation

    Description 4 Switch Operation Table 4.3 - Switch Operation Switch Name Description Hazard Light Switch Pressing the button will cause all four direction (When Fitted) indicator lights to begin flashing and will continue to do so until the button is pressed again Horn Button (Power When pressed, this button will cause the horn...

  • Page 54: Stop Function

    Description 4 The “Stop-Start” system defaults to ON each time the engine ignition switch is switched on. Pressing the “Stop-Start” button toggles the system between on and off. A light on the dash lights up when the system is active and the engine is running. When the system is active and it stops the engine the light will flash.

  • Page 55: Forward/Reverse Switch - "Synchro Shuttle" Transmission

    Description 4 • The “Stop-Start” system is ON • The operator sits on the seat • The forward/reverse lever is in the “Neutral” position • The engine canopy doors are closed • The throttle pedal is at idle (not pressed down) •...

  • Page 56: Highway Lighting (When Fitted)

    Description 4 4.14 Highway Lighting (when fitted) Direction Indicators The direction indicators are controlled by a 3 position switch, Figure 4.12. refers. COV00571 Figure 4.12. - Direction Indicator Switch Direction Indicator switch with the switch in the OFF position (0) the indicators do not operate. Move the switch forward (A) and the Left Hand indicators will operate.

  • Page 57: Rear Light Unit

    Description 4 Rear Light Unit Each rear light unit contains a rear light, brake light, indicator and reflector. Figure 4.14. refers. COV00543 Figure 4.14. - Rear Light Unit Indicator Reflector Tail Light Brake Light Registration Plate Lights Separate light units that operate in conjunction with the side and tail lights illuminate the rear registration plate.

  • Page 58: Foot Brake And Throttle Pedals

    Description 4 When the beacon is not required it can be removed and placed in its storage position within the engine compartment to prevent theft or vandalism. When the beacon is removed from the ROPS a rubber cover is fitted over the mounting stem to prevent the ingress of water. COV0396 Figure 4.16.

  • Page 59: Gear Selector Lever "Synchro-Shuttle" Machines

    Description 4 4.17 Gear Selector Lever “Synchro-Shuttle” Machines The lever, Figure 4.18. allows any of the gearbox’s 4 speed ratios to be selected. The lever moves in a conventional H pattern. COV00437A Figure 4.18. Gear Change Pattern An interrupt button on the knob, Figure 4.19. refers is depressed and held while changing from one gear to another.

  • Page 60: Gear Change - "Power Shift" Machines

    Description 4 4.18 Gear Change - “Power Shift” Machines The control arm is mounted on the left side of the control panel, Figure 4.20 refers. COV00637 Figure 4.20 - Control Arm - “Power Shift” Machines Control Arm This arm enables both direction of travel (forward and reverse) and the chosen gear to be selected.

  • Page 61: Parking Brake

    Description 4 4.19 Parking Brake A lever to the side of the drivers seat; Figure 4.22. refers activates a calliper operating on a disc on the output shaft of the gearbox to provide braking. COV00423 Figure 4.22. - Parking Brake Lever. Parking Brake Lever Release Catch With the lever vertical the brake is applied.

  • Page 62: Skip Control Lever

    Description 4 4.20 Skip Control Lever The skip control lever is positioned to the right of the operators seat, Figure 4 23 refers.Refer to the Standard Operating Procedures (Chapter 7) for functions of the lever. COV00572 Figure 4.23 - Skip Control Lever Skip Control Lever 4.21 Tow Hitch...

  • Page 63: Accessory Socket

    Description 4 4.22 12v Accessory Socket A 12v socket is located in the engine compartment above the battery isolator switch, Figure 4.25 refers. COV00695 Figure 4.25 - 12v Socket. The socket is useful for connecting inspection lamps etc. It has a cover to protect it when not in Operations Manual United Kingdom 1-March 2016...
  • Page 64 Description 4 1-March 2016 United Kingdom Operations Manual Page 4 - 24 TA9 & TA10 Tier 4 Final...

  • Page 65: Transportation

    Transportation 5 Transportation Before transporting the machine on a railway wagon or on the public highway on a lorry or trailer where speeds will exceed 50 m.p.h. (80 kph) the beacon must be removed from the ROP’s. It may be necessary to lower the ROP’s when transporting the machine by rail or on a lorry or trailer.

  • Page 66: Articulation Lock

    Transportation 5 Articulation Lock The articulation lock, Figure 5.1 prevents chassis movement during transport or maintenance. COV00525 Figure 5.1 - Articulation Lock Lock Bar Grip Clip Tie Down Points PROCEDURE To fit the lock bar remove the grip clip and pin from the lock bar in its storage position. Pivot the locking bar around until the holes in the bar are in line with the holes in rear chassis bracket.

  • Page 67: Forward Tip Machines

    Transportation 5 Forward Tip Machines COV00501 Figure 5.2 - Front Tie Down Point - Forward Tip Tie Down Point Swing Skip Machine COV00699 Figure 5.3 - Front Tie Down Point - Swing Skip Tie Down Point Operations Manual United Kingdom 1-March-2016 TA9 &...

  • Page 68: Rear Tie Down

    Transportation 5 Rear Tie Down The rear towing eye is utilized as the rear tie down point. COV00407 Figure 5.4 - Rear Tie Down Point Towing Eye R Clip Tie Down When the machine has been put in an acceptable position on the lorry or trailer it must be secured in place.
  • Page 69 Transportation 5 COV00050 Figure 5.5 - Alternative Tie Down Method Operations Manual United Kingdom 1-March-2016 TA9 & 10 Tier 4 Final Page 5 - 5...
  • Page 70 Transportation 5 Intentionally Left Blank 1-March-2016 United Kingdom Operations Manual Page 5 - 6 TA9 & 10 Tier 4 Final...

  • Page 71: Initial Setup And Adjustments Delivery Checks

    Initial Setup and Adjustments 6 Initial Setup and Adjustments Delivery Checks On delivery of the machine:- • Remove any packaging and shipping supports. • Release any transport locks. • Clean any protective coating from bright metal parts. • Check for damage and missing parts. •...

  • Page 72: Start Up

    Initial Setup and Adjustments 6 PROCEDURE 1. Remove the lynch pins from the locking pins either side of the ROPS. 2. Remove the locking pins. 3. Push the top half of the ROPS upwards to the working position. 4. Refit the locking pins. 5.

  • Page 73: Standard Operating Procedures

    Standard Operating Procedures 7 Standard Operating Procedures Before using this equipment the operator must read and fully understand this Instruction Manual and pay particular attention to Section 2 - Safety and Section 4 - Description which describes the major components of the machine and the layout and function of all the controls. ALL Operators of this machine must be authorised, mentally and physically capable of operating this machine and fully trained in its operation.

  • Page 74: Seat

    Standard Operating Procedures 7 Seat The seat is adjustable for operator comfort. The adjustments allow the seat to be moved forwards and backwards, the back of the seat may be tipped forwards and backwards and the seat suspension may be adjusted to the weight of the operator - Figure 7.3 Refers. COV00090 Figure 7.3.
  • Page 75 Standard Operating Procedures 7 Weight Adjustment The weight adjustment knob (2) is used to adjust the seat characteristics to suit the weight of the operator. Turning knob clockwise adjusts the seat for the larger person and anticlockwise for the smaller person.

  • Page 76: Seat Belt

    Standard Operating Procedures 7 (4) Seat belt Refer to Figure 7.6. Sit on the seat, place the seat belt across the hips and insert the latch (3) into the buckle (1) until it locks into position. Adjust by pulling the belt through buckle until it is a firm, comfortable fit across the hips. To remove the seat belt, press the button (2) and lift the latch (3) out of the buckle (1).

  • Page 77: To Start The Engine

    Standard Operating Procedures 7 To Start the Engine Before starting the engine check to see that there are no obvious faults with the machine. Refer to Figure 7.7 for start key positions. COV00433 Figure 7.7. - Start Key Positions Start Key Switch PROCEDURE Sit on the seat.

  • Page 78: To Stop The Engine

    Standard Operating Procedures 7 To Stop the Engine PROCEDURE Stop the machine in a safe position on firm level ground. Apply parking brake and place the forward/reverse switch in Neutral. Place the gear selector lever in Neutral Leave the machine for 2 minutes at low idle. Turn start key anticlockwise to OFF;...

  • Page 79: To Stop The Machine

    Standard Operating Procedures 7 To Select Reverse Gear PROCEDURE Reduce engine speed by easing off the accelerator pedal. Bring the machine to a halt with the brakes. Move the forward/reverse switch to Reverse. If necessary select another gear. Gently press the accelerator pedal to increase speed DANGER Only reverse at slow speeds.

  • Page 80: To Move The Machine - "Power Shift Transmission

    Standard Operating Procedures 7 To Move the Machine - “Power Shift” Transmission Moving Off PROCEDURE Select a gear. If 4th gear is selected the machine will be in automatic mode and will start in 2nd gear and change up or down gear automatically as required. Select forward or reverse.

  • Page 81: To Stop The Machine

    Standard Operating Procedures 7 To Stop the Machine PROCEDURE Reduce engine speed by easing off the accelerator pedal. Bring the machine to a halt with the brakes. Apply the parking brake Move the forward/reverse switch to Neutral. Move the gear selector to Neutral. Stop the engine.

  • Page 82: Skip Operation

    Standard Operating Procedures 7 7.10 Skip Operation WARNING The machine must be in the “Straight ahead” position before tipping. Do not attempt to tip the load when the machine is turned. WARNING Only tip or lower the skip while sitting on the operators seat. It is prohibited to tip or lower the skip from ground level.

  • Page 83: To Lower The Skip

    Standard Operating Procedures 7 To Lower the Skip PROCEDURE When the load has been discharged. Move the control lever towards the back of the machine (B). The skip will lower. To Tip the Load - Swing Skip Machines Refer to Figure 7.9 COV00412 Figure 7.9 Control Lever - Swing Skip Control Lever...

  • Page 84: To Rotate And Tip The Skip

    Standard Operating Procedures 7 To Rotate and Tip the Skip PROCEDURE Position the machine where the load is to be discharged. Make sure the area is clear of bystanders. Push the control lever forwards towards the front of the machine to raise the skip by 75mm to enable the catch to clear the skip lock.

  • Page 85: Emergency Operating Procedures

    Emergency Operating Procedures 8 Emergency Operating Procedures In the event of an emergency or system failure try and place the machine in a position of safety or in a safe condition. Once the machine has been rendered safe the start key and battery isolator key must be removed to prevent start up and a warning tag placed in a prominent position warning others not to use the machine.
  • Page 86 Emergency Operating Procedures 8 COV00027 It is necessary to remove the floor plate to gain access to the battery - see Battery Access in Maintenance section. Figure 8.1. - Battery “Jump” Starting Positive (+) Jump Lead Discharged Battery on Machine Machine Chassis Jump Lead Connection on Chassis Negative (-) Jump Lead...

  • Page 87: Maintenance And Lubrication General Information

    For detailed servicing or maintenance procedures refer to the maintenance manual for this machine available from Terex or consult your dealer. Regular maintenance and lubrication will prolong the life of the machine and keep it in a safe working condition.

  • Page 88: Cleaning The Machine

    Maintenance 9 Cleaning The Machine Clean the dumper thoroughly, this will make it easier to find oil leaks and loose fittings etc. • Take care to clean the oil and fuel tank filler necks. • Drain plugs must also be cleaned. •...

  • Page 89: Skip Support

    Maintenance 9 Skip Support A skip support or other method of supporting the skip in the raised position MUST be fitted and locked in position before working under a raised skip. DANGER NEVER reach or work under a raised skip unless a prop or similar method of supporting the skip safely is fitted.

  • Page 90: Articulation Lock

    Maintenance 9 To fit the Skip Support Forward Tip PROCEDURE Raise the skip. Remove the grip clip and pin and lower the skip support from its storage position. Align the hole in the support with the holes in the chassis Refit the pin and secure with the grip clip.

  • Page 91: Rops

    If you have any doubts regarding the integrity of the ROPS and for replacement parts consult your Terex dealer. Floor Plate Removal To gain access to the battery and other components it may be necessary to remove the floor plate - Figure 9.4 refers.

  • Page 92: Engine Coolant

    Maintenance 9 9.10 Engine Coolant The cooling system is pressurised to increase boiling point of the coolant and therefore extreme caution must be taken when the cooling system is hot to prevent scalding. Refer to Fluids and Lubricants - 9.17 for the correct type of coolant. WARNING NEVER perform checks or maintenance on the cooling system when it is hot.

  • Page 93: Engine Oil

    Maintenance 9 9.11 Engine Oil The oil level is checked using the dip stick - Figure 9.6 refers. The engine oil level must always be between the MIN and MAX on the dip stick. If the engine is warm switch OFF and leave for 5 Minutes before checking levels.

  • Page 94: To Add Oil

    Maintenance 9 COV00033 Figure 9.7. - Dipstick MAX and MIN marks Maximum (MAX) Oil Level Minimum (MIN) Oil Level PROCEDURE Pull out the dipstick and wipe off with a lint free cloth or paper. Re-insert the dipstick as far as it will go. Extract the dipstick and read off the level Add oil of the correct specification if necessary.

  • Page 95: Synchro Shuttle Gearbox

    Maintenance 9 PROCEDURE Remove the filler cap. Add oil of the recommended grade. Check the dipstick at regular intervals and make sure the level does not exceed the MAX mark. When the oil reaches the required level replace the filler cap. Wipe up any spilt oil.

  • Page 96: To Check The Level

    Maintenance 9 NOTICE Never overfill the transmission as this will result in oil breakdown due to excessive heat and aeration of the oil caused by the churning action of the oil. Breakdown of the oil will cause heavy sludge deposits that will block oil ports and build up on splines and bearings. To Check the Level PROCEDURE Drive the machine for about 1 minute and then stop and park up on flat level ground.
  • Page 97 Maintenance 9 COV00415 Figure 9.12. - Dipstick MIN and MAX Marks. MAX Mark MIN Mark NOTICE Never overfill the transmission as this will result in oil breakdown due to excessive heat and aeration of the oil caused by the churning action of the oil. Breakdown of the oil will cause heavy sludge deposits that will block oil ports and build up on splines and bearings.

  • Page 98: Hydraulic System

    Maintenance 9 9.14 Hydraulic System WARNING Damaged hydraulic components and hoses can cause serious injury. Do not use a machine if a component or hose is damaged. During ANY maintenance extreme care must be taken to make sure the cleanliness of the hydraulic circuit is maintained.

  • Page 99: To Add Hydraulic Oil

    Maintenance 9 COV00417 Figure 9.14. - Hydraulic Tank Dipstick MAX Mark MIN Mark PROCEDURE Remove the dipstick/filler cap, take care not to lose the O ring. Wipe all traces of oil from the dipstick with lint free cloth or paper. Replace the dipstick.
  • Page 100 Maintenance 9 DANGER Avoid sparks, naked flames or other sources of ignition when filling or maintaining the fuel system. Do not smoke when filling the fuel tank or maintaining the fuel system. Do not leave the engine running when filling or maintaining on the fuel system. COV00578 Figure 9.15.

  • Page 101: To Add Fuel

    Maintenance 9 To Add Fuel PROCEDURE Clean the area around the fuel filler cap. Remove the filler cap and add the correct grade of diesel until the fuel level gauge reads full. Replace the filler cap. Clean up any spilt fuel. 9.16 Braking System Brake Arrangement...

  • Page 102: To Add Fluid

    Maintenance 9 To Add Fluid PROCEDURE Remove the access cover Clean the area around the filler cap. Remove filler cap and add fluid. Replace access cover. Parking Brake Test When adjusted correctly the parking brake should hold the machine without movement at 1450 RPM in 3rd gear.

  • Page 103: Fuses And Relays

    Maintenance 9 9.17 Fuses and Relays The fuses and relays are located behind a removable panel on the front bulkhead, Figure 9.17 refers. COV00608 Fig 9.17 Location of Fuses and Relays Details of the relays and fuses are shown in Figures 9-19 and 9-20. An electrical diagram will be found in Appendix 1.

  • Page 104: Power Shift And "Stop-Start" Machines

    Maintenance 9 Fuse Box 1 Fuse Box 2 7.5A BEACON ECM FEED 2 IGN. SENSE WATER IN FUEL GAUGE SENSOR FEED START SIGNAL ECM FEED 4 INPUT TO ECM ECM FEED 3 DIAGNOSTICS ECM FEED 1 AUX. SOCKET SUPPLY TO FUEL PUMP FEED START RELAY POWER HOLD...

  • Page 105: Air Cleaner

    Maintenance 9 9.18 Air Cleaner To maintain maximum engine protection from dust the air cleaner must be serviced at regular intervals. No hard and fast rules apply to servicing intervals as operating conditions vary so much. The only way to determine if the air cleaner requires servicing is to physically check it. A warning light on the dash display will light up if there is a blockage in the air inlet system but the 10 hour (daily) check as prescribed in the Service Schedule must still be performed.

  • Page 106: Maintenance Schedule

    Maintenance 9 9.19 Maintenance Schedule Service engineers should, if necessary, refer to the Maintenance Manual for the machine which is available from Terex or your local dealer. Service Schedule Period Operation Responsibility 10 Hours Engine Oil - Check Level Operator Coolant - Check Level “...
  • Page 107 Maintenance 9 Service Schedule Period Operation Responsibility 500 Hours Perform 10, 50 & 250 Hour Checks Service Engineer Cooling System Supplemental Coolant Additive - Test/Add “ Radiator - Clean “ Cyclone Air Cleaner Elements - Clean “ Engine Oil - Change (every 250 if sulphur content exceeds 15ppm) “...

  • Page 108: Fluids And Lubricants

    Maintenance 9 Service Schedule Period Operation Responsibility 8000 Hours Perform 10, 50, 250, 500,100,1500 & 2000 Hour Checks Service Engineer Engine Front End Accessory Drive - Change Belt “ Injectors - Change “ Injector(s) Leak Off Rail - Change “ High Pressure Fuel Lines - Change “...

  • Page 109: Brake Reservoir

    Maintenance 9 Brake Reservoir Recommended Fluid:- Shell Tellus T46 Hydraulic System Recommended Fluid:- Shell Tellus T46 Engine Coolant Antifreeze/Water Mixture. Antifreeze to Specification:- ASTM D6210 Minimum Concentration 50% - Protection to - 40°C Maximum Concentration 60% - Protection to - 56°C Fuel System Diesel to Specification:- EN590 Ultra Low Sulphur...
  • Page 110 Maintenance 9 1-March 2016 United Kingdom Operations Manual Page 9 - 24 TA9 & TA10 Tier 4 Final...

  • Page 111: In The Event Of A Breakdown

    Recovery 11 Recovery 11.1 In the Event of a Breakdown In the event of engine failure or other breakdown it is possible to tow the machine for a maximum distance of 1 mile (1.6 km) at speeds not exceeding 9 m.p.h. (15 kph). For distances exceeding this the machine must be transported on a lorry or trailer.
  • Page 112 Recovery 11 Intentionally Left Blank 1-March-2016 United Kingdom Operations Manual Page 11 - 2 TA9 & TA10 Tier 4 Final...

  • Page 113: Storage, Decommissioning And Disposal

    Storage, Decomissioning & Disposal Storage, Decomissioning and Disposal 12.1 Long Term Storage The machine must be stored in a dry environment protected from the elements and on a hard standing. Any contaminated Water / Fluids / Oils removed from the machine must be disposed of legally.

  • Page 114: If Stored For More Than A Period Of 6 Months

    When the battery reaches the end of its usual life it must be removed from the machine and recycled in an approved way in accordance with local environmental regulations. This service is usually operated by battery vendors. Machine users that cannot find a suitable battery recycling facility should contact Terex for assistance. 1-March-2016...

  • Page 115: Glossary Of Terms

    Glossary of Terms 13 Glossary of Terms ANSI - American National Standards Institute. Articulation Lock - Device preventing chassis elements moving during maintenance, transport etc. Battery Isolator - Device to shut of electrical supply from the battery. Chock - Device placed in front of and behind wheels to prevent movement. Hour Meter - An instrument that records and displays the total number of hours the engine has been running.
  • Page 116 13 Glossary of Terms Intentionally Left Blank 1-March-2016 United Kingdom Operations Manual Page 13 -2 TA9 & TA10 Tier 4 Final...

  • Page 117: Appendix 1 - Electrical Diagrams

    Appendices Appendix 1 - Electrical Diagrams Operations Manual United Kingdom 1-March - 2016 TA9 & TA10 Tier 4 Final Page 1...
  • Page 118 Appendices PU/GN (T138808-1) COV00617 Electrical Diagram 1 - Synchro Shuttle Transmission 1-March - 2016 United Kingdom Operations Manual Page 2 TA9 & TA10 Tier 4 Final...
  • Page 119 Appendices Battery Isolator 350 Amp Colour Codes Battery - 12V RD - Red Circuit Breaker - Main WH - White Circuit Breaker - Headlights YE - Yellow Ignition Switch GN - Green Starter Motor BU - Blue Relay - Starter GY - Grey Alternator OR - Orange...
  • Page 120 Appendices X31.b 1.00 mm 1.00 mm PU/WH Forward Signal XS3-4-A 1.00 mm PU/WH 1.00 mm PU/WH XS3-3-B Forward Signal 12/16 12/16 Forward Signal XS3-2-A XS3-1-B 0.5 mm WH/PU /1.E10 Neutral Gear Signal X31.b 1.00 mm PU/GN XS3-4-B XS3-3-A 1.00 mm 1.00 mm PU/GN 1.00 mm...
  • Page 121 Appendices Forward Solenoid Colour Codes Transmission Lever RD - Red A - Forward WH - White B - Neutral YE - Yellow C - Reverse GN - Green Reverse Solenoid BU - Blue Reverse Alarm GY - Grey Power Relay - Normally Open OR - Orange Seat Switch BK - Black...
  • Page 122 Appendices XK 14 XK14 1.00 mm 1.00 mm Engine B/14 Connector XK14 1.00 mm RD/GY A/14 0.50 mm CAN 1 L C/14 0.50 mm D/14 CAN 1 H XK62 0.50 mm 45/62 CAN 1 H 0.50 mm 50/62 CAN 1 L XK62 1.00 mm BU/GY...
  • Page 123 Appendices Resistor Connector - 120 Ohm Colour Codes Throttle Pedal - MT4000 RD - Red TMAF Sensor WH - White Engine Control Module - DCM3.3+ YE - Yellow Sensor - Water in Fuel GN - Green Fuses F9 - EGR -10A BU - Blue F10 - ECM#2 - 10A GY - Grey...
  • Page 124 Appendices A B C GN/WH Indicator RH GN/WH GN/WH Indicator RH Indicator RH Indicator RH GN/WH GN/WH GN/RD GN/RD GN/RD GN/RD Indicator LH Indicator LH Indicator LH GN/RD Indicator LH (T138808-4) COV00620 Electrical Diagram 4 1-March - 2016 United Kingdom Operations Manual Page 8 TA9 &...
  • Page 125 Appendices Switch - Hazard Lights Colour Codes Switch - Highway Lighting RD - Red A - Side & Head Lights WH - White B - Side Lights YE - Yellow C - Off GN - Green Flasher Unit BU - Blue Switch - Direction Indicators GY - Grey Light Unit - Rear LH...
  • Page 126 Appendices 6,00 mmý BN 95,00 mmý BK 4,00 mmý BN 6,00 mmý Battery XCB1-2 XCB1-1 4,00 mmý BN/WH 6,00 mmý BN 1,00 mmý BN/WH Main Circuit Breaker XCB2-2 XCB2-1 1,50 mmý BN/BU 3,00 mmý /5,C2 1,00 mmý BU/GY 4, A2 1,00 mmý...
  • Page 127 Appendices Battery Isolator 350 Amp Colour Codes Battery - 12V RD - Red Circuit Breaker - Main WH - White Circuit Breaker - Headlights YE - Yellow Ignition Switch GN - Green Ignition Relay BU - Blue Fuses GY - Grey UPS Module OR - Orange Gauge - Multi Function...
  • Page 128 Appendices Park Brake Switch Horn Seat Switch INPUT INPUT Park Brake Signal Seat Switch /6.C2 IN08 /6.C2 IN06 Ground Point (Main Machine) T138808 Sheet 2 COV00642 Electrical Diagram - “Stopstart” Machines 1-March - 2016 United Kingdom Operations Manual Page 12 TA9 &...
  • Page 129 Appendices Seat Switch Colour Codes Park Brake Switch RD - Red Horn WH - White YE - Yellow GN - Green BU - Blue GY - Grey OR - Orange BK - Black PU - Purple PK - Pink BN - Brown T138808 Sheet 2 Operations Manual United Kingdom...
  • Page 130 Appendices Transmission Oil Temperature Signal /1, E12 YE/PU 1,00 mmý 1,00 mmý X31,d Forward Low Solenoid 15/55 1,00 mmý 1,00 mmý X31,d Forward High Solenoid 16/55 BU/WH 1,00 mmý 1,00 mmý X31,d Reverse Low Solenoid 12/55 BU/GN 1,00 mmý X31,d 1,00 mmý...
  • Page 131 Appendices Switch - Transmission Oil Temperature Colour Codes Solenoid - Forward - Low RD - Red Solenoid - Forward - High WH - White Solenoid - Reverse - Low YE - Yellow Solenoid - Reverse - High GN - Green Solenoid - Main Shaft BU - Blue Solenoid - Lay Shaft...
  • Page 132 Appendices Fuel Pump BU/YE 1,50 mmý 1,50 mmý X31, c 1,50 mmý CAN O H /1, E9 0,50 mmý CAN O L /1, E9 0,50 mmý 30/5 87/5 23/62 CAN O L Fuel Pump Relay - CAN O L 40/62 CAN O L 86/5 85/5...
  • Page 133 Appendices Fuel Pump Colour Codes Relay - Fuel Pump RD - Red 120 Ohm Resistor Connector WH - White Diagnostic Connector YE - Yellow Sensor - Water In Fuel GN - Green TMAF Sensor BU - Blue Throttle Pedal MT4000 GY - Grey 120 Ohm Resistor Connector OR - Orange...
  • Page 134 Appendices Side Lights 1,00 mmý Indicator RH GN/WH 1,00 mmý Brake Lights GN/PU 1,00 mmý XE-1 XE-2 Dip Beam Side Lights BU/RD 1,00 mmý 1,00 mmý 1,00 mmý Indicator RH Indicator RH Indicator RH 1,00 mmý GN/WH 1,00 mmý GN/WH 1,00 mmý...
  • Page 135 Appendices Rear Tail Light - RH Colour Codes Number Plate Light - RH RD - Red Brake Light Switch WH - White Number Plate Light - LH YE - Yellow Rear Tail Light - LH GN - Green Indicator Switch BU - Blue Flasher Unit GY - Grey...
  • Page 136 Appendices Mobile Controller Module CR2530 Inputs Outputs Location Pin Number Signal PLC Name Function Function PLC Name Signal Name Pin Number Location /3, H1 IN00 Forward Signal OUT00 /3, H2 IN01 OUT01 Reverse Signal /3, H1 IN02 Neutral Signal /3, E10 OUT02 Forward High Sol IN08...

  • Page 137: Appendix 2 - Hydraulic Diagrams

    Appendices Appendix 2 - Hydraulic Diagrams Operations Manual United Kingdom 1-March - 2016 TA9 & TA10 Tier 4 Final Page 21...
  • Page 138 Appendices COV00604 Hydraulic Diagram - Forward Tip 1-March - 2016 United Kingdom Operations Manual Page 22 TA9 & TA10 Tier 4 Final...
  • Page 139 Appendices Skip Ram - Right Hand Skip Ram - Left Hand Skip Control Valve Relief Valve - System Pressure 210 Bar Steering Unit Steering Cylinder Pressure Test Point - On Valve Pump - 26cc/rev (61.2 L/Min) Engine Mounted Engine Hydraulic Tank Filter Gearbox Transmission Cooler...
  • Page 140 Appendices COV00605 Hydraulic Diagram - Swing Skip 1-March - 2016 United Kingdom Operations Manual Page 24 TA9 & TA10 Tier 4 Final...
  • Page 141 Appendices Skip Tip Ram Relief Valve - System Pressure 210 Bar Skip Control Valve Pressure Test Point - On Valve Pump - 26cc/rev (61.2 L/Min) Engine Mounted Engine Gearbox Hydraulic Tank Filter Transmission Cooler Hydraulic System Cooler Check Valve - 10 Bar (Fitted to Chassis) Steering Cylinder Steering Unit Slew Ram LH...
  • Page 142 Appendices Intentionally Left Blank 1-March - 2016 United Kingdom Operations Manual Page 26 TA9 & TA10 Tier 4 Final...

  • Page 143: Appendix 3 - Fuel System Diagram

    Appendices Appendix 3 - Fuel System Diagram Operations Manual United Kingdom 1-March - 2016 TA9 & TA10 Tier 4 Final Page 27...
  • Page 144 Appendices COV00603 Fuel System Diagram 1-March - 2016 United Kingdom Operations Manual Page 28 TA9 & TA10 Tier 4 Final...
  • Page 145 Appendices Fuel Cooler - Part of Cooling Pack Engine Fuel Return Fuel IN - Engine Mounted Main Filter Combined Water Seperator and Lift Pump - Mounted on Cooling Pack Sender Unit Fuel Tank Operations Manual United Kingdom 1-March - 2016 TA9 &...
  • Page 146 Appendices Intentionally Left Blank 1-March - 2016 United Kingdom Operations Manual Page 30 TA9 & TA10 Tier 4 Final...
  • Page 147 Troubleshooting 10 Troubleshooting 10.1 General Troubleshooting Engine will not start Check fuel level. Incorrect type or grade of fuel. Contaminated fuel. Fuel supply pipe blocked. Blocked fuel filter. Air in fuel system. Leak in fuel injection line. Below starting limit temperature for machine Wrong SAE viscosity class of engine lubricating oil.
  • Page 148 Troubleshooting 10 System Dead Check battery isolator is set to “ON”. Check battery connections. Battery defective or discharged (flat). Check circuit breaker has not “tripped”. Charge warning light remains On with engine running Check if fan belt is loose or missing. Lights and direction indicators do not work Check circuit breaker has not “tripped”.
  • Page 149 Terex Construction Party that manufactured or sold the equipment, to have been defective in manufacture or materials. Such parts shall be provided at no cost to the owner, FCA the Terex Construction Party parts facility from which the parts were purchased.
  • Page 150 June 2014 United Kingdom Warranty Certificate Page GB - 2...
  • Page 152 Terex Construction, Central Boulevard, Prologis Park, Coventry CV6 4BX, England Tel: + 44 (0)24 7633 9400 Fax: + 44 (0)24 7633 9500 Email: sales@terex.com...

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