Professional Documents
Culture Documents
OM 532-06435-En-Collahuasi Rev000
OM 532-06435-En-Collahuasi Rev000
Haul Truck
T 282C-532
S/N 06435 to 06436
Document ID
Order number: 10880899
Issued: 2011-01-21
Version: Preliminary Issue
Author: LME / Technical Publication and
Documentation Department
Product ID
Manufacturer: Liebherr Mining Equipment Newport News Co.
Type: T 282C
Type no.: 532
Serial no.: 06435 to 06436
Contact
Address: Liebherr Mining Equipment Newport News Co.
4100, Chestnut Avenue
Newport News, Virginia 23607 USA
Machine data:
Enter the following information on taking delivery. *You will find the information on the
type plate of the machine. This will also be useful when you order spares.
* Vehicle ID number:
..........................................................
* Year of construction:
.............................
Commissioning date:
.................. / ................. / .................
LME/10880899/Preliminary Issue/2011-01-21/en
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This operator manual gives basic operations information for the T282C haul truck
made by the Liebherr Mining Equipment Company (LME). This manual is prepared
for the approved haul truck operator, who has received specified operator training.
This publication does not contain all information possible on the T282C haul truck
operations.
Before you begin first-time operations, you must read this manual carefully and
completely. Operator training and reading of this manual at intervals can help you
to keep your skills current. Your LME service person can help if you have
questions or require additional information.
This operator manual is an important part of the haul truck. Keep the operator
manual in the operator cab. Replace the operator manual if the manual is
damaged, or pages cannot be read. Get publications from the LME Spare Parts
Department.
WARNING
The haul truck has operating limitations!
Loss of life, injury to persons, or damage to the haul truck can occur from incorrect
methods of operations.
u Keep all methods of operations within the limits shown in this operator manual.
Language
In case of any inconsistency between this English-language document and its
translation into another language, this English-language document controls.
Statement of Accuracy
The accuracy of the published information contained in this manual is not part of
any warranty. This manual contains the most current and accurate information on a
range of operations related to the limitations, information and materials produced,
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Copyright
This manual or any part of this manual cannot be reproduced, stored in any
system, transmitted in any format, mechanical, photocopy, or recorded without
written permission from the manufacturer.
List of Acronyms
AC - Alternating Current
ATCP - Automatic Temperature Control Panel
CB - Circuit Breaker
DC - Direct Current
DEF - Defrost
EVW - Empty Vehicle Weight
EXT - External Temperature
GVW - Gross Vehicle Weight
ISO - International Standards Organization
LCD - Liquid Crystal Display
LED - Light Emitting Diode
LME - Liebherr Mining Equipment Company
MSHA - Mine Safety and Health Administration
OEM - Original Equipment Manufacturer
OSHA - Occupational Safety and Health Administration
Ref. - Reference
ROPS - Roll-Over Protective Structure
LME/10880899/Preliminary Issue/2011-01-21/en
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We need your help to continually improve our documentation. Please copy this
page and fax it or e-mail it to us with your comments, ideas and suggestions for
improvement.
E-mail: lmetechpubs@liebherr.com
Excellent
Very good
Good
Satisfactory
Poor
Last name:
Address:
Telephone number:
Dealer:
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Notes:
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1 Product Description 11
1.1 Technical Description 11
1.1.1 Primary Haul Truck Components 11
1.1.2 Functional Description 12
1.1.3 Haul Truck Payload Policy 13
1.1.4 Haul Truck Orientation 15
1.1.5 Standard Lighting Configurations 15
1.2 Technical Data 18
1.2.1 Engine MTU DD 20V4000 18
1.2.2 Engine Air Cleaners 18
1.2.3 Electric Drive System 18
1.2.4 Tires 18
1.2.5 Brake System 18
1.2.6 Steering System 19
1.2.7 Dump System 19
1.2.8 Frame 19
1.2.9 Weight Capacity 20
1.2.10 Travel Gear 20
1.2.11 Fluid Capacities 20
1.2.12 Operator Cab 21
1.2.13 Sound Emission/Suppression 21
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3 Control, Operation 35
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4 Malfunctions 103
4.1 Fault Handling 103
4.1.1 Fault Categories 104
4.2 Fault Banners 107
Index 109
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10 Fuel Tank
Frame
The two-rail, hollow box frame is made of A 720 steel. The torque tubes that
connect the two frame rails can absorb and envelop the force. The frame rails are
connected on the inside and the outside. The stress flow cast steel components
are installed on the high-stress areas of the structure. The cast cross carriage
transfers the force from the rear axle and the dump cylinders in a direct line in the
frame rails.
Front Suspensions
The front suspension has a two layer frame (a-frame) with a lever action design.
This design lets the tire contact point straight line movement during travel and load
operations. This increases the accuracy of payload weighing, because side loads
on the struts, and vertical wheel travel are removed. Another quality of this design
is decreased tire deflection.
Rear Suspensions
The special rear wheel suspension replaces the standard nose cone with two drag
links and a triangle rear control arm. All force from the rear axle is transferred to the
frame in straight lines. Two suspension struts transfer all loads from the frame to
the top of the axle box directly to the wheels. This design decreases the weight of
the frame as torque from within the axle box is removed.
Engine
A large diesel engine attached to an alternator/rectifier assembly gives electrical
power to the control box. The control box has two AC inverters that temporarily
convert the DC current into three-phase AC current to the two rear traction motors.
The diesel engine, fan, radiator, and alternator components are referred as the
power module. The components of the power module are removable as one unit.
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Operator Cab
The operator cab has two-panel walls and floors. The operator cab is made of steel
with thermal and acoustical insulation to protect the operator from outside noises
and vibrations. The operator cab is the control station where all haul truck move-
ment is controlled.
10/10/20 Rule
The Liebherr haul truck is designed to have a maximum gross vehicle weight
based on the specifications of the drive system, other major systems and compo-
nents that comprise the haul truck. Since the gross vehicle weight can not be
exceeded, the nominal payload of the haul truck is dependant upon the empty
vehicle weight as per the following equation:
NOMINAL PAYLOAD = GVW- EVW
Where:
Gross Vehicle Weight (GVW) - the maximum weight of the complete haul truck
including the dump body, tires, rims, fuel, lubricants, all customer specific options
AND payload.
Empty Vehicle Weight (EVW) - The weight of the complete haul truck including the
dump body, tires, rims, fuel, lubricants, all customer specific options.
The dump body installed on the haul truck is designed to carry the nominal payload
to maximum the productivity of the haul truck while minimizing operating cost. The
dump body is designed specifically for the site at which it operates based on mine
parameters such as material density, abrasiveness and angle of repose.
Changes that occur in material density, angle of repose, fill factors, and the use of
various types of loading equipment throughout the site may cause the actual
payload to vary and possibly exceed the nominal payload. To regulate the payload
in the haul truck, Liebherr has created this Payload Policy.
Liebherr uses the 10, 10, 20 rule to govern all payloads. Based on the 10, 10, 20
rule, the distribution of the payloads over the nominal payload must be as follows:
1. The average of all payloads in any given month cannot be greater than the
nominal payload.
2. Not more than 10% of all loads may be between 110% and 120% of nominal
payload in any given month.
3. No load may be above 120% of the nominal payload.
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Should this policy not be adhered to, it is necessary for the Operator to be aware of
and understand the implications of this decision as all components of the haul truck
can be adversely affected. In addition, an increased GVW may affect compliance
with braking, steering and other standards and regulations as well as tire limitations
creating a risk to operational safety.
Adherence to this Payload Policy is a requirement of Liebherr's Standard and
Extended Haul Truck Warranty. The payload data for each haul truck must be
downloaded monthly. If it is determined that the Payload Policy is not being
adhered to, the payload data download frequency will be increased to weekly and
Liebherr and the mine operator will work to bring the loading of the haul truck into
compliance with the Payload Policy.
Warranty claims for Liehberr's haul trucks may be reduced or denied by Liebherr if
payload data is not provided by the mine operator.
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1 Tail, Stop, and Directional Indi- 3 Service Brake, Tail, and Direc-
cator Lights tional Indicator Lights
2 Dynamic Braking Lights 4 Backup Lights
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1.2.4 Tires
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A) This is a calculation that depends on the ground surface, the strut length and tie
rod length.
1.2.8 Frame
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mph 5,0
Dump Body Override km/h 12,87
mph 28,0
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The serial number is found between the bumper and the front wheel on the right of
the haul truck frame. The label identifies the haul truck by model, serial number,
and the date of assembly.
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2.1 Safety
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– Park the haul truck on level ground and prevent any movement.
– Unless you have other instructions, set the parking brake.
– Make sure you have sufficient lighting to see the platform, steps, and possible
obstruction.
– Before you use the ladder, make sure the ladder is extended.
– Never leap from the haul truck!
– Use three-point contact to go on and get from the haul truck.
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– Do not position any part of the body between heavy parts or energized equip-
ment.
– Know the crush-zone areas and the haul truck crush-hazards.
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Visual safety devices in this operator manual are specified signal words with
messages that communicate hazards, results of hazard avoidance, and the steps
to follow that can prevent the hazard.
The signal words follow:
DANGER
WARNING
CAUTION
NOTICE
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Visual safety devices on the haul truck graphically show the dangerous areas and
conditions of the haul truck. The visual safety devices on the haul truck follow:
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– Before you begin a loading or dumping operation, give the correct safety
instructions to all persons near the haul truck.
– Make sure all persons are a safe distance from the loading or dumping areas.
– Make sure the loading or dumping areas are without objection.
– Stop the haul truck on level ground, if possible.
– Stay in the operator cab during loading or dumping operations.
– The haul truck weight can cause an edge of a slope to break. Keep at least one
truck width away from the edge of a slope.
– Monitor the weather conditions. The fluctuation in temperatures can decrease
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the strength of the loading and dumping areas. Even in acceptable weather
conditions, loading or dumping operations can be dangerous.
– Make sure enough light is available for the loading or dumping operation.
– Never load the haul truck more than the specifications allow. Get the load speci-
fications from the correct service person.
– Always follow the applicable site safety procedures for loading and dumping
operations.
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WARNING
The hand brake is designed to hold the haul truck in position during loading and
dumping operations!
The components of the parking brakes can get damaged if the parking brakes are
applied during loading and dumping operations.
u Apply only the hand brakes during loading and dumping operations.
WARNING
Incorrect towing procedures can damage the haul truck!
u Only the service personnel with the correct authorization and approval must tow
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2.5.7 Anti-Roll-Back
The anti-roll-back mechanism is automatically controlled by the drive system. The
drive system applies the required torque that can hold and accelerate the haul
truck. The haul truck cannot move on a grade when the shift selector switch in the
FORWARD, or REVERSE position. The mechanism only lets the rear wheels turn
in the selected direction of travel. If the sensors on the rear wheels sense any
movement in the opposite direction from the set position of the shift selector switch,
the service brake calipers automatically and immediately engage.
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For description purposes, the Main Dash Panel is separated into three separate
panels.
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Headlight Switch
The headlight switch 3 is a maintaining switch operated to turn ON or OFF the haul
truck headlights.
– Press the bottom half of the switch to turn ON the headlights.
– Press the top half of the switch to turn OFF the headlights.
Inactive Switches
The Inactive Switches 4, and 7 are reserved for optional systems. These switches
have no operations.
– Press the bottom half of the switch to set the parking brakes.
– Press the top half of the switch to release the parking brakes.
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Speedometer
The speedometer 1 shows the current haul truck travel speed in miles per hour
(mph) and kilometers per hour (km/h).
Tachometer
The tachometer 2 shows the current engine speed in revolutions per minute (rpm).
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Indicator Panel
The indicator panel 7 has twelve light-emitting diode (LED) lights that indicate
separate fault conditions, and warnings. During the illumination of any of these indi-
cators, the related cause and remedy information can show on the touch screen.
Always check the information shown on the touch screen to know the action you
must take to correct the fault, or to position the haul truck for service personnel to
diagnose the problem.
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The propel inhibit indicator 6 illuminates RED when propel torque has been disa-
bled.
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Direction Indicators
The directional indicators illuminate when the left or right indicators are operated.
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The haul truck is equipped with a 3.05 cm (12 in) interactive touch screen display
panel 3.
The touch screen display panel energizes when the starter isolator switch is put to
the ON position. The auxiliary power switch 1 has no operation. The touch screen
display panel shows the information necessary for the operator to operate the haul
truck and to monitor its performance during operations. The operator can access
additional screens when requested by service technicians.
The brightness and contrast adjust switches 2 are adjusted to control the bright-
ness and the sharpness of the on-screen display. The brightness adjustment
switch is operated to adjust the backlight luminance, and the contrast control is
operated to adjust the sharpness of the picture. The ambient light can make it
necessary to change the brightness and the contrast settings. Adjust these settings
as necessary.
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During the power-on cycle, the main splash screen shows on the touch screen
display panel. This screen continues until the power-on cycle is complete. After the
power-on cycle is complete, the main splash screen changes to the main operator
screen.
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The date, time 1, and the ton and haul cycle 2 display gives the operator a quick
reference to the current date, time, load tons, and haul cycles.
The dynamic speed control set speed indicator 3 shows the operator-set speed of
the dynamic speed control system. The dynamic speed control set speed indicator
is gray when the dynamic speed control system is not active.
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The shift selector switch position indicator 4 shows the current shift selector switch
position. The shift selector switch can be moved to the following possible positions:
– F = FORWARD
– N = NEUTRAL
– R = REVERSE
Tonnage Icon
The select available help information icon 6 is an interactive icon that is touched to
change the current screen to a help screen. The help screen gives the available
help information.
Additional operator screens are available. Through the additional screens, the
operator can get more detailed information, for example, specified system temper-
atures, pressure, and performance current performance information about the
following systems: (For more information see: Additional Screens, page 56)
Brake System
AC Drive System
Dump System
Engine
Steering System
Suspensions
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The fault/error screens icon 7 is an interactive icon that is touched to change the
current screen to the screen that shows the faults and errors that occurred during
operations.
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The service and diagnostic icon 8is an interactive icon that is touched to change
the current screen to the service screen. The service screen contains information
for service technicians.
The previous and next page icons 9 are interactive icons that are touched to navi-
gate to the previous < screen or advance to the next > screen.
The return to TOP/MAIN screen icon 10 is interactive icon that is touched to navi-
gate to the main operator screen from any location on the touch screen display
panel. (For more information see: Engine Startup Screen, page 50)
The engine startup icons include the parking brake, starter isolator switch, shift
selector switch, and the hydraulic shutoff valve engine start icons. A GREEN icon
indicates that the related system is in the correct state to enable engine start. A
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RED icon indicates that the state of the related system must be changed to permit
engine start.
The parking brake engine startup icon 1 illuminates RED when the parking brake is
not set. If the parking brake icon illuminates RED, operate the parking brake switch
on the left dash panel to set the parking brakes. If the icon continues to illuminate
RED when the parking brakes are set, immediately give a report of the problem to
the correct service person. The icon illuminates GREEN when the related system is
in the correct state to permit engine start. (For more information see: Parking Brake
Switch, page 39)
The starter isolator switch engine startup icon 1 illuminates RED when the starter
isolator switch is in the OFF position. If the starter isolator icon illuminates RED,
check the position of the starter isolator switch. Make sure the switch is in the ON
position. If the icon continues to illuminate RED when the starter isolator switch is
in the ON position, immediately give a report of the problem to the correct service
person. The icon illuminates GREEN when the related system is in the correct
state to permit engine start. (For more information see: Starter Isolator Switch,
page 74)
The shift selector switch engine startup icon 1 illuminates RED when the shift
selector switch is not in the NEUTRAL position to enable engine start. If the icon
illuminates RED, move the shift selector switch to the NEUTRAL position. If the
icon continues to illuminate RED when the shift selector switch in the NEUTRAL
position, immediately give a report of the problem to the correct service person.
The icon illuminates GREEN when the related system is in the correct sate to
permit engine start. (For more information see: Shift Selector Switch, page 65)
A hydraulic shutoff valve indicator 1 that illuminates red can show possible
hydraulic flow prevention. Check the on the ground level to make sure the indicator
is not illuminated. If the indicator is illuminated, the brake and steering hydraulic
shutoff valve 2, or the dump system hydraulic shutoff valve 3 is possibly closed.
Open the hydraulic valves, and check to make sure the indicator extinguishes. If a
RED indicator on the touch screen display panel continues after the hydraulic
shutoff valves have been opened, immediately give a report of the problem to the
correct service person. The icon illuminates GREEN when the related system is in
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After the engine start, the engine startup screen changes to the post-engine start
screen. The main operator screen that has all of the necessary icons and informa-
tion to operate and monitor the haul truck during operations.
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The shift information screen is a screen that gives the operator a visual reference
to their shift information. This information cannot be recorded, or saved for future
use.
The shift start icon is touched to stop the internal timers and remove the shift statis-
tics information from the screen. If it is necessary to continue the internal timers
and keep the shift statistics information, operate the previous, or the next screen
icons to return to the previous screen, or advance to the next screen. If the shift
start icon is touched, the information disappears from view.
The shift stop icon is touched to stop the internal timers. The operator can then
manually record the shift statistics values.
Shift Start
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The time that the operator operated the shift start icon is entered into this location.
Shift Payload
The shift payload displays the number of loads carried from the start of the shift.
Total Cycles
The total cycles displays the amount of dumps the haul truck has made from the
start of the shift.
Fuel Consumption
The fuel consumption displays the average fuel consumption during the shift.
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Elapsed Time
The elapsed time displays the time passed from the start of the shift.
This interactive icon is touched to change the current screen to the fault screen.
The fault screen contains various faults that occurred during the haul truck opera-
tions.
The severity of the fault, and operator actions are shown on the fault information
banner 1 that come into view across the touch screen display during a fault condi-
tion. The top banner shows the fault message, and the necessary operator action
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to correct the fault, or to position the haul truck, and the fault description 2 is shown
on the banner beneath. Refer to the related section of this operator manual for the
description of fault categories and additional haul handling information. (For more
information see: 4.1 Fault Handling, page 103)
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The operator service screen is accessed when the service and diagnostic icon is
touched. When requested by service personnel, you can access the different
service screens 1 to 8 to get the necessary information about the related systems.
You can also access these screens for general information about the specific
system performance.
Touch the main dash light adjustment 9 icon to get to the main dash light adjust-
ment screen. Operate the left arrow icon to dim, or the right arrow icon to brighten
the main dashboard lights.
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Additional Screens
The interactive service and diagnostic icon is touched to access the haul truck
speed limits screen.
The haul truck limitation screen shows following factory-programmed speed limits:
– empty haul truck travel speed limit
– loaded haul truck travel speed limit
– dump body up travel speed limit
– reverse travel speed limit
– OEM haul truck identification number
The OEM haul truck identification number also appears on the haul truck limitations
screen.
This screen is available to the operator as a reference screen.
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The interactive service and diagnostic icon is touched to access the haul truck
information screen.
The haul truck information screen shows factory-installed features for the following
systems:
– tire size
– gear ratio
– engine hours
– engine type
– engine power
– maximum speed
– dump body UP speed
This screen is available to the operator as a reference screen.
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The interactive service and diagnostic icon is touched to access the haul truck
engine monitoring screen. The operator can monitor the engine speed in revolu-
tions per minute, engine oil pressure, coolant temperature, engine operating hours,
and engine fault messages through the haul truck engine monitoring screen. This
screen is available to the operator as a reference screen.
The interface is an electrical panel enclosure that provides universal serial buses
(USBs), and Ethernet communication connectors. Through the connectors on this
panel, communication between devices and a host controller, or personal
computers can be established for downloading data, troubleshooting, and a variety
communication functions.
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Ethernet Connector
The ethernet connector 1 easily connects one or more standardized IEEE 802.3.
Use the standard operation to connect the Ethernet cable to the correct port.
– Push the RJ-45 plug with the clip facing down or away from you into the
Ethernet connector port.
Use the standard operation to remove the Ethernet cable from the port.
– Press the clip on the RJ-45 plug to remove the cable from the Ethernet
connector port.
Use the standard operation to remove the USB connection device from the panel
connector.
– Pull the USB male connection port from the port.
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The windshield wiper and washer controls 4 are on the direction indicator lever of
the steering column.
The flow of washer fluid and wiper movement stops when the lever is released.
If the washer control is operated and fluid does not flow, it is possible that the
washer fluid reservoir bottle is without fluid.
Wiper Control
The windshield wipers speed is adjustable from an intermittent delay, or a contin-
uous LO to HI speed. The speed adjustments are selected through the operation of
the rotating knob at the end of the directional indicator lever.
The wipers have the following speed adjustments:
– HI (High)
– LO (Low)
– INT (Intermittent)
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– PARK (OFF)
When the HI speed is selected,
– the wipers operate continuously very second.
When the LO speed is selected,
– the wipers operate continuously every three seconds.
When INT speed is selected,
– the wipers operate to wipe once every five seconds instead of continuously.
There are five speed delay options within the intermittent speed selection. The
INT feature permits the operator to set a time delay according to the need and
the weather conditions. The top INT speed mark permits a delay of five
seconds. When the INT speed mark point is moved to the next INT speed mark,
the speed delay increases by one second. For each downward interval, the
wiper speed decreases by one second, and for each upward interval, the wiper
speed increases by one second.
– the PARK selection stops the operation of the wipers and parks the wiper
blades at the bottom of the windshield.
Horn Button
The horn button 6 is in the center of the steering wheel.
– Push the horn button to operate the horn.
The horn can also be activated from the switch on the side of the dump control
lever.
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WARNING
Conditions of operation of the service brake pedal can change the rate of the brake
disc wear!
One operation of the service brake pedal to stop the haul truck quickly is enough to
damage the brake discs.
u After each operation of the service brakes to stop the haul truck quickly, get an
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Accelerator Pedal
The accelerator pedal 3 is the right of the foot pedal controls. The accelerator
pedal is operated to increase the travel speed. Press the accelerator pedal to
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increase the travel speed. Gradually release the accelerator pedal to decrease the
travel speed.
Switches
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The shift selector switch is the lever used by the operator to change the haul truck
direction of movement, and to position the haul truck for parking, loading, and
dumping operations.
shift selector switch has the FORWARD, NEUTRAL, and the REVERSE positions.
This NEUTRAL position has no direction of movement. The NEUTRAL position is
selected to enable engine start, and when the haul truck is in position for loading
and dumping operations.
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This FORWARD position is selected to move the haul truck in the forward direction.
The REVERSE position is selected to move the haul truck in the reverse position.
The white lights behind the axle box illuminate and alarm is activated when the
shift selector switch is in the REVERSE position.
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The dump body control lever is a four-function, self-centering controller that has
three positions.
The following are the four functions of the dump body control lever:
– LOWER
– RAISE
– FLOAT
– HOLD
The following are the dump body control lever positions:
– FORWARD
– CENTER
– BACK
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Tab. 3 Dump Body Control Lever Function, Position, and Dump Body Movement
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The dome lighting ON/OFF switch operates the interior LED lights on the ceiling of
the operator cab.
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Cup Holder
The cup holder is a device to hold a cup or other drinking vessel. Always make
sure that the cup holder is cleaned if any fluid spills into the device.
The circuit breaker panel has the circuit breakers that operate to protect electrical
circuits. If a system does not have power, you can access this panel to make sure
that none of the circuit breakers have opened. The are other circuit breakers in the
battery disconnect switch box on the ground level. Contact the correct service
person to know the circuits protected by the circuit breakers in this panel and those
in the battery disconnect switch box. (For more information see: Circuit Breakers,
page 73)
NOTICE
The reset of circuit breakers is a service personnel task.
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The payload weigh system is integrated into the Litronics Plus computer system.
The system monitors the pressure in the haul truck suspensions and uses this data
to calculate the weight of the load in the dump body. The system then subtracts the
loaded weight from the empty weight to determine the payload being carried.
The payload information screen shows the calculated payload for each strut. If a
payload overload condition occurs, the computer system communicates the fault to
the operator through the integrated fault handling mechanism to warn the operator.
The operator can monitor the payload from the payload monitoring screen.
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WARNING
The engine shutdown switch is operated during specified condition.
Each site has specified procedures for the operation of the engine shutdown
switch.
u Know the safety and operating conditions that apply to the engine shutdown
switch.
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The two switches have the same operations and operate the same lights. The OFF
position of one of the switches calculates the OFF position of the other switch.
The battery disconnect switch box 3 is on the left of the haul truck between the
front wheel and the bumper.
Circuit Breakers
The circuit breakers 1 in the battery disconnect switch box operate to protect elec-
trical circuits from damaged caused by oversupply of current and short circuit
LME/10880899/Preliminary Issue/2011-01-21/en
conditions. If the circuit through the circuit breaker is more than the set level. the
circuit breaker can open. There is a circuit breaker panel at the back of the floor
mounted center console. To know the circuit breaker panel protect the flow of elec-
trical current for specified circuit breakers.
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Access Ladder
LME/10880899/Preliminary Issue/2011-01-21/en
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The is retractable and designed to help operator and service personnel safely
ascend and descend the haul truck. The ladder is raised and lowered through a
remote toggle switch on the ground level controls, and an in-cab control panel.
The ladder position is shown through the status indicator windows on the in-cab
ladder control box. Because the ground control is a remote mechanism operated
by a toggle switch that returns to the center position after the ladder is fully raised
or lowered, the operator must visually check the ladder position when on the
ground to know the correct ladder position.
Note
To lower the ladder,
The ladder does not lower if the parking brake is not applied.
u Make sure the parking brake is applied before you lower the ladder from the
operator cab, or the ground level.
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In an emergency condition,
– Move the release handle in the direction of the RED arrow on the EMER-
GENCY ladder DOWN control.
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The operator has access to the ladder UP 1 and the ladder DOWN 2 touch
buttons.
To raise the ladder,
– Press and release the ladder UP touch button.
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Note
To lower the ladder,
The ladder does not lower if the parking brake is not applied.
u Make sure the parking brake is applied before you lower the ladder from the
operator cab, or the ground level.
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3.2 Control
Gradeability Label
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The gradeability label is in the operator cab between the operator cab door 1 and
the front right corner window.The gradeability label shows the performance of the
haul truck on various inclines, measured in grade percentage. (For more informa-
tion see: 1.1.3 Haul Truck Payload Policy, page 13)
There are two LED dome lights 1 mounted on the left- and right-side of the oper-
ator cab ceiling. The LED dome lights operate from the 12V auxiliary power.
The switch that operates the LED dome lights is the switch next to the window
down switch on the floor mounted center console. (For more information see:
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Exterior Mirrors
The haul truck has the operator-side exterior 1, and the right-side exterior 2exterior
mirrors mounted on the superstructure of the haul truck.
Before you start operations, make sure the mirrors are free of dirt and debris and
that you have good visibility through the mirrors.
A mirror is also located on the platform to give visibility to persons on the platform
of personnel below the diagonal ladder on the ground level.
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Windows
The switches that operate the operator-side cab window 1 is the left-most switches
of the are on the (For more information see: 3.1.10 Floor Mounted Center Console,
page 64) .
u To open or close the operator-side or the trainer-side window: press the correct
switch directional arrow to raise or lower the window pane to the desired vertical
position.
Door Latches
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Each door in the operator cab has key-operated cab door latch 2. The cab doors
do not lock from the inside of the cab.
To open any operator cab door,
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The heating and air conditioning system can remove humidity from the operator
cab, or supply heat, and outdoor air into the operator cab. The heat and air condi-
tioning control unit is on the right dash panel below the touch screen display, and
its mechanical controls are under the main dash panel in front of the trainer-side
seat in the operator cab. The heat and air conditioning operator control unit has the
controls operated to change the ambient air conditions in the operator cab. (For
more information see: 3.1.6 Right Dash Panel, page 45)
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The air conditioning system display panel shows the temperature set-point, and
error codes if the system does not have the correct operation. This panel illumi-
nates when the system is energized.
ON Switch
The ON switch powers the heat and air conditioning system ON. The LED numeric
display illuminates when the unit is powered on and the current set-point tempera-
ture is displayed.
OFF Switch
The OFF switch powers OFF the heat and air conditioning system and the LED
numeric display turns off.
AUTO Switch
This AUTO switch is operated to put the heat and air condition system in a fully
automatic temperature control mode.
LME/10880899/Preliminary Issue/2011-01-21/en
The indicator light illuminates to indicate that the AUTO system is active. The
system will adjust the blower fan speed to the lowest setting necessary to maintain
the cab temperature at the displayed set-point temperature.
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Defrost Switch
The defrost icon energizes the air conditioning system and opens the fresh air vent
to quick removal of the humidity from the operator cab. The operation of this switch
enables the air conditioning even if the set-point temperature requires heat. The air
conditioning system display panel indicator light indicates when the defrost mode is
active.
Fan Switch
The fan increase/decrease switch is operated to override the automatic fan speed
control feature. Increments fan speed UP or DOWN in 11 steps. The operator
display shows the fan speed as a percentage or “HI” when the maximum fan speed
is reached, or “LO” when the minimum fan speed is reached. The display returns to
normal 5 seconds after the switch is released. The set-point fan speed is main-
tained until the AUTO key is pressed.
The fan speed UP switch is operated to increase the fan speed. The air condi-
tioning system display shows the fan speed as a percentage or “HI” when the
maximum fan speed is reached.
The fan speed DOWN switch is operated to decrease the fan speed. The air condi-
tioning system display shows the fan speed as a percentage or “LOW” when the
minimum fan speed is reached.
The temperature DOWN switch is operated to decrease the operator cab tempera-
ture to a set-point temperature. This switch decreases the temperature in incre-
ments of 1 unit per touch.
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The operator seat 1 has air suspension and a retractable seat belt 2. The seat has
an integrated pneumatic system (IPS) designed to reduce pressure on the lower
back. The armrests 3 and seat cushion 4, is adjustable to give the operator unre-
stricted arm, and leg movement. The operator has eight adjustment controls, such
as the , headrest 5, and lumbar support, to position the seat for personal comfort.
There is also the standard heated seat that can give additional comfort during cold
weather conditions.
Seat Belt
The seat belt is a heavy-duty 3-point harness belt.
Each seat in the operator cab has a seat belt with the same adjustment controls.
Always check the condition of the seat belt before you start operations. The seat
belt must be free of damage, and the buckle must operate correctly.
CAUTION
Seat belts can help to keep the operator in the operator seat during a rollover
condition or accident!
u If the trainer-side seat has an occupant, make sure the occupant has their seat
belt fastened.
u Keep your seat belt fastened when in the operator seat.
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Do the seat adjustment to have easy access to the foot pedals, controls and instru-
ments, and full travel comfort during operations.
Do all seat adjustments before you begin any operations, and while the parking
brake is set. Do not do any seat adjustments while the haul truck is in motion.
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u Pull the lever upward to move the seat forward or backward to the correct posi-
tion.
When the correct horizontal position is reached,
u release the lever to lock the position.
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The left of the height adjustment switches is operated to activate the seat height
adjustment control.
u Press the “+” part of the seat height increase/decrease switch to raise the seat.
u Press the “-” of the seat height increase/decrease switch to lower the seat.
When you have the correct seat height position,
u release the seat height increase/decrease switch to lock the seat height posi-
tion.
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3.3 Operation
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– Store all loose items safely in one of the cab storage compartments.
– Make sure none of the circuit breakers in the circuit breaker panel on the floor-
mounted center console have opened. (For more information see: Circuit
Breaker Panel, page 70)
– Make sure the lights and the horn operate correctly.
– Operate the alarm test switch to cycle through the payload display, test the
gauges on the center dash panel, and the alarm. (For more information see:
Alarm Test Switch, page 36)
– Remove any obstruction from the clean air vents, and louvers.
– Make sure the windshield wipers operate correctly.
– Do all adjustments of the operator seat, steering wheel, and other controls so
that you can be comfortable during your operations.
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WARNING
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u immediately put the ignition master switch to the OFF position, and engage the
parking brakes.
u Apply the parking brakes.
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Tab. 4 Using the Different Brake Systems While the Haul Truck is Moving
Tab. 5 Using the Different Brake Systems While the Haul Truck is Stopped
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Dynamic Braking
During dynamic braking, the energy to decrease travel speed changes to electric
energy. The electric energy is removed through the electric resistors. When the
dynamic braking pedal is pressed, the inverters can reverse the motor torque to
give the necessary brake force. The electrical current made by the traction motors
goes through the resistors. The amount of electricity made, depends on the posi-
tion of the dynamic braking pedal. (For more information see: 3.1.9 Foot Pedal
Controls, page 63)
The dynamic braking pedal is the center pedal of the foot pedal controls. This
pedal is operated to decrease the travel speed during normal operating conditions.
When the haul truck is moving during normal operating conditions,
u use the dynamic braking pedal to decrease the travel speed.
Note
The dynamic braking pedal does not give enough braking force to stop the haul
truck in conditions when you must stop quickly.
In conditions when you must quickly stop the haul truck,
u use only the service brake pedal.
Service Brakes
The service brake pedal controls the front and rear disc brakes. The service brakes
can safely bring a loaded haul truck to a stop five successive times on 10%
maximum grade.
The service brake pedal is the left of the foot pedal controls and its operated during
conditions when you must stop quickly. (For more information see: 3.1.9 Foot
Pedal Controls, page 63)
When a condition occurs when you must slow the haul truck to within the dynamic
braking envelope,
u use the service brake pedal.
When a condition occurs when you must stop the haul truck quickly,
u use the service brake pedal with the dynamic braking pedal.
Note
Sole operation of the service brakes must be only in a panic emergency!
u Use the service brakes to slow the haul truck to within the dynamic braking
envelope.
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Hand Brakes
The operation of the hand brake switch starts the action that decreases the brake
pressure from the two brake accumulators to all service brakes calipers.
The normal operation of the hand brakes is to hold the haul truck in position. The
hand brake switch is on the floor mounted center console. (For more information
see: Hand Brake Switch, page 66)
When the haul truck is stopped,
u use the hand brakes to hold the stopped haul truck in position during loading
and dumping operations.
During loading operations,
u release the hand brakes after the last loaded shovel is put into the dump body.
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WARNING
Damage to the parking brake components can occur if the parking brakes are
applied to hold the haul truck during loading and dumping operations.
u Use only the hand brakes to hold the haul truck in position during loading and
dumping operations.
Parking Brakes
The operation of the parking brakes switch starts the action that removes the
power from the parking brake solenoid, and the illumination of the parking brakes
and the propulsion inhibit indicators. The results of these actions engage the
parking brakes to prevent the haul truck propulsion.
Hydraulic pressure is used to release the parking brakes. If the hydraulic pressure
is not available, the parking brakes automatically engage.
During normal operations where electrical and hydraulic power is available, the
release of the parking brake switch starts the actions that energize the parking
brake solenoid. The hydraulic pressure of 217 bar (3150 psi) opens the parking
brakes springs, extinguishes the related indicators, and lets haul truck propulsion.
The parking brakes on the rear wheels can hold the completely loaded haul truck
on a 15% maximum grade.
The parking brake switch is on the left dash panel, and the related indicator is on
the indicator panel. (For more information see: Parking Brake Switch, page 39)
When the haul truck is stopped,
u the engine cannot start without the parking brakes set.
w The parking brake indicator on the indicator panel illuminates to let the oper-
ator know that the parking brake is applied. (For more information see:
Parking Brake Indicator, page 43)
Before you exit the operator cab,
u make sure the parking brakes are set.
If the parking brake does not hold,
u apply the hand brake and immediately tell the correct service person about the
problem.
Brake Blending
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Brake blending automatically occurs when the dynamic braking pedal is more than
75% of pedal travel, and the travel speed is less than 0.8 km/h (0.5 mph).
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Forward Travel
u If necessary, do the Engine Start Procedure. (For more information see:
3.3.3 How to Start the Engine, page 93)
u Give the correct safety instructions to all persons near the haul truck.
u Before you release the parking brakes, make sure your direction of travel is
without other vehicles, persons, or obstruction.
u Put one foot on the service brake pedal.
u Release the parking and the hand brakes.
u Put the shift selector switch to the FORWARD (F) position for forward move-
ment.
u Gradually apply some pressure to the accelerator pedal and control the travel
speed with the dynamic braking and the accelerator pedals.
Note
The simultaneous operation of the dynamic braking and the accelerator pedals can
cause an inverter fault condition.
u Do not operate the dynamic braking and accelerator pedal at the same time.
Reverse Travel
u If necessary, do the engine start procedure. (For more information see:
3.3.3 How to Start the Engine, page 93)
u Give the correct safety instructions to all persons near the haul truck.
u Keep one foot on the service brake pedal.
u Put the shift selector switch to the REVERSE (R) position. An alarm activates
and the backup lights behind the axle box illuminate while the shift selector
switch is in the REVERSE position.
u Before you remove your foot from the service brake pedal, make sure your
direction of travel is without other vehicles, persons, or obstruction.
u Gradually apply some pressure to the accelerator pedal and gradually release
pressure from the service brake pedal and control the travel speed with the
dynamic braking and accelerator pedals.
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Downhill
u Make sure the dynamic braking speed control system is ON and a maximum
travel speed is set. If the haul truck is operated downhill without the operation of
the dynamic braking speed control, use the dynamic braking pedal to control the
travel speed.
u Monitor and control the travel speed, and keep the travel speed below the set
maximum speed limit.
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Parking
u Park the haul truck on level ground, if possible.
u Put the shift selector switch to the NEUTRAL (N) position.
u Make sure the dump body is lowered completely.
u Set the parking brake.
u If necessary, do the engine shutdown procedure to turn off the engine. (For
more information see: 3.3.4 How to Shutdown the Engine , page 94)
Parking on a Grade
u Position the front wheels in the direction of the face wall when parking on a
grade.
u Set the parking brakes and make sure it holds. If the parking brakes do not
hold, engage the hand brakes and immediately tell the correct service person
about the failure.
u Turn the ignition master switch to the OFF position.
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The downhill and haulage roads travel speeds can increase because of the force of
gravity, gross vehicle weight, haulage roads grades and lengths, rolling resistance,
curve angles, and other parameters. Without speed-assist, you have to continu-
ously use the dynamic braking pedal to maintain the travel speed. With speed-
assist, the dynamic braking speed control system can automatically apply enough
braking power to maintain and keep the haul truck travel speed from exceeding the
maximum programmed speed without the use of the foot pedal controls, especially
during downhill travel.
A good operating procedure is to energize the dynamic braking speed control
system, use the dynamic braking speed control system adjustment switch to pre-
programme a maximum travel speed, and keep the system energized throughout
your shift. The dynamic braking speed control system permits speed sets at
1 km/h (0.6 mph) increments to a total maximum haul truck travel speed that is
programmed at the OEM factory. For safety, reference the gradebility label in the
operator cab to find the optimum grade percentage that matches a travel speed
where a haul truck can safely travel downhill.
WARNING
Service brakes can fail!
After each application of the service brakes to stop the haul truck quickly,
u immediately get the service brakes inspected before you continue any opera-
tions.
LME/10880899/Preliminary Issue/2011-01-21/en
u The foot pedal controls operate independently from the dynamic braking speed
control system.
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LME/10880899/Preliminary Issue/2011-01-21/en
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The built-in fault management system is the set of functions that detect, isolate,
and correct malfunctions in the drive system, and general haul truck performance
detection systems. These built-in systems permit system monitoring and the exami-
nation of error logs, acceptance, and error detection notifications. The service
personnel can carry out sequences of diagnostic tests, and fault corrections tasks
and procedures to correct the problems. The system localizes these faults and
handles the degree of fault through the fault management system.
There are active and passive fault management modes. Passive fault management
is done by collecting alarms from components when something happens in the
component. The passive fault management mode is intelligent enough to know if a
component it is monitoring is enough to generate an error and report it to the fault
management database. The active fault management mode actively monitors
components through various sensors to determine if the component is active and
responding. If the component stops responding, active monitoring will activate an
alarm showing the component as prohibited and permits a proactive fault correc-
tion.
There faults are communicated to the operator through the touch screen display
panel. For the operator to recognize the fault mode, the haul truck has been
equipped with a fault handling system.
The fault monitoring within the Litronic Plus system gives fault messages to the
operator and service personnel when it detects a haul truck performance, compo-
nent, or system fault. The fault information and corrective action is communicated
to the operator and the service personnel through the touch screen display panel.
The degree of possible faults messages and alarms are categorized and described
in this section. The operator response necessary to position the haul truck for
future diagnoses, or to permit enough time for the fault correction is also described
LME/10880899/Preliminary Issue/2011-01-21/en
in this section.
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Critical
The critical fault category is used for faults that require immediate action to avoid
severe component damage or operator injury.
This category is rated as the highest fault category. An audible alarm normally is
activated during a critical fault condition, and the alarm cannot be silenced, or the
fault cannot be reset by the operator.
If a critical fault occurs,
u follow the instructions shown in the fault banner.
u Immediately communicate the fault condition to the correct service personnel.
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Major
The major fault category is used for faults that require quick action by the operator
to avoid component damage or operator injury.
If a major fault occurs,
u follow the instructions shown in the fault banner.
If the fault cannot be reset,
u service personnel must be called to repair the component, or system, and reset
the fault.
High
The high fault category is used for faults that require quick action by the operator
to avoid component damage or operator injury.
If a high fault occurs,
u Immediately park the haul truck and keep the engine running.
After the haul truck has come to a complete stop, and the engine speed is > 0, and
the fault is still active,
u operate the fault reset switch on the left dash panel to try to stop the alarm, and
LME/10880899/Preliminary Issue/2011-01-21/en
reset the fault. (For more information see: Fault Reset Switch, page 39)
If the fault cannot be reset,
u service personnel must be called to repair the component, or system, and reset
the fault.
Medium
The medium fault category is used for faults that require quick action by the oper-
ator to avoid component damage or operator injury.
If a medium fault occurs,
u Take immediate action to remedy the condition and notify service
personnel, if necessary.
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u Operate the fault reset switch on the left dash panel to register and reset the
fault. (For more information see: Fault Reset Switch, page 39)
Low
The low fault category is used for faults that require action by the operator but do
not require immediate action. For example, the loss of a sensor or an operating
condition that has not caused a major overheating condition within a component or
system.
If a low fault occurs,
u take the necessary action to change the operating condition to avoid
continued system heating.
u The audible alarm sounds for 1 second to alert the operator of the specified
fault condition.
u The fault can also require the repair or replacement of the component at shift
change or at the next preventive maintenance interval.
u Operate the fault reset switch on the left dash panel to register and reset the
fault. (For more information see: Fault Reset Switch, page 39)
u Operate the fault reset switch on the left dash panel to register the fault, and
report the fault to the service personnel.
Help/Information
The help/information fault category is used for information faults.
If a help/information fault occurs,
u take the necessary action to avoid the condition in the future.
u The fault will reset if the condition changes and the system no longer operates
outside of the intended range or the condition that caused the fault is no longer
present.
u No audible alarm is activated during a help/information fault condition.
Silent
The silent fault category is used for silent faults that are not reported to the oper-
ator but are stored in the computer memory for future analysis.
If a silent fault occurs,
u no operator action is necessary.
u A fault reset operation is not necessary during a silent fault condition.
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The fault banners appear on the touch screen display panel during a fault condi-
tion. The top banner shows the fault category, and banner below shows the actual
fault. Not all fault conditions are shown. The operator can access the fault screen
to find a list of faults that occurred during operations.
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LME/10880899/Preliminary Issue/2011-01-21/en
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1 D
10/10/20 Rule 13 Daily Inspections and Checks 91
12V DC Cigarette Lighter, Power Plug 46 Dashboard Light Adjustment 55
Date, Time, Ton, and Haul Cycle Display 48
Defrost Switch 84
2 Direction Indicator Lever 60
24 VDC Battery Isolator Switch 73 Direction Indicators 44
DO NOT OPERATE WITHOUT GUARDS 29
DO NOT STAND BETWEEN TIRES AND FRAME 31
A Dome Light ON/OFF Switch 69
Accelerator Pedal 63 Door Latches 81
Access Ladder 74 Downhill 98
Additional Screens 56 Drive System Fault Indicator 44
Air Conditioning System Display Panel 83 Dump Body Control Lever 67
Air Conditioning System Switches and Controls 83 Dump Body High Idle Switch 68
Alarm Test Switch 36 Dump Body Override Switch 68
Anti-Roll-Back 34 Dump Body Safety Precautions 33
Armrest Adjustment Knobs 87 Dump Body Travel Position 99
Ashtray and Pocket Storage 82 Dump System 19
AUTHORIZED PERSONNEL ONLY (Sign) 31 Dynamic Brake Pedal 63
Auto Lube Switch 36 Dynamic Braking 96
AUTO Switch 83 Dynamic Braking Speed Adjustment Switch 40
Auxiliary Horn Switch 65 Dynamic Braking Speed Control Speed Set
Switch 101
Dynamic Braking Speed Control System 99
B Dynamic Braking Speed Control System
Backrest Adjustment Lever 88 Activation 100
Backup Light Switch 39 Dynamic Braking Speed Control System Activation
Battery / 24V Alternator Fault Indicator 44 Switch 40
Battery Disconnect Switch Box 73 Dynamic Braking Speed Control System
Battery Jump Start Receptacle 74 Limitations 100
Battery Safety 28 Dynamic Speed Control Set Speed Indicator 48
Battery Voltage Gauge 41
Brake Blending 97
E
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H M
Hand Brake Indicator 43 Main Alarm Indicator 43
Hand Brake Switch 66 Main Dash Panel 37
Hand Brakes 96 Main Operator Screen 48
Haul Truck Dimensions 23 Main Screen with Faults 54
Haul Truck Engine Monitoring Screen 58 Main Splash Screen 47
Haul Truck Information Screen 57 Major 105
Haul Truck Orientation 15 Malfunctions 103
Haul Truck Payload Policy 13 Master Ignition Switch 60
Haul Truck Speed Limits Screen 56 Medium 105
Haul Truck Travel 98
Hazard Flasher Switch 62
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W
Weight Capacity 20
WEIGHT WARNING 31
When to use the Different Brakes 95
Windows 81
Windshield Washer Control 61
Windshield Wiper and Washer Controls 61
Wiper Control 61
World Radio and Compact Disc Player 37
LME/10880899/Preliminary Issue/2011-01-21/en
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