TEREX Equipment Limited Operator Handbook

TEREX Equipment Limited Operator Handbook
TA35/40 G7
Operator Handbook
15502483
OHE862/865/
917/946
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TEREX Equipment Limited Operator Handbook Re-order
Issued by;
Customer Support Department
Terex Equipment Limited
Newhouse Industrial Estate
TA35/40 G7
Motherwell, ML1 5RY

Scotland
Tel; +44 (0) 1698 732121

Fax; +44 (0) 1698 503210
www.terex.com
OHE862/865/917/946
Operator Handbook
Re-order Part Number

15502483
This controlled document is the original instructions and

should remain with the vehicle at all times.
Revision: May 2012
15502483
OHE862/865/
917/946
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TEREX Equipment Limited Operator Handbook - Introduction
For further information on the subject matter detailed within this operator handbook,
please refer to Terex Equipment Limited Service Manuals and Product Parts Books.
Alternatively, please contact;
Customer Support Department

TA35/40 G7
Terex Equipment Limited

Newhouse Industrial Estate
Motherwell, ML1 5RY
Tel; +44 (0) 1698 732121

Fax; +44 (0) 1698 503210
The illustrations, technical information, data and descriptive text in this manual, to the
best of our knowledge, were correct at the time of print. The right to change
specifications, equipment and maintenance instructions at any time without notice, is
reserved as part of the Terex Equipment Limited policy of continuous development
and improvement of the product.
Operator Handbook
No part of this publication may be reproduced, transmitted in any form - electronic,

mechanical, photocopying, recording, translating or by any other means without prior
permission of Customer Support Department - Terex Equipment Limited.
Please refer to TEREX Specification Sheets or consult Factory Representatives to

ensure that information is current.
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ONLY TRAINED PERSONNEL SHOULD BE
ALLOWED TO OPERATE THIS VEHICLE
The operator is responsible and must be
familiar with the contents of the Operator's
Handbook and any local regulations prior to
operating this vehicle.
Blank P age
CALIFORNIA
Proposition 65 Warnings
WARNING: Diesel engine e xhaust and
some of its constituents are known to the
State of Calif ornia to cause cancer , bir th
defects, and other reproductiv e har m.
WARNING: Batter y posts , ter minals
and related accessor ies contain lead
and lead compounds , chemicals
known to the State of Calif ornia to cause
cancer and reproductiv e har m.
Wash hands after handling.
SPARE PARTS STATEMENT
When carrying out repairs, alterations or fitting attachments, it is important that only genuine
spare parts are used to ensure the operating safety of the machine is not impaired.
It is only by using genuine parts that the technical requirements stipulated by the manufacturer
can be maintained.
If a General Operating Approval is issued for this machine, it may be considered null and void
if non-genuine parts are used.
EC DECLARATION OF CONFORMITY
MANUFACTURERS NAME AND FULL ADDRESS

TEREX EQUIPMENT LIMITED,
MOTHERWELL,
SCOTLAND,
ML1 5RY
DESCRIPTION OF MACHINERY DIRECTIVES COMPLIED WITH

MAKE: TEREX 87/404/EEC 97/23/EC
MODEL: TA35 ARTICULATED TRUCK 89/336/EEC
TA40 ARTICULATED TRUCK 98/37/EEC
2000/14/EC
UNIT SERIAL NO. DATE OF MANUFACTURE:
INSPECTOR:
THE ABOVE MACHINERY, TAKING INTO ACCOUNT THE STATE OF THE ART,
COMPLIES WITH, OR IS DESIGNED AND CONSTRUCTED AS FAR AS POSSIBLE TO COMPLY WITH,
THE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS OF THE MACHINERY DIRECTIVE.
FOR AND ON BEHALF OF THE MANUFACTURER:
NAME: PAUL DOUGLAS SIGNATURE:

POSITION: CHIEF ENGINEER
can be maintained.
EC DECLARATION OF CONFORMITY
MANUFACTURERS NAME AND FULL ADDRESS

TEREX EQUIPMENT LIMITED,
MOTHERWELL,
SCOTLAND,
ML1 5RY
DESCRIPTION OF MACHINERY DIRECTIVES COMPLIED WITH

MAKE: TEREX 87/404/EEC 97/23/EC
MODEL: TA35 ARTICULATED TRUCK 89/336/EEC
TA40 ARTICULATED TRUCK 98/37/EEC
2000/14/EC
UNIT SERIAL NO. DATE OF MANUFACTURE:
INSPECTOR:
THE ABOVE MACHINERY, TAKING INTO ACCOUNT THE STATE OF THE ART,
COMPLIES WITH, OR IS DESIGNED AND CONSTRUCTED AS FAR AS POSSIBLE TO COMPLY WITH,
THE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS OF THE MACHINERY DIRECTIVE.
FOR AND ON BEHALF OF THE MANUFACTURER:
NAME: PAUL DOUGLAS SIGNATURE:

POSITION: CHIEF ENGINEER
can be maintained.
CONTENTS
1. INTRODUCTION
Introduction 1-5
Safety Precautions 1-5
Machine Identification 1-6
Theft Deterrent Practices 1-6
2. SAFETY PRECAUTIONS
General 2-4
Articulation and Oscillation Locks 2-5
Vehicle Lifting Precautions 2-5
Vehicle Tie Down Precautions 2-5
Preventing Fire Hazards 2-6
Mounting and Dismounting 2-7
Pre-Starting 2-8
Starting 2-8
Operating 2-8
Roading 2-10
Lubrication and Servicing 2-10
Wheels and Tyres 2-12
Avoid Tyre Explosion Hazard 2-13
Decals and Instruction Plates 2-14
3. CONTROLS AND OPERATING

Controls and Instruments 3-3
Fuse / Relay Box 3-4
Basic Data 3-5
Warning Lights 3-5
Instruments 3-7
Switches 3-9
Controls 3-12
Heater 3-13
Air Conditioning 3-13
Operator's Seat -
Air Suspension 3-14
Operator's Seat - Operation 3-15
Seat Belt 3-17
Machine Controls 3-18
Braking 3-18
Transmission Retarder 3-19
Engine Brake 3-20
Engine 3-21
Electronic Foot Pedal 3-21
Detroit Diesel Electronic
Control 3-21
Description 3-22
Operation 3-23
Allison Series 4000 Automatic
Shift Transmission 3-30
4th GEN Shift Controller 3-31
Dropbox 3-37
1-1
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1-2
3. CONTROLS AND OPERATING (cont.)
Differential Lock 3-37
Hydraulic Controls 3-38
Steering 3-39
Body Control 3-40
Tilting Cab 3-41
Hood 3-42
4. OPERATING THE TRUCK

Pre-Starting Inspection 4-3
Component Checks 4-3
Engine Operation 4-6
Starting the Engine 4-7
Starting the Engine
with Jumper Cables 4-9
Pre-Operating Checks 4-10
Brake Function Checks 4-11
Driving and Stopping 4-12
Stopping the Engine 4-14
Parking 4-15
5. WORKING THE TRUCK
Working the Truck ............... 5-3
Loading ............................ 5-3
Hauling ............................. 5-5
Dumping ........................... 5-6
Empty Return ................... 5-7
6. ROADING
Roading .............................. 6-3
General ............................ 6-3
Preparation Prior to Roading 6-3
In Case Of Trouble 6-4
7. MOVING DISABLED TRUCK

Moving Disabled Truck 7-3
8. LUBRICATION AND SERVICING

Safety Precautions 8-3
Lubrication and Servicing 8-4
Lubrication and Service Chart 8-5
Miscellaneous Servicing Information 8-7
Recommended Lubricants 8-10
9. TECHNICAL DATA
TA35 A862 9-3
TA35 A917 9-9
TA35 A946 9-15
TA40 A865 9-21
10. SYMBOL IDENTIFICATION
1-3
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1-4
Introduction
INTRODUCTION
This Handbook is provided as a guide to familiarize the operator and
serviceman with the controls, recommended inspections, start-up,
operating, shutdown and parking procedures for TA35/TA40
Articulated Trucks.
Pay particular attention to the safety alert symbol, which is intended to Safety alert symbol
alert you to important safety precautions. It signifies:
ATTENTION! BECOME ALERT! YOUR SAFETY AND THE

SAFETY OF OTHERS IS INVOLVED!
Safety Precautions
The machine should be properly operated and maintained to keep it
in safe, efficient operating condition. Be sure that all controls are free
of mud, grease, or other matter that might cause slips hazardous to
the operator, serviceman, or other personnel or equipment. Report all
malfunctions to those responsible for maintenance, and, do not
operate the equipment until corrected. Normal service or
maintenance performed as required can prevent unexpected and
unnecessary downtime.
This Handbook describes general inspections, servicing and

operation with the normal safety precautions required for normal
servicing and operating conditions. It is not a guide however, for other
than normal conditions or situations, and therefore, servicemen and
operators must be safety conscious and alert to recognize potential
servicing or operating safety hazards at all times, and take necessary
precautions to assure safe servicing and operation of the machine.
WARNING
These machines are equipped with cylinders containing
compressed nitrogen gas. Transportation of these machines
by any method may require a special permit from the
appropriate authority of the country involved. Consult your
dealer for details.
All information, illustrations and specifications contained in this

publication are based on the latest product information available at
the time of publication. The right is reserved to make changes at any
time without notice.
Continuing improvement and advancement of the design may cause

changes to your machine which may not be included in this
publication. Each publication is reviewed and revised, as required, to
update and include these changes in later editions.
This Handbook contains lubrication and routine servicing

instructions, most of which can be performed in the field. Maintenance
manuals containing repair/rebuild procedures can be obtained from
your dealer.
1-5
Introduction
1759
Intended use of machine

This product and its approved attachments are primarily intended to
be used as described in this manual.
Use of this product in any other way is prohibited and contrary to its
intended use.
Machine Identification
While reading this handbook you will notice references to controls
and equipment which may not be found on all machines. It is
important that you know your machine and its equipment and how to
operate it properly.
Information regarding the machine model, code and chassis serial

number is found on the unit serial number plate on the rear right of the
front frame. The machine model and serial number should always be
referenced in any correspondence with your dealer or factory.
There is a dealer serving every part of the world where these

products are sold. Your dealer is ready to provide you with any
additional information needed and should be consulted for additional
publications for this machine.
Theft Deterrent Practices

General
The owner/operator should take the following precautions to
discourage theft, to aid in the recovery in the event that the machine is
stolen, or to reduce vandalism.
Actions to Discourage Theft and Vandalism

Remove all keys any time the machine is left unattended.
At night lock all doors and attach, secure or lock all anti-vandalism
and anti-theft devices on the machine.
Immobilize the machine by removing a critical electrical or starting
1-6
Introduction
system device, for example Fuse 31 or 32.
Upon receipt of a machine, record the machine serial number and

the serial numbers of all major components and attachments. Keep
this list up to date and filed in a safe location for fast retrieval.
Place a decal or notice on the machine that all serial numbers are
recorded.
Discourage the thief! Inspect the gates and fences of the machinery
storage yard or construction site. Keep machines in well-lit areas and
ask the local law enforcement authorities to make frequent checks
around the storage yard or work site.
Establish liaison with neighbours and ask them to watch equipment

left at job sites and to report any suspicious activities to the local law
enforcement authorities.
Make frequent inventories of machines to promptly detect losses or

vandalism.
Actions to Aid in Recovery of Stolen Machines

In the event of theft, immediately notify the law enforcement
authorities having jurisdiction. Provide the investigating officer with
name, type of equipment, chassis and serial numbers of major
attachments and components. It is helpful to show the investigating
officer an Operator’s Handbook, photographs, and advertising, to
familiarize him with the appearance of the machine.
Report the theft to the insurance company. Provide the model and all
serial numbers.
Report the model and serial numbers of the stolen machine to a

dealer handling the respective line of equipment. Request that the
dealer forward this same information to the equipment manufacturer.
1-7
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1-8
Safety Precautions
2 - Safety Precautions
2-1
Safety Precautions
Blank P age
2-2
Safety Precautions
SAFETY
Safety Alert Symbol

The safety alert symbol is used to alert you to a potential personal
injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.
Safety alert symbol
Hazard Classification
A multi-tier hazard classification system is used to communicate
potential personal injury hazards. The following signal words used
with the safety alert symbol indicate a specific level of severity of the
potential hazard. Signal words used without the safety alert symbol
relate to property damage and protection only. All are used as
attention getting devices throughout this manual as well as on decals
and labels fixed to the machinery to assist in potential hazard
recognition and prevention.
DANGER indicates an imminently hazardous situation which, if

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

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

not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a poten-

CAUTION tially hazardous situation which, if not avoided, may result in prop-
erty damage.
2-3
Safety Precautions
SAFETY PRECAUTIONS
General
* Read this Operator’s Handbook and learn the operating
characteristics and limitations of the vehicle. Know what
operating clearances the vehicle requires. TY L
A FE UA
S A N
M
* Read the AEM Safety Manual and follow the recommended
safety precautions.
* Know clearances of all side and overhead obstructions such as

wires, bridges, etc., for operating safely.
• Be especially aware of overhead power lines. 1767
* Always know all traffic rules, signs, flags and hand signals used
on the job and know who has the responsibility for signalling.
* Be aware of operating hazards that weather changes can create

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

physically fit. 1768
* Know what safety equipment is required and use it. Such

equipment may be: Hard hat, safety glasses, reflector type vests,
respirators and ear plugs.
* Never wear loose clothing, rings, watches etc., that might catch
levers and controls and cause loss of control.
* Keep hands and controls free from water, grease and mud to
assure nonslip control.
* Handle fuels and lubricants carefully and clean up spills to

avoid fire and slipping hazards. 1769
* Clean any mud, grease or oil from controls, handrails, ladders

and decks. Lash necessary tools securely and remove all loose
items before operating the vehicle. Never rush. Walk, do not run.
* Never carry more than one passenger and only in the passenger
seat.
WARNING
The protection offered by the roll over and falling object
protective structure may be impaired if it has been
subjected to any modification or damage. Unauthorized
modification will void certification. 1782
2-4
Safety Precautions
Articulation and Oscillation Lock

* Always connect the articulation and oscillation lock bar before
working in the articulation area, before lifting the vehicle and
during transportation of this vehicle by trailer/vessel.
* Always disconnect the articulation and oscillation lock bar and Articulation and Oscillation
secure in the 'Stowed' position before operating the vehicle. The 1743 Lock - 'Locked' Position
vehicle would not be free to steer otherwise.
Articulation and Oscillation

1762 Lock - 'Stowed' Position
Vehicle Lifting Precautions
* Prior to lifting, the vehicle should be parked on a level surface,
LIFTING POINTS
wheels blocked, articulation and oscillation lock bar connected,
and the parking brake disengaged.
* The vehicle should be lifted using a spreader bar if possible. Lift

using FOUR slings from the lifting points provided at the bumper
end of the front chassis and at the rear of the body.
Note: Be aware that this vehicle is free to oscillate if not lifted

correctly. If in any doubt contact your dealer for further
TIE DOWN POINTS
information. 1705
Vehicle Tie Down Precautions

* The vehicle should be secured at the tie down points located at
the bumper end of the front chassis, the front face of the trailer
REAR
chassis and the tow pin at the rear of the trailer chassis.
FRONT
CENTRE
1744 Vehicle Tie Down Instructions
2-5
Safety Precautions
Preventing Fire Hazards

General Fire Precautions
* Make sure the vehicle has a fire extinguisher and that it is
accessible and fully charged. (Not furnished with the vehicle.)
* Never use an open flame as a light anywhere on, or around, the

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

debris that could cause fires before starting the engine.
* Don’t let greasy, oily rags or similar hazards accumulate in the 1789
cab.
* If the vehicle has been operated with an under inflated tyre.

Make sure that the tyre has cooled sufficiently before parking
and leaving the vehicle unattended.
Flammable Fluid Precautions

* Don’t use diesel fuel or other flammable fluids for cleaning
purposes. Use approved, nonflammable solvents.
* Make sure all fluid system caps, drain cocks, valves, fittings,
lines, etc., are secure and leak free.
FUEL
* Never use an open flame (match, lighter, etc.) when checking

fuel, lubricant, coolant and battery fluid levels, or when checking
for fluid leaks. Use a flashlight or other safe lighting only.
* Shut off engine and use extra caution if engine is hot when
refuelling. Ground the hose spout to prevent sparks when spout
1770
is touched to fuel tank filler tube.
* Never smoke while checking or adding fuel or other fluids or

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

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

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

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

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

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

avoid danger of fire-causing sparks. Disconnect the battery
ground cable first and reconnect it last.
* Always disconnect batteries, alternator leads, engine ECM,

hydraulic system ECU, body control lever, transmission ECU,
instrument panel ECU and all harness connections at the front
of the cab before carrying out any welding on the vehicle.
* Never check the battery charge by placing metal objects across

the battery posts, to avoid sparks at battery posts.
1771
* Use jumper cables only as recommended. Improper use can
result in battery explosion or unexpected vehicle motion.
* Never operate the engine starter for more than 30 seconds, and
allow two minutes between long cranking periods for cooling.
An overheated starter could cause a fire.
* If electric coolant or lubricant heaters are used, be sure to follow

heater manufacturer’s recommendations for use to avoid
electrical or fire hazards or both.
Mounting and Dismounting

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

points of support to mount or dismount the vehicle.
* Always use care when mounting the vehicle with oil covered,
frosted, or iced fenders, decks, hand holds or steps.
* Never mount or dismount a moving vehicle. Never jump off the

vehicle. 1772
2-7
Safety Precautions
Pre-Starting
* If engine is to be started and run indoors, ensure proper
ventilation to remove deadly exhaust gases.
* Always perform 'Pre-Starting Inspection' instructions described

on page 4-3 to ensure the vehicle is ready for operation.
* Always walk around the vehicle to make sure no-one is working on,
underneath or close to the vehicle before starting the engine or
operating the vehicle.
1773
* Adjust, secure and latch the seat and fasten the seat belt before
starting the vehicle.
* Sound horn before starting the engine or beginning to move the

vehicle; two blasts for forward and three blasts for reverse.
Starting
* Do not start the engine or operate any control if there is a 'DO
NOT OPERATE' or similar warning sign attached to any control. DO NOT
OPE RATE
* Use jumper cables only as recommended. Improper use can
result in battery explosion or unexpected vehicle motion.
* Always obey 'Starting the Engine' instructions described on

page 4-7.
1775
* Do not bypass the vehicle’s neutral-start system. The neutral-

start system must be repaired if it malfunctions.
* Start and operate the vehicle only from the operator’s seat.
Operating
* Ensure all cab glass, mirrors and light lenses are clean during
vehicle operation for maximum visibility. Ensure mirrors are
properly set / positioned.
* Always keep cab floor clear of anything that could restrict full
operation of pedals. 1790
* Always make sure all gauges, warning/indicator lights and

controls are working properly before operating the vehicle.
* Always perform 'Pre-Operating Checks' described on page 4-10 P 15 20
to ensure the vehicle is ready for operating.

P
10
25
STO
00
in x1
r/m
2
5
1
30
0
30
* Always wear seat belts when operating the vehicle. 20

30
40
mp
/h
h
50
60 40
70
L
H
°F
20 km
10
80
10 50
* Do not operate if exposed personnel enter the immediate work 0
area.
* Sound horn before starting engine or beginning to move the 1776
vehicle; two blasts for forward and three blasts for reverse.
2-8
Safety Precautions
* Watch for ground crew and other personnel on foot. Sound horn
as a warning before setting the vehicle in motion and when
approaching ground crew.
* Be sure the body is fully down before moving the vehicle.
* Always try to face or look in the direction the vehicle is

travelling.
* Use extreme caution and turn on lights at night or when fog, dust
or similar hazards limit visibility. Do not overdrive your 1774
headlights.
* Observe instruments frequently. Report any defects or unusual

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

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

the transmission will automatically lock in a gear range. If this
occurs, stop the vehicle using the service brakes, apply the
parking brake and do not operate until the fault is corrected.
* Always operate straight up or down slopes whenever possible,

side-hill operation can cause sideslip and possible roll-over.
* Slow down when moving in congested areas. Do not race with

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

operate the vehicle if a warning light indicates a fault in the 1778
braking system.
* Always give loaded vehicles the right-of-way when your vehicle

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

backing to dump over a spoil bank.
* Always apply the brakes with the Parking-Emergency brake

control when the vehicle is being loaded or when dumping a
load.
* Always stay in cab when being loaded.

1779
* Always lower the body and shut down the vehicle according to
2-9
Safety Precautions
the procedure under 'Stopping The Engine' described on page

4-14 before leaving the vehicle unattended. If on a grade wheels
should be blocked.
Roading
* Match speed to road conditions.
* Yield the right of way when required. Obey the rules of the road.
* Stay as close to the side of the road as possible. Pass other

equipment only when the road is clear and enough room / space
to pass and reserve power is available.
* Stop at appropriate intervals to inspect the vehicle and allow the 1777
tyres to cool. Tyre air pressure will rise during operation. Do not
reduce tyre pressure. Excess speed will cause tyres to heat up.
Reduce your travel speed, not tyre pressure.
* Use accessory lights and devices at night or in poor visibility.

Carry a flare kit. Do not overdrive your headlights.
Lubrication and Servicing

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

the ignition switch or a prominent control before cleaning, 1794 Body Safety Prop
lubricating or servicing the vehicle.
* Never allow anyone to work on the vehicle while it is moving.

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

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

linkage, part or vehicle.
* Always install the steering lock bar before making adjustments

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

'Stopping The Engine', described on page 4-14, and turn off the 1780
master switch before cleaning, lubricating or servicing the
vehicle except as called for in this Operator’s Handbook or the
2-10
Safety Precautions
Maintenance Manual.
* Always relieve pressure before servicing any pressurised

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

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

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

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

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

operator’s cab. Always use the operator’s cab safety prop with 1727 Operators Cab Safety Prop
the locking pin.

1993
Operators Cab Safety Prop & Locking Pin

With Cab Raised
2-11
Safety Precautions
Wheels and Tyres

If tyres on the vehicle were inflated at the factory with dry nitrogen
gas, the tyre walls will be marked 'N' and the following factory
installed decal will be found mounted on the fenders.
NOTICE
TYRES ON THIS VEHICLE ARE FACTORY INFLATED WITH
DRY NITROGEN. IT IS RECOMMENDED THAT DRY
NITROGEN BE USED EXCLUSIVELY FOR ALL TYRE
PRESSURE ADJUSTMENTS AS WELL AS INFLATION OF
REPLACEMENT TYRES.
Nitrogen gas improves tyre pressure retention, increases tyre life by

reducing carcass oxidation from within, minimizes rim rust, and has
no known detrimental effect on the tyre. It also reduces the potential of
a tyre explosion because it is an inert gas and will not support
combustion inside the tyre. The same tyre inflation pressure used for
air inflation should be used for nitrogen inflation. Refer to Section
160-0050, Wheel, Rim and Tyre of the vehicle Service Manual for
recommended procedures for inflating and pressure adjusting tyres
with dry nitrogen gas. Only proper nitrogen charging equipment
operated by personnel trained in its use should be used.
WARNING
Never mix components of one manufacturer’s rims with those
of another. Using the rim base of one manufacturer with the
lock ring of another or vice versa is dangerous. The lock ring
of one may not fully engage with the lock ring groove of the
other. Always consult the rim manufacturers for proper
matching, assembly and safety instructions. Also, use and
servicing of damaged, worn out or improperly assembled rim
assemblies is a very dangerous practice. Failure to comply
with the above warnings could result in an explosion from
tyre pressure causing serious property damage and serious
personnel injury or death.
2-12
Safety Precautions
Avoid Tyre Explosion Hazard
WARNING AT LEAST
AT LEAST 460 m (1 500 ft)
Whenever a vehicle’s tyre(s) is (are) 15 m (50 ft)
exposed to excessive heat such as a
vehicle fire or extremely hot brakes, the
hazard of a subsequent violent tyre
explosion must be recognized. All nearby
persons must avoid approaching the
vehicle so as not to be physically
endangered in the event of an explosion of
the tyre and rim parts. The vehicle should
be moved to a remote area, but only when
this can be done with complete safety of
the operator operating or towing the
vehicle. All other persons should stay
clear of the vehicle. The fire or overheated
brakes, wheel, etc., should be extinguished
or cooled from a safe distance. Do not
attempt to extinguish the fire or cool the 172
vehicle by use of hand-held fire
extinguishers. If it is absolutely necessary
to approach a vehicle with a suspect tyre,
approach only from the front or the back.
Stay at least 15 m (50 ft) from the tread
area. Keep observers out of the area and at
least 460 m (1500 ft) from the tyre sidewall.
Refer to the accompanying sketch. The
tyre(s) should be allowed at least eight (8)
hours cooling time after the vehicle is shut
down or the fire extinguished before
approaching closer.
2-13
Safety Precautions
Emergency Exit from Cab

Normal access to, and egress from, the cab is 2082
facilitated via the door on the left-hand side .
However, in an emergency, an alternative exit can
be gained via the side windows. A hammer is
provided to break the left-hand or right-hand side
window glass to facilitate safe egress.
The hammer is mounted on a bracket on the rear

wall of the cab, and can be easily lifted off in an
emergency.
WARNINGS
Do not attempt to break the windscreen
with the Emergency hammer. It is ONLY
provided to allow access through the
left-hand and right-hand windows.
Exercise extreme care when breaking

the window glass to protect your face
and body from airborne glass particles.
Be careful when passing through the

window aperture to avoid contact with
shards of glass that may remain
attached to the frame, or loose within or
outside of the cab.
2-14
Safety Precautions
Decals and Instruction Plates

Decals and instruction plates fitted to
vehicles may vary from country to
country to suit local needs. These 10 28
pages contain a brief description and

34 21
the location of the decals and 30 G E N E R AT I O N
instruction plates that may appear on

5
your vehicle.
1. Reverse Warning
2. Hydraulic Oil Notice
3. Cab Jacking Notice 2 17 4 6 39 36 40 35 37 27 5 23 20 37
4. Lubrication Service Chart
5. Hook Point
6. Battery Earth
7. CE Safety 3
1 5 1
8. Body Control Lever

33
9. Steering Column Adjustment 31
32
10. Diagnostic Manifold Plate
HEADER TANK
11. Fuse/Relay Indentification
5 5
12. Emergency Exit
13. Park Brake Control
14. Hood Raise/Lower 1745
15. Safety Lift Instruction
16. Serial Plate
17. Sound Power
13 8
18. Articulation Warning 1
2 STOP P
15
29
20 30
40 10 20
30 50
20 mph 60
10 40 r / min x100
km/h 5 25
19. Reverse Alarm Warning

10 70
80
0 50 L H 0 30
°C 100 135°C 165

70
40 120 60 200
150 210 275 320
105 °F 250 °F 390
140
20. Body Prop Warning

17
ON
21. Cab Prop Warning WINDOW
12
22. Accumulator Charging
9
23. Driveline Warning 26 38
24. Accumulator Warning 25
25. Loss of Electrics Warning 19
26. Park Brake Warning 11
27. Skin Injection Warning
28. Cab Foam Warning
29. Operator Handbook Warning
22
30. Hood Raise Warning 24
31. Hot Surface Warning 26
32. Radiator Warning
18 18 14
33. Anti-freeze Notice
PASSENGER SEAT
34. Cab Tilt Notice SUPPORT RAIL
35. Filters Notice
16 7
36. Jump Start Notice
1746
37. Nitrogen Warning
38. Power Down Notice
39. Welding Notice
40. Hydraulic Tank Pressurization
2-15
Safety Precautions
Pictorial Decal Set
WA
9361787
Battery Earth (1798)

CE Marking (1799)
9271069 15331997
Hook Point (1797) Sound Power (1976)
15314811 WA
Body Control (1800)
15318464
Steering Column
15321634
Adjustment (1801)
15331998
Sound Power (1977)
WA
1
Emergency Exit (1804)
15321636
Hood Catch (1837)
P 15332624
Sound Power (1809)

P
15321641
15332852
Park Brake (1805)
Hood Raise Lower
(1806) WA
TA27 / 30 TA25 TA27 / 30 TA25
15314033
Sound Power (1975)
TEREX : 15273572 TEREX : 15271723

ZF : O750 131 061 ZF : O750 131 063
15323834
Transmission Filter (1838)
2-16
Safety Precautions
Pictorial Decal Set
F12 F24 12V F36 F'L'

R
K23 K17 K50 K32
(7.5A) (10A) 24V (15A) (10A)
F11 F23 F35 H HYD R
(10A) (3A) (5A) L
ECU
F10 F22 H F34
(15A) (3A) L
(15A) F'M' AUX SUPPLIES
F9 F21 F33 (15A)
N
K66 K23 K14 K23 K52
(7.5A) (3A) (10A)
F8 24V
F20 F32
(10A)
F7
(15A)
F19
(30A)
F31 N
(10A) (3A) (10A)
F6 F18 F30 K48 K34 K65 K27 K64
(10A) (15A) (5A)
F5 F17 F29 F'K' H H
(10A) (7.5A) (15A) (20A)
L L
F4 F16 F28
P
(10A) (3A) (15A)
24V
F3 F15 TV F27 K25 K15 K63 K4 K23
(7.5A) (5A) (10A)
F2 F14 F26
(15A) (5A) (15A)
F1 HYD F13 F25
(20A) ECU (30A) (30A)
15333012
TA35/40 G7 Fuse Relay Box (1803)
R F12 F24 F36 F'M' K23 K17 K50 K32

12V
(7.5A) (10A) (15A) (10A)
F11 F23 F35 H HYD R
(10A) (3A) (5A) L
ECU
F10 F22 F34
(15A) (3A) (3A) F'L' AUX SUPPLIES
F9 F21 F33 (15A)
N
K23 K14 K23 K52
(7.5A) (3A) (10A)
F8 24V
F20 F32
(10A)
F7
(15A)
F19
(30A)
F31 N
(10A) (3A) (10A)
F6 F18 F30 K58 K34 K5 K27
(10A) (15A) (5A)
F5 F17 F29 F'K'
(10A) (7.5A) (15A) (20A)
F4 F16 F28 24V
P
(10A) (3A) (15A)
12V
F3 F15 TV F27 K57 K15 K4 K23
(7.5A) (5A) (10A)
F2 F14 F26
(15A) (5A) (15A) 1/R
F1 HYD F13 F25
(20A) ECU (30A) (30A)
15333633
TA27/30 Fuse Relay Box (1978)
3
1 1 1500 PSI
800 PSI 1500 PSI 103 bar
55 bar 103 bar
1
1500 PSI
2 3 2 3 103 bar
800 PSI 1500 PSI 1500 PSI 1500 PSI
55 bar 103 bar 103 bar 103 bar
2
1500 PSI
103 bar
15333286
15333287
TA40 G7 Accumulator TA35 G7 Accumulator 15334426
Nitrogen Precharge Nitrogen Precharge TA27/30 Accumulator

(1831) (1832) Nitrogen Precharge
(1979)
1
2
3
MAX. 4
S.A.E. A.P.I. MIL
MIN. 5
-54°C (-65°F) 54°C (130°F) MIL-H-5606A
6
-29°C (-20°F) 74°C (165°F) DEXRON® AUTO.
-18°C (-0°F) 82°C (180°F) 10W CC/CD MIL-L-210B / C

0°C (32°F) 99°C (210°F) 20W-20 CC/CD MIL-L-210B / C 15334887
7°C (45°F) 99°C (210°F) 30W CC/CD MIL-L-210B / C TA35/40 G7
15334778 Transmission Retarder
TA35/40 G7 Hydraulic Oil (1980) (1981)
2-17
Safety Precautions
Pictorial Decal Set
A. P. I. MIL
CF, CD, SF MIL-L-2104 E

MIL-L-46152 B / C
15334899
TA40 G7 Brake Cooling Oil (1982)
I.D kg
TA25 20870 kg ( 46010 lb )
TA27 21900 kg ( 48280 lb )
TA30 22420 kg ( 49430 lb )
TA35 29279 kg ( 64549 lb )
TA40 30820 kg ( 67946 lb )
15333031
Lift Instruction (1807)
Serial Plate
TEREX EQUIPMENT LIMITED

NEWHOUSE INDUSTRIAL ESTATE
MOTHERWELL, SCOTLAND. ML1 5RY.
MODEL NO.
PRODUCT IDENTIFICATION NO.
MAX. RATED PAYLOAD lb /kg
MASS UNLADEN lb /kg
STRUCK CAPACITY yd³ /m³
ENGINE POWER hp /kW
YEAR OF MANUFACTURE
15316595
Serial Plate (1808)
2-18
Safety Precautions
Safety Decals Set ISO Standard
% KPH MPH % KPH MPH
0 6 50 31 0 6 50 31
5 5 27 17 5 6 48 30
10 4 15 9 10 5 28 17
15 3 9 6 15 5 22 14
20 2 8 5 20 4 16 10
25 2 6 4 25 3 12 7
30 1 5 3 30 3 11 7 1. 2.
15334645
P N
TA27/30 Gradeability Chart (1867)
15334761
%
Crush Hazard Warning, Apply park
KPH MPH % KPH MPH
0 6 39 24 0 6 39 24 brake, Shift to neutral (1876)
5 5 28 17 5 6 39 24
10 3 14 9 10 5 32 20
L 15 2 9 6 15 4 21 13
20 2 7 4 20 3 15 9
25 2 6 4 25 3 12 7
30 1 5 3 30 2 9 6
0 6 60 37 0 6 60 37
5 4 28 17 5 6 60 37
10 2 14 9 10 4 32 20
H 15 2 9 6 15 3 21 13
20 1 7 4 20 2 15 9
25 1 6 4 25 2 12 7
30 1 5 3 30 2 9 6
15334646
TA35/40 G7 Gradeability Chart (1866)

15334762
1. Skin Injection Warning, Relieve pressure before

service, Use card to search for leaks (1877)
2.
15334754
Crush From Articulation Warning, Use 15334764
safety lock (1873) Read And Understand Operator

Handbook (1878)
15334756
Crush Hazard Warning, Use safety 15334765
prop (1874) Entanglement Warning, Stop

engine before servicing (1879)
PSI / BAR
N2
15334759
Accumulator Warning, Maintain nitrogen

15334766
precharge for proper operation (1875) Hot Surface Warning, Allow to cool
before servicing (1880)
2-19
Safety Precautions
N
15334772
Nitrogen Filled Tyres, Use nitrogen

only to fill (1886)
15334767
Burn Hazard, allow to cool before

opening (1881)
15334773
Power Down Notice, Power down

15334768
truck when not in use (1887)
Anti-freeze Notice, See handbook
for correct concentration (1882)
1.
15334774
2.
15334769
Welding Notice, See handbook for
Cab Tilt Notice, Raise hood before welding procedures (1888)
tilting cab (1883)
15334777
15334770 Cab Jack Notice (1889)

Filters Notice, See handbook for
replacement intervals (1884)
15334780
15334771
Reverse Warning, Keep clear of
Jump Start Notice, Jump start using
truck when it is reversing (1890)
identical battery pack (1885)
2-20
Safety Precautions
PSI / BAR
15343325
Hydraulic Tank Pressurization Warning (2022)
kV d
0 - 50 kV 10 ft (3m)
50 - 200 kV 15 ft (4.6m)
200 - 350 kV 20 ft (6.1m)
350 - 500 kV 25 ft (7.6m)
500 - 750 kV 35 ft (10.7m)
15335077
750 - 1000 kV 45 ft (13.7m)
Batteries Warning, Explosive, keep 15335078
all flames and sparks away (1891) Power Lines Warning, Maintain required
clearance (1892)
24
6 3
2
2 2
2 2
H2 O
10h
2 4 4 2 72
50h
2
250h
500h
1000h - 4000h
15335663
TA27/30 Service Lubrication Chart, See Operator Handbook section 8 for detail (1973)
2-21
Safety Precautions
PSI / BAR
15335079 15335080
Pressurised Accumulator Warning, Do not Fall Hazard Warning, Use access

not weld, keep away from flames. Relieve system provided (1894)
all pressure before servicing (1893)
2 6 3
2
2 2
TA40
H2 O
10h
2 4 4 2 138
50h
2
250h
H
L 500h
1000h - 6000h
15335665
TA35/40 G7 Service Lubrication Chart, See Operator Handbook Section 8 for detail (1974)
Safety Decals Set ANSI Standard
WARNING
0
PSI / BAR
WARNING
AIR
OIL
Pressurised Before working on the

hydraulic tank. tank, open the ball valve Crush Hazard Before servicing:
to remove pressure. Death or serious injury 1. Turn key switch off
Close valve after from crushing can occur and remove key.
pressure has relieved. in articulating area 2. Install articulation
when machine turns. lock arm.
15343324
15333263
Hydraulic Tank Pressurization Warning (2021) Crush From Articulation Warning (1810)
2-22
Safety Precautions
WARNING % KPH MPH % KPH MPH WARNING %

0 6 39 24 0 6 39 24 KPH MPH % KPH MPH
5 5 28 17 5 6 39 24
0 6 50 31 0 6 50 31
10 3 14 9 10 5 32 20
L 15 2 9 6 15 4 21 13 5 5 27 17 5 6 48 30
TA35/40G7
20 2 7 4 20 3 15 9
25 2 6 4 25 3 12 7 10 4 15 9 10 5 28 17
Operating the Do not operate Operating the Do not operate
truck outside truck outside 30 1 5 3 30 2 9 6 truck outside truck outside 15 3 9 6 15 5 22 14
the stated limits the limits stated the stated limits the limits stated
0 6 60 37 0 6 60 37
on the chart on the chart. on the chart on the chart. 20 2 8 5 20 4 16 10
could result in 5 4 28 17 5 6 60 37 could result in
death or serious Select the correct 10 2 14 9 10 4 32 20 death or serious Select the correct 25 2 6 4 25 3 12 7
injury. gear for the H 15 2 9 6 15 3 21 13 injury. gear for the
gradient you are on. 30 1 5 3 30 3 11 7
gradient you are on. 20 1 7 4 20 2 15 9 15333268
25 1 6 4 25 2 12 7
30 1 5 3 30 2 9 6 TA25/27/30 Gradeability Chart (1859)
15333267
WARNING WARNING 0
PSI / BAR
N2
Accumulators. Maintain nitrogen

Incorrectly maintained precharge in accumulators
accumulators can result for proper operation of
Crush Hazard Install support in brake failure, which brake system.
Death or serious before servicing. can result in death or Read manual for brake
injury may result. serious injury. system imformation.
15333265 15333270
Crush Hazard (1812) Accumulator Warning (1922)
WARNING
WARNING
Crush Hazard.
Sudden and unwanted
machine movement can
result in serious
injury or death.
Burn Hazard. Do not touch.

Always ensure when
Contact with hot Allow surfaces to
surfaces can cool before
1.
P starting / stopping
engine to :
1. Apply park brake.
result in burns. servicing. 2. Shift transmission
into neutral.
15333277
2. N
Hot Surface Warning (1822)
15333272
Park Brake Warning (1817)
WARNING
WARNING
Injection Hazard. Relieve pressure before

Escaping fluid under pressure disconnecting hydraulic lines.
can penetrate skin, resulting Keep away from leaks and pin
in serious injury. holes. Use a piece of
cardboard or paper to search
for leaks. Do not use hand.
Fluid injected into skin must be Burn Hazard. Allow to cool before
surgically removed within a few
hours by a doctor familiar with Hot fluid under opening.
this type of injury or gangrene pressure can scald.
will result.
15333278
15333273
Skin Injection Warning (1818) Hot Radiator Steam Warning (1823)
2-23
Safety Precautions
WARNING WARNING
Improper operation or Read and understand

maintenance can result operator's manual and all
in serious injury or safety signs before using
death. or maintaining machine.
If you do not understand
the information in the
manuals, consult your
supervisor, the owner or Entanglement Hazard. Keep away from fan
the manufacturer.
15333275
Rotating parts can and belt when engine
result in personal is running. Stop
Read Operator Handbook Warning injury. engine before
servicing.
(1820) 15333276
Moving Parts Warning (1821)
WARNING NOTICE
Truck can crush Keep clear of Using incorrect See hand book
when reversing. truck when it is concentration of for correct
Deathor serious reversing. anti-freeze may concentration of
injury may result. result in damage. anti-freeze.
15333279
15333454
Reverse Warning (1835) Anti-freeze Notice (1824)
NOTICE NOTICE
Using filters past See maintenance

their replacement manual for When tilting cab, Raise hood before
intervals may replacement damage to hood tilting cab.
result in damage. intervals. may result.
15333281 15333280
Filters Notice (1826) Cab Tilt Notice (1825)
DANGER DANGER
Explosion/Burn Hazard Keep all open flames and sparks away. Wear
Will cause death, burns or personal protective equipment, including Electrocution Hazard Maintain required clearance
blindness due to ignition of face shield, gloves and long sleeve shirt. Death or serious injury can Line Required
explosive gases or contact result from contacting voltage clearance
with corrosive acid. READ MANUALS electric power lines.
Read all manuals prior to operation. 0 - 50 kV 10 ft (3m)
Always contact the electric 50 - 200 kV 15 ft (4.6m)
DO NOT OPERATE equipment if you do not power line owner. The electric 200 - 350 kV 20 ft (6.1m)
understand the information in the manuals. power shall be disconnected
or the power lines moved or 350 - 500 kV 25 ft (7.6m)
Consult your supervisor, the owner or the insulated before machine 500 - 750 kV 35 ft (10.7m)
manufacturer. operations begin. 750 - 1000 kV 45 ft (13.7m)
15334867 15334868
Danger Batteries (1983) Danger Power Lines (1984)
2-24
Safety Precautions
NOTICE
NOTICE NOTICE
AIR N
Use nitrogen only
to inflate tyres. Power down truck
Jump starting with Jump start using 15333283 when not in use
welding equipment will identical battery Nitrogen Filled Tyres Notice or damage may
result in damage to the pack. occur.
electrial system. (1828) 15333284
15333282
Power Down Notice (1829)
Jump Start Notice (1827)
LUBRICATION AND SERVICE CHART

INTERVAL REF SERVICE INSTRUCTIONS NO. LUBRICANT SERVICE QUANTITIES
IDENTIFICATION
HOURS PTS PTS OR COOLER
1 ENGINE CHECK OIL LEVEL. ADD OIL IF LOW 1 EO AS REQUIRED
2 TRANSMISSION CHECK OIL LEVEL. ADD OIL IF LOW 1 EO AS REQUIRED
3 HYDRAULIC TANK CHECK OIL LEVEL. ADD OIL IF LOW 1 HO AS REQUIRED 5
17
4 RADIATOR EXPANSION TANK CHECK COOLANT LEVEL. ADD IF LOW 1 ETHYLENE
18
10 GLYCOL 33
DAILY 6 FUEL FILTER / WATER SEPARATOR DRAIN 1 -
7 ENGINE AIR CLEANER CHECK. RENEW ELEMENT IF REQ'D 1 - 8
18 DRIVE BELTS VISUAL INSPECTION FOR DAMAGE 2 - -
1 ENGINE CRANKCASE BREATHER INSPECT AND CLEAN IF REQUIRED 1 -
3 HYD. FILTER RESTRICTION GAUGE CHECK. RENEW ELEMENT IF REQ'D 1 - - 6 1
24 TYRES CHECK CONDITION & PRESSURE 6 - MAINTENANCE MANUAL,
SEC 160-0050 32
16
9 OSCILLATION BUSHES LUBRICATE 2 EP, NLGI SEE NOTE 3
12 SUSPENSION BEAM BUSHINGS LUBRICATE 2 EP, NLGI SEE NOTE 3 7 4
50 10 STEERING CYLINDER PINS LUBRICATE 4 EP, NLGI SEE NOTE 3

WEEKLY 11 BODY CYLINDER PINS LUBRICATE 4 EP, NLGI SEE NOTE 3
13 BODY HINGE /TAILGATE PINS LUBRICATE 2 EP, NLGI SEE NOTE 3 30
15 WHEEL RIM NUTS CHECK TORQUE 72 - 600 Nm (442 lbf ft)

30 CAB FRESH AIR FILTER INSPECT & CLEAN IF REQUIRED 1 -
14 PANHARD ROD BEARINGS LUBRICATE 4 EP, NLGI SEE NOTE 3
8 BATTERY ELECTROLYTE CHECK LEVEL. ADD ELECTRO IF LOW 2 - AS REQUIRED 29
19 WHEEL PLANETARIES CHECK OIL LEVEL. ADD IF LOW 6 EPL AS REQUIRED
20 DIFFERENTIALS CHECK OIL LEVEL. ADD IF LOW 3 EPL AS REQUIRED 2
250 3 31
21 OSCILLATION PIVOT CHECK END FLOAT. ADJUST IF REQ'D 1 - -
MONTHLY 25 ARTICULATION BEARINGS LUBRICATE 2 EP, NLGI SEE NOTE 3 28
27 PARKING BRAKE PADS CHECK WEAR. RENEW IF REQ'D 2 - -
18 DRIVE BELTS CHECK TENSION. TIGHTEN IF REQ'D 2 - - 35
35 FRONT AXLE (IFS) LUBRICATE 1 EP,NLGI SEE NOTE 3
10 25
1 ENGINE DRAIN OIL & REFILL WITH NEW OIL 1 EO -
500 -
16 ENGINE OIL FILTER RENEW 1 - 11
3 MONTHLY
22
2 TRANSMISSION DRAIN OIL & REFILL WITH NEW OIL 1 EO -
2 TRANSMISSION RUN AEB STARTER 1 - - 9
3 HYDRAULIC TANK BREATHER RENEW 1 - REF. SERVICE MANUAL 27
6 FUEL FILTER / WATER SEPARATOR RENEW 1 - - 21
1000 17 DCA4 COOLANT FILTER RENEW 1 - -
6 MONTHLY 2 TRANSMISSION BREATHER CLEAN IF REQUIRED 1 - -
28 TRANSMISSION OIL FILTERS RENEW 2 - -
29 TRANSMISSION INTERNAL CLEAN 1 - -
STRAINER
22 DRIVESHAFT BEARINGS CHECK OIL LEVEL. ADD IF LOW 1 EPL SEE NOTE 4 19
30 CAB FRESH AIR FILTER RENEW 1 - -
32 FUEL TANK RENEW CAP FILTER / CATRIDGE 1 - -
23
12
3 HYDRAULIC TANK DRAIN OIL & REFILL WITH NEW OIL 1 HO -
19 BRAKE PACKS CHECK BRAKE WEAR 6 - REF. SERVICE MANUAL
19 WHEEL PLANETARIES DRAIN OIL & REFILL WITH NEW OIL 6 EPL - 15 20
20 DIFFERENTIALS DRAIN OIL & REFILL WITH NEW OIL 3 EPL SEE NOTE 2
2000 25 ARTICULATION PIVOT NUT CHECK TORQUE 1 - 1425 Nm (1050 lbf ft)
ANNUALLY 31 HYDRAULIC OIL FILTER RENEW 1 - -
3 HYDRAULIC TANK STRAINER CLEAN 1 - -
23 DRIVELINES CHECK FOR LEAKS & DAMAGE 5 - -
1 ENGINE MOUNTING BOLTS CHECK TORQUE 4 - 298 Nm (220 lbf ft) 13
2 TRANSMISSION MOUNTING BOLTS CHECK TORQUE 3 - 920 Nm (679 lbf ft)
1 TURBOCHARGER MOUNTING CHECK TORQUE 4 - 65 Nm (50 lbf ft) 26
BOLTS
1 ENGINE WATER PUMP INSPECT DRAIN HOLE. 1 - - 24
CLEAN IF REQUIRED 34
34 AXLE MOUNTING BOLTS CHECK TORQUE 24 - 671 Nm (495 lbf ft)
5 COOLING SYSTEM DRAIN, FLUSH & REFILL WITH NEW - - - 14

4000
COOLANT
33 AIR CON. COMPRESSOR DRAIN, FLUSH & REFILL WITH NEW 1 PAG OIL -
REFRIGERANT OIL
NOTES ON LUBRICATION AND SERVICE CHART

NOTE 1 - CAPACITIES GIVEN ARE APPROXIMATE - WORK TO DIPSTICK, SIGHT GAUGES OR LEVEL PLUGS.
NOTE 2 - CAPACITY OF FRONT AND REAR DIFFERENTIALS IS 21 LTR (5.5 US GAL)
CAPACITY OF CENTRE DIFFERENTIAL IS 23 LTR (6 US GAL)
NOTE 3 - LUBRICATE SLOWLY UNTIL EXCESS LUBE IS SEEN.
NOTE 4 - REMOVE PLUG FROM PORT ON UNDERSIDE OF OSCILLATION HUB. PLUG IS REMOVED TO DRAIN THE CAVITY OF ANY OIL THAT
ENTERS THE CAVITY WHEN FILLING. REMOVE THE COVER PLATE AND LEVEL PLUG ON SIDE OF OSCILLATION HUB. ADD OIL
IF REQUIRED. REFIT ALL PLUGS.
NOTE 5 - CLEAN RADIATOR AND COOLER FINS MORE OFTEN WHEN OPERATING UNDER EXTREMELY DUSTY CONDITIONS.
NOTE 6 - CHANGE SAFETY ELEMENT AFTER EVERY THIRD PRIMARY ELEMENT SERVICE.
NOTE 7 - INDEPENDENT FRONT SUSPENSION (IFS) GREASE POINTS (2). REMOVE EXCESS GREASE FROM THE GREASE HOLES IN THE PIVOT BLOCKS (8 PER SIDE) AND AT THE DAMPER PINS (2 PER SIDE).
LUBRICATE THE LEFT-HAND IFS GREASE MANIFOLD UNTIL EXCESS IS OBSERVED EXITING THROUGH THE GREASE HOLES IN THE PIVOT BLOCKS (8) AND AT THE DAMPER PINS (2).
LUBRICATE THE RIGHT-HAND IFS GREASE MANIFOLD UNTIL EXCESS IS OBSERVED EXITING THROUGH THE GREASE HOLES IN THE PIVOT BLOCKS (8) AND AT THE DAMPER PINS (2).
NOTE 8 - THIS SERVICE INTERVAL IS DEPENDANT ON FUEL QUALITY. IF A LESSER GRADE OF FUEL IS USED THAN THAT SPECIFIED WITHIN THE RECOMMENDED LUBRICANTS, THE SERVICE INTERVAL
SHOULD BE REDUCED ACCORDINGLY.
NOTE 9 - CHECK THE AIR CLEANER RESTRICTION GAUGE AND OPERATE THE VACUATORVALVE. RENEW THE ELEMENT IF THE INDICATOR DENOTES A BLOCKAGE.
EO - ENGINE OIL. REFER TO "RECOMMENDED LUBRICANTS" AND "ENGINE OIL DRAIN INTERVALS".
HO - HYDRUALIC TRANSMISSION OIL. REFER TO "RECOMMENDED LURICANTS".
EPL - EXTREME PRESSURE GEAR LUBRICANT. REFER TO "RECOMENDED LUBRICANTS".
EP,NLGI - EXTREME PRESSURE LITHIUM No. 2 GREASE (WITHOUT "MOLYBDENUM").
PAG OIL - POLYALKLENE GLYCOL (PAG) COMPRESSOR LUBRICATING OIL - LOW VISCOSITY (ISO46)
15347627
TA25/27/30 Service Lubrication Chart (2191_Decal)
2-25
Safety Precautions
WARNING
NOTICE Disconnect the following,
in order, before welding: 0
1. Turn off master switch.
PSI / BAR
2. Battery earth cable.
3. Battery supply cable.
4. Alternator earth cable. Explosion Hazard Do not weld or drill
5. Alternator supply cable. Death or serious into accumulator.
6. Body control lever. injury can result Keep away from flames.
7. Engine ECM. from release of Relieve all pressure
8. Transmission ECU. pressurised liquids. before performing
Welding truck can seriously 9. Hydraulic ECU.
damage ECUs and service on accumulator.
10. Instrument panel ECU. 15334869
components. 11. Cab bulkhead connectors
15333285
Accumulator Warning (1985)
Welding Notice (1830)
NOTICE WARNING
Fall Hazard Use the access

Death or serious system provided
injury can result when servicing
15333288 from falling. the machine.
Cab Jack Notice (1833) 15334870
Fall Hazard Warning (1986)

INTER NO.
-VAL REF SERVICE OF LUBRICANT SERVICE
IDENTIFICATION
HOURS NO. INSTRUCTIONS PTS OR COOLANT QUANTITIES
1 ENGINE CHECK OIL LEVEL. ADD OIL IF LOW 1 EO AS REQUIRED

1 ENGINE CRANKCASE BREATHER INSPECT AND CLEAN IF REQUIRED 1
2 TRANSMISSION CHECK OIL LEVEL. ADD OIL IF LOW 1 TRANSYND SEE NOTE 2
10
13 29 11 9 12 18 19 25 17 16 10 DAILY 3 HYDRAULIC TANK CHECK OIL LEVEL. ADD OIL IF LOW 1 HO AS REQUIRED
4 RADIATOR EXPANSION TANK CHECK COOLANT LEVEL. ADD IF LOW 1 ETHYLENE AS REQUIRED
28 GLYCOL
5 PRIMARY FUEL FILTER/WATER SEP CHECK. DRAIN AS REQUIRED 1
35 14 DROPBOX CHECK OIL LEVEL. ADD OIL IF LOW 1 EO SEE NOTE 7.
32 OCDB TANK CHECK OIL LEVEL. ADD OIL IF LOW 1 TEXTRAN TDH AS REQUIRED
PREMIUM
24 11 ENGINE AIR CLEANER CHECK. REPLACE ELEMENT IF REQUIRED
6 DRIVE BELT VISUAL INSPECTION FOR DAMAGE 1
27 TYRES CHECK CONDITION & PRESSURE 6
6
7 BATTERY ELECTROLITE CHECK LEVEL. ADD ELECTROLITE IF LOW 2 AS REQUIRED
50 8 WHEEL RIM NUTS CHECK TORQUE 114 600 Nm / 442 lbf ft
WEEKLY 9 CAB FRESH AIR FILTER INSPECT AND CLEAN IF REQUIRED 1
10 PANHARD ROD BEARINGS LUBE 4 EP. NLGI SEE NOTE 3
19 OSCILLATION BUSH LUBE 2 EP, NLGI SEE NOTE 3
20 SUSPENSION BEAM BUSHINGS LUBE 2 EP, NLGI SEE NOTE 3
21 STEERING CYLINDER PINS LUBE 4 EP, NLGI SEE NOTE 3
22 BODY CYLINDER PINS LUBE 4 EP, NLGI SEE NOTE 3
23 BODY HINGE/TAILGATE PINS LUBE 2 EP, NLGI SEE NOTE 3
2 TRANSMISSION BREATHER CLEAN IF RQUIRED 1
5 PRIMARY FUEL FILTER/WATER SEP RENEW 1
15 SECONDARY FUEL FILTER RENEW 1
16 DIFFERENTIALS CHECK OIL LEVEL. ADD IF LOW 3 EPL & LZ AS REQUIRED
250 17 WHEEL PLANETARIES CHECK OIL LEVEL. ADD IF LOW 6 EPL AS REQUIRED
MONTHLY
1 18 ARTICULATION BEARINGS LUBE 2 EP LI COMP SEE NOTE 3 & 4
19 OSCILLATION PIVOT CHECK END FLOAT. ADJUST IF REQUIRED 1
25 PARKING BRAKE PADS CHECK WEAR. REPLACE IF REQUIRED 2
31 6 DRIVE BELT CHECK TENSION. TIGHTEN IF REQUIRED 1
500 1 ENGINE DRAIN OIL AND REFILL WITH NEW OIL 1 EO 32 LITRES / 8.4 US GAL
5 3 MONTH 13 ENGINE OIL FILTERS RENEW 2
7 14 DROPBOX DRAIN OIL AND REFILL WITH NEW OIL 1 EO 13 LITRES / 3.4 US GAL
33 32 30 15 2 12 21 14 34 22 26 17 20 8 27 23
14 DROPBOX OIL FILTER RENEW 1
4 3 11 ENGINE AIR CLEANER RENEW ELEMENT
28 COOLANT ADDITIVE RENEW
9 CAB FRESH AIR FILTER RENEW 1
29 FUEL TANK BREATHER RENEW 1
1000 30 HYDRAULIC TANK BREATHER RENEW 1
6 MONTH 31 OCDB TANK BREATHER RENEW 1
26 DRIVESHAFT BEARINGS CHECK OIL LEVEL. ADD IF LOW 1 EPL SEE NOTE 6
NOTES ON LUBRICATION AND SERVICE CHART 32 OCDB TANK DRAIN OIL AND REFILL WITH NEW OIL 1 TEXTRAN TDH 115 LITRES / 30.5 US GAL
PREMIUM
NOTE 1 - CAPACITIES GIVEN ARE APPROXIMATE - WORK TO DIPSTICK, SIGHT GAUGES OR LEVEL PLUGS. 16 DIFFERENTIALS DRAIN OIL AND REFILL WITH NEW OIL 3 EPL & LZ SEE NOTE 5
1500
NOTE 2 - CHECK WITH THE ENGINE IDLING AND THE TRANSMISSION AT ITS NORMAL OPERATING TEMPERATURE. 17 WHEEL PLANETARIES DRAIN OIL AND REFILL WITH NEW OIL 6 EPL 9 LITRE / 2.4 US GAL
9 MONTH
NOTE 3 - LUBRICATE SLOWLY UNTIL EXCESS LUBE IS SEEN. 33 OCDB FILTER RENEW 1
NOTE 4 - REMOVE PLUGS AND FIT LUBE FITTINGS. LUBRICATE SLOWLY UNTIL EXCESS LUBE IS SEEN. REMOVE FITTINGS AND REFIT PLUGS. 33 OCDB STRAINER CLEAN 1
NOTE 5 - CAPACITY OF FRONT AND REAR DIFFERENTIALS 33 LITRE (8.7 USGAL). CAPACITY OF CENTRE DIFFERENTIAL 34 LITRE (9 USGAL) 3 HYDRAULIC TANK DRAIN OIL AND REFILL WITH NEW OIL 1 HO 298 LITRE / 79 US GAL
PLUS 1 LITRE (2 PINTS) FOR PRIMING THE 3RD DIFFERENTIAL UNIT. (36 LITRE EPL + 2 LITRE LZ 6178). 3 HYDRAULIC OIL FILTER RENEW 1
NOTE 6 - REMOVE PLUG FROM PORT ON UNDERSIDE OF OSCILLATION HUB. PLUG IS REMOVED TO DRAIN THE CAVITY OF ANY OIL THAT ENTERS 6 DRIVE BELT RENEW BELT 1
THE CAVITY WHEN FILLING. REMOVE GROMMET AND LEVEL PLUG ON SIDE OF OSCILLATION HUB. ADD OIL IF REQUIRED. REFIT ALL PLUGS. 24 COOLING SYSTEM CHECK CONCENTRATION. ADD BOOSTER 1 ETHYLENE 67 LITRES / 18 US GAL
2000
NOTE 7 - CHECK DROPBOX LEVEL COLD WITH ENGINE RUNNING. GLYCOL
ANNUALLY
EO - ENGINE OIL. REFER TO "RECOMMENDED LUBRICANTS". 34 ARTICULATION PIVOT NUT CHECK TORQUE (TORQUE SEAL) 1 1425 Nm / 1050 lbf ft
2 TRANSMISSION MTG. BOLTS CHECK TORQUE (TORQUE SEAL) 2 921 Nm / 680 lbf ft
* - REFER TO CHART UNDER "RECOMMENDED LUBRICANTS".
1 TURBOCHARGER MTG. NUTS CHECK TORQUE (TORQUE SEAL) 2 921 Nm / 680 lbf ft
HO - HYDRUALIC OIL. REFER TO "RECOMMENDED LURICANTS". 1 ENGINE MOUNTING BOLTS CHECK TORQUE (TORQUE SEAL) 2 330 Nm / 239 lbf ft
EPL - EXTREME PRESSURE LUBRICANT SPEC. MIL-L21058.
EP,NLGI - EXTREME PRESSURE LITHIUM No. 2 GREASE (WITHOUT "MOLYBDENUM"). REF. EEMS 19014 3000 12 TRANSMISSION OIL FILTERS RENEW 2
EP,LI COMP - EXTREME PRESSURE LITHIUM COMPLEX GREASE. REF. EEMS 19057.
4000 35 AIR CONDITIONING COMPRESSOR DRAIN FLUSH AND REFILL WITH NEW OIL 1 PAG OIL 0.125 LITRES
LZ - LUBRIZOL 6178
PAG OIL - POLYALKLENE GLYCOL (PAG) COMPRESSOR LUBRICATING OIL - LOW VISCOSITY (ISO46).
6000 2 TRANSMISSION DRAIN OIL AND REFILL WITH NEW OIL 1 TRANSYND 61 LITRES / 16 US GAL
15353114
A35/40 G7 Service Lubrication Chart (1795_Decal)
2-26
Controls and Operating
3 - Controls and Operating
3-1
Blank P age
3-2
CONTROLS AND INSTRUMENTS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1
2 STOP P
1
20
30
40
mph
30
50
10
15
20
16
17
20 60
10 40 r / min x100
km/h 5 25
10 70
80
0 50 L H 0 30
40
70
105
°C 100
150 210
°F 250
120 60
140
135°C 165
275 320
°F 390
200
18
19
20
21
22
23
35 28 21 34
33 24
32 31 30
36
29 27
26 25
1704
1. Side Window Demister 20. Park/Emergency Brake Control

2. Storage Pocket 21. Heater Vent
3. Retarder Request Switch 22. Transmission Gear Shift Control
4. Engine Brake Request Switch 23. Body Control Lever
5. Engine Diagnostic Switch 24. Cup Holder
6. Dropbox - Low ratio Request Switch 25. Body Lower Emergency Switch (not fitted
on TA35 and TA40)
7. Engine Brake - Medium/High Switch
26. Fuse Box
8. Diff-lock Request Switch.
27. Accelerator Control
9. Visual Display Unit (VDU)
28. Radio Facia
10. N/A
29. Service Brake Control
11. Hazard Warning Lights
30. Ignition and Starter Key Switch
12. Main Lights
31. Steering Wheel
13. Front Working Lights
32. Steering Wheel Adjustment Lock
14. Rear Wash/Wipe
33. 12V / 24V Jack points
15. Retarder Lever
34. Headlight Dipper, Direction Indicator,
16. Heated Mirrors
Windscreen Wiper/Wash, Horn Control
17. Rear Working Lights
35. Heater/Air Conditioner & Radio Controls
18. Flashing/Rotating Beacon
36. Battery Master Switch
19. Rear Fog Lamp
3-3
FUSE / RELAY BOX
12 24 36
FD FH FM A E I M Q
FC FG FL B F J N R
FB FF FK C G K O S
FA FE FJ D H L P T
1 13 25
1788
1. Ignition sensed equipment 20A FL. Hood raise/lower actuator 10A

2. Keyswitch 15A FM. Instrument cluster / CPU Battery 15A
3. Hazard warning lights 7.5A FK. Auxiliary 12V supply 20A
4. Rear wash/wipe 10A
5. Horn front wash/wipe 10A A. Not used
6. Air seat compressor 10A B. Engine overspeed K66
7. Dipped beam lights 10A C. Range inhibit K48
8. Main beam lights 10A D. Service brake status K25
9. Front wiper motor park 7.5A E. Air conditioner / heater ignition K23
10. Transmission TCU battery 15A F. Wiper / ignition K23
11. Transmission TCU ignition 10A G. Horns K34
12. Reverse alarm/lights 7.5A H. Headlights K15
13. IFM controller ignition 30A I. Reverse alarm / lights K17
14. Cab interior light 5A J. Neutral start K14
15. Direction indicators 5A K. Dropbox ratio selected K65
16. Emergency/park brake 3A L. Retarder warning light K63
17. Instrument cluster/CPU ign. 7.5A M. Brake lights K50
18. Heated mirrors 15A N. Engine ECU ignition K23
19. Ignition sensed relays 5A O. Mid axle differential lock K27
20. 24V work socket battery 15A P. Indicator flasher unit K4
21. Neutral start 3A Q. Engine brake K32
22. Front washer pump 3A R. Body proximity switch K52
23. Rear washer pump 3A S. Dropbox differential lock K64
24. Horns 10A T. Radio / auxiliary function K23
25. Ignition sensed equipment 30A
26. Air conditioner/heater 15A
27. Reverse camera/monitor 10A
28. Front working lights 15A
29. Rear working lights 15A
30. Rotating/flashing beacon 5A
31. Engine ECU ignition 10A
32. Engine ECU battery 30A
33. Proximity switch 10A
34. Dropbox/Diff Lock controls 15A
35. Brake pedal controls 5A
36. 24V/12V Voltage Converter 15A
3-4
BASIC DATA
2 STOP P
1
3 4 5 6 7
2 8 9
1 10
1694 Instrument Panel - 'Warning Lights'
Warning Lights
1. Front Brakes Accumulator Pressure (Red) - Illuminates to warn
of low pressure in the front brake system accumulator. A buzzer also
sounds. If light illuminates, stop machine and investigate the cause.
2. Rear Brakes Accumulator Pressure (Red) - Illuminates to warn

of low pressure in the rear brake system accumulator. A buzzer also
sounds. If light illuminates, stop machine and investigate the cause.
3. Main Beam (Blue) - Illuminates when headlights are switched on

and dip control is not engaged.
4. Direction Indicators (Green) - Flashes when the indicator lights

are operating.
5. Engine Stop Light (Red) - When the 'Stop Engine' light comes on,
the computer has detected a major malfunction in the engine that
requires immediate attention. It is the operators responsibility to shut
down the engine to avoid serious damage. This lamp is also used to
flash out active fault codes in diagnostic mode.
6. Engine Check Light (Amber) - When the 'Check Engine' light

comes on, the computer has detected a fault in the engine. The fault
should be diagnosed and corrected at the earliest opportunity.
In diagnostic mode, the 'Check Engine' light will flash out inactive
fault codes.
7. Parking Brake (Green) - Illuminates when the parking brake is

applied.
8. Transmission Check Light (Amber) - Illuminates when the

computer has detected a fault in the transmission. The fault should be
diagnosed and corrected at the earliest opportunity.
9. Emergency Steering (Red) - Illuminates to warn of a fault in the

steering system supply pressure. Illuminates when the ignition is
turned on and should go out when the engine starts. If light
illuminates, stop machine and investigate the cause.
10. Differential Locks (Amber) - Illuminates when the differential

locks are applied.
3-5
Warning Symbols.
Note: Contained on the Warning screen of the VDU, this displays all 1 2 3 4 5
possible symbols displayed on 3-lines ( top to bottom) as shown.
8
1. Low Fuel - Indicates that the level of fuel in the system should be 6 9
monitored and action to rectify this is imminent 7 10
L H
2.Alternator Charging - Indicates that the system batteries are in a

state of overcharging, undercharging or battery voltage low. 14 13 12 11
1692b VDU - 'Warning Screen'
3. Hydraulic Oil Filter Change -Notifies the operator that the

hydraulic oil filter is restricted and should be replaced.
4. Engine Air filter Change - Notifies the operator that the air filter is
restricted and should be cleaned / replaced accordingly.
5. Oil Brake Cooling Pressure - Indicates that the brake cooling

pressure is outwith the prescribed operating range and should be
investigated.
6. Body Up - Indicates the body has been raised and is off the
chassis bed. Transmission upshift is restricted while this light is
illuminated.
7. Brake Cooling Oil Temp - Indicates that brake cooling oil temp. is
outwith the prescribed operating range and should be investigated.
8. Trans. oil temperature high -Indicates that the temperature of the

oil in the transmission is at a critical level, outwith the prescribed
operating range for the system and should be investigated.
9. Trans. DropBox oil temp high - Indicates that dropbox oil temp is
at a level outwith the prescribed operating range and should be
investigated.
10.Trans. DropBox high/ low oil pressure -Indicates that the

dropbox oil pressure is outwith the prescribed operating range and
should be investigated.
11. Trans. Dropbox, High Ratio Selected - Indicates that the

dropbox is engaged in high range.
12. Trans. Dropbox, Low Ratio Selected - Indicates that the

dropbox is engaged in low range.
13. Engine Brake - Indicates that the engine Jake brake has been
requested and is active. Will remain till the brake is deactivated.
14. Retarder - Indicates that the retarder has been requested and is
active. Will remain till the retarder is deactivated.
3-6
Instruments
2 3
2 STOP P
1
20 30 15
40 10 20
30 50
20 mph 60
10 40 r / min x100
km/h 5 25
10 70
80
0 0000000
50 L H 0 30
0000
1 8 7 6 5 4
1691 Instrument Panel
1. Engine Water Temp. gauge - This gauge should read in the green
sector after the engine has warmed. If the gauge reads above this,
(the red sector) stop the engine and investigate the cause.
2. Speedometer - The speedometer indicates travel speed in

kilometres per hour (displayed grey) and miles per hour, displayed
(white). A digital odometer is centred at the base of the speedometer,
consiting of a 2-line LCD. The upper line displays 7-digits, which
show the total miles travelled. The lower line displays a 4-digit
reading which displays the trip mileage. The trip mileage can be reset
by pressing the reset button for approximately 1 second. The
readings can be used for operating and service records.
3. Tachometer - Driven from the engine ECU, the tachometer

indicates the number of engine crankshaft revolutions per minute.
The needle shows the variations in engine operating speed. Never
accelerate the engine to speeds indicated by the red zone on the dial
face.
4. Transmission Oil Temperature Gauge - Indicates transmission

oil operating temperature. Gauge should read in the green sector
during normal operation and may the yellow sector when using the
retarder or in converter mode. If the gauge reads above this (the red
area), stop the vehicle and investigate the cause.
5. Visual Display Unit (VDU) - Monochrome LCD display. Centred in

the instrument panel. This unit is the primary monitor within the
instrument panel.The screen holds and displays critical systems
information based on the inputs which are received from the various
vehicle sensors and monitors.
6. Dimming button - To dim or increase the illumination for the

instruments on the VDU.
7. Not used - (Buttons blanked-off)
3-7
8. Reset Button - Trip counter reset button, when depressed for

approx. 1 second, will reset the trip.
The following show the multi-level display in its 3 possible

conditions. On initial starting of the vehicle, the VDU will display the
screens and scroll through them in the order in which they are
displayed here, assuming the system is in correct working order.
Screen 1- Displays the TEREX logo.
1692a 'Start-Up' Screen
Screen 2- Displays the Warning screen, consisting of Warning

symbol graphics which have been pre-programmed into the system. 1 2 3 4 5
(These are described in the BASIC DATA, Warning lights/symbol 8

6 9
section prior to this.) 7 10
L H
14 13 12 11
1692b 'Warning' Sceen
Screen 3 - Main Screen, this is the default screen which will remain Fuel Level
1
active at all times, unless another screen has been activated via a 0 25 50
Voltmeter
75 100
warning or is triggered by the operator requesting a screen change 2 8 12 16 20 24 28 32
using the request button. If an active warning is present the VDU will 3
Brake Cooling
50 75 100 125 150

toggle between screen 3 and screen 2. The screens will toggle L H
00000
between 'warning' and 'main' screen until the warning light
disappears.The main screen contains information / monitoring of the 1692c
4 5
'Main' Screen
6 7 8
following vehicle functions-
1. Fuel level - Bargraph monitors fuel level within the tank. Should
the fuel level drop below 25% a warning light (1) on the instrument
display will light. Capacity 450 litres (119 US gal). Fill the tank
overnight to minimise condensation in the tank. Avoid a dry tank
condition which requires bleeding the fuel system.
2. System Voltage - Monitors the potential voltage on the system.

Should the level drop to a critical level, indicating a discharged
battery / fault, a warning light (2) on the instrument display will light.
3. Brake Cooling - Monitors Brake oil temperature, should the temp

rise above 60°C (140°F), a warning light (7) will illuminate.
4. Retarder - Indicates that the transmission retarder has been

requested and is active.
3-8
5. Engine Brake - Indicates that the engine Jake brake has been Fuel Level
1
requested and is active. 0 25 50
Voltmeter
75 100
2 8 12 16 20 24 28 32
Brake Cooling
6. Engine Hours Counter - Records the number of hours on the 3 50 75 100 125 150
engine. 00000
L H
4 5 6 7 8
7. Trans. Dropbox, Low Ratio Selected - Indicates that the dropbox 1692c 'Main' Screen
is engaged in low range.
8. Trans. Dropbox, High Ratio Selected - Indicates that the dropbox

is engaged in high range.
Switches
1. Retarder Request Switch - Press bottom of switch to request the 3
4
transmission retarder. To disengage the retarder press the switch to L
the off position. The retarder symbol will illuminate on the VDU when 2
5
the retarder is activated.
1
6
2. Engine Brake Request Switch - Press bottom of switch to request
the engine brake 'Low'. The engine brake symbol will illuminate on 1706 Left of instrument panel
the VDU when the engine Jake brake is activated.
3. Engine Diagnostic Switch - To check for active fault codes:

a. - turn the ignition key switch to position ‘1’.
b. - press the diagnostic switch to the 'ON' position.
Any active codes will then be flashed out on the engine ‘STOP’ light
followed by any inactive codes being flashed out on the engine
‘CHECK’ light. A flash code ‘25’ indicates that the engine ECU is
clear of any faults. Refer to pages 3-23 to 3- 28 for details of the fault
codes.
4. Dropbox - Low ratio Request Switch - Pressing bottom of switch

engages the low gear ratio in the dropbox. With the switch in the off
position the dropbox defaults to the high ratio.
Note: It is only possible to select ranges when certain conditions are

met; (See page 3-36)
The relevant high/low ratio symbol will illuminate on the VDU.
5. Engine Brake - Medium / High request Switch - Different levels

of engine braking can be attained by using this switch when the
engine brake request switch has been activated. Pressing the top of
the switch forward once will request 'medium' braking, pressing the
top of the switch forward to the second switch position will then
request engine brake 'high'. Only when the engine brake request
switch (1) is pressed and active will the switch (2) for greater levels of
braking be operative. Otherwise switch (2) will be inactive.
3-9
6. Differential Lock Request Switch - Press bottom of switch to

engage the inter-axle differential locks. The differential lock warning
lamp on the instrument panel will illuminate. Pressing the switch to
the off position will disengage the differential locks.
7. Hazard Warning Lights - Press bottom of switch to make

indicators flash simultaneously as hazard warning lights. The
direction indicator warning lamp on the instrument panel will flash. To
switch hazard lights off; press the top of the switch.
8. Main Lights - Press the bottom of switch to the first postion to

operate side, tail and panel lights. The lights in the other switches will
illuminate. Press switch to the second position to operate the
headlights. To switch lights off; press the top of the switch.
9. Front Working Lights - Press bottom of switch to operate the front

work lights. To switch off, press top of switch. 9
8
10
10. Rear Wash/Wipe - Press bottom of switch to operate the rear 7
screen wiper. Press the switch again for wash. To switch Off; press
11
the top of the switch.
11. Retarder Lever - The transmission retarder has six stages of 1707 Right of instrument panel
retardation. When the retarder is engaged it is at its maximum level

when the retarder lever is in its downmost position. When the lever is
at its uppermost position the retarder is Off.
12. Heated Mirrors - Press bottom of switch to activate the heated

mirrors. To switch off; press top of switch.
13. Rear Working Lights - Press bottom of switch to operate rear

working lights. To switch off; press top of switch.
12 13 14 15
14. Flashing/Rotating Beacon - Press bottom of switch to operate
flashing/rotating beacon. To switch off; press top of switch.
15. Rear Fog Lamp - Press bottom of switch to operate rear fog lamp.
To switch off; press top of switch.
Right Bank
1708
16. Body Lower Emergency Switch - Not currently fitted to TA35/40

machines.
17. Ignition and Starter Key Switch - The combined switch

operates the ignition and starter motor.
1501 16
3-10
'0' - Ignition switched off. All electrical systems are inoperative. This
position also cuts off fuel to shut down the engine.
'1' - Ignition switched on, instruments, gauges and warning lights
register as appropriate. All electrical systems are operative. The key
must remain in this position whilst operating the machine.
'2' - Starter motor operates. The key when released will return to
407 17
position '1'.
The key can only be withdrawn from position '0'.
18. Diagnostic Test Point - (Located at the right hand side of the
instructor or trainer seat). Plug in connector for engine, transmission
and instrument panel / VDU diagnostic equipment.
19. Battery Master Switch - (Located at the left hand side of the truck
at the battery box.) Turn key clockwise to connect the batteries to the
electrical circuits. Switch key off and remove when leaving machine
unattended.
1765 18
1709 19
3-11
Controls
Headlight Dipper, Direction Indicator, Windscreen Wiper/Washer
and Horn
1. Headlight Dipper and Flasher:
Neutral Position = Dipped Beam
Control Upwards = Headlight Flash
Control Upwards
with main lights on = Main beam 1710 1
2. Direction Indicator:
Control Rearwards = Left Indicators
Control Forwards = Right Indicators
1711 2
3. Windscreen Wiper/Washer:
Position 0 = Neutral Position
Position 1 = Intermittent Sweep
Position 2 = Wiper Slow Speed
Position 3 = Wiper Fast Speed
Slide grip inward = Windscreen Wash
1712 3
4. Horn:
Button pushed in = Horn Sounds
1713 4
3-12
Heater
Blower control (3) is rotated to select one of three blower speeds. Air
direction can be adjusted by turning direction controls (4 & 5). 1
2 3
Temperature control (1) is rotated to vary heater output temperature.

Heater output air is unheated with the control turned fully
3
anticlockwise and heated by turning clockwise. 1 2
1731
Heater/air conditioner outlets (6) may be adjusted to control air flow

output by opening and closing the control flaps. Air direction can be
adjusted by rotating complete outlet.
Air Conditioner
Keep all windows and vents closed.
5
4
Blower control (3) is rotated to select one of three blower speeds. The 1730
air conditioning will not operate if the blower control is not switched
on. Air direction can be adjusted by turning direction controls (4 & 5).
6 6 6 6
Turning control (2) to the right switches on the air conditioning. Air
conditioner output temperature can be contolled using temperature
control (1).
Heater/air conditioner outlets (6) may be adjusted to control air flow 1714
output by opening and closing the control flaps. Air direction can be
adjusted by rotating complete outlet.
Note: When the air conditioning is switched on, the engine cooling
fan automatically engages.
AIR CONDITIONING RE-START PROCEDURE

If the machine has been idle for an extended period of time (2 weeks), the refrigerant in the air condition-
ing unit converts from a gas to a liquid.This puts the compressor unit under a great deal of strain trying
to compress a liquid instead of a gas and could cause aailure
f in the air conditioning unit.The following
commissioning procedure allows the air conditioning unit to achieve normal operating parameters.
1. Start the machine and allow it to run until the engine is at a nor mal operating temperature of
80°C (176°F)
2. Turn the blower control to setting 1.
3. Turn on the air conditioning unit on f or 5 seconds then off for 5 seconds.
4. Repeatedly switch the air conditioning on and off f or at least 1 minute. This should be at least 12
repetitions.
5. Commissioning the air conditioning unit is complete and ready f or use.
3-13
Operator's Seat - Air Suspension

The air seat only reacts when the driver sits on the
seat. When unoccupied, the seat sinks to the lowest
position to allow easier access.
The following is the list of controls to adjust the seat:
1. Height and weight adjustment.
2. Horizontal adjustment (sliderails). 6
3. Adjustable damper.
4. Seat belt. 9
(behind)
5. Backrest angle adjustment.

10
5 11
6. Headrest height adjustment.
7
8 4
7. Fore/Aft isolator (forward position - unlocked, 1 2
rearmost position - locked). 3
8. Seat cushion fore/aft adjustment. 2081
9. Seat cushion angle adjustment.
10. Lumber support adjustment.
11. Arm rest adjustment (x2).
WARNING
Do not attempt to adjust the seat or the seat belt
while the machine is moving. Loss of control may
result. Stop the machine; apply the brakes; then
carry out adjustments.
3-14
Operator's Seat - Operation

To achieve the most comfortable driving position,
adjust the seat as follows;
1. Sit in the seat.
2. Pull up and immediately release the height and

weight adjustment (1) handle - this will set the seat
to cater for the operator’s weight. Sit completely
still while carrying out the adjustment . The seat
6
position is now adjusted correctly to cater for the
operator’s weight. Further lifting or pressing down
on this lever will raise or respectively lower the
seat, if the height requires adjustment.
9
(behind)
CAUTION
Do not operate the height and weight
10
adjustment lever for a period longer than one 5 11
minute, otherwise the inbuilt compressor may
7
be damaged. 8 4
1 2
3
3. Angular adjustment of the base cushion (seat
pan) about the horizontal axis is achieved by lifting 2081
lever 8 and exerting pressure on front or rear of the
seat pan to tilt it to the desired horizontal attitude.
Release the handle when the required position is
achieved.
4. Pull up the depth adjustment handle (7) to

facilitate movement of the seat forwards or
backwards. Release the handle when the required
position is achieved.
5. If adjustment of the armrest angles is desired,

this can be achieved turning the rotary adjusters
(10). If the armrests are not required, they can be
folded up out of the way. This is achieved by
removing the caps (11) on each side of the frame,
undoing the hexagon nuts thus exposed, and
hinging the armrest upwards. Tighten the nuts and
refit the caps (11) on completion.
WARNING
6. Pull up (or push down) the headrest (6) to the The cab is for protection of the operator
required height. This can be achieved, by and adheres to the mandatory standard for
increments, up to its end stop. The angle of the Roll Over Protection Structure (ROPS).
headrest (6) can also be adjusted, by pushing or A prerequisite for protection is that the
pulling it in the desired direction, and completely operator remain in the cab, with the seat
removed by lifting it off over the end stop. belt securely fastened. Should the vehicle
begin to roll, hold on to the steering wheel.
3-15
7. The height and curvature of the backrest cushion can be adjusted byrotation of the lumber support
(9) at the rear of the cushion.
8. Pull up the handle (5) and adjust the backrest to the required angle, release the handle when the
required position is achieved.
9. Set the fore/aft isolator (3) position to suit the driving conditions. When active, shock impacts in the
driving direction can be more readily absorbed by the driver’s seat. (Forward position - off, rearmost
position - on.)
10. If necessary carry out fore/aft seat adjustments by first lifting the lever (2), moving the driver to the
required position, then lowering the lever again until it locks. It should not be possible to move the
driver’s seat in the forward/rearward plane with the lever in its locked position.
11. Engage the seat belt (4).
3-16
Seat Belt
Retractable seat belts are installed on both the operator’s seat and
the trainer/instructor seat. The seat belts require no external
adjustment and allow freedom of movement for proper manipulation
of all controls.
Note: To extract the trainer/instructor seat belt, the button on housing

must be pressed.
WARNINGS
Always the wear seat belt when operating the machine.
Always check the condition of the seat belts and mounting
hardware before operating the machine. 495
Typical Retractable Seat Belt
Any signs of looseness or wear should be reported to your
Service Department or Dealer for repair or replacement
immediately.
Replace the seat belt at least once every three years,
regardless of appearance.
Do not attempt to adjust the seat or the seat belt while the
machine is moving. Loss of control may result. Stop the
machine; apply the brakes; then carry out adjustments.
Trainer/Instructor Seat
The trainer/instructor seat has only to be used when operator training
or instruction is being performed or for service personnel performing
service diagnostics.
Note: The trainer / instructor seat is NOT for continuous passenger

use.
1656 Trainer / Instructor Seat
To access the compartment below the Trainer/Instructor seat, lift the
seat (1) and use the strap to hold the seat in position (2).The seat
backrest can be folded down when not in use. Pull the seat release
catch, located on the side of the seat, to unlock the backrest (3). The
backrest can now be folded down (4).
Note: The backrest must be unlocked using the release catch before
attempting to fold it down. Failure to do this will damage the seat.
1 2 3 4
1972
3-17
MACHINE CONTROLS
Braking
The dual circuit brake system is applied during normal operation by
using the Service Brake Pedal or, in an emergency, by using the
Parking-Emergency Brake Control.
'Front Brake System' warning light and 'Rear Brake System' warning
light are located on the instrument panel. A buzzer will also sound if
the brake pressure is low. If any of these lights illuminate and/or the
buzzer sounds, stop the machine, apply parking brake and do not
operate until the fault is corrected.
Service Brake
This is a cab wall mounted pedal operated by the right foot. Depress
the pedal as required by speed, load and road conditions, to slow or
stop the machine. Release the pedal as the machine slows until,
when stopped, the pedal is depressed just enough to hold it
stationary. Do not 'FAN' the pedal. 1716
Note: Pedal movement will be experienced when applying or

releasing the Parking-Emergency Brake Control when the engine is
running.
Parking - Emergency Brake

Pushing the control in will apply the spring operated driveline
mounted parking brake and the service brakes at all wheels. The
parking brake warning light on the instrument panel will illuminate
when the control is pushed in. To release the brakes; twist and pull the
control out.
1715
The Parking-Emergency Brake Control should only be used to stop
the machine in an emergency, or, for applying the parking brake once
the machine has been stopped. For normal braking the service brake
pedal should be employed.
WARNING
Always apply the
parking brake before
leaving the operator's
seat.
3-18
Transmission Retarder
This switch (1) is used to request the transmission retarder. The
retarder is engaged when the bottom of the switch is pressed, L
provided that the transmission 'Check' warning light is 'OUT', the

transmission is in 'lockup' and the accelerator is released (off gas).
The retarder lever (2) is then used to determine the level of
retardation required. It is a six stage retarder that is at its maximum
when the retarder lever is in its downmost position. To disengage the 1717 1
retarder; press the top of the switch (1) or re-apply accelerator pedal
(on gas).
The retarder is used to apply a continuous braking force to hold the

truck to a safe steady speed when descending grades, to reduce the
need for service brake applications, thus reducing service brake wear
and preventing overheating. The retarder may be used any time to
2
slow down. If additional braking is required apply the engine brake. 1718
The retarder is not meant for bringing the machine to a halt, or for
sudden deceleration - the service brakes should be employed for this
purpose.
Retarder Operation
Before the machine starts down the grade, request the retarder and
release the accelerator (off gas). For maximum retardation, oil
circulation and cooling, the machine downgrade speed (retarder
applied) gear range should be manually selected and should be high
enough to keep the engine operating at governed speed. Generally
the gear used to ascend a grade fully laden is also correct for its
descent. If the rate of descent is too fast, the engine brake should be
applied which will allow a safe descent and efficient retarder
operation. If further braking is required still, apply the service brakes.
For recommended downgrade speed gear selection, please refer to

the gradeability chart.
Frequent use of the retarder will result in higher transmission oil

temperatures. Therefore, the oil temperature gauge should be
checked frequently. During normal operation the gauge should read
in the green sector. However, during converter mode, and during
retarder operation, temperatures may reach the yellow sector.
The transmission 'CHECK' warning light and transmission

temperature warning symbol on the VDU screen will illuminate when
the transmission sump oil temperature reaches 121° C (250° F). The
retarder will automatically disengage when the oil temperature
reaches 166° C (330° F), a transmission ‘CHECK’ Warning light will
illuminate and a fault code will be displayed and recorded by the
ECU. The speed must be reduced by using the service brakes so that
the oil is cooled down. Reduce downgrade travel speed to avoid the
oil overheating and possible damage to the transmission.
3-19
WARNING % KPH MPH % KPH MPH

0 6 39 24 0 6 39 24
5 5 28 17 5 6 39 24
10 3 14 9 10 5 32 20
L 15 2 9 6 15 4 21 13
TA35/40G7
20 2 7 4 20 3 15 9
Operating the Do not operate 25 2 6 4 25 3 12 7
truck outside truck outside 30 1 5 3 30 2 9 6
the stated limits the limits stated
0 6 60 37 0 6 60 37
on the chart on the chart.
could result in 5 4 28 17 5 6 60 37
death or serious Select the correct 10 2 14 9 10 4 32 20
injury. gear for the H 15 2 9 6 15 3 21 13
gradient you are on. 20 1 7 4 20 2 15 9
25 1 6 4 25 2 12 7
30 1 5 3 30 2 9 6
15333267

Engine Brake
The engine brake is activated by pressing the engine brake request
switch (1). This will engage 'low' engine brake level. Should L
1
increased levels of braking be desired, pressing the engine brake - 2
medium / high switch (2) forward once will engage 'medium'. Pushing
the switch a second time will engage 'high' braking effort. Only when
the engine brake request switch (1) is pressed and active will the
switch (2) for greater levels of braking be operative. Otherwise switch 1719
(2) will be inactive. The engine brake applies a continuous braking
force to hold the truck to a safe steady speed when descending
grades, to reduce the need for service brake applications, thus
reducing service brake wear and preventing overheating. The engine
brake may be used any time to slow down. If additional braking is
required, apply the service brakes. The engine brake is not meant for
bringing the machine to a halt, or for sudden deceleration - the
service brakes should be employed for this purpose.
Operation
Certain conditions must be met before the engine will allow the
engine brake to become active; accelerator released (off gas),
engine speed greater than 1300 rpm and the transmission must be
in lockup. If these conditions are met, the engine brake will become
active if it has been requested by the operator.
Before the machine starts down the grade, request the engine brake
and release the accelerator (off gas). It is recommended to manually
select the correct downgrade speed gear range before decent. For
recommended downgrade speed gear selection, please refer to the
gradeability chart. Generally the gear used to ascend a grade fully
laden is also correct for its descent. If the rate of descent is too fast,
the transmission retarder should be applied which will allow a safe
descent and efficient engine braking. If further braking is required
still, apply the service brakes.
3-20
If the vehicle is approaching an overspeed condition, the engine

brake is automatically applied and throttle inhibited to decrease
engine speed. The engine brake will automatically apply at
2350rpm and disengage at 1950 rev/min.
Engine
Electronic Foot Pedal
The electronic foot pedal provides an electrical signal to the
engine's fuel control system in proportion to the degree of
pedal actuation.
Note: The engine MUST be started with foot 'OFF' the

electronic foot pedal.
1720
Do not place engine under full load at full speed immediately
after starting. Always allow the engine to fully circulate
lubricant and warm up gradually before operating at full
speed and full load. Operate engine at top rated speed when
maximum power is needed for the load.
Detroit Diesel Electronic Control (DDEC)

This machine is equipped with the Detroit Diesel Electronic
Control (DDEC) which continually monitors the engine and
warns the operator when a problem develops. The DDEC
system also takes action to prevent damage to the engine
and provides the serviceman with diagnostic capabilities so
that problems can be corrected quickly and easily.
WARNING
Before any welding is done on a machine equipped with the
DDEC System, disconnect the following in this order: Battery
earth cable, battery supply cable, alternator earth cables,
alternator supply cables and electrical connections at the engine
ECM, transmission ECU, body control lever, hydraulics ECU
and cab bulkhead to avoid damage to electrical components.
Turn off battery master switch to isolate the batteries before
disconnecting any components.
After welding connect all of the above in the reverse order.
3-21
5 6
3 2 STOP P
1
7
8
L
1,2
1 - Electronic Control Module (ECM) 4 - Electronic Foot Pedal 7 - Diagnostic / Override

2 - Programmable Read Only Memory (PROM) 5 - 'Stop' Light Switch
3 - DDEC System N3 Injectors 6 - 'Check' Light 8 - Diagnostic Test Point
1732
DDEC V Description
1. Electronic Control Module (ECM) - Receives electronic inputs from the driver
as well as from sensors that provide information electronically, such as oil
pressure and temperature and intake manifold pressure. This information is used
to control both the quantity of fuel injected and injection timing.
2. Programmable Read Only Memory (PROM) - Located in the ECM and

encoded with the operating software. Additional information is programmed into
the EEPROM. This information controls the horsepower rating, torque curve,
maximum engine speed and engine protection devices. The ECM processes this
information and sends electronic signals to the Electronic Unit Injectors (EUI)
where the precise amount of fuel is injected into the engine.
3. Electronic Unit Injectors (EUI) - The EUI is a lightweight, compact unit that
injects diesel fuel directly into the combustion chamber. The amount of fuel
injected and the beginning of injection timing is determined by the ECM. The
ECM sends a command pulse which activates the injector solenoid.
The EUI performs four functions:
a - Creates the high fuel pressure required for efficient injection.

b - Meters and injects the exact amount of fuel required to handle the load.
c - Atomizes the fuel for mixing with the air in the combustion chamber.
d - Permits continuous fuel flow for component cooling.
3-22
Electronic unit injectors are self compensating and virtually eliminate

engine tune-ups.
Note: Never apply 12 or 24 volts directly to terminals on the injector or

engine sensors as they will burn out. Before removing injectors, the fuel
passages must be blown out to prevent fuel flow from entering the
cylinder head.
DDEC V Operation
The DDEC system operates from a 24 volt supply. However, in the

event of a loss of power supply, the system will operate at reduced
voltage. At reduced voltage the electronic control system will detect a
malfunction and the check engine light on the dash panel will illuminate.
At this point the ECM will go into backup control and a change in engine
operation will be noticed. The engine will operate only at reduced rev/
min until the battery voltage reaches a point where it wil no longer
function and the engine will shut down. The machine can still be
operated when the check engine light is illuminated, however, the fault
should be diagnosed and corrected at the earliest possible opportunity.
Note: When the stop engine light on the dash panel illuminates, the
computer has detected a major malfunction in the engine that requires
immediate attention. It is the operators responsibility to shut down the
engine to avoid serious damage.
The machine is equipped with the DDEC engine protection system,

which records the stop engine malfunction in the ECM. The stop engine
and check engine lights illuminate when the engine protection system is
initiated. The engine will immediately reduce to 70% of the available
torque. Rampdown then commences over a 30 second period and
reduces the engine to 40% of the available torque. WARNING
To allow for the possibility of the engine protection system being The engine override
activated while the machine is operating in a critical situation, a stop switch should only be
engine override switch (7) is provided. If the switch is pressed and used in a safety critical
released during rampdown, the 30 second timer will reset, restoring situation.
torque to the level immediately following illumination of the stop engine
and check engine lights. The switch must be pressed and released
again to obtain a subsequent override.
Note: The operator must continue to reset the automatic engine
protection system by pressing and releasing the stop engine override
switch at intervals of approximately 15 to 20 seconds. The ECM will
record the number of times the override is activated after the fault occurs.
Available Torque is the actual torque available from the engine when
the fault occurred based on the actual rev/min when the fault occurred.
The engine should not be restarted after it has been shut down after
3-23
activation of the engine protection system unless the problem has been
diagnosed and corrected. WARNINGS
The operator of a
DDEC-equipped vehicle
Conditions that will cause the Stop Engine Light to come on are; Low must not attempt to use
Coolant Level, High Coolant Temperature, Low Oil Pressure and High or read a DDR of any
Oil Temperature. kind while the vehicle is
operating. Doing so can
result in loss of control,
Whenever the check engine light or stop engine light comes on, the
which may cause
DDEC computer will determine where the problem is and will store this
vehicle damage and
information in its memory. If the malfunction is intermittent, the lights will
may result in personal
come on and go off as the computer senses the changing engine
injury.
condition.
When engine or
A special diagnostic data reader (DDR) or laptop based Detroit Diesel electronics system
Diagnostic Link (DDDL) are available that can be plugged into the diagnosis is required on
engine computer memory to extract information related to the cause of a DDEC-equipped
the problem. Once the malfunction has been corrected, the DDEC vehicle, this must be
system will return the engine to normal operation. The DDR and DDDL done by a person other
can distinguish between active codes and those stored in the historic than the operator. The
code memory. The malfunction code recorded in the ECM memory will operator must maintain
remain until it is erased by a technician. control of the moving
vehicle while the
assistant performs the
When the engine is not running and the ignition is on, or, the engine is diagnosis.
idling and not in an engine protection condition, engine faults can be
diagnosed by the operator. Pressing and releasing the diagnostic
request switch will cause the check engine light or stop engine light to
flash a code number indicating the fault, e.g. flash twice - pause - flash
five times - pause indicates a code 25. Code 25 indicates all systems
are operating correctly. Pressing the switch a second time will stop the
engine codes flashing. Refer to 'DDEC V Diagnostic Codes' table for
other code descriptions.
Note: Only one light will be flashing at any one time. When code flashing L
is initiated, the active codes (or code 25) will be flashed on the stop engine
light, then the inactive codes (or code 25) will be flashed on the check
engine light.When all of the inactive codes have been flashed, the process
of flashing the codes will repeat until the conditions for code flashing are
no longer satisfied. 1721
RED - SEL YELLOW - CEL
1 FLASH 3 FLASHES 2 FLASHES 1 FLASH
SHORT LONG SHORT

PAUSE PAUSE PAUSE
½ SEC 3 SEC ½ SEC
CODE 13 CODE 21
ACTIVE Flash code example INACTIVE 1792
3-24
DDEC V DIAGNOSTIC CODES

DDEC Code
# (Flashed) PID SID FMI DDEC Description
- 240 - 2 Fram checksum incorrect
- 251 - 10 Clock module abnormal rate
- 251 - 13 Clock module fault/failure
- - 253 13 Incompatible calibration version
- - 254 0 External failed RAM
- - 254 1 Internal failed RAM
- - 254 6 Entered boot via switches
11 187 - 4 VSG sensor voltage low
11 187 - 7 VSG switch system not responding
12 187 - 3 VSG sensor high
13 111 - 4 Coolant level sensor input voltage low
13 111 - 6 Add coolant level sensor input voltage low
14 110 - 3 Coolant temperature sensor input voltage high
14 175 - 3 Oil temperature sensor input voltage high
15 110 - 4 Coolant temperature sensor input voltage low
15 175 - 4 Oil temperature sensor input voltage low
16 111 - 3 Coolant level sensor input voltage high
16 111 - 5 Add coolant level sensor input voltage high
21 91 - 3 TPS input voltage high
22 91 - 4 TPS input voltage low
23 174 - 3 Fuel temperature sensor input voltage high
24 174 - 4 Fuel temperature sensor input voltage low
25 - - - Reserved for 'No Codes'
26 - 25 1 Auxiliary shutdown #1 active
26 - 61 11 Auxiliary shutdown #2 active
27 171 - 3 Ambient air temperature sensor input voltage high
(Release 2.00 or later only)
27 172 - 3 Air temperature sensor input voltage high
27 105 - 3 Intake manifold temperature sensor input voltage high
28 171 - 4 Ambient air temperature circuit failed low
28 172 - 4 Air temperature sensor input voltage low
28 105 - 4 Intake manifold temperature sensor input voltage low
31 - 51 3 Aux. output #3 open circuit (high side) (E-49)
31 - 51 4 Aux. output #3 short to ground (high side) (E-49)
31 - 51 7 Aux. output #3 mechanical system fail (E-49)
32 - 238 4 SEL open circuit
32 - 238 3 SEL short to battery (+)
32 - 239 3 CEL short to battery (+)
32 - 239 4 CEL open circuit
33 102 - 3 Turbo boost pressure sensor input voltage high
34 102 - 4 Turbo boost pressure sensor input voltage low
35 100 - 3 Oil pressure sensor input voltage high
36 100 - 4 Oil pressure sensor input voltage low
37 94 - 3 Fuel pressure sensor input voltage high
37 95 - 3 Fuel restriction sensor input voltage high
3-25

DDEC Code
38 94 4 Fuel pressure sensor input voltage low
38 95 - 4 Fuel restriction sensor input voltage low
41 - 21 0 Too many SRS (missing TRS)
42 - 21 1 Too few SRS (missing SRS)
43 111 - 1 Coolant level low
44 110 - 0 Coolant temperature high
44 172 - 0 Air inlet temperature high
44 175 - 0 Oil temperature high
27 105 - 3 Intake manifold temperature sensor input voltage high
28 171 - 4 Ambient air temperature circuit failed low
28 172 - 4 Air temperature sensor input voltage low
28 105 - 4 Intake manifold temperature sensor input voltage low
32 - 238 4 SEL open circuit
32 - 238 3 SEL short to battery (+)
32 - 239 3 CEL short to battery (+)
32 - 239 4 CEL open circuit
33 102 - 3 Turbo boost pressure sensor input voltage high
34 102 - 4 Turbo boost pressure sensor input voltage low
35 100 - 3 Oil pressure sensor input voltage high
36 100 - 4 Oil pressure sensor input voltage low
37 94 - 3 Fuel pressure sensor input voltage high
37 95 - 3 Fuel restriction sensor input voltage high
38 94 4 Fuel pressure sensor input voltage low
38 95 - 4 Fuel restriction sensor input voltage low
41 - 21 0 Too many SRS (missing TRS)
42 - 21 1 Too few SRS (missing SRS)
43 111 - 1 Coolant level low
44 110 - 0 Coolant temperature high
44 172 - 0 Air inlet temperature high
44 175 - 0 Oil temperature high
44 105 - 0 Intake manifold temperature high
45 100 - 1 Oil pressure low
46 - 155 4 Injector Vreg voltage failed low
46 168 - 1 ECM battery voltage low
46 - 211 1 Vehicle sensor supply voltage low (V-11, V-12)
46 - 212 4 Injector Vslope voltage failed low
46 - 214 1 RTC backup battery voltage low
46 - 221 4 Injector Ipullin voltage failed low
46 - 232 1 Engine sensor supply voltage low (E-12, E-26)
47 94 - 0 Fuel pressure high
47 102 - 0 Turbo boost pressure high
47 106 - 0 Air inlet pressure high
3-26

DDEC Code
48 94 - 1 Fuel pressure low
48 106 - 1 Air inlet pressure low
52 - 254 12 A/D conversion fail
53 - 253 2 Memory check failed on startup
53 - 253 12 Memory write error - single location
53 - 253 13 Calibration memory error
53 - 253 14 Memory write error - all locations
54 84 - 12 Vehicle speed sensor fault
55 - 216 14 Missing other ECU information
55 - 231 12 J1939 data link fault
56 - 250 12 J1587 data link fault
58 92 - 0 Torque overload
61 - xxx 0 Injector xxx response time long
61 - xxx 6 Injector xxx circuit short to ground
62 - 26 3 Aux. output #1 short to battery (+) (V-04)
62 - 26 4 Aux. output #1 open circuit (V-04)
62 - 259 3 Aux. output #11 short to battery (+) (E-13)
62 - 259 4 Aux. output #11 open circuit (E-13)
62 - 26 7 Aux. output #1 mechanical system failure (V-04)
62 - 259 7 Aux. output #11 mechanical system failure (E-13)
63 - 57 3 PWM #1 short to battery (+) (V-52)
63 - 57 4 PWM #1 open circuit (V-52)
63 - 58 3 PWM #2 short to battery (+) (V-46)
63 - 58 4 PWM #2 open circuit (V-46)
63 - 59 3 PWM #3 short to battery (+) (E-01)
63 - 59 4 PWM #3 open circuit (E-01)
3-27

DDEC Code
63 - 57 0 PWM #1 above normal range (V-52)
63 - 57 1 PWM #1 below normal range (V-52)
63 - 58 0 PWM #2 above normal range (V-46)
63 - 58 1 PWM #2 below normal range (V-46)
63 - 59 0 PWM #3 above normal range (E-01)
63 - 59 1 PWM #3 below normal range (E-01)
63 - 57 7 PWM #1 mechanical system failure (V-52)
63 - 58 7 PWM #2 mechanical system failure (V-46)
63 - 59 7 PWM #3 mechanical system failure (E-01)
64 103 - 8 Turbo speed sensor input failure
64 103 - 0 Turbo overspeed
65 107 - 3 Air filter restriction sensor voltage high
65 107 - 4 Air filter restriction sensor voltage low
66 - 99 3 Oil filter restriction sensor voltage high
66 - 99 4 Oil filter restriction sensor voltage low
67 109 - 3 Coolant pressure sensor input voltage high
67 109 - 4 Coolant pressure sensor input voltage low
67 106 - 3 Air inlet pressure sensor input voltage high
67 106 - 4 Air inlet pressure sensor input voltage low
68 - 230 6 TPS idle validation circuit fault (short to ground)
68 - 230 5 TPS idle validation circuit fault (open circuit)
71 - xxx 1 Injector xxx response time short
72 84 - 0 Vehicle overspeed
72 84 - 11 Vehicle overspeed (absolute)
73 107 - 0 Air filter restriction high
74 99 - 0 Oil filter restriction high
75 - 155 3 Injector Vreg voltage failed high
75 168 - 0 ECM battery voltage high
75 - 211 0 Vehicle sensor supply voltage failed high (V-11, V-12)
75 - 212 3 Injector Vslope voltage failed high
75 - 214 0 RTC backup battery voltage high
75 - 221 3 Injector Ipullin voltage failed high
75 - 232 0 Engine sensor supply voltage high (E-12, E-26)
76 121 - 0 Engine overspeed with engine brake
77 21 - 0 ECU temperature above range
77 21 - 1 ECU temperature below range
3-28

DDEC Code
77 21 - 3 ECU temperature failed high
77 21 - 4 ECU temperature failed low
77 100 - 0 Oil pressure high
77 102 - 1 Turbo boost pressure low
77 108 - 0 Barometric pressure high
77 108 - 1 Barometric pressure low
77 171 - 0 Ambient air temperature high
77 171 - 1 Ambient air temperature low
77 174 - 0 Fuel temp high
77 251 - 10 Clock incorrect
77 251 - 13 Clock failure
77 252 - 10 Date incorrect
77 252 - 13 Clock/Date failure
81 98 - 3 Oil level sensor input voltage high
81 173 - 3 Exhaust temperature sensor input voltage high
82 98 - 4 Oil level sensor input voltage low
82 173 - 4 Exhaust temperature sensor input voltage low
83 173 - 0 Exhaust temperature high
83 173 - 4 Exhaust temperature sensor input voltage low
83 73 - 0 Pump pressure high
84 98 - 1 Oil level low
85 190 - 0 Engine overspeed
86 73 - 3 Pump pressure sensor input voltage high
86 108 - 3 Barometric pressure sensor input voltage high
87 73 - 4 Pump pressure sensor input voltage low
87 108 - 4 Barometric pressure sensor input voltage low
88 109 - 1 Coolant pressure low
89 95 - 0 Fuel restriction high
89 111 - 12 Maintenance alert coolant level fault
3-29
Allison Series 4000 Automatic Shift Transmission

The Allison Series 4000 transmission is equipped with an electronic
control unit (ECU) which continually monitors the transmission and WARNING
shift system electrical components and warns the operator when a Before any welding is
problem develops. It also takes action to prevent damage to the done on a machine
transmission, and provides the serviceman with diagnostic equipped with 4th GEN
capabilities so that problems can be corrected quickly and easily. control shift system,
When a fault occurs, the 'check transmission' lamp will illuminate and disconnect the following
an error code will be generated. The error code can be accessed in this order: Battery earth
through the 4th GEN gearshift lever. The error code is also recorded cable, battery supply
in the transmission ECU, and can be accessed by the serviceman by cable, alternator earth
plugging in a data reader to extract information relating to the fault. cables, alternator supply
The error code recorded in the ECU memory will remain until it is cables and electrical
erased by a technician. connections at the engine
ECM, transmission ECU,
If a major fault is detected, it is the operators responsibility to shut hydraulic ECU, VDU ECU
down the machine as soon as it is safe to do so. The machine should and cab bulkhead to
not be restarted until the fault has been diagnosed and corrected. avoid damage to electrical
Refer to 'Transmission 4th GEN control fault codes' table for a list of components. Turn off
fault codes (page 3-33 to 3-35). battery master switch to
isolate the bateries before
The Series 4000 transmission with 4th GEN control has been disconnecting any
designed to provide the driver with six forward gears, one reverse components.
gear and a neutral position. The gear position is indicated by the LCD After welding connect all
display on the gearshift lever. The transmission is full automatic of the above in reverse
control. order.
3-30
4th GEN Shift Controller

The 4th GEN shift controller has 6 forward ranges and 1 reverse
range as well as a neutral position. WARNING
The shift selector has a two digit LED display, that during normal Do not allow the vehicle to
operation will display the range selected and the range attained. coast in Neutral. This
Diagnostic information can be displayed on the two digit LED display practice can result in
by pressing the diagnostic mode button. There is a hold override severe transmission
button on the lever that must be pressed when shifting between Drive damage.
(D), Neutral (N) and Reverse (R). The hold override button is
released when the desired selector position is reached. The selector 1
can move between Drive (D) and the number of ranges without
pressing the hold override button.
The transmission upshifts and downshifts automatically between first
1
2
3
DE
4
CT
MO
5
LE
D
SE
N
range and the highest range selected on the range selector in direct
R
OR
NIT
MO
2
response to the throttle position and transmission output speed. 3
4
5
When reverse range is selected the 'Reverse alarm' sounds and the
'Reverse light' illuminates to warn personnel at the rear of the 1. Hold override 4. Range attained
machine that reverse gear has been selected. 2. Mode button 5. Display mode
3. Range selected button 1793
When drive (D) is selected, the transmission automatically upshifts

and downshifts through all six forward ranges as required by loads
and travel speeds. Selecting a lower range (4th, 3rd etc.) limits the
highest range to which the transmission will automatically upshift. If a
lower range is selected while moving forward, the transmission
automatically downshifts sequentially to the selected lower range at
maximum controlled engine speeds. Downshifts will not occur until
machine is slowed by use of the service brakes and/or retarder.
When shifting from neutral to start from a standstill, or to reverse
direction, decelerate the engine to idle speed. To move forward,
select Drive (D) and accelerate the engine to the machine load and
speed requirements. The transmission will automatically upshift from
1st through 6th ranges as travel speed increases.
With the throttle fully depressed, and the Mode Button in the 'POWER'
(primary shift schedule) position, the transmission upshifts to the next
higher range when the engine attains maximum rated speed, since
maximum power train output is needed under this condition. At lower
throttle settings where minimum power train performance is required,
the transmission will upshift to the next higher range at less than
maximum rated engine speed.
Upgrades or soft spots might slow travel speed, even at full throttle,
requiring transmission downshifts to maintain maximum powertrain
performance. When this occurs, the transmission downshifts
automatically.
Shift the transmission to the next lowest range if transmission

'Hunting' or 'Shift Cycling' occurs.
3-31
When temporarily stopped, such as for yielding the right of way to a

loaded machine, the transmission can be left in the selected range WARNING
and the machine held stationary with the service brakes. When Always select Neutral and
stopped for a more extended period with the engine left running,shift apply the parking brake
the transmission to Neutral to avoid unnecesary heat buildup, and before leaving the
apply the parking brake. operators' seat.
The mode button gives the option to select between transmission

'POWER' (primary shift schedule) and 'ECONOMY' (secondary shift
schedule). The transmission must be in Neutral before the switch
will function. Proper selection of these shift schedules permits vehicle
operation to be tailored towards maximised performance or fuel
economy.
The primary shift schedule is the default setting each time the vehicle
is started. The secondary shift shedule can be requested by pressing IDLE
the mode button. A red LED on the display indicates that the
FULL LOAD/THROTTLE
secondary schedule is active.
1509
The 'POWER' mode is designed for applications involving heavy

loads and hilly duty cycles where performance is of prime importance.
The 'ECONOMY' mode is designed for applications involving lighter
loads and level duty cycles or where fuel economy is more important
than performance. This mode allows earlier upshifts at a lower RPM.
Displaying Data
Oil level information can be displayed on the gear shift diplay. To
access the oil information sequence, press the Display Mode button
once on the gear shift lever. A 2 minute countdown begins when the
following conditions of the vehicle systems are met -
1. Engine at idle.
2. Oil is at operating temp. within range 82-104°C (140-220°F).
3. Transmission is in Neutral 'N'.
4. Transmission output shaft is stationary.
The oil level will be displayed at at the end of the 2 minute

countdown. During the countdown, the display flashes out a
numerical value starting at '8' in 15 second intervals, decreasing in
number value by 1 each time in the sequence ie. 8,7,6,5,4,3,2,1. After
the number sequence, the display will then sequentially flash the oil
level information, 2 characters at a time.
• oL ; oK Oil level OK.

• oL ; Lo 1 Oil level is low 1 quart - or as many quarts as required.
• oL ; HI 1 Oil level is high 1 quart - or as many quarts overfilled.
(1 US quart = 0.95 litre = 0.2 gallon)
3-32
Note: Failure to meet any of the previous conditions 1-4, will stop the
2 minute countdown. The gear shifter will display one of the following
codes -
• oL0X : Setting time too short • oL70 : Sump fluid temp too low
• oL50 : Engine RPM too low • oL79 : Sump fluid temp too high
• oL59 : Engine RPM too high • oL89 : Output shaft rotation

detected
• oL65 : Neutral not selected • oL95 : Sensor failed
Displaying Diagnostic Fault Codes

Diagnostic codes can be displayed on the gear shift lever display. To
access the diagnostic code sequence, press the Display Mode
button twice on the gear shifter. Each code consists of 4 sequential
elements; each being either 1 or 2 characters. The display for each
code will repeat continuously until the next code is displayed (if
present). To display the next code if present, press themode button.
The following cycle illustrates the display cycle:
• d1 Code list position (d1 newest, d5 oldest)

•P
• 27
• 14
• Code repeats until the next code (d2) is accessed by pressing the
mode button
Clearing Diagnostic Codes

• To clear active codes, press and hold mode button for 3 to 5
seconds.
• To clear inactive codes, press and hold mode button for 8 to 10
seconds.
Exiting Diagnostic Mode

Any of the following methods may be used to exit the diagnostic
display mode:
• Momentarily press the display mode button.
• Move the gear shift lever to any other position than the one
selected when the diagnostic display mode was activated.
• Wait until time out (approx. 10 minutes). The system automatically
returns to normal operating mode.
• Turn off the vehicle - illuminating power to transmission ECU.
3-33
Allison 4th GEN Diagnostic Codes
Code Meaning of code / Possible Cause of Fault
C1312 Retarder Request Sensor Failed Low
C1313 Retarder Request Sensor Failed High
P0122 Pedal Position Sensor Circuit Low Voltage
P0123 Pedal Position Sensor Circuit High Voltage
P0218 Transmission Fluid Over temperature
P0561 System Voltage Low Performance
P0562 System Voltage Low
P0563 System Voltage High
P0602 TCM Not Programmed
P0610 TCM Vehicle Options Error (Trans ID)
P0613 TCM Processor
P0614 Torque Control Mismatch (ECM/ TCM)
P0634 TCM Internal Temperature Too High
P063E Auto Configuration Throttle Input Not Present
P063F Auto Configuration Engine Coolant Temperature Input Not
Present
P0658 Actuator Supply Voltage 1 Low (HSD 1 open/gnd)
P0659 Actuator Supply Voltage 1 High (HSD 1 batt)
P0701 Transmission Control System Performance
P0702 Transmission Control System Electrical (Trans ID)
P0703 Brake Switch Circuit
P0708 Transmission Range Sensor Circuit - High Input
P070C Transmission Fluid Level Sensor Circuit - Low Input
P070D Transmission Fluid Level Sensor Circuit - High Input
P0711 Transmission Fluid Temp. Sensor Circuit Performance
P0712 Transmission Fluid Temperature Sensor Circuit Low Input
P0713 Transmission Fluid Temperature Sensor Circuit High Input
P0716 Turbine Speed Sensor Circuit Performance
P0717 Turbine Speed Sensor Circuit No Signal
P071D General Purpose Input Fault
P071A RELS Input Failed On
P0720 Output Speed Sensor Circuit
P0721 Output Speed Sensor Circuit Performance
P0722 Output Speed Sensor Circuit No Signal
P0726 Engine Speed Input Circuit Performance
P0727 Engine Speed Input Circuit No Signal
P0729 Incorrect 6th Gear Ratio
P0730 Incorrect Gear Ratio
P0731 Incorrect 1st Gear Ratio
P0732 Incorrect 2nd Gear Ratio
P0733 Incorrect 3rd Gear Ratio
3-34
P0736 Incorrect Reverse Ratio
P0741 Torque Convertor Clutch System Stuck Off
P0776 Pressure Control Solenoid 2 Controlled Clutch Stuck Off
P0777 Pressure Control Solenoid 2 Controlled Clutch Stuck On
P0842 Transmission Pressure Switch Solenoid 1 Circuit Lo w
P0843 Transmission Pressure Switch Solenoid 1 Circuit High
P0880 TCM Power Input Signal
P0881 TCM Power Input Signal Performance (Battery Voltage)
P0882 TCM Power Input Signal Low (Battery Voltage)
P0883 TCM Power Input Signal High (Battery Voltage)
P0960 Main Pressure Modulation Solenoid Control Circuit Open
P0961 Main Pressure Modulation Solenoid System Performance
P0962 Main Pressure Modulation Solenoid Control Circuit Low
P0963 Main Pressure Modulation Solenoid Control Circuit High
P0964 Pressure Control (PC) Solenoid 2 Control Circuit Open
P0965 Pressure Control (PC) Solenoid 2 System Performance
P0966 Pressure Control (PC) Solenoid 2 Control Circuit Low
P0967 Pressure Control (PC) Solenoid 2 Control Circuit High
P0968 Pressure Control (PC) Solenoid 3 Control Circuit Open
P0972 Shift Solenoid (SS) 1 Control Circuit Open
P0973 Shift Solenoid (SS) 1 Control Circuit Low
P0974 Shift Solenoid (SS) 1 Control Circuit High
P0975 Shift Solenoid (SS) 2 Control Circuit Open
P0976 Shift Solenoid (SS) 2 Control Circuit Low
P0977 Shift Solenoid (SS) Control Circuit High
P0989 Retarder Pressure Sensor Failed Low
P0990 Retarder Pressure Senosr Failed High
P1739 Incorrect Low Gear Ratio
P1891 Throttle Position Sensor PWM Signal Low Input
P1892 Throttle Position Sensor PWM Signal High Input
P2184 Engine Coolant Temperature Sensor 2 Circuit Low
P2185 Engine Coolant Temperature Sensor 2 Circuit High
P2637 Torque Management Feedback Signal (SEM)
P2641 Torque Management Feedback Signal (LRTP)
P2670 Actuator Supply Voltage 2 Low (HSD 2 gnd)
P2671 Actuator Supply Voltage 2 High (HSD 2 batt/open)
P2685 Actuator Supply Voltage 3 Low (HSD 2 gnd)
3-35
P2686 Actuator Supply Voltage 3 High (HSD 3 batt/open)
P2718 Pressure Control (PC) Solenoid 4 System Open
P2740 Retarder Oil Temperature Hot
P2742 Retarder Oil Temperature Sensor Circuit - Low Input
P2743 Retarder Oil Temperature Sensor Circuit - High Input
P2761 TCC PCS Control Circuit Open
P2762 TCC PCS Control Circuit Range/ Performance
P2763 TCC PCS Control Ciruit High
P2764 TCC PCS Control Circuit Low
P278A Kickdown Input Switch Circuit
P2793 Gear Shift Direction Circuit
U0001 Hi Speed CAN Bus Reset Counter Overrun (CAN2/IES CAN)
U0010 CAN Bus Reset Counter Overrun (CAN1/J1939)
U0100 Lost Communication with ECM / PCM "A"
U0103 Lost Communication With Gear Shift Module 1
U0115 Lost Communication with ECM / PCM "B"
U0291 Lost Communication with Gear Shift Module 2
U0292 Invalid Data received from Gear Shift Control Module 2
U0304 Software Incompatability With Gear Shift Control Module 1
U0333 Software Incompatability With Gear Shift Control Module 2
3-36
Dropbox
The dropbox is a remote mounted two speed transfer gearbox, taking
drive from the engine and transmission and feeding it to the front and
centre axles via a lockable differential. It has self contained hydraulic
gear selection and differential locking mechanisms.
The dropbox is equipped with two gear ratios; high and low. To select
the low ratio use the following procedure:
1. Bring the vehicle to a stop with the service brakes. Maintain
pressure on the service brake.
2. Engine RPM must be less than 750 and transmission in neutral. L
3. Press the bottom of the low ratio request switch.

4. The park/emergency brake will now automatically apply.
5. Low ratio will be activated.
6. Release the service brake pedal.
7. The park/emergency brake will now automatically disengage. 1736
To return to high ratio use the same procedure except on step 3

press the top of the low ratio request switch.
High ratio: Used where maximum performance is required.

Low ratio: Should only be used in adverse conditions to give more
control.
Note: In electrical failure dropbox will fail to the last preselected

range.
Differential Lock
The differential lock switch engages the differential lock in the
dropbox and the centre axle thru-drive differential for improved
traction when operating in soft or slippery conditions. The amber
'differential lock' warning light on the instrument panel will illuminate
when the differential locks are actually engaged.
Note: Automatically- acting limited slip differentials in each axle will L
retain traction on most surfaces, therefore it should only be necessary

to engage the differential locks in extreme conditions.
To apply the differential locks, stop the machine with the service
brakes and operate the differential lock switch. Stop the machine and 1723
disengage the differential locks as soon as conditions allow.
Note: The diferential locks can be preselected when the machine is

moving however, they will only engage on the move when the vehicle
speed is below 5 km/hr.
Note: Before driving in soft or slippery conditions, stop and engage

differential locks. Spinning wheels can result in damage to the
dropbox and axle differentials.
Note: Disengage differential locks when driving on firm ground.
3-37
Hydraulic Controls
The braking, steering, body control, engine cooling fan drive and
transmission oil cooler fan drive are all controlled by the main
hydraulic valve, which is mounted on the chassis. However, the body
control, engine cooling fan drive and transmission oil cooler fan drive
are electronically monitored by the IFM CR0020 ECU. The IFM
communicates with a variety of input and output devices. The ECU
continuously monitors the system and warns the operator when a 1734
fault develops and also helps diagnose the nature of the fault. The
ECU is located inside the cab, underneath the passenger seat.
WARNING
A three colour LED on the ECU is used to give the status of the ECU Before any welding is
and system. The following colours indicate the status levels: done on a machine
equipped with an IFM
LED Colour Status Description hydraulic system,
- Off No Operating Voltage disconnect the following
Orange 1 X on Initialisation or reset checks in this order: Battery
5Hz No operating system Loaded earth cable, battery
Green 0.5Hz Run,CANopen;PREOPERATIONAL supply cable, alternator
2Hz Run,CANopen;OPERATIONAL earth cables, alternator
Constant Stop,CANopen;PREPARED supply cables and
Red 0.5Hz Run with error electrical connections at
(CANopen;PREOPERATIONAL) the engine ECM,
2Hz Run with error transmission ECU, body
(CANopen;OPERATIONAL) control lever, hydraulics
On Fatal error or stop with error ECU and cab bulkhead
Blue 0.5Hz Internal communication, Extended to avoid damage to
Controller electrical components.
Turn off battery master
switch to isolate the
The ECU has a RS232 interface which plugs directly into a laptop. batteries before
This allows communication with the ECU using IFM software to gain disconnecting any
more information about the ECU's status. components.
After welding connect all
of the above in the
reverse order.
3-38
Steering
The steering wheel position can be adjusted as required for the most
convenient operating position. To adjust, pull out adjustment lock and
tilt steering wheel up or down as desired; release lever to lock
adjustment.
To steer the machine, rotate the steering wheel in the desired

direction to the required radius of turn. The machine will turn only as 1724
the steering wheel is turned and at a rate of turning directly

proportional to steering wheel speed. The machine will stop and hold
position when the steering wheel is stopped. To return the machine to
the straight ahead position or to the opposite direction, turn the
steering wheel in the opposite direction.
1725
WARNING
Do not attempt to adjust the steering wheel
while the machine is moving. Loss of control
may result. Stop the machine; apply the
brakes; then carry out the adjustments.
3-39
Body Control
This lever operates the body hoist cylinders. The three operating
positions of the lever are -
Raise - Pulling the lever back and holding in this position will raise
the body. When released, the lever will spring back to the 'neutral'
position.
1726
Neutral - If the body is above the body proximity switch, the lever in
this position will stop and hold the body at any desired height. If the
body is below the proximity switch, the ECU defaults the main
hydraulic valve to the float position. The body should be fully lowered
and in the 'neutral' position while the machine is in motion. The lever
will remain in the 'neutral' position when released.
Power Down - Pushing the lever forward provides hydraulic force to

power down the body. Pushing the lever fully forward will engage the
electric detent. When the body reaches the proximity switch, the lever
springs back to the 'neutral' position and power down is ramped back
to allow a smooth transition to the float position.
Note: The body must remain lowered with lever in the 'neutral'
position until it is necessary to operate the body again. Failure to
comply to this could result in overheating the hydraulic oil and failure 1512
of the hydraulic system components
3-40
Tilting Cab
The operators cab can be tilted to improve accessibility to
components below, by using hydraulic hand pump housed under the
hood on the left hand side.
To tilt the cab, remove the 4 cab mounting bolts on the left hand side.
Using the lever in the hand pump, charge hydraulic cylinder until the
cab is fully tilted and hold in place with cab prop and locate cab prop
1729
retaining pin.
To lower the cab, ensure the weight of cab is off the safety prop,
remove cab prop and slowly open valve on hand pump to gently
lower cab until holes in cab line up with holes in mounts. Reinstall the
4 cab mounting bolts.
WARNING
Do not work under or near an unblocked
or unsupported raised operator’s cab.
Always use the operator’s cab safety prop
with the locking pin.
1727
1993
3-41
Hood
The vehicle is fitted with a electrically powered hood. The hood is
activated from the hood control switch. The hood control switch is
located in the cab on the passenger seat support rail. It is a three
position switch; Centre:off; Up:raise; Down:lower. Operating the
hood control switch will send an electrical signal to the motor fitted to
the actuator. As the motor is powered the actuator extends outwards
to raise the hood or retracts inwards to lower the hood. 1791
WARNING
Do not lower the hood when the cab is
tilted.
3-42
Operating the Truck
4 - Operating the Truck
4-1
Operating the Truck
Blank P age
4-2
Operating the Truck
OPERATING THE TRUCK

Pre-Starting Inspection BRAKE COOLING OIL TANK ENGINE
* Before the engine is started ensure (TA40 only)
Check oil level.
Check oil level.
Check for leaks
the machine is ready for operation. Check for leaks.
HYDRAULIC TANK TRANSMISSION
Check oil level. Check oil level.
Check for leaks. Check for leaks.
Check indicator.
* The machine should be in a level HAND PUMP
Check oil level. SHOCK ABSORBERS
position to permit accurate checking RADIATOR HEADER TANK
Check for debris, leaks and
damage.
of fluid quantities in the engine and Check coolant level.
Check for leaks. WHEELS AND TYRES
Check condition, inflation,
other components. FRONT SUSPENSION wheel nuts and for
Check for debris and damaged rims.
damage.
DROPBOX
* Make sure parking brake is set and OPERATORS COMPARTMENT Check oil level.
Check for leaks.
AND STEPS
block wheels if necessary to Check for cleanliness.
Check seat belts.
prevent accidental movement of the ACCUMULATORS
machine while checking component Check for leaks.

STEERING CYLINDERS BODY CYLINDERS
levels. Check for debris, leaks
and damage. Check hoses
Check for debris, leaks
and damage. Check hoses
for wear and leaks. for wear and leaks.
* Test all lights and horn for proper

operation. INTERLEAF MOUNTINGS
Check for damage.
WHEELS AND TYRES
* Walk around the machine and carry Check condition, inflation,
wheel nuts and for
SUSPENSION LINKS
Check for damage.
out the Inspections and Component damaged rims.
DIFFERENTIAL
WHEEL PLANETARIES
Checks described in the drawing Check for leaks.
Check for leaks.
opposite and on the following

pages. 1747
Component Checks
1. Engine - With engine off, check oil level. The level should be
between the two marks on the dipstick. Up to the upper mark is
preferable. Add oil if low.
1748 1
2. Fuel Filter/Water Separator - Drain sediment and water until fuel

runs clear.
037 2
3. Radiator Header Tank - Check coolant level when cold.
WARNING
Partially unscrew cap to slowly release pressure before
removing cap completely. Fill to bottom of filler neck.
In subfreezing temperatures, be sure that the coolant contains 1375 3

sufficient antifreeze.
4-3
Operating the Truck
4. Engine Air Cleaner Dust Valve - Check for plugged dust cap
valve. Unplug valve and clean air cleaner dust cup if required.
1749 4
5. Transmission - Cold Oil Level - Engine Off -This check is made

only to determine if the transmission contains sufficient oil for safe
starting. Make sure oil level is well above the upper mark on the
dipstick. Add oil if low.
HOT
FULL
HOT
ADD
COLD
FULL
COLD
ADD
1750 5
6. Hydraulic Tank - Oil Level Check -Operate the body hoist

cylinders to their fully-extended positions to charge cylinders and
lines then lower the body. With the engine off, oil should show in the
sight gauge.
1751 6
7. Add oil, if low, through the hose adapter on the top of the tank.The
larger tank filler cap, should not be used for tank replenishment, and
features a lockable hinged cover to prevent its removal
WARNING
The hydraulic tank is pressurized from the engine inlet manifold 2056 7
during normal operation, and remains pressurized for 1-2 hours
after the engine is stopped. Before working on the tank, or
replenishing it with oil, relieve the tank pressure by opening the
miniature ball valve adjacent to the pressure regulator. Close
this valve after the pressure has been relieved.
8. Brake Cooling Tank - Oil Level Check - With the engine off, oil
should show in the sight gauge.
2058 8
4-4
Operating the Truck
9. Add oil, if low, through the tank filler cap.
2057 9
10. Tyres - Carefully inspect all tyres for cuts, bruises, or other
damage, and, proper inflation for the loads to be carried. Inflate all
tyres to the recommended pressure while cold.
041 10
11. Check the Fuel Level Gauge - The fuel tank should be filled at 00.00 Fuel Level 00.00.00
end of each shift.
0 25 50 75 100
Voltmeter
8 12 16 20 24 28 32
Brake Cooling
1752 11
12. Seat and Seat Belts - Adjust the seat position as required, to
allow complete machine control at all times with minimum fatigue.
Make sure the seat belt does not restrict movement for proper
machine operation.
1754 12
4-5
Operating the Truck
Engine Operation
Do not place engine under FULL LOAD at FULL SPEED
IMMEDIATELY after starting. ALWAYS allow the engine to fully
circulate lubricant and warm up gradually before operating at full
speed and full load.
Operate engine at top rated speed when maximum power is needed

for the load. Operation of the engine below top rated speed can occur
during gear shifting due to the difference of ratios between
transmission gears, but engine operation MUST NOT be sustained
more than 30 seconds at full throttle below top rated speed.
NEVER idle the engine for more than 5 minutes at a time; shut it off.
If any gauge operates outwith its normal operating range, or a

warning light illuminates, shut engine down immediately and report to
service or maintenance personnel.
WARNINGS
Never start the engine indoors unless proper exhaust
ventilation is provided to remove deadly exhaust gases. Once
the engine is running, move the machine outdoors as soon
as possible. Exhaust gases are hazardous and can cause
unconsciousness and death.
Operating the engine beyond high idle speed can cause

severe engine damage. The engine speed must not exceed
2300 rev/min under any circumstances. When descending a
steep grade, use a combination of transmission gears,
retarder, engine brake and service brakes to control the
vehicle and engine speed.
4-6
Operating the Truck
Starting the Engine

Attention to the warning lights and instruments when starting the
engine, and operating, will help the operator monitor the machine
systems and components.
1. Make sure park-emergency brake lever is in 'PARK' position.

(Button pushed ‘In’)
1715 1
2. Turn master switch, located behind panel on battery box, to 'ON'

position.
1737 2
3. Make sure the body control lever is in the 'NEUTRAL' position.
1525 3
4. Make sure the transmission gear shift control is in the 'NEUTRAL'

position.
1
2
3
DE
4
CT
MO
5
LE
D
SE
N
R
OR
NIT
MO
1733 4
5. Press horn control to sound horn.
Note: Always sound horn before starting engine or operating any

control.
1713 5
6. Insert switch key and turn clockwise to position '1' to switch on the
ignition.
575 6
4-7
Operating the Truck
7. Turn key farther clockwise against spring pressure to position '2' to

crank engine; release key as soon as engine starts firing.
Note: Never crank the engine more than 30 seconds continuously.

Allow starter at least 2 minutes cooling time between long cranking
periods to avoid overheating.
407 7
8. The amber 'Check Engine' (2) and red 'Stop Engine' (1) lights
should come on, and then go out after 6 - 10 seconds. If the amber 1 2
'Check Engine' light does not go out, have the system checked out as
soon as possible. If the red 'Stop Engine' light does not go out after 6 - 1
2 STOP P
10 seconds, or illuminates during operation, stop the engine

immediately.
1738 8
4-8
Operating the Truck
Starting the Engine with Jumper Cables
WARNINGS
Hazardous hydrogen gas and sulphuric acid. Check for
required voltage and polarity connections to discharged
batteries. Excessive booster voltage and/or incorrect jumper
cable connections, open flame, lighted cigar, or other ignition
source can cause battery explosion/fire. Keep all sources of
ignition away from batteries. Do not lean over batteries, and,
wear eye protection at all times to prevent personal injury.
Do not jump start a vehicle by using arc welding

equipment. Currents and voltages are dangerously high and
cannot be sufficiently reduced to make the method safe.
Note: Be sure machines are not touching each other. Use cables that
are equal to cable size on the machine. Booster battery should be the
same specification as discharged battery.
If jumper cables are used to start an engine, be sure to follow this

procedure:
Connect one end of a jumper cable, usually coloured red, to the

discharged battery 'POSITIVE' (+) post. Connect the other end of the
same cable to the 'POSITIVE' (+) post on the booster or charged
battery.
Connect one end of the second cable, usually coloured black, to the
'NEGATIVE' (-) post of the booster battery. Connect the other end of
the 'NEGATIVE' (-) cable to machine frame for grounding so that if a
spark occurs, it is away from battery fumes (explosive hydrogen).
Check for cause of failure on the dead battery.
4-9
Operating the Truck
Pre-Operating Checks
Make sure all cab glass, mirrors and lights are clean. Test all controls
to ensure they are functioning properly. Move transmission gear shift
control momentarily to 'REVERSE' to make sure the reverse alarm
sounds.
1. Transmission - Hot Oil Level - The parking brake must be applied

and the machines wheels securely blocked while carrying out this 1755 1
check. With the engine idling, transmission in 'NEUTRAL' and at
normal operating temperature 80° C (176° F), the oil level should be
up to, but not over, the upper mark on the dipstick. Add oil if low.
HOT
FULL
HOT
ADD
COLD
FULL
COLD
ADD
1750 1b
2. Mirrors - Ensure mirrors are positioned correctly to maximise

visibility.
1790
4-10
Operating the Truck
Brake Function Checks

In addition to the above checks, the following brake function checks
can be carried out to determine if both the service and emergency
brake systems are functional before operating the machine.
WARNING
Make sure the area around the machine is clear of personnel
and obstructions before carrying out these checks.
Note: The following checks are NOT intended to measure maximum

brake holding ability. If NEW brake pads are fitted, they MUST be
burnished as per the manufacturers recommendations before carrying
out the checks.
Service Brake Holding Ability Check

Depress service brake pedal and move transmission gear shift to
Drive. Pull the parking-emergency brake control out to release the
brakes. Depress accelerator control and accelerate engine to 1 350
rev/min. The machine should not move. Decelerate engine, shift
transmission to 'NEUTRAL' and apply the parking brake before
releasing the service brake.
Emergency Brake Holding Ability Check

Push parking-emergency brake control in to apply 'EMERGENCY'
brakes and move transmission gear shift to Drive. Depress
accelerator control and accelerate engine to 1 350 rev/min. The
machine should not move. Decelerate engine, move gear shift control
to 'NEUTRAL' and apply the parking brake.
Note: Brake holding effort required to hold a machine static at a
specific rev/min, can vary from machine to machine due to differences
in engine performance, powertrain efficiencies, etc., as well as
differences in brake holding ability.
Note: As an indication of system deterioration, the engine rev/min at
which point the machine moved, with the service or emergency
brakes applied, can be compared against the engine rev/min your
specific machine was able to hold to on a previous check.
WARNING
If the machine moves during the above checks, stop the
machine, apply the parking brake and do not operate until the
fault is corrected.
4-11
Operating the Truck
Driving and Stopping

Before driving off observe all instruments and warning lights. All
instruments should operate in their normal range and all warning
lights should be out except possibly the Direction Indicator, Headlight
Mainbeam and Differential Lock warning lights.
Make sure the area around the machine is clear of personnel and
obstructions before driving off.
In the first few minutes of travel check carefully for the required
steering, braking, engine and transmission power response for
maximum operating safety.
1. Make sure the body is fully down and the body control lever is in
the 'NEUTRAL' position.
1525 1
2. Apply the service brake and release the parking brake.
1756 2
3. Select the driving direction and the required gear.
1739 3
4. Sound horn; two blasts for forward and three blasts for reverse.
1713 4
5. Release the service brake, apply the accelerator and move off. The
transmission will automatically shift up and down the gears as speed
and conditions allow. If necessary the machine should be slowed by
use of the service brake and/or the retarder and/or engine brake.
1740 5
4-12
Operating the Truck
6. To stop the machine release the accelerator and depress the

service brake pedal. Release the service brake as the machine slows
until, when stopped, the pedal is depressed just enough to hold the
machine stationary. Do not 'FAN' the pedal.
1741 6
7. When the machine has stopped, apply the parking brake, shift the
transmission to 'NEUTRAL' and release the service brake.
1757 7
8. If the service brake does not stop the machine, apply the parking-
emergency brake. This should only be applied to stop the machine in
an emergency.
WARNING
There is no mechanical connection between the engine and
wheels on machines with converter transmissions. The 1742 8
parking brake must always be applied when the engine is
switched off.
4-13
Operating the Truck
Stopping the Engine

1. Make sure parking-emergency brake control is in 'PARK' position.
1758 1
2. Make sure the transmission is in 'NEUTRAL'.
1
2
3
DE
4
CT
MO
5
LE
D
SE
N
R
OR
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MO
1733 2
3. Allow the engine to run between idle and 1 000 rev/min with no
load for 4 or 5 minutes. This allows the engine to cool and the 15
10 min-1 20
turbocharger to slow down. Shutdown the engine. x100
5 25
Note: Stopping a turbocharged engine immediately after high speed
0 30
operation may cause damage to the turbocharger as it will continue to
turn without an oil supply to the bearings. 1534 3
4. Turn ignition key switch to the 'OFF' position. This cuts off the
power supply to the DDEC system which in turn shuts down the
engine.
281 4
5. Make sure body control lever is in 'NEUTRAL'.
1525 5
6. Turn master switch 'OFF'. This prevents batteries being drained.
1709 6
4-14
Operating the Truck
Parking
When parking the machine overnight, or for an extended period, the 00.00 Fuel Level 00.00.00
following procedure in addition to that given in 'Stopping the Engine'
0 25 50 75 100
will help maintain it in good condition for subsequent use: Voltmeter
8 12 16 20 24 28 32
1. Fill the fuel tank completely before parking the machine overnight Brake Cooling
or for extended periods, to prevent condensation. If security kit is
supplied, keep it locked. 1752 1
2. Always park on level ground where possible. If it must be parked

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

system has sufficient antifreeze to prevent the coolant freezing. If
antifreeze cannot be added to the cooling system, drain the system 2037 2
completely.
Check all tyres, hoses, wiring, tubing and fittings for cuts, ply
separation, abrasion, fraying, or other damage or deterioration.
Inspect for structural damage to the cab, body and chassis. Attach
warning signs to the steering wheel or to a control to alert others if
lubricant has been drained, batteries removed, or the vehicle has
been immobilized by any other means.
4-15
Operating the Truck
Blank P age
4-16
Working the Truck
5 - Working the Truck
5-1
Working the Truck
Blank P age
5-2
Working the Truck
WORKING THE TRUCK

Off-highway articulated trucks are used on a variety of hauling jobs,
from sand and gravel pits to road construction and mining. Every truck
operation, regardless of the type of job, can be divided into four
phases; loading, hauling, dumping and the empty return.
Note: After coming to a stop for loading or unloading the truck, the
parking-emergency brake control can be pushed in to hold the brakes 1758 Holding Truck Stationary
in the applied position as though the foot brake is depressed.
Loading
WARNING
Should the vehicle be fitted with a tailgate. Cohesive material
must not be loaded into the body. There is a risk of injury to
the driver if a tailgate is used with a cohesive material.
Note: When loading the operator should be diligent and always

aware of the material which is to be loaded onto the vehicle. At any
time, should he feel that a load constitutes an obvious safety hazard,
he has the right and duty to refuse to load this onto the vehicle.
The most common methods of loading articulated trucks are with 2023 Minimize Bucket Swing
hydraulic excavators, and front end loaders. The trucks can be loaded
equally well from the rear or the side using hydraulic excavators or
rope shovels. Ideally, excavators should require 90° or less swing.
With a backhoe excavator a very efficient loading method is with the
backhoe on top of the bank loading over the rear of the truck at the
base of the bank. Backhoe slew angles can be small, leading to very
short cycle times.
2024 Loading From Rear
For maximum material movement, the truck operator must help the
loading machine operator keep loading time to a minimum. The
shorter the distance the loading unit bucket must travel between the
cut, or stockpile and the truck body, the more passes it can make in a
given period of time and the quicker the truck can be loaded.
The fewer manoeuvres the truck must make to get into the loading
position, the sooner loading can start. In restricted areas it may be
necessary to turn and reverse the truck into the loading position. 2025 Manoeuvring In Restricted Areas
If the required space is available the truck can travel round without
the need to reverse. Waiting trucks should stay about two truck-
lengths behind the one being loaded to avoid any spillage from the
loading machine bucket or truck body. The operator of the waiting
truck is also able to judge the best spot for the truck when it is his/her
turn to be loaded.
2026 Semicircular Loading
5-3
Working the Truck
On some jobs, the loading machine might work most efficiently when
trucks are positioned on both sides of the loader. Thus, while one
truck is being loaded, another can move into position on the opposite
side of the loader and the loading machine can swing over to load the
next truck with a minimum of lost time. Since the truck is usually
backed into the loading position with this method, the operator must
be alert and careful while backing. 2027 Loading Both Sides
For fastest, most accurate loading, when being loaded by a front end
loader, the truck operator should stop the truck on the most level area
and at an angle to the face of the bank or stockpile. This minimizes
loader travel time, particularly with a raised, full bucket. Where
possible, the truck should also locate downwind of the loader when
dusty material is being loaded on a windy day. This practice improves
both working conditions and visibility for the loader operator.
2028 Loading With Front End Loader
A cleanup dozer or small loader is often worked in conjunction with

the main loading machine to keep the area clear of bucket spillage for
maximum efficiency of the loading operation. The truck operator must
always be alert to the position of the cleanup machine when entering
the loading area to avoid congestion, and, for maximum safety.
The following precautions should be observed when approaching the

loading area and while being loaded - 2029 Watch Cleanup Machine
Avoid rocks and other shovel spillage that can needlessly damage
tyres or other truck components. Allow the cleanup machine
sufficient time to clear up such debris.
Do not move the truck into loading position with the shovel bucket
swinging overhead. Large rocks that might fall from the bucket can
be dangerous to both the operator and the truck.
Keep your head and arms inside the cab during loading to avoid the
danger of falling rocks or other shovel spillage.
When the loader operator signals that the truck is loaded, sound two
blasts on the horn, select the correct gear and release the brakes.
Move out of the loading area and onto the haul road, with the least
possible delay, to allow any waiting truck to move into the loading
position as soon as possible.
5-4
Working the Truck
Hauling
While travelling the haul road, always maintain a safe speed for the
haul road conditions and grades. Never allow the truck to move or L
coast with the transmission in 'NEUTRAL'!
When approaching or encountering extremely soft or slippery

conditions, stop the truck and engage the differential locks. Do not
engage the differential locks when the truck is moving or wheels are 1723 Driving On Soft Or Slippery Conditions
spinning. Disengage the locks as soon as conditions return to normal.

20 30
When approaching downgrades, select the proper transmission gear

40
30 50
20 mph 60
10 40
km/h
10 70
range and use the retarder and service brakes as required to maintain
80
0 0000000
0000 50
safe descent speed, without over-speeding the engine, or gaining

excess travel speed. Generally, the transmission range required for
ascending is also correct for descending a grade.
2030 Maintain Safe Speeds
Always remain a safe distance behind the machine ahead,
particularly on downgrades. A good rule-of-thumb to follow is to allow
two truck-lengths between machines for each 16 km/h (10 mile/h) of TWO MINIMUM
travel speed under normal operating conditions. Under adverse
conditions, allow more room for safe operation. On jobs on which
minimum distance between machines is specified for the haul road,
be sure to observe the regulations at all times. Such regulations are
established for the safety of everyone on the job.
2031 Safety First
Pay attention to haul road conditions to avoid rocks, holes, or other

obstacles. Such obstacles not only present hazards to safe operation,
but can needlessly damage tyres and suspensions if not avoided.
Be sure to reduce speed and come to a full stop, as required, at

intersections, railroads, public highways etc. Where a 'FLAGMAN' is
stationed to direct traffic, always stay alert and follow his/her
2032 Avoid Obstacles
directions.
5-5
Working the Truck
Dumping
When dumping the operator should steer the vehicle ensuring that it
is straight and with the loaded body on level ground. The dumping
operation usually depends upon the type of material being hauled.
For instance, overburden and other waste material is usually dumped
over a spoil bank or piled into large mounds. The dumping on a job of
this type might be controlled by a dump 'SPOTTER', 'FLAGMAN' or
'BANKSMAN' or second person who directs the truck to its dumping 2033 Manoeuvring To Dump
area. While backing to dump, the operator must watch the

'SPOTTER' at all times and follow his/her direction. Under no
circumstances should the operator leave the seat to gain better
visibility while backing. Always remain seated to maintain maximum
machine control.
Mineral ores, blasted rock etc., are usually dumped into a hopper, or
crusher, where it is processed. When dumping into a hopper, the
operator, in order to avoid excess wear on the tyres, must avoid
hitting the protecting rail at the hopper. If a DRIVEOVER HOPPER is
used, the operator must avoid rubbing the tyre inner sidewalls.
When hauling dirt or rock from a borrow pit into a fill area such as an
earth-fill dam, the load is usually dumped in a string with other loads
and the loads smoothed out with a crawler tractor. When dumping on
a fill of this type, the operator usually works alone and picks his/her
own dumping place. To save bulldozer work and cleaning up, the
load should be dumped as close as possible to the preceding load.
The operator should pull past the preceding load, turn in line with the
string and back the truck until it is within a few feet of the last load.
This assures that the load will fall in the right place. No matter what
kind of job the operator is working, there are a few things which are
common to all jobs and which the operator should observe -
2034 Keep A Safe Distance From The Edge
When dumping over a spoil bank without a 'SPOTTER', know how
close the truck can safely approach the edge under all weather
conditions. If in doubt as to dumping safety, dump the load a safe
distance from the edge so that it can be pushed over the edge later.
Before raising the body, make sure that the rear wheels are on firm
level ground. If one wheel is higher than the other, a twisting strain is
imposed upon the body hinge pins, hoists and chassis. Stop the
truck, allow the engine to slow to idle, shift the transmission to 2035 Keep Wheels Level
'NEUTRAL' and apply the brakes with the Parking-Emergency Brake

control, to hold the truck stationary.
Push the body control lever back into the 'RAISE' position and
accelerate the engine. Decelerate the engine to slow the raising
speed as the hoists approach their maximum extension. When the
body has been raised to the desired height, release the control lever
into the 'HOLD' position until the body is to be lowered. Do not hold
the lever in the 'RAISE' position when the hoists are fully extended to
prevent unnecessary hydraulic system relief valve operation.
5-6
Working the Truck
Never 'JUMP DUMP' the truck by bouncing the rear tyres against a
stop block, or otherwise jarring the body in its raised position, to
dislodge stuck or frozen material. The tremendous loads that this
practice develops on the body pin area, chassis and hydraulic system
can cause needless, extensive stresses.
2036 Don't Jump Dump
Once the load has been dumped, push the control lever fully forward
into the detent 'POWER DOWN' position and accelerate the engine.
As the hoists approach their fully retracted positions, decelerate the
engine. At a predetermined body height a proximity sensor causes
the body control lever to spring back to 'NEUTRAL' position, allowing
the body to float onto the chassis under it's own weight.
Empty Return
Make sure the body is completely lowered, the body control lever is in
the 'NEUTRAL' position and transmission is in correct gear range
before releasing the brakes and moving away from the dump site.
WARNING
Do NOT drive the truck with the body up. No articulated truck
1759 Make Sure Body is Fully Down
is stable in this condition and, apart from the risk of a rear-end
topple, there can be severe danger from contacting overhead
electric cables, trees, or bridges over the haul route.
Except for the above, the procedure for returning empty to the loading
area is the same as that given earlier for 'HAULING'.
1525 Keep Control Lever in 'NEUTRAL'
5-7
Working the Truck
Blank P age
5-8
Roading
6 - Roading
6-1
Roading
Blank P age
6-2
Roading
ROADING
Note: Make sure the body

WARNING is lowered and body
These machines are equipped with cylinders containing control lever is in the
compressed nitrogen gas. Transportation of these machines 'NEUTRAL' position.
by any method may require a special permit from the Failure to comply to this
appropriate authority of the country involved. Consult your could result in overheating
Dealer for details. the hydraulic oil and failure
of the hydraulic system
General components.
'ROADING' (operating a truck over public highways) requires special Note: Make sure the
care and attention. Trucks, because of their large size, are slower and differential lock switch
less manoeuvrable than most other machines encountered on the remains in the 'OFF'
road. Yet, while on the road, they must be operated for extended position when roading.
periods of time at, or near, maximum speeds. Failure to comply to this
Before 'ROADING' a truck for an extended distance between jobs, or could result in damage to
between widely scattered sections of a job, the machine must be the transmission and axle
properly equipped and in good condition. It is also recommended to components.
carry a 'Warning Triangle'.
The operator must use extra care while on the public highways and
remain constantly alert, especially for overhead cables and low
bridges.
Necessary permits must be obtained from the proper authorities
before the machine is 'ROADED' on public highways.
Preparation Prior to Roading

Lubrication
Thoroughly lubricate and service all components and systems as
described under 'LUBRICATION AND SERVICING' in this handbook
and/or maintenance manuals for this machine.
Inspection
Perform all pre-starting and post-starting checks described in this
Handbook. Pay particular attention to the function of all instruments
and lights, and make any repairs necessary.
Note: Improper tyre inflation during over-the-road operation can
cause rapid tyre deterioration by overheating. Tyre pressures
increase with heat. Always check pressures while tyre is cold.
Consult your tyre dealer for proper pressures and tyre speed limits for
roading.
Check the inflation pressures of all tyres, while cold, with an accurate
tyre pressure gauge. Inflate tyres if necessary, while cold, to the
recommended pressure for 'ROADING'. Inspect all tyres thoroughly
and carefully for stones or other debris embedded in the treads or
carcasses. Inspect for cuts, bruises, burned beads abnormal wear
and damaged wheels rims. Replace any damaged or excessively
worn tyres.
6-3
Roading
Check all hoses, drain cocks, fuel level check cocks, and other
potential sources of leaks. Make sure that all leaks are repaired and
that all drain cocks are sufficiently tightened to avoid subsequent
loosening. Make sure that all warning flags, oversize load signs etc.
are in place and secure.
Clean all glass and adjust the seat for proper operation of all controls.
Check the lights, horn, windscreen wipers, heater, defroster,
headlight dip control, and all controls for proper operation.
Make sure the truck body is empty, fully lowered and the body control
lever is in the 'NEUTRAL' position.
Make sure the differential lock switch is in the 'OFF' position.
Drive transmission through all gears while slowly accelerating
engine.
In Case of Trouble
If trouble develops on route, move machine off the road at the first
safe parking place, and shut off the engine. Carefully note as many of
the symptoms of the trouble as possible, such as rough engine
operation with loss of power and overheating, or loss of speed and
transmission clutch pressure with normal engine operation etc.
If the area in which the trouble occurs requires that the machine be
left unattended while the trouble is reported by phone, disconnect a
battery cable and apply security locks, if so equipped, before leaving
the parked machine. Make sure body is completely lowered and the
parking brake is applied.
Report the following data as soon as possible:
1. Exact location.
2. Destination.
3. Truck Serial Number
4. The nature of the trouble (with as many details as possible) and the
time and conditions under which it happened.
5. The telephone number at which the machine operator can be
reached.
Note: Do not attempt to restart or operate the machine unless
instructed to do so. An engine, pump, transmission or other
component that develops a minor defect can be completely destroyed
in just a few extra minutes of unnecessary operation.
6-4
Moving a Disab led Truck
7 - Moving a Disabled Truck
7-1
Blank P age
7-2
MOVING DISABLED TRUCK

Any unusual power train noises noted while operating the truck WARNINGS
should be reported to those responsible for maintenance. Should the
power train, hydraulic or electrical systems fail, the vehicle should be Removing the driveline
stopped and shut down immediately until suitable repairs can be between the parking
made. If the failure is in the power train and the truck must be moved brake and the rear axles
to a service area or workshop to make required repairs, it is advisable or removing the axle
to carry out the following procedures to prevent any possible shafts and planetary
additional damage, which may be caused by the wheels turning the covers or pinion gears
power train as the vehicle is driven or towed. from the axles will make
the parking brake
If the transmission is at fault, disconnect the drivelines to the axles ineffective.
and dropbox before moving the vehicle.
Uncontrolled
If a differential or planetary is at fault, carry out the following vehicle
procedure for the component concerned: Disconnect drivelines, movement hazard.
remove planetary covers and remove the axle shafts. Remove the There is no mechanical
pinion gears from their covers. Replace the planetary pins in the connection between the
covers, and refit the planetary covers on the drive wheels to retain vehicle wheels and the
lubricant and prevent ingress of dirt. engine when the
parking brake is
If possible, start the engine to provide the required hydraulic pressure released. Before
for steering and braking. If the nature of the trouble prevents engine releasing the parking
operation, repairs must be made on the site of the breakdown, or brake, make sure the
special arrangements made for towing the vehicle safely to the repair vehicle wheels are
area without braking and steering power. secured with chock
blocks to prevent or
Note: Never allow riders on a vehicle being towed without sufficient restrict unexpected
hydraulic pressure for safe braking. vehicle movement.
If the parking brake must be released, but the engine cannot be WARNINGS
operated to provide the required hydraulic pressure, the brake can be When moving the
released manually by following this procedure: vehicle with insufficient
hydraulic pressure, for
Block all wheels securely. Turn the hex-head on the parking brake safe braking and
actuator anticlockwise until the brake pads are free from the disc. steering, use extreme
When the hydraulic system is repaired, return the actuator to its caution to ensure
original position by turning the hex-head fully clockwise. personnel and property
safety.
Connect a suitable towing bar to one of the lugs on the tractor frame
of the disabled vehicle and reverse another vehicle, in a straight and Make sure the
parking
in-line manoeuvre, towards the disabled vehicle. Connect the
brake actuator is
opposite end of the towing bar to the towing pin of the recovery
returned to its original
vehicle and ensure that it is securely locked.
position, and the
parking brake is
Note: An alternative method of towing a disabled vehicle is by
operating correctly,
connecting an A-Frame arrangement to the lugs on the tractor frame
before removing the
of the disabled vehicle and the towing pin of the recovery vehicle.
chock blocks from the
wheels.
To prevent possible damage to the transmission, the towing speed
should never exceed 10 km/h (6.2 mile/h) and the distance towed
should not be longer than 10 km (6.2 miles).
7-3
Blank P age
7-4
8 - Lubrication and Servicing
8-1
Blank Page
8-2
SAFETY PRECAUTIONS
Do not allow unauthorized personnel to service or maintain this
machine. Study the Operator’s Handbook and Maintenance Manual
before starting, operating or servicing this machine. Always follow TY L
FE UA
procedures and safety precautions detailed in the Maintenance SA AN
M
Manual.
Always attach a 'DO NOT OPERATE' or similar warning sign to
ignition switch or a control before cleaning, lubricating or servicing
the machine.
Never allow anyone to work on the machine while it is moving. Make 1767
sure no one is on the machine before working on it.
Do not work under or near unblocked or unsupported body. Always
use the body safety prop. Body prop must only be used when the
body is empty.
Do not work under or near any unblocked or unsupported linkage,
part or machine. D O N OT
OPE RATE
Always shut down machine according to the procedure under
'Stopping The Engine', described on Page 4-14. Turn off the master
switch before cleaning, lubricating or servicing the machine except as
called for in this Handbook or Maintenance Manual.
Always install steering lock bar before adjusting or servicing the 1775
machine with the engine running. Refer to 'General' safety section on
Page 2-4.
Always relieve pressure before servicing any pressurized system.
Follow the procedures and safety precautions detailed in the relevant
Maintenance Manual section.
When changing oil in the engine, transmission and hydraulic
systems, or removing hydraulic lines, remember that the oil may be
hot and can cause burns to unprotected skin.
When working on or around exhaust components, remember that the
components may be hot and can cause burns to unprotected skin.
Always deflate tyre before attempting to remove any embedded
objects or removing the tyre and rim assembly from the machine.
Always use a self-attaching chuck with a long airline and stand to one 1781
side while the tyre is inflating. Refer to Section 160-0050, Wheel Rim
and Tyre in the Maintenance Manual.
WARNING
Injection Hazard. Relieve pressure before

Escaping fluid under pressure disconnecting hydraulic lines.
can penetrate skin, causing Keep away from leaks and pin
serious injury. holes. Use a piece of
cardboard or paper to search
for leaks. Do not use hand.
Fluid injected into the skin must be

surgically removed within a few
hours by a doctor familiar with
this type of injury or gangrene
will result.
15333273
8-3
LUBRICATION AND SERVICING

Lubrication is an essential part of preventive maintenance. It is
important that the instructions regarding types of lubricants and the
frequency of their application be followed to prolong the useful life of
the machine. Periodic lubrication of moving parts reduces to a
minimum the possibility of mechanical failures.
Thoroughly clean all fittings, caps and plugs to prevent contaminants
from entering the system while servicing.
Lubricants must be at operating temperature when draining.
Do not operate any system unless oil level is within the operating
range as indicated on oil level dip stick, sight gauge or level plug.
Small circles on the following illustrations represent points at which
lubrication or servicing must take place, at the intervals indicated on
the left-hand side of the lubrication chart.
The numbered circles on the illustrations contain reference numbers
which correspond to the 'Ref. Points' column of the chart.
All change and service periods are recommendations based on
average operating conditions. Lubricants showing evidence of
excessive heat, oxidation or dirt should be changed more frequently
to prevent these conditions. Lubricant change and service periods
must be established on the basis of individual job conditions.
8-4
24 35 28 27 13 11 9 12 21 16 18 22 19 25 22 16 20 16 23 10
1 33 32 5 4 3 7 15 2 12 21 14 34 22 26 22 17 10 20 8 23
1760 Lubrication and Servicing Points

Interval Ref. No. of Service
Hours Points Identification Service Instructions Points Lubricant Quantities
1 Engine Check oil level. Add oil if low. 1 EO As required.
10 2 Transmission Check oil level. Add oil if low 1 TranSynd / As required.
(Daily) TES 295*
3 Hydraulic Tank Check oil level. Add if low. See Note 7. 2 HO / Textran HD10 As required.
4 Radiator Expansion Tank Check coolant level. Add if low 1 Ethylene Glycol As required.
5 Primary Fuel Filter / Check. Drain as required. 1 - -
Water Separator
1 Drive Belt Check for damage. 1 See engine Manual
27 Fuel Tank Check fuel level. Add if low. 1 - As required.
1 Engine Crankcase Breather Inspect and clean if required. - -
24 Cooling Fans Check for damage.
6 Hydraulic Filter Restriction Check. Replace element if required. 1
Indicator See Note 7.
Tyres Check condition and pressure. 6
14 Dropbox Check oil level. Add oil if low 1 EO As required.
General Walk round vehicle, check for debris, - Refer to chart.
leaks and damage.
1 Engine Air Cleaner Check. Renew element if required 1 - See Note 8
50 7 Battery Electrolyte Check level. Add electrolyte if low. 2 - As required.

(Weekly) 8 Wheel rim nuts Check Torque. 114 - 600 Nm (442 Ibf ft)
9 Cab Ventilation Filter Inspect and clean if required. 1
10 Panhard Rod Bearings Lubricate 4 EP, NLGI See Note 1.
19 Oscillation Bush Lubricate 2 EP, NLGI See Note 1.
20 Suspension Beam Bushings Lubricate 2 EP, NLGI See Note 1.
23 Body Hinge/Optional Tailgate Pins Lubricate 2 EP, NLGI See Note 1.
21 Steering Cylinder Pins Lubricate 4 EP, NLGI See Note 1.
22 Body Cylinder Pins Lubricate 4 EP, NLGI See Note 1.
16 Differential Breathers Clean if required. 3
18 Articulation Bearings Lubricate 2 EP LI COMP See Notes 1 and 2.

250 25 Parking Brake Pads Check wear. Renew if required. 2
(Monthly) Service Brake Pads (A862) Check wear, Renew if required 12
2 Transmission Breather Clean if required. 1
24 Radiator and Coolers Clean and inspect fins. See Note 6.
26 OCDB Plate Check wear. Replace if required.
1 Engine Drain oil and refill with new oil. 1 EO 32 Litres
13 Engine Oil Filters Renew 2
15 Secondary Fuel Filter Renew 1
17 Wheel planetaries Check oil level. Add oil if low 6 EPL As required.
16 Differentials Check oil level. Add oil if low 3 EPL & LZ See Note 4.
5 PrimaryFuel Filter/Water Renew 1
Separator
19 Oscillation Pivot Check end float. Adjust if required. 2
1 Drive Belt Check tension. Tighten if required 1
8-5
LUBRICATION AND SERVICE CHART (Continued)

Interval Ref. No. of Service
Hours Points Identification Service Instructions Points Lubricant Quantities
500 27 Fuel Tank Clean filler neck, screen and cap. 1

(3 14 Dropbox Oil Filter Renew 1
Monthly) 14 Dropbox Drain oil and refill with new oil. 1 EO 13 l (3.4 US Gal.)
17 Wheel Planetaries (862) Drain oil and refill with new oil. 6 EPL 9 l (2.4 US Gal.)
16 Differentials (862) Drain oil and refill with new oil. 3 EPL and LZ See Note 4
9 Cab Ventilation Filters Renew 1
28 Coolant Additive Renew 1
1000 29 Fuel Tank Breather Renew 1
(6 31 OCDB Tank Breather Renew 1
Monthly) Driveshaft Bearing Check oil level. Add if low. 1 EPL
3 Hydraulic Tank Breather Renew 1
32 OCDB Tank Drain oil and refill with new oil. 1 Textran TDH
1500 Premium
33 OCDB Filter Renew 1
33 OCDB Strainer Clean. 1
7 Wheel Planetaries (865/917/946) Drain oil and refill with new oil. 6 EPL 9 l (2.4 US Gal.)
16 Differentials (865/917/946) Drain oil and refill with new oil. 3 EPL and LZ See Note 4
1 Engine Mtg. Bolts Check torque. (Torque seal) 2 330 Nm (239 Ibf ft)
1 Drive Belt Renew belt
3 Hydraulic Tank Drain oil and refill with new oil. HO / Textran 275 l (73 US Gal.)
See Note 7. 1 HD10
2000 34 Articulation Pivot Nut Check torque. 1 1425 Nm (1050 lbf ft)
(Annually) 3 Hydraulic Oil Filter Renew. See Note 7. 1
2 Transmission Mtg. Bolts Check Torque. (Torque Seal). 2 921 Nm (680 Ibf ft).
1 Turbocharger Mtg. Nuts Check Torque. (Torque Seal). 2 921 Nm (680 Ibf ft).
24 Cooling System Check concentration, add booster. - Ethylene 67 l (18 US Gal.)
Glycol
3000 2 Transmission Oil Filters Renew 2

4000 35 Air Conditioning Compressor Drain flush and refill with new oil 1 PAG Oil 0.125 l
6000 2 Transmission Drain oil and refill with new oil. 1 TranSynd / 61 l (16 US Gal.)
TES 295*
* - When determining whether a fluid is TES 295 approved or not look and/or ask for one of two things - The Allison
TES 295 approval number or the Allison approved logo . TES 295 approved fluids are listed on page 8-10. If
uncertain if a fluid is approved, consult Allison Transmission for confirmation.
Note: Failure to useTerex filters and approved lubricants as illustrated may invalidate all
warranty cover.
Note: Use the 'Lubrication and Service Chart' in conjunction with the 'Notes on Lubrication
and Service Chart' and 'Miscellaneous Servicing' contained on the following pages.
8-6
Notes on 'Lubrication and Service Chart' MISCELLANEOUS SERVICING

Note - Capacities given are approximate - work to
dipstick, sight gauges or level plugs. WHEN REQUIRED
Seat Belts - Inspect for damage and replace if required.
Note 1 - Lubricate slowly until excess lube is seen.
Note: Replace seat belts at least once every three
Note 2 - Remove plugs and fit lube fittings. Lubricate years, regardless of appearance.
slowly until excess lube is seen. Remove fittings and
refit plugs. Windscreen Wipers and Washers - Inspect wiper
blades and replace if damaged. Top up washer
Note 3 - Check with the engine idling and the reservoir.
transmission at its normal operating temperature.
Note 4 - When refilling the centre axle ensure that the 3rd Wheel Rim Nuts - After the first 10 hours of operation,
differential unit is primed with 1 l (1.75 UK pints) re-torque the nuts to 600 Nm (442 lbf ft).
of oil before filling the drive head.
Note: Torque should be applied in three stages. Nuts
Note 5 - Remove plug from the port on the underside of the are to be torqued crosswise (opposing pairs). Check the
oscillation hub. Plug is removed to drain the torque every 50 hours (weekly) thereafter.
cavity of any oil that enters the cavity when filling.
Remove grommet and level plug on the side of the Engine - Steam clean the engine prior to performing any
oscillation hub. Add oil if required. Refit all plugs. repair or service work on it, and if heavily contaminated
due to prevailing site conditions.
Note 6 - Clean the radiator, condenser and cooler fins more
often when operating under extremely dusty CAUTION
conditions.
Electrical and electronic connections. The Engine
ECM and harness connections should be protected
Note 7 - The hydraulic tank remains pressurized for 1-2
or not directly steam cleaned when on or removed
hours after the engine is stopped. Before
from the engine.
carrying out any maintenance work on the tank or
filter, relieve the tank pressure by opening the
miniature ball valve on the pressurization
regulator. Close this valve after the pressure has Note: The engine and its components that are scheduled
been relieved. to be checked, serviced or replaced must be cleaned in
accordance with the manufacturer's recommendations.
Note 8 - Check the air cleaner restriction gauge and
operate the vacuator valve. Renew the element if the Oil Cooled Disc Brakes - A squeaking noise is an
indicator moves from the yellow to the orange indication of abnormal wear, and necessitates internal
section. examination of the brakes.
EO - Engine Oil. Refer to 'Recommended

Lubricants' EVERY 10 HOURS OF OPERATION (DAILY)
* - Refer to chart under 'Recommended Walk Around Inspection - Inspect the vehicle as
Lubricants' described in Section 4.
HO - Hydraulic Oil. Refer to Engine - Visually check engine for damage, loose or
'Recommended Lubricants' frayed belts and listen for any unusual noises.
EPL - Extreme Pressure Lubricant, Engine Air Cleaner - Change air cleaner element only
specification MIL-L-2105 D when the yellow band of the air restriction gauge locks
EP, NLGI - Extreme Pressure, Lithium No. 2 up in the orange. Service vacuator valve daily. Inspect
Grease (which may, or may not, and remove any obstructions from the vacuator valve
contain Molybdenum) lips which should be open and pliable with the engine
stopped.
*EP, NLGI - Extreme Pressure, Lithium No. 2
Grease (without Molybdenum) Note: Service air cleaners more often when operating
under extremely dusty conditions.
EP LI COMP - Extreme pressure Lithium Complex
Grease. Ref. EEMS 19057
Engine Crankcase - Check oil level and add if low.
LZ - Lubrizol 6178 A cold level check should always be done prior to
starting the vehicle. To ensure that sufficient oil is in the
PAG Oil - Polyalklene Glycol (PAG) Compressor system to allow the unit ot be run to operating temp to
Lubricating Oil - Low Viscosity perform a hot level check.
(ISO46).
Transmission - Check the oil level and add oil if low.
Hydraulic Tank - Check the oil level and add oil if low.
Brake Coolant Tank (A917/A865/A946) - Check the oil

level and add if low.
8-7
Radiator - Check coolant level and add if low. Fill the radiator EVERY 500 HOURS OF OPERATION
header tank with coolant until coolant reaches the bottom of
Dropbox Oil Filter - Remove and renew.
the filler neck and holds at that level.
Note: Any time a significant amount of coolant is added, Dropbox - Drain oil and refill with new oil.
the coolant inhibitor MUST be checked. If the EVERY 1000 HOURS OF OPERATION (6 MONTHS)
concentration is low, engine damage will result.
Brake Coolant Tank (A917/A865) - Replace breather.
Conversely, over-inhibiting antifreeze solutions can result
in silicate dropout.
Axles (A862) - Drain the lubricant and refill to the level
plug.
AFTER FIRST 100 HOURS OF OPERATING NEW OR
REBUILT COMPONENTS
Note: When refilling the centre axle, ensure that the
3rd differential unit is primed with 1 l (1.75 UK pints)
Differentials - Drain lubricant and refill to level plug.
Note: When refilling the centre axle ensure that 3rd
Parking Brake - Check pads and disc for wear.
differential unit is primed with 1 l (1.75 UK pints) of oil
Adjust or replace if required. Test for proper
before filling drive head.
function. Thickness of pad friction material should
never be allowed to wear below 3 mm (0.12 in).
Planetaries - Drain lubricant and refill to level plug.
Articulation Vertical Bearings - Remove plugs
Hydraulic Oil Filter - Clean filter housing and install new
and fit lube fittings. Lubricate slowly until excess
element at 100 hours of operation, or when indicated,
lube is seen. Remove lube fittings and refit plugs.
whichever occurs first.
Driveshaft Bearings - Remove plug from port on
Note: A 6 µm filter is used to flush the system. This is
underside of oscillation hub. Plug is removed to drain
replaced with a 12 µm filter for normal use. See vehicle
the cavity of any oil that enters the cavity when filling.
Parts Book for filter part numbers.
Remove grommet and level plug on side of oscillation
hub. Add oil if required. Refit all plugs.
Brake Cooling Oil Filter (A917/A865/A946) - Clean filter
within the brake coolant tank after 100 hours of operation.
Grease Points - Grease the door hinges.
AFTER FIRST 250 HOURS OF OPERATING NEW OR
REBUILT COMPONENTS EVERY 1500 HOURS
Axles (A917/A865/A946) - Drain lubricant and refill
Front Suspension - Check that the pre-compressed
to level plugs.
length of the rubber mounts is 203 mm.
Note: When refilling the centre axle, ensure that the
EVERY 250 HOURS OF OPERATION 3rd differential unit is primed with 1 l (1.75 UK pints)
General Inspection - Check entire vehicle for leaks,
loose bolts and nuts or damaged parts. Examine the
vehicle, particularly the chassis, for cracks or broken EVERY 2000 HOURS
welds. Repair where necessary.
Drivelines - Visually check Low Maintenance
drivelines for leaking or damaged seals.
Service Brakes (A862) - Check pads and discs for wear
and renew where necessary. Test for proper function.
Note: Low Maintenance drivelines can be identified
by having plugs fitted to the spiders, not grease
Note: This service interval applies to normal driving. Check
nipples.
the pads more frequently under more severe conditions.
Thickness of pad friction material should never be allowed
Note: When service is required, remove plug and fit
to wear below 3 mm (0.12 in).
grease nipple. Grease spider and refit plug when
finished. Use Type K lubricating grease in
Parking Brake - Check pads and discs for wear and replace
accordance to DIN 51825-KP2-K-40.
where necessary. Test for proper function.
Hydraulic Oil Tank - Drain oil, remove and clean
Note: This service interval applies to normal driving.
suction screens and strainers. Reinstall suction
Check the pads more frequently under more severe
screens and strainers and refill hydraulic oil tank.
conditions. Thickness of pad friction material should never
be allowed to wear below 3 mm (0.12 in).
Hydraulic Oil Filter - Clean filter housing and install
new element when indicated, or after 2000 hours of
Oil Can Points - Oil working parts with engine oil.
8-8
operation, whichever occurs first.
EVERY 3000 HOURS AIR CONDITIONING RE-START PROCEDURE

Transmission - Replace oil filter and lube oil filter. If the machine has been idle for an extended period of time (2
weeks), the refrigerant in the air conditioning unit converts
EVERY 6000 HOURS
from a gas to a liquid. This puts the compressor unit under a
Transmission - Drain oil and refill to level. great deal of strain as it tries to compress a liquid instead of a
gas, and could cause a failure in the air conditioning unit. The
following commissioning procedure allows the air conditioning
ENGINES AND TRANSMISSIONS unit to achieve normal operating parameters.
All information contained in the 'Lubrication and Service 1. Start the machine and allow it to run until the engine is
Chart' was extracted from the relevant manufacturer’s at a normal operating temperature of 80 °C (176 °F)
Operator’s Manual and was correct at time of publication. 2. Turn the blower control to setting 1.
Users should ensure that information contained in this 3. Turn on the air conditioning unit for 5 seconds then
chart, regarding Engines and Transmissions, reflects the off for 5 seconds.
information shown in the relevant manufacturer’s 4. Repeatedly switch the air conditioning on and off for at
Operator’s Manuals supplied with the vehicle. least 1 minute. This should be at least 12 repetitions.
Maintenance procedures should be carried out in 5. Commissioning of the air conditioning unit is complete, and
conjunction with any additional procedures contained in it is ready for use.
the relevant manufacturer’s 'Operation and Maintenance
Manual', at the intervals specified.
8-9
RECOMMENDED LUBRICANTS
COMPONENT LUBRICANT *CAPACITY SPECIFICATIONS API CODE SAE GRADE
Engine Engine Oil with 1.00% 32 litre CH-4 15W-40
(Including Filters) sulphated ash limit is (9.8 US gal)
recommended. Sulphated ash
must not exceed 1.85% limit
Transmission 61 litre See Trans.
(Including Filters) TranSynd / TES 295 (16.1 US gal) TranSynd / TES 295 - TES 295
(dry fill) Oil Table.
Hydraulic System Hydraulic Transmission Oil 330 litre Textran HD10 See Hydraulic Oil Table
(Including Lines) (87 US gal) (See Note 2)
Cooling System Anti-freeze, Ethylene 67 litre

Glycol (18 US gal)
Differential Extreme Pressure 33 litre MIL-L-2105 D GL-5 80W-90 LS
(Front) Gear Lubricant (8.7 US gal) (See Note 3)
(Centre) Gear Lubricant (9 US gal) (See Note 3)
(Rear) Gear Lubricant (8.7 US gal) (See Note 3)
Planetaries - Extreme Pressure 9 litre each MIL-L-2105 D GL-5 80W-90 LS
Gear Lubricant (2.4 US gal) (See Note 3)
Dropbox Engine Oil 13 litre CH-4 15W-40
(3.4 US gal)
Fuel Tank Diesel Fuel Oil with 481 litre DIN EN590
max. sulphur 0.5% (127 US gal)
Grease Nipples** Extreme Pressure No.2
Lithium Grease Consistency
Driveshaft through Extreme Pressure 1.50 litre MIL-L-2105 D GL-5 80W-90
Bearings Gear Lubricant (0.40 US gal)
Articulation Extreme Pressure EEMS 19057
Bearings Lithium Complex
Air Conditioning Polyalklene Glycol (PAG) 0.125 litre ISO46
Compressor Compressor Lubricating Oil - (0.033 US gal) SP 10
Low Viscosity
Brake Cooling UTTO (Universal Tractor 175 litre (SAE) J2360 ZF 03E, 05F 10W-30
System Transmission Oil) (Refer to (42.6 US gal)
ZF Approved List)
TES295 APPROVED OILS

Approval Number Approved Maker Product Brand Name
AN-011001 Castrol Heavy Duty Lubricants Transynd
AN-031002 BP Autran Syn 295
AN-031003 Cognis Corporation Emgard 2805
AN-031004 International Truck & Engine Co. Fleetrite Synthetic ATF
AN-031005 Exxon Mobile Lubricants Mobile Delvac Synthetic ATF
and Petroleum Specialities Co.
* - When determining whether a fluid is TES 295 approved or not look and/or ask for one of two things - The
Allison TES 295 approval number or the Allison approved logo . TES 295 approved fluids are listed on the
following page. If uncertain if a fluid is approved, consult Allison Transmission for confirmation.
8-10
Recommended Lubricant notes Note 2 - Hydraulic Transmission Oil is suitable for use in
the hydraulic system.
* - Capacities given are approximate, work to dipstick, sight Typical SAE 10W oils:
gauges or level plugs.
SHELL DONAX TEXACO TEXTRAN KUWAIT TO4
** - Refer to the 'Lubrication and Service Chart' for the MOBILTRANS HD BP AUTRAN 4 CASTROL TFC
different applications. DO NOT use on the Articulation ESSO TORQUE FLUID
bearings.
Note 3 - Axles have limited slip differentials. If use of a
Note 1 - Operation below the minimum temperatures listed standard SAE 90 oil results in very loud noise and jerking of
for the oil used without proper pre-heat or warm-up results the wheels when driving slowly round sharp corners, an EP
in greatly reduced transmission life. Proper warm-up oil with limited slip additives should be used.
requires 20 minutes minimum operation in neutral (with
engine at part throttle) before operating the transmission in Note 4 - Automatic Transmission Fluids (ATF) may only be
gear. used when the ambient temperature is less than - 10° C
(14° F). Should the temperature increase, it is necessary to
switch to engine oil.
LUBRICANT GRADE SELECTION GUIDE AT AMBIENT (START-UP) TEMPERATURE

Sm - 637
HYDRAULIC OIL
API
SAE CODE MIL-SPEC
1 - - MIL-H-5606A
2 DEXRON Auto Trans. Fluid
3 10W CC/CD MIL-L-2104 B/C
4 20W/20 CC/CD MIL-L-2104 B/C
5 30 CC/CD MIL-L-2104 B/C
Sm - 639
ENGINE OIL
ENGINE OIL
(See Note 4)
Note - Consult your lubricant supplier for correct viscosity of lubricant when ambient temperatures are
consistently above or below those listed.
8-11
TYRE PRESSURES
Tyre pressures on this pages apply to the truck serial number range specified only. Gross Vehicle Weight (G.V.W.) and axle weights
may vary between truck derivatives. Tyre pressure should be recalculated if not shown for a particular truck. Contact TEREX for
assistance.
The tyre inflation pressures listed are manufacturers’ recommendations for G.V.W. travelling at maximum speed. TEREX advise that
operators check tyre inflation pressures with tyre manufacturers to ensure the correct setting for each particular application.
TYRE INFLATION PRESSURE

Front Centre Rear
Truck Brand Size Pattern b lbs/in2 b lbs/in2 b lbs/in2
TA35 Bridgestone 26.5 R25 VLT 4.5 65 5.7 82 5.7 82
A862 Bridgestone 26.5 R25 VMT 4.5 65 5.7 82 5.7 82
A917 Michelin 26.5 R25 XADN 3.2 47 4.5 65 4.5 65
A946 Michelin 26.5 R25 XADT 3.2 47 4.5 65 4.5 65
Double Coin 26.5 R25 REM5 4.5 65 5.5 80 5.5 80
Triangle 26.5 R25 TB516 4 58 5.9 86 5.9 86
TA40 Bridgestone 29.5 R25 VLT 4 58 5 73 5 73

A865 Bridgestone 29.5 R25 VMT 4 58 5 73 5 73
Michelin 29.5 R25 XADN 2.8 40 3.8 55 3.8 55
Triangle 29.5 R25 TB516 4 58 4.9 71 4.9 71
****
8-12
Technical Data
9 - Technical Data
9-1
Technical Data
Blank P age
9-2
Technical Data
TECHNICAL DATA TA35 (A862)
3 315
Max 1 380 (10-11)
Body (4-6)
Depth 3 130
(10-3)
6 872
(22-7)
66°
3 888 GEN ER AT I ON
(12-9)
3 686 2 967
(12-1) (9-9)
3 494 2 414
(11-5) (7-11)
851
553 (2-9)
(1-10)
1 837 2 914 1 310 2 990 1 950 1 780
(6-0) (9-7) (4-4) (9-10) (6-5) (5-10)
2 520
(8-3) 10 944
3 206 (35-11)
(10-6)
Dimensions in mm (ft-in)
1761
ENGINE
Make/Model........................................................ Detroit Diesel Series 60
Type .......................6 Cylinder, in line , Four cycle diesel, water cooled,
turbocharged with air to air cooling, electronic engine management.
Gross power at 2110 rev/min..........................298 kW (400 hp, 405 PS)

Net power at 2110 rev/min..............................289 kW (388 hp, 393 PS)
Note: Gross power rated to SAE J1995 Jun 90. Engine emission
meets USA EPA Tier 3 /CARB MOH 40 CFR 89 Tier 3 and proposed
EU NRMM (non-road mobile machinery) Tier 3 directive.
Maximum Torque........................2 000 Nm (1475 lbf ft) at 1 200 rev/min

Number of cylinders/configuration...............................................6, in line
Bore x Stroke..............................................133 x 168 mm (5.24 x 6.61 in)
Piston Displacement...............................................................14 l (855 in³)
Air cleaner...........................................................Dry type, double element
Starting...............................................................................................Electric
Maximum Speed (No load)...................................................2300 rev/min
Maximum Speed (Full load).................................................2200 rev/min
Idle Speed................................................................................. 700 rev/min
9-3
Technical Data
TRANSMISSION
Make/Model..........Allison 4000 Series with integral retarder mounted
directly to the engine, fully automatic transmission with planetary
gearing, lock-up in all gear ranges. Electronic control with six forward
and one reverse gear.
Main........................................................18.5 + 3.4 bar (269 + 50 lbf/in²)
Temperatures:
Normal.............................................60C°C - 135C° C (140 °F - 275 °F)
Maximum.........................................................................165° C (329 ° F)
Ratios:
Transmission .............. Refer to table below
Low Range
Forward
Gear 1 2 3 4 5 6
km/h 5.2 11.0 15.9 24.3 31.0 35.2
mile/h 3.2 6.8 9.9 15.1 19.3 21.9
Reverse
Gear 1
km/h 4.6
mile/h 2.9
High Range
Forward
Gear 1 2 3 4 5 6
km/h 7.9 16.8 24.3 37.1 47.7 53.9
mile/h 4.9 10.4 15.1 23.1 29.6 33.5
Reverse
Gear 1
km/h 7.0
mile/h 4.3
DROPBOX
Remote mounted transfer gearbox taking drive from the transmission
and feeding it via a lockable differential to the front and rear wheels.
Ratios:
Low........................................................1.129:1
High.......................................................0.738:1
Pressure:
High/Low actuation......................15 ±0.2 bar
Differential lock actuation..............34-50 bar
Lubrication..........................................2 ±1 bar
Temperature:
Maximum......................................100 °C (212 °F)
9-4
Technical Data
AXLES
Three axles in permanent all-wheel drive (6 X 6) with differential
coupling between each axle to prevent driveline wind-up. Heavy
duty axles with fully-floating axle shafts and outboard planetary
reduction gearing.
Automatic limited slip differentials in each axle. Centre axle

incorporates a through-drive differential to transmit drive to the rear
axle. This differential and the dropbox output differential are locked
simultaneously using one switch selected by the operator.
Ratios:
Differential ........................................ 3.70:1
Planetary .......................................... 6.35:1
Total Reduction .............................. 23.50:1
SUSPENSION
Front: Four trailing links and a Panhard rod locate the front axle
giving a high roll centre. The optimized front axle position along with
the wide spaced main and rebound mounts, mounted directly above
the axle and long suspension travel, combine with two heavy duty
dampers each side to give excellent handling and ride.
Rear: Each axle is coupled to the frame by three rubber- bushed links
with lateral restraint by a transverse link. Pivoting inter-axle balance
beams equalize load on each axle. Suspension movement is
cushioned by rubber/metal laminated compression units between
each axle and underside of balance beam ends. Pivot points on
rear suspension linkages are rubber-bushed and maintenance-free.
WHEELS AND TYRES
Wheels:3-piece earthmover rims with 19 stud fixing
Size:
Standard............................................25 x 22.00 in for 26.5 R25** tyres
Tyres:
Standard...................................................................................26.5 R25**
Inflation Pressures :
Please refer to page 8-12 for a full list of tyre inflation pressures.
Note: Tyre pressures should be regarded as nominal only. It is

recommended that for tyres both listed and unlisted, the user should
consult the tyre manufacturer and evaluate all job conditions in order
to make the proper selection.
9-5
Technical Data
HYDRAULIC SYSTEM
Braking, steering and body hoist systems are controlled by a main
hydraulic valve mounted on frame. Systems are supplied with oil from a
common tank by the main hydraulic pump, driven from power takeoff on
transmission. System components are protected by full flow filtration on
the return line.
Pump:
Type..................................................................................................Piston
Capacity at 2 700 rev/min..........................5.4 litre/s (85.6 US gal/min)
Brakes
Full hydraulic braking system with dry disc on each wheel and a single
heavy duty caliper per disc. Independent circuits for front and rear brake
systems. Warning lights and audible alarm indicate low brake system
pressure. Brake system conforms to ISO 3450, SAE J1473.
Actuating Pressure.................................158 ± 2.4 bar (2290 ± 35 lbf/in²)

Discs:
Diameter...........................................................................470 mm (18.5 in)
Thickness..............................................................................19 mm (0.7 in)
Parking.......Spring-applied, hydraulically-released disc on rear

driveline.
Emergency.................Automatic application of driveline brake should

pressure fall in main brake hydraulic system. Service brakes may also
be applied using the parking-emergency brake control.
Steering
Hydrostatic power steering by two single-stage, double-acting,
cushioned steering cylinders. Emergency steering pressure is provided
by a ground driven pump mounted on the rear of the transmission. An
audible alarm and warning light indicates should the emergency
system activate. Conforms to ISO 5010, SAE J53.
System Pressure......................................................240 bar (3500 lbf/in²)

Steering Angle to either side.................................................................45°
Lock to Lock Turns, steering wheel.........................................................4
Body Hoist
Two single-stage, double-acting hoist rams, cushioned at both ends of
stroke. Electro servo assisted hoist control.

Control Valve ...........................................Pilot Operated, Closed Centre
Body Raise Time (loaded)...........................................................12.5 sec
Body Lower Time (power down)......................................................8 sec
9-6
Technical Data
ELECTRICAL SYSTEM
Type.....................................................................24 volt, Negative Ground
Battery...............................................................Two, 12 Volt, 175 Ah each
Accessories.......................................................................................24 Volt
Alternator.........................................................................................100 Amp
BODY
Of all welded construction, fabricated from high hardness (min. 360
BHN) 1 000 MPa (145 000 lbf/in²) yield strength steel. 25° tail chute
angle provides good load retention without tailgate.
Plate Thicknesses:
Floor and Tailchute..........................................................15 mm (0.58 in)
Sides..................................................................................12 mm (0.47 in)
Front.....................................................................................8 mm (0.39 in)
Volume:
Struck (SAE)..................................................................15.5 m³ (20.3 yd³)
Heaped 2:1 (SAE)........................................................21.0 m³ (27.5 yd³)
SERVICE CAPACITIES
Fuel tank..................................................................481 l (127 US gal)
Hydraulic System..................................................330 l (87.2 US gal)
Engine Crankcase and filters....................................32 l (8.4 US gal)
Cooling System........................................................67 l (17.7 US gal)
Transmission (including cooler).............................61 l (16.1 US gal)
Dropbox...................................................................... 13 l (3.4 US gal)
Differential - Front........................................................33 l (8.7 US gal)
Differential - Centre.......................................................34 l (9 US gal)
Differential - Rear.......................................................33 l (8.7 US gal)
Planetaries (each)......................................................9 l (2.37 US gal)
Hand Pump Tank.......................................................1 l (0.26 US gal)
Air Conditioning Compressor..........................0.125 l (0.033 US gal)
TYPICAL NOISE LEVELS

Operator Ear (ISO 6394)..................................................................76 dbA
*Exterior Sound Rating (ISO 6395)..............................................109 dbA

* - The above result is for the mode giving the highest exterior sound
level when measured and operated as per the prescribed procedures of
the standard. Results shown are for the vehicle in base configuration.
Note: Noise Exposure Level to the operator and bystander personnel

may be higher depending upon proximity to buildings, rock piles,
machinery, etc.. The actual job site Noise Exposure Level must be
measured and applicable regulations complied with in respect to
Employee Hearing Protection .
9-7
Technical Data
Vehicle Weights 26.5 R25 Tyres

Standard Vehicle kg lb
Net Distribution
Front Axle 15086 32258
Centre Axle 7125 15707
Rear Axle 7068 15582
Vehicle, Net 29279 64547
Payload 34000 74956
Gross Distribution
Rear Axle 23000 50705
Vehicle, Gross 63279 139506
Bare Chassis 23669 52177
Body 4950 10915
Body Hoists (Pair) 660 1455
9-8
Technical Data
3 315
Max 1 380 (10-11)
Body (4-6)
Depth 3 130
(10-3)
6 872
(22-7)
66°
3 888 GENERATION
(12-9)
3 686 2 967
(12-1) (9-9)
3 494 2 414
(11-5) (7-11)
851
553 (2-9)
(1-10)
1 837 2 914 1 310 2 990 1 950 1 780
(6-0) (9-7) (4-4) (9-10) (6-5) (5-10)
2 520
(8-3) 10 944
3 206 (35-11)
(10-6)
1761
ENGINE
Type .......................6 Cylinder, in line , Four cycle diesel, water
cooled, turbocharged with air to air cooling, electronic engine
management.
Gross power at 2 110 rev/min..........................298 kW (400 hp, 405 PS)

Net power at 2 110 rev/min..............................289 kW (388 hp, 393 PS)
meets USA EPA Tier 3 /CARB MOH 40 CFR 89 Tier 3 and
proposed EU NRMM (non-road mobile machinery) Tier 3 directive.
Maximum Torque........................2000 Nm (1475 lbf ft) at 1200 rev/min

Piston Displacement ........................................................14 l (855 in³)
9-9
Technical Data
TRANSMISSION
Main......................................................18.5 + 3.4 bar (269 + 50 lbf/in²)
Temperatures:
Normal..................................................60 °C - 135° C (140 ° F- 275 °F)
Maximum........................................................................165 ° C (329 ° F)
Ratios:
Transmission .........Refer to the table below
Low Range
Forward
Gear 1 2 3 4 5 6
km/h 5.2 11.0 15.9 24.3 31.0 35.2
mile/h 3.2 6.8 9.9 15.1 19.3 21.9
Reverse
Gear 1
km/h 4.6
mile/h 2.9
High Range
Forward
Gear 1 2 3 4 5 6
km/h 7.9 16.8 24.3 37.1 47.7 53.9
mile/h 4.9 10.4 15.1 23.1 29.6 33.5
Reverse
Gear 1
km/h 7.0
mile/h 4.3
DROPBOX
Ratios:
Low........................................................1.129:1
High.......................................................0.738:1
Pressure:
Differential lock actuation..............34-50 bar
Lubrication..........................................2 ±1 bar
Temperature:
Maximum......................................100 °C (212 °F)
9-10
Technical Data
AXLES
reduction gearing.

Ratios:
Differential ........................................ 3.70:1
Planetary .......................................... 6.35:1
Total Reduction .............................. 23.50:1
SUSPENSION
Front: Four trailing links and a Panhard rod locate the front axle
beams equalize load on each axle. Suspension movement is
WHEELS AND TYRES
Size:
Tyres:
Standard...................................................................................26.5 R25**
Please refer to page 8-12 for a full list of tyre inflation pressures.

9-11
Technical Data
HYDRAULIC SYSTEM
hydraulic valve mounted on frame. Systems are supplied with oil from
a common tank by the main hydraulic pump, driven from power
takeoff on transmission. System components are protected by full
flow filtration on the return line.
Pump:
Type..................................................................................................Piston
Capacity at 2 700 rev/min..........................5.4 l/s (85.6 US gal/min)
Brakes
Full hydraulic braking system with enclosed, forced oil- cooled
multiple discs on each wheel. Independent circuits for front and rear
brake systems. Warning lights and audible alarm indicate low brake
system pressure. Brake system conforms to ISO 3450, SAE J1473.
Actuating Pressure....................................48 ± 2.4 bar (700 ± 35 lbf/in²)

Pump Type.......................................................................Triple stage gear
Capacity at 1 685 rev/min................................8.9l/s (2.35 US gal/min)
Braking surface (tractor)............................590240 mm2 (914.9 in2)/brake

Braking surface (trailer).............................590240 mm2 (914.9 in2)/brake
Parking.......Spring-applied, hydraulic-released disc on rear driveline.

pressure fall in main brake hydraulic system. Service brakes may
also be applied using the parking-emergency brake control.
Steering
cushioned steering cylinders. Emergency steering pressure is
provided by a ground driven pump mounted on the rear of the
transmission. An audible alarm and warning light indicates should
the emergency system activate. Conforms to ISO 5010, SAE J53.

Body Hoist
Two single-stage, double-acting hoist rams, cushioned at both ends
of stroke. Electro servo assisted hoist control.

Body Raise Time (loaded)...............................................................12.5 s
Body Lower Time (power down)..........................................................8 s
9-12
Technical Data
ELECTRICAL SYSTEM
Type.....................................................................24 volt, Negative Ground
Battery...............................................................Two, 12 Volt, 175 Ah each
Accessories.......................................................................................24 Volt
Alternator.........................................................................................100 Amp
BODY
Of all welded construction, fabricated from high hardness (min. 360 BHN) 1
000 MPa (145 000 lbf/in²) yield strength steel. 25° tail chute angle provides
good load retention without tailgate.
Plate Thicknesses:
Sides..................................................................................12 mm (0.47 in)
Front.....................................................................................8 mm (0.39 in)
Volume:
Struck (SAE)................................................................15.5 m³ (20.3 yd³)
Heaped 2:1 (SAE)......................................................21.0 m³ (27.5 yd³)
SERVICE CAPACITIES
Fuel tank........................................................................481 l (127 US gal)
Hydraulic System.........................................................330 l (87.2 US gal)
Engine Crankcase and filters..........................................32 l (8.4 US gal)
Cooling System...............................................................67 l (17.7 US gal)
Transmission (including cooler)....................................61 l (16.1 US gal)
Dropbox............................................................................. 13 l (3.4 US gal)
Differential - Front..............................................................33 l (8.7 US gal)
Differential - Centre..............................................................34 l (9 US gal)
Differential - Rear...............................................................33 l (8.7 US gal)
Planetaries (each)............................................................9 l (2.37 US gal)
Hand Pump Tank..............................................................1 l (0.26 US gal)
Air Conditioning Compressor ..............................0.125 l (0.033 US gal)
Brake cooling................................................................175 l (42.6 US gal)

* - The above result is for the mode giving the highest exterior sound level
when measured and operated as per the prescribed procedures of the
standard. Results shown are for the vehicle in base configuration.
Note: Noise Exposure Level to the operator and bystander personnel may be
higher depending upon proximity to buildings, rock piles, machinery, etc. The
actual job site Noise Exposure Level must be measured and applicable
regulations complied with in respect to Employee Hearing Protection.
9-13
Technical Data

Net Distribution
Payload 34000 74956
Gross Distribution
Rear Axle 23000 50705
Body 4950 10915
9-14
Technical Data
3 315
Max 1 380 (10-11)
Body (4-6)
Depth 3 130
(10-3)
6 872
(22-7)
66°
3 888 GENERATION
(12-9)
3 686 2 967
(12-1) (9-9)
3 494 2 414
(11-5) (7-11)
851
553 (2-9)
(1-10)
1 837 2 914 1 310 2 990 1 950 1 780
(6-0) (9-7) (4-4) (9-10) (6-5) (5-10)
2 520
(8-3) 10 944
3 206 (35-11)
(10-6)
1761
ENGINE
Type .......................6 Cylinder, in line , Four cycle diesel, water
cooled, turbocharged with air to air cooling, electronic engine
management.


9-15
Technical Data
TRANSMISSION
Main......................................................18.5 + 3.4 bar (269 + 50 lbf/in²)
Temperatures:
Normal.................................................60 °C - 135 ° C (140 ° F- 275 °F)
Maximum........................................................................165 ° C (329 ° F)
Ratios:
Transmission....................................................Refer to the table below
Low Range
Forward
Gear 1 2 3 4 5 6
km/h 5.2 11.0 15.9 24.3 31.0 35.2
mile/h 3.2 6.8 9.9 15.1 19.3 21.9
Reverse
Gear 1
km/h 4.6
mile/h 2.9
High Range
Forward
Gear 1 2 3 4 5 6
km/h 7.9 16.8 24.3 37.1 47.7 53.9
mile/h 4.9 10.4 15.1 23.1 29.6 33.5
Reverse
Gear 1
km/h 7.0
mile/h 4.3
DROPBOX
Ratios:
Low...........................................................................................1.129:1
High..........................................................................................0.738:1
Pressure:
High/Low actuation.......................................................15 ±0.2 bar
Differential lock actuation...............................................27.5 ± bar
Lubrication...........................................................................2 ±1 bar
Temperature:
Maximum.........................................................................100 °C (212 °F)
9-16
Technical Data
AXLES
reduction gearing.

Ratios:
Differential ........................................ 3.70:1
Planetary .......................................... 6.35:1
Total Reduction .............................. 23.50:1
SUSPENSION
Front: Four trailing links and a panhard rod locate the front axle
beams equalise load on each axle. Suspension movement is
WHEELS AND TYRES
Size:
Tyres:
Standard...................................................................................26.5 R25**
Please refer to page 8-12 for full list of tyre inflation pressures.

9-17
Technical Data
HYDRAULIC SYSTEM
Pump:
Type..................................................................................................Piston
Capacity at 2 700 rev/min...............................5.4 l/s (85.6 US gal/min)
Brakes
Actuating Pressure....................................48 ± 2.4 bar (700 ± 35 lbf/in²)

Pump Type......................................................................Triple stage gear
Capacity at 1 685 rev/min................................8.9l/s (2.35 US gal/min)


Steering

Body Hoist

Body Lower Time (power down)..........................................................8 s
9-18
Technical Data
ELECTRICAL SYSTEM
Type.......................................................................24 V, Negative Ground
Battery.................................................................Two, 12 V, 175 Ah each
Accessories..........................................................................................24 V
Alternator.........................................................................................100 Amp
BODY
Of all welded construction, fabricated from high hardness (min. 360 BHN)
1000 MPa (145000 lbf/in²) yield strength steel. 25° tail chute angle
provides good load retention without tailgate.
Plate Thicknesses:
Sides..................................................................................12 mm (0.47 in)
Front.....................................................................................8 mm (0.39 in)
Volume:
Struck (SAE)..................................................................15.5 m³ (20.3 yd³)
Heaped 2:1 (SAE)........................................................21.0 m³ (27.5 yd³)
SERVICE CAPACITIES
Fuel tank..................................................................481 l (127 US gal)
Hydraulic System...................................................330 l (87.2 US gal)
Engine Crankcase and filters....................................32 l (8.4 US gal)
Cooling System........................................................67 l (17.7 US gal)
Transmission (including cooler)..............................61 l (16.1 US gal)
Dropbox....................................................................... 13 l (3.4 US gal)
Differential - Front........................................................33 l (8.7 US gal)
Differential - Centre.......................................................34 l (9 US gal)
Differential - Rear.......................................................33 l (8.7 US gal)
Planetaries (each)......................................................9 l (2.37 US gal)
Hand Pump Tank.......................................................1 l (0.26 US gal)
Air Conditioning Compressor.........................0.125 l (0.033 US gal)
Brake cooling.........................................................175 l (42.6 US gal)

* - The above result is for the mode giving the highest exterior sound level
when measured and operated as per the prescribed procedures of the
standard. Results shown are for the vehicle in base configuration.
Note: Noise Exposure Level to the operator and bystander personnel may
be higher depending upon proximity to buildings, rock piles, machinery,
etc.. The actual job site Noise Exposure Level must be measured and
applicable regulations complied with in respect to Employee Hearing
Protection.
9-19
Technical Data

Net Distribution
Payload 34000 74956
Gross Distribution
Rear Axle 23000 50705
Body 4950 10915
9-20
Technical Data
3 315
Max 1 495 (10-11)
Body (4-11) 3 130
Depth (10-3)
6 930
(22-9)
66°
3 945 GE N E R ATI ON
(12-11)
3 740 3 140
(12-3) (10-4)
3 550 2 470
(11-8) (8-1)
905
605 (2-9)
(2-0)
1 840 3 025 1 310 2 990 1 950 1 780
(6-0) (9-11) (4-4) (9-10) (6-5) (5-10)
2 595
(8-6) 11 055
3 360 (36-3)
(11-3)
1695
ENGINE
Type ......................6 Cylinder, in line , Four cycle diesel, water cooled,
turbocharged with air to air cooling, electronic engine management.


9-21
Technical Data
TRANSMISSION
Main......................................................18.5 + 3.4 bar (269 + 50 lbf/in²)
Temperatures:
Normal..................................................60 °C - 135 °C (140 ° F- 275 °F)
Maximum........................................................................165 ° C (329 °F)
Ratios:
Transmission .............. Refer to table below
Low Range
Forward
Gear 1 2 3 4 5 6
km/h 5.5 11.7 16.9 25.8 33.0 37.5
mile/h 3.4 7.3 10.5 16.0 20.5 23.3
Reverse
Gear 1
km/h 4.8
mile/h 3.0
High Range
Forward
Gear 1 2 3 4 5 6
km/h 8.4 17.8 25.8 39.5 50.4 60.0
mile/h 5.2 11.0 16.0 24.5 31.3 37.3
Reverse
Gear 1
km/h 7.4
mile/h 4.6
DROPBOX
Ratios:
Low........................................................1.129:1
High.......................................................0.738:1
Pressure:
Differential lock actuation................34-50 bar
Lubrication..........................................2 ±1 bar
Temperature:
Maximum......................................100 ° C (212 °F)
9-22
Technical Data
AXLES
reduction gearing.

Ratios:
Differential ........................................ 3.70:1
Planetary .......................................... 6.35:1
Total Reduction .............................. 23.50:1
SUSPENSION
Front: Four trailing links and a panhard rod locate the front axle
beams equalise load on each axle. Suspension movement is
WHEELS AND TYRES
Size:
Tyres:
Standard...................................................................................29.5 R25**
Please refer to page 8-12 for full list of tyre inflation pressures.

9-23
Technical Data
HYDRAULIC SYSTEM
Pump:
Type..................................................................................................Piston
Capacity at 2700 rev/min..........................5.4 l/s (85.6 US gal/min)
Brakes
Actuating Pressure...................................48 ± 2.4 bar (700 ± 35 lbf/in²)

Pump Type...............................................................Triple stage gear
Capacity at 1 685 rev/min...............................8.9l/s (2.35 US gal/min)


Steering

Body Hoist

Body Lower Time (power down)...........................................................8 s
9-24
Technical Data
ELECTRICAL SYSTEM
Type.........................................................................24 V, Negative Ground
Battery..................................................................Two, 12 V, 175 Ah each
Accessories............................................................................................24 V
Alternator.............................................................................................100 A
BODY
Of all welded construction, fabricated from high hardness (min. 360
BHN) 1000 MPa (145000 lbf/in²) yield strength steel. 25° tail chute
angle provides good load retention without tailgate.
Plate Thicknesses:
Sides..................................................................................12 mm (0.47 in)
Front.....................................................................................8 mm (0.39 in)
Volume:
Struck (SAE)..................................................................17.4 m³ (22.8 yd³)
Heaped 2:1 (SAE)........................................................23.3 m³ (30.3 yd³)
SERVICE CAPACITIES
Fuel tank..........................................................................481 l (127 US gal)
Hydraulic System..........................................................330 l (87.2 US gal)
Engine Crankcase and filters...........................................32 l (8.4 US gal)
Cooling System................................................................67 l (17.7 US gal)
Transmission (including cooler)............................... 61 l (16.1 US gal)
Dropbox............................................................................ 13 \ l (3.4 US gal)
Differential - Front...............................................................33 l (8.7 US gal)
Differential - Centre...............................................................34 l (9 US gal)
Differential - Rear..............................................................33 l (8.7 US gal)
Planetaries (each)............................................................9 l (2.37 US gal)
Hand Pump Tank...............................................................1 l (0.26 US gal)
Air Conditioning Compressor............................ 0.125 l (0.033 US gal)
Brake cooling................................................................175 l (42.6 US gal)


* - The above result is for the mode giving the highest exterior sound
level when measured and operated as per the prescribed procedures of
the standard. Results shown are for the vehicle in base configuration.
Note: Noise Exposure Level to the operator and bystander personnel

may be higher depending upon proximity to buildings, rock piles,
machinery, etc.. The actual job site Noise Exposure Level must be
measured and applicable regulations complied with in respect to
Employee Hearing Protection .
9-25
Technical Data

Net Distribution
Payload 38000 83775
Gross Distribution
Rear Axle 25000 55000
Body 5400 11905
9-26
Symbol Identification
10 - Symbol Identification
10-1
Blank P age
10-2
SYMBOL IDENTIFICATION
These pages explain the meaning of symbols that may appear on your machine.
Basic Switch
Warning 'Off' Hourmeter Lock
Symbol
Pressurised Negative Fast Basic

Compartment G round Engine
Master Ammeter Slow Engine

Switch Starter
Switch Circuit Lock Engine

'On' Breaker Rev/Min
Engine 'Off' Basic Transmission Minimum

Transmission Convertor or
Lockup Low
Emergency Transmission Air Maximum

Engine Oil Pressure or
Shut Off High
Engine Transmission Air Filter Basic

Oil Oil or Hydraulic
Pressure Restriction Oil Symbol
Engine Transmission Starter Hydraulic

Oil Oil Air Oil
Pressure Temperature Pressure Filter
Engine Transmission Oil level Hydraulic

Oil Oil Filter Oil Filter
Filter Pressure
10-3
Hot Heating Light Flood Horn

Hydraulic
Coolant Fuel Gauge Light Low Windshield

Temperature Or Beam Wiper
Fill tube
Coolant 'cold' Fuel Filter Light High Windshield

Beam Defroster
Coolant 'Hot' Fuel Instrument Windshield

Shut-Off Panel light Washer
Cooling Basic Lamp Test Blower Fan

Lights
Symbol
Heater Parking Low Steering Body 'Hold'

Brake P ressure S
Air Brake Oil High Speed Body

Conditioner Temperature or Level 'Lower'
Inside Turn Left Low Speed Body

Air or Level Float'
Circulation
Outside Turn Right Body Up Dumpertruck

Air 'Retarder'
Parking Brake
P Tilt Steering Body 'Raise' Neutral
N
10-4
Lift Point Clutch Bowl Engine

'Disengaed' Suspension Stop STOP
Brake Trans.
Do Not Lift Applied Maintenance Over speed
Clutch
Engaged
Forward Brake Battery

Applied Transmission Power
Clutch Convertor
Disengaged
Reverse Water in Brake air Engine

Fuel Pressure Air Filter
Clutch W ait to Engine Brake

'Engaged' S tart Check Cooling
Oil
Pressure
Brake Cooling Body up Trans. Dropbox

Oil Temp. Oil Temp. Oil Temp.
L
Dropbox Oil Trans. Engine Dropbox
Pressure Retarder Brake Low Ratio
Dropbox
High Ratio
H
10-5
NOTES
10-6
NOTES
10-7
NOTES
10-8

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TEREX Equipment Limited Operator Handbook

Motherwell, ML1 5RY

Tel; +44 (0) 1698 732121

Re-order Part Number

This controlled document is the original instructions and

Revision: May 2012

Alternatively, please contact;

Customer Support Department

Terex Equipment Limited

Tel; +44 (0) 1698 732121

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

Please refer to TEREX Specification Sheets or consult Factory Representatives to

MANUFACTURERS NAME AND FULL ADDRESS

DESCRIPTION OF MACHINERY DIRECTIVES COMPLIED WITH

FOR AND ON BEHALF OF THE MANUFACTURER:

NAME: PAUL DOUGLAS SIGNATURE:

MANUFACTURERS NAME AND FULL ADDRESS

DESCRIPTION OF MACHINERY DIRECTIVES COMPLIED WITH

FOR AND ON BEHALF OF THE MANUFACTURER:

NAME: PAUL DOUGLAS SIGNATURE:

3. CONTROLS AND OPERATING

4. OPERATING THE TRUCK

7. MOVING DISABLED TRUCK

8. LUBRICATION AND SERVICING

10. SYMBOL IDENTIFICATION

ATTENTION! BECOME ALERT! YOUR SAFETY AND THE

This Handbook describes general inspections, servicing and

All information, illustrations and specifications contained in this

Continuing improvement and advancement of the design may cause

This Handbook contains lubrication and routine servicing

Intended use of machine

Information regarding the machine model, code and chassis serial

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

Theft Deterrent Practices

Actions to Discourage Theft and Vandalism

Immobilize the machine by removing a critical electrical or starting

system device, for example Fuse 31 or 32.

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

Establish liaison with neighbours and ask them to watch equipment

Make frequent inventories of machines to promptly detect losses or

Actions to Aid in Recovery of Stolen Machines

Report the model and serial numbers of the stolen machine to a

Safety Alert Symbol

DANGER indicates an imminently hazardous situation which, if

WARNING indicates a potentially hazardous situation which, if

CAUTION CAUTION indicates a potentially hazardous situation which, if

CAUTION used without the safety alert symbol indicates a poten-

* Know clearances of all side and overhead obstructions such as

• Be especially aware of overhead power lines. 1767

* Be aware of operating hazards that weather changes can create

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

* Know what safety equipment is required and use it. Such

* Handle fuels and lubricants carefully and clean up spills to

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

Articulation and Oscillation Lock

vehicle would not be free to steer otherwise.

Articulation and Oscillation

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