TR70 OHE789

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Operation - Safety - Maintenance

TR70
http://../oh-index.pdf

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WHEN RE-ORDERING THIS HANDBOOK,

SPECIFY -PART NUMBER 15273742

TECHNICAL PUBLICATIONS DEPARTMENTTEREX EQUIPMENT LIMITEDMOTHERWELL, SCOTLAND ML1 5RYRef No. OHE 789 Mar 2006

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ONLY TRAINED PERSONNEL SHOULD BEALLOWED TO OPERATE THIS VEHICLE

The operator is responsible and must befamiliar with the contents of the Operator's

Handbook and any local regulations prior tooperating this vehicle.

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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: TR70 RIGID TRUCK 89/336/EEC98/37/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

EC DECLARATION OF CONFORMITY

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SPARE PARTS STATEMENT

When carrying out repairs, alterations or fitting attachments, it is important that only genuine spare parts areused 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 bemaintained.

If a General Operating Approval is issued for this machine, it may be considered null and void if non-genuineparts are used.

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MANUFACTURERS NAME AND FULL ADDRESSTEREX EQUIPMENT LIMITED,MOTHERWELL,SCOTLAND,ML1 5RY

DESCRIPTION OF MACHINERY DIRECTIVES COMPLIED WITH

MAKE: TEREX 87/404/EEC 97/23/EC

MODEL: TR70 RIGID TRUCK 89/336/EEC98/37/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

EC DECLARATION OF CONFORMITY

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SPARE PARTS STATEMENT

When carrying out repairs, alterations or fitting attachments, it is important that only genuine spare parts areused 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 bemaintained.

If a General Operating Approval is issued for this machine, it may be considered null and void if non-genuineparts are used.

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1-

CONTENTS

1. INTRODUCTIONIntroduction ........................................ 1-2Safety Precautions ............................ 1-2Machine Identification........................ 1-4Theft Deterrent Practices .................. 1-5

2. SAFETY PRECAUTIONSGeneral .............................................. 2-2Vehicle Lifting Precautions ................ 2-3Vehicle Tie Down Precautions .......... 2-3Preventing Fire Hazards .................... 2-4Mounting and Dismounting................ 2-6Pre-Starting ........................................ 2-7Starting ............................................... 2-7Operating ........................................... 2-8Roading............................................ 2-10Lubrication and Servicing ................ 2-11Wheels and Tyres ............................ 2-12

Avoid Tyre Explosion Hazard .......... 2-13Decals and Instruction Plates .......... 2-14

3. CONTROLS AND OPERATINGControls and Instruments .................. 3-3Basic Data ......................................... 3-4

Warning Lights ............................... 3-4Instruments .................................... 3-7Switches ......................................... 3-9Controls ........................................ 3-13Heater ........................................... 3-14Air Conditioner .............................. 3-14Operator's Seat -

Air Suspension ......................... 3-15Seat Belt ....................................... 3-16

5. WORKING THE TRUCKWorking the Truck .............................. 5-2

Loading ........................................... 5-2Hauling............................................ 5-4Dumping ......................................... 5-5Empty Return ................................. 5-7

6. ROADINGRoading.............................................. 6-2

General .......................................... 6-2Preparation Prior to Roading ......... 6-2In Case Of Trouble ........................ 6-4

7. MOVING DISABLED TRUCKMoving Disabled Truck ...................... 7-2

8. LUBRICATION AND SERVICINGSafety Precautions ............................ 8-2

Lubrication and Servicing .................. 8-3Lubrication and Service Chart ........... 8-5Miscellaneous Servicing .................... 8-8Service Capacities .......................... 8-13Recommended Lubricants ..............8-14

9. TECHNICAL DATATechnical Data - TR70 ........................ 9-3

10. SYMBOL IDENTIFICATION

3. CONTROLS AND OPERATING

(Cont)Machine Controls ............................ 3-17

Braking .......................................... 3-17Service Brake ............................ 3-17Park/Emergency Brake ............. 3-17Retarder ..................................... 3-18

Engine ........................................... 3-20Electronic Foot Control .............. 3-20DDEC IV ..................................... 3-20Description ................................. 3-22Operation .................................... 3-23

Steering ......................................... 3-32Transmission ................................ 3-33

Description and Operation......... 3-36General Operation ..................... 3-41CEC2 Diagnostic Codes............ 3-43

Body Control ................................. 3-45

Raising the Body ........................ 3-46Lowering the Body ..................... 3-46

4. OPERATING THE TRUCKPre-Starting Inspection ...................... 4-2Component Checks ........................... 4-3Suspension Ride Struts .................... 4-5Engine Operation............................... 4-6Starting the Engine ............................ 4-7Starting the Engine with

Jumper Cables .............................. 4-9Pre-Operating Checks .................... 4-10Brake Function Checks ..................4-10Driving and Stopping ....................... 4-12Stopping the Engine ........................4-14Parking ............................................. 4-16

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1-2

INTRODUCTION

This Handbook is provided as a guide to familiarize the operator and servicemanwith the controls, recommended inspections, start-up, operating, shutdown andparking procedures for the TR70 Trucks.

Look for this symbol to point out important safety precautions. It means:ATTENTION! BECOME ALERT! YOUR SAFETY AND THE SAFETY OFOTHERS IS INVOLVED!

Safety Precautions

The truck should be properly operated and maintained to keep it in safe, efficientoperating condition. Be sure that all controls are free of mud, grease, or othermatter that might cause slips hazardous to the operator, serviceman, or otherpersonnel or equipment. Report all malfunctions to those responsible formaintenance and do not operate the equipment until corrected. Normal service ormaintenance performed as required can prevent unexpected and unnecessarydowntime.

This Handbook describes general inspections, servicing and operation with thenormal safety precautions required for normal servicing and operating conditions.It is not a guide however, for other than normal conditions or situations, andtherefore, servicemen and operators must be safety conscious and alert torecognize potential servicing or operating safety hazards at all times, and, takenecessary precautions to ensure safe servicing and operation of the truck.

READ the CIMA Safety Manual supplied with this truck.

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1-3

WARNINGThese trucks are equipped with cylinders containing compressednitrogen gas. Transportation of these trucks by any method mayrequire a special permit from the appropriate authority of the countryinvolved. Consult your dealer for details.

All information, illustrations and specifications contained in this publication arebased on the latest product information available at the time of publication. Theright is reserved to make changes at any time without notice.

Continuing improvement and advancement of the design may cause changes toyour truck which may not be included in this publication. Each publication isreviewed and revised, as required, to update and include these changes in latereditions.

This Handbook contains lubrication and routine servicing instructions, most ofwhich can be performed in the field. Maintenance manuals containing repair/rebuildprocedures can be obtained from your dealer.

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1-4

Truck Identification

While reading this handbook you willnotice references to controls andequipment which may not be found onall trucks. It is important that you knowyour truck and its equipment and how

to operate it properly.

Information regarding the truck model,code and chassis serial number isfound on the unit serial number platemounted on the left-hand side of thetruck adjacent to the steps. The truckmodel and serial number shouldalways be referenced in anycorrespondence with your dealer orfactory.

There is a dealer serving every part ofthe world where these products aresold. Your dealer is ready to provideyou with any additional informationneeded and should be consulted foradditional publications for this truck.

1647

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1-5

Theft Deterrent Practices

General

The owner/operator should take the following precautions to discourage theft, to aidin the recovery in the event that the truck is stolen, or to reduce vandalism.

Actions to Discourage Theft and Vandalism

Remove all keys any time the truck is left unattended.

At night lock all doors and attach, secure or lock all anti-vandalism andanti-theft devices on the truck.

Immobilize the truck by removing a critical electrical or starting system device.

Upon receipt of a truck, record the truck serial number and the serial numbers ofall major components and attachments. Keep this list up to date and filed in asafe location for fast retrieval.

Place a decal or notice on the truck that all serial numbers are recorded.

Discourage the thief! Inspect the gates and fences of the machinery storage yardor construction site. Keep trucks in well-lit areas and ask the local lawenforcement authorities to make frequent checks around the storage yard orwork site.

Establish liaison with neighbours and ask them to watch equipment left at jobsites and to report any suspicious activities to the local law enforcementauthorities.

Make frequent inventories of trucks to promptly detect losses or vandalism.

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1-6

Actions to Aid in Recovery of Stolen Trucks

In the event of theft, immediately notify the law enforcement authorities havingjurisdiction. Provide the investigating officer with name, type of equipment,chassis and serial numbers of major attachments and components. It is helpful toshow the investigating officer an Operators Handbook, photographs andadvertising, to familiarize him with the appearance of the truck.

Report the theft to the insurance company. Provide the model and all serialnumbers.

Report the model and serial numbers of the stolen truck to a dealer handling therespective line of equipment. Request that the dealer forward this sameinformation to the equipment manufacturer.

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2-

2 - Safety Precautions

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2-2

SAFETY PRECAUTIONS

General

* Read this Operators Handbook and learn the operating characteristics andlimitations of the machine. Know what operating clearances the machinerequires.

* Read the CIMA Safety Manual and follow the recommended safety precautions.

* Know clearances of all side and overhead obstructions such as wires, bridges,etc., for operating safely.

* Always know all traffic rules, signs, flags and hand signals used on the job andknow 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 machine when not feeling physically fit.

* Know what safety equipment is required and use it. Such equipment maybe - Hard hat, safety glasses, reflector type vests, respirators and ear plugs.

* Never wear loose clothing, rings, watches etc., that might catch levers andcontrols and cause loss of control.

* Keep hands and controls free from water, grease and mud to assure nonslipcontrol.

* Handle fuels and lubricants carefully and clean up spills to avoid fire and slippinghazards.

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2-3

* Clean any mud, grease or oil from controls, handrails, ladders and decks. Lashnecessary tools securely and remove all loose items before operating machine.

* Never rush. Walk, do not run.

* Never carry more than one passenger and only in the passenger seat.

WARNINGThe protection offered by the roll over protective structure may beimpaired if the Cab Guard or Body Guides have been subjected to anymodification or damage.

Vehicle Lifting Precautions

* Prior to lifting, the vehicle should be parked on a level surface, wheels blockedand the park/emergency brake disengaged.

* The vehicle should be lifted using a speader bar if possible. Lift using FOURslings from the lifting points provided at the front bumper and the rear of thechassis. Refer to the 'SLINGING INSTRUCTIONS' decal mounted on the left-hand side of the machine, adjacent to the ladders. If in any doubt contact yourdealer for further information.

Vehicle Tie Down Precautions

* The vehicle should be secured at the tie down points located at the frontbumper, the transmission guard and at the safety pin location at the rear of the

chassis.

1042

1043

Vehicle Lifting Instructions

Vehicle Tie Down Instructions

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2-4

Preventing Fire Hazards

General Fire Precautions

* Make sure machine has fire extinguisher and that it is accessible and fullycharged. (Not furnished with machine).

* Never use an open flame as a light anywhere on or around the machine.

* Clean all dirt, oil, grease and other fluids from systems and components tominimize fire hazards and aid in spotting loose or leaking hoses, fittings etc.

* Check the engine compartment for trash, oily rags or other debris that couldcause fires before starting the engine.

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

* If the machine has been operated with an under inflated tyre. Make sure that thetyre has cooled sufficiently before parking and leaving the machine unattended.

Flammable Fluid Precautions

* Dont use diesel fuel or other flammable fluids for cleaning purposes. Useapproved, nonflammable solvents.

* Make sure all fluid system caps, drain cocks, valves, fittings, hoses, etc., aresecure and leak free.

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

coolant and battery fluid levels or when checking for fluid leaks. Use a flashlightor other safe lighting only.

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2-5

* Shut off engine and use extra caution if engine is hot when refuelling. Groundthe hose spout to prevent sparks when spout is touched to fuel tank filler tube.

* Never smoke while checking or adding fuel or other fluids or handling fluidcontainers and hoses.

* 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 machines or components for storage, seal and tape allopenings and close containers tightly to seal in all volatile inhibitor fluids andcompounds used.

* Follow manufacturers recommendations when handling and using engine-starting fluids and disposing of spent containers. Do not puncture or burn emptycontainers. 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 machine for adequateventilation of explosive gas (hydrogen) produced.

* Always disconnect batteries before repairing electrical system to avoiddanger of fire-causing sparks. Disconnect battery ground cable first and

reconnect last.

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2-6

* Always disconnect batteries and alternator leads before carrying out anywelding on the machine.

* Never check battery charge by placing metal objects across battery posts toavoid sparks at battery posts.

* Use jumper cables only as recommended. Improper use can result in battery

explosion or unexpected machine motion.

* Never operate engine starter for more than 30 seconds and allow two minutesbetween cranking periods for cooling. An overheated starter could cause a fire.

* If electric coolant or lubricant heaters are used, be sure to follow heatermanufacturers recommendations for use to avoid electrical and/or fire hazards.

Mounting and Dismounting

* Only use steps and handrails provided to mount or dismount machine. Do notgrasp steering wheel; any pressure in the accumulator will turn the front wheels.

* Always face the access system and maintain at least three points of support tomount or dismount machine.

* Always use care when mounting machine with oil covered, frosted, or icedfenders, decks, handrails or steps.

* Never mount or dismount a moving machine. Never jump off the machine.

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2-7

Pre-Starting

* If engine is to be started and run indoors, ensure proper ventilation toremove deadly exhaust gases.

* Always perform 'Pre-Starting Inspection' instructions described on page 4-2 toensure the machine is ready for operation.

* Always walk around the machine to make sure no-one is working on,underneath or close to the machine before starting the engine or operating themachine.

* Adjust, secure and latch the seat and fasten the seat belt before starting themachine.

* Sound horn before starting the engine or beginning to move the machine; twoblasts 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.

* Use jumper cables only as recommended. Improper use can result in batteryexplosion or unexpected machine motion.

* Always obey 'Starting the Engine' instructions described on page 4-7.

* Do not bypass the machines neutral-start system. The neutral-start systemmust be repaired if it malfunctions.

* Start and operate the machine only from the operators station.

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2-8

Operating

* Ensure all cab glass, mirrors and light lenses are clean during machineoperation for maximum visibility.

* Always keep cab floor clear of anything that could restrict full operation ofpedals.

* Always make sure all gauges, warning/indicator lights and controls are workingproperly before operating machine.

* Always perform 'Pre-Operating Checks' described on page 4-10 to ensure themachine is ready for operating.

* Always wear seat belts when operating the machine.

* In the event of a loss of steering pump output pressure, a fully-pressurizedaccumulator provides a maximum of two lock to lock turns of the front wheels. A

red warning light on the instrument panel illuminates when steering pressure fallsbelow 83 bar (1 200 lbf/in) If this light illuminates, indicating a loss of steeringpower, the machine must be stopped immediately and no further operationattempted until the fault is corrected.

* Do not operate if exposed personnel enter the immediate work area.

* Sound horn before starting engine or beginning to move machine; twoblasts for forward and three blasts for reverse.

* Watch for ground crew and other personnel on foot. Sound horn as a warningbefore setting machine in motion and when approaching ground crew.

* Be sure the body is fully down before moving the machine.

* Always try to face or look in the direction the machine is travelling.

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2-9

* Use extreme caution and turn on lights at night or when fog, dust or similarhazards limit visibility. Do not overdrive your headlights.

* Observe instruments frequently. Report any defects or unusual noises inmachine 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/andretarder (if fitted). Always maintain safe speeds for haul road operatingconditions for maximum control. Reduce speed before turning.

* Always operate straight up or down slopes whenever possible, side-hilloperation can cause sideslip and possible roll-over.

* Slow down when moving in congested areas. Do not race with other machines.Stop in authorized areas only, except in emergency.

* Brake firmly in one application. Do not FAN the pedal. Never operate themachine if a warning light indicates a fault in the brake system.

* Always give loaded machines the right-of-way when your machine is empty.

* Always watch for holes, soft edges or other hazards when backing to dumpover a spoil bank.

* Always apply the brakes with the Parking-Emergency brake control when themachine is being loaded or when dumping a load.

* Always stay in the cab when machine is being loaded.

* Always lower the body and shut down the machine, according to the procedureunder 'Stopping The Engine' described on page 4-14, before leaving themachine unattended. If on a grade wheels should be blocked.

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2-10

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 onlywhen the road is clear and enough room and reserve power are available.

* Stop at appropriate intervals to inspect the machine and allow the tyres to cool.Tyre air pressure will rise during operation. Do not reduce tyre pressure.Excess speed will cause tyres to heat up. Reduce your travel speed, not tyrepressure.

* Use accessory lights and devices at night or in poor visibility. Carry a flare kit.Do not overdrive your headlights.

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2-1

Lubrication and Servicing

* Do not allow unauthorized personnel to service or maintain this machine.Study the Operators Handbook and Maintenance Manual before starting,operating or servicing this machine. Always follow procedures and safetyprecautions detailed throughout the Maintenance Manual.

* Always attach a 'DO NOT OPERATE' or similar warning sign to ignition

switch or a control before cleaning, lubricating or servicing the machine.* Never allow anyone to work on the machine while it is moving. Make sure no

one is on the machine before working on it.

* Do not work under or near unblocked or unsupported body. Always use thebody safety pins.

* Do not work under or near any unblocked or unsupported linkage, part or truck.

* Always relieve pressure before servicing any pressurized system. Follow theprocedures and safety precautions detailed in the Maintenance Manual.

* Always shut down machine according to the procedure under 'Stopping TheEngine' described on page 4-14 before cleaning, lubricating or servicing themachine except as called for in this Handbook or the Maintenance Manual.

* When changing oil in the engine, transmission and hydraulic systems, orremoving hydraulic lines, remember that the oil may be hot and can cause burnsto unprotected skin.

* When working on or around exhaust components, remember that thecomponents may be hot and can cause burns to unprotected skin.

* Always deflate tyre before attempting to remove any embedded objects orremoving the tyre and rim assembly from the machine.

* Always use a self-attaching chuck with a long airline and stand to one side whilethe tyre is inflating. Refer to Section 160-0050, WHEEL RIM AND TYRE in theMaintenance Manual.

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2-12

Wheels and Tyres

If tyres on a machine were inflated at the factory with dry nitrogen gas, the tyrewalls will be marked 'N' and the following factory installed decal will be foundmounted on either side of the cab platform and the body.

NOTICETYRES ON THIS MACHINE ARE FACTORY INFLATED WITH DRY

NITROGEN. IT IS RECOMMENDED THAT DRY NITROGEN BE USEDEXCLUSIVELY FOR ALL TYRE PRESSURE ADJUSTMENTS AS WELL ASINFLATION OF REPLACEMENT TYRES.

Nitrogen gas improves tyre pressure retention, increases tyre life by reducingcarcass oxidation from within, minimizes rim rust, and has no known detrimentaleffect on the tyre. It also reduces the potential of a tyre explosion because it is aninert gas and will not support combustion inside the tyre. The same tyre inflationpressure used for air inflation should be used for nitrogen inflation. Refer to Section160-0050, 'WHEEL RIM AND TYRES' of the machine Maintenance Manual forrecommended procedures for inflating and pressure adjusting tyres with dry

nitrogen gas. Only proper nitrogen charging equipment operated by personneltrained in its use should be used.

WARNINGNever mix components of one manufacturers rims with those of another.Using the rim base of one manufacturer with the lock ring of another orvice versa is dangerous. The lock ring of one may not fully engage withthe lock ring groove of the other. Always consult the rim manufacturer forproper matching, assembly and safety instructions. Also, use and

servicing of damaged, worn out or improperly assembled rim assembliesis a very dangerous practice. Failure to comply with the above warningscould result in an explosion from tyre pressure causing serious propertydamage and serious personnel injury or death.

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2-1

Avoid Tyre Explosion Hazard

WARNINGWhenever a machines tyre(s) is (are) exposed toexcessive heat such as a machine fire or extremely

hot brakes, the hazard of a subsequent violent tyreexplosion must be recognized. All nearby personsmust avoid approaching the machine so as not to bephysically endangered in the event of an explosion ofthe tyre and rim parts. The machine should be movedto a remote area, but only when this can be done withcomplete safety of the operator operating or towingthe machine. All other persons should stay clear ofthe machine. The fire or overheated brakes, wheeletc., should be extinguished or cooled from a safedistance. Do not attempt to extinguish the fire or cool

the machine by use of hand-held fire extinguishers. Ifit is absolutely necessary to approach a machine witha suspect tyre, approach only from the front or theback. Stay at least 15 m (50 ft) from the tread area.Keep observers out of the area and at least 460 m(1 500 ft) from the tyre sidewall. Refer to theaccompanying sketch. The tyre(s) should be allowedat least eight (8) hours cooling time after the machineis shut down or the fire extinguished beforeapproaching closer.

AT LEAST 460 m(1 500 ft)AT LEAST 15 m (50 ft)

454

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2-14

Decals and Instruction Plates

Decals and instruction plates fitted tothese machines may vary from countryto country to suit local needs. Thesepages contain a brief description and thelocation of the decals and instructionplates that may appear on your machine.

1. Tyre Warning

2. Operating On A Grade Instructions

3. Vehicle Parking Instructions

4. Accumulator Precautions

5. Accumulator Charging Instructions

6. Acoustic Foam Precautions

7. Vehicle Overall Height

8. Steering Wheel Lock

9. Symbol Identification Chart

10. Radiator Cap Warning

11. Radiator Fill Instructions

12. Air Cleaner Information

13. Negative Earth

14. Battery Cable Warning

15. Ride Strut Pressure Warning

1348

1

1

2,3 64,5 7,8 910,11

1213,1415

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2-1

1. Alternator Precautions

2. CEC (ATEC) Welding Warning

3. Engine Instructions

4. Body Control Lever Positions

5. Retarder Positions

6. CEC (ATEC) Switches

7. Pre-operating Instructions

8. Acoustic Foam Precautions

9. Pre-operating Instructions

10. Hydraulic Oil Decal

11. Sight Gauge Plate

12. Hydraulic Oil Pressure Plate

13. Anti-Syphon Instructions

14. Instruction Plate

15. Hydraulic Oil Level16. Instruction Decal

17. Hydraulic Oil Level

18. Lubrication Chart

19. Pressure Test Points

20. Vehicle Lifting Hook

21. Accumulator ChargingInstructions

22. Accumulator Precautions23. Ride Strut Pressure Warning

24. Machine Serial Plate

1349

1

2,3,4,5,6,7

8 9

24 23 2020

19

21,22

10

11

12

13

14

15 16 17 14

13

18

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2-16

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3-

3 - Controls and Operating

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3-2 1477

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

17

18

1920

21

22232425

26

2728

29

303132

33

34

35

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3-3

CONTROLS AND INSTRUMENTS

1. Face Vent/Side Window Demister

2. Warning Lights

3. Tachometer/Hourmeter

4. Engine Oil Pressure Gauge5. Engine Water Temperature Gauge

6. Fuel Gauge

7. Warning Lights

8. Transmission Oil Temperature Gauge

9. Transmission Oil Pressure Gauge

10. Speedometer/Odometer

11. Warning Lights

12. Face Vent

13. Park/Emergency Brake Control

14. Cup Location

15. Windscreen Demister

16. Side Window Demister

17. Document Holder

18. Fuse Box Cover

19. Transmission Gear Shift Selector

20. Retarder Control

21. Ignition and Starter Key Switch

22. Switches

23. Blower Control24. Air Conditioner Control

25. Heater Control

26. Accessory Lamp Socket

27. Accelerator Control

28. Service Brake Control

29. Steering Wheel

30. Steering Wheel Adjustment Lock

31. Headlight Dipper, Direction Indicator, WindscreenWiper/Washer and Horn Control

32. Radio/Cassette Player

33. Foot Rest

34. Body Control Lever

35. Electric Window Switch

36. Interior Light (Not Shown). Located above dash.

37. Cup Holder (Not Shown). Located on back wall.

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3-4

STOP

P

1 2

1

2

3

4

5

6

7

8

9 10 11 12

13 14 15 16

17

18

19

20

21

22

23

24

BASIC DATA

Warning Lights

1. Alternator Charging (Red) -Illuminates to indicate when thealternator is not charging.

2. Engine Water Temperature (Red) -

Illuminates when the engine watertemperature rises above the safeoperating temperature.

3. Engine Water Level (Amber) -Illuminates when the engine water leveldrops below the safe operating level.

4. Air Cleaner Restriction (Amber) -Illuminates to indicate that the air filtersare needing cleaned or replaced.

5. Engine Oil Pressure (Red) -Illuminates when the engine oil pressuredrops below the safe operatingpressure.

6. Engine Stop Light (Red) -When the'Stop' light comes on, the computer hasdetected a major malfunction in theengine that requires immediate attention.Stop the machine when this lightilluminates and do not operate until thefault is corrected.

7. Engine Check Light (Amber) -When the 'Check' light comes on, thecomputer has detected a fault in the

1626

accumulator. Stop the machine if thislight illuminates and do not operate untilthe fault is corrected.

10. Rear Brake Accumulator Pressure(Red) -Illuminates to warn of lowpressure in the rear brake systemaccumulator. Stop the machine if thislight illuminates and do not operate untilthe fault is corrected.

engine. The fault should be diagnosedand corrected at the earliestopportunity.

8. Warning Light - Not used on thismachine.

9. Front Brake AccumulatorPressure (Red) - Illuminates to warn oflow pressure in the front brake system

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11. Low Steering Pressure (Red) - Illuminates when the steering system oilpressure drops below 83 bar (1200 lbf/in). Stop the machine when this lightilluminates and do not operate until the fault is corrected.

12. Steering & Braking Tank Low Oil Level (Red) -Illuminates when the levelin the tank falls below the safe operating level. Stop the machine when this lightilluminates and do not operate until the fault is corrected.

13. Parking Brake (Red) -Illuminates when the parking brake is applied.

14. Headlight Main Beam (Blue) -Illuminates when headlights are operated onmain beam.

15. Direction Indicator (Green) -Flashes when the indicator lights are operating.

16. Standard Body-up (Amber) -Illuminates to indicate that the body is NOTresting on the chassis. Never move the machine until this light goes OUT.

16. Optional Flashing Body-up (Amber) -Warning light flashes and a buzzersounds to indicate that the body is NOT resting on the chassis. Never move themachine until this light goes OUT.

17. Transmission Oil Temperature (Red) -Illuminates when the transmission oil

temperature rises above the safe operating temperature.18. Brake Hydraulic Oil Temperature (Red) - Illuminates if brake cooling hydraulicoil overheats. Reduce speed and shift transmission to the range that will maintain anengine speed as high as possible, without exceeding the maximumrecommendation, to increase oil circulation and cooling. If the trouble persists, stopthe machine and have the fault corrected.

19. Retarder Indicator (Amber) - Illuminates when the retarder is applied.

20. In-converter Indicator (Green) - Illuminates when the transmission is inTorque Converter drive. It goes OUT when Lockup is engaged.

21. Check Trans (Red) - Illuminates to alert of a minor fault in the transmission shift

system or abnormal transmission temperature. The light will illuminate when theignition keyswitch is turned to position '1' to provide a bulb and system check andshould go off a few seconds after the engine is started.

22. Steering Filter Restriction (Red) -Illuminates when the filter is restricted,indicating that a filter change is required.

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23. Transmission Oil Filter Restriction (Amber) - Illuminates when the filter isrestricted, indicating that a filter change is required. Transmission will not upshiftfrom first gear while this light is illuminated.

24. Transmission Overspeed Light - Illuminates when the transmission ECUsenses transmission speed above 2350 rev/min.

Note: For further information on items 21 and 24, refer to 'Transmission' sectionon page 33.

I

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3-7

0

5

1015

20

25

RPM x100

30

STOP

ENG

WATER TEMP

ENGOIL PRESS

P

1 2

2

1 3

4

1387

Instruments

1. Tachometer/Hourmeter - Drivenfrom the engine ECM, the tachometerindicates the engine speed inrevolutions per minute. The needleshows the variations in engineoperating speed. Never accelerate

the engine to speeds indicated by thered zone on the dial face. A digitalhourmeter is incorporated in thetachometer to record total hours ofengine operation. The readings canbe used for operating and servicerecords.

2. Engine Water TemperatureGauge - This gauge should read inthe green zone, after the engine has

warmed. If gauge reads in the red zone,stop the engine until the fault iscorrected.

3. Engine Oil Pressure Gauge - Thisgauge should read in the lower end ofthe green zone at normal operatingspeeds and may fall to the lower endof the yellow zone at engine idle. Stopthe engine if the needle does not riseabove the red zone until the fault is

corrected.4. Fuel Gauge - Indicates the level inthe fuel tank. Fill the tank before parkingthe machine overnight to minimizecondensation in the tank. Avoid a drytank condition which requires bleeding

the f el s stem

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3-8

0

10

3020

40

km/h

50

MPH20

20

20

20

OIL TEMP

TRANS50 150

120140

OIL PRESSTRANS

P

1 2

5

6

7

the fuel system.

5. Transmission Oil PressureGauge - Indicates transmission clutchapplication oil pressure. The readingwill vary during shifts and with varyingspeeds and loads. The needle shouldremain in the green zone during normal

operation but might rise into the upperred zone for short periods under heavyloading. When the load decreases, theneedle should return to the green zoneand may fall momentarily into the lowerred zone. If the needle remains ineither of the extreme zones forextended periods, stop the machineuntil the fault is corrected.

6. Transmission Oil Temperature

Gauge - This gauge should read inthe green zone during normaloperation. Refer also to 'GeneralTransmission Operation' on page 3-41 and 'Retarder' section on page 3-18 for variations from normal.

7. Speedometer/Odometer -Drivenby a signal from the CEC, thespeedometer indicates travel speed inkilometres per hour and miles per hour.

A digital odometer is incorporated in thespeedometer to record the distancetravelled by the vehicle at any giventime.

1645

Switches

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HAZARD

50%

(0)

1 2 3 4 5 6Switches

1. Hazard Warning Lights -Press bottom of switch to make turn indicators flashsimultaneously as hazard warning lights. The light in the switch and directionindicator warning light on the right hand dash panel will flash. To switch hazardlights off; press the top of the switch.

2. Position not used.



5. Front Brake Pressure Reduction (Optional) -Press bottom of switch to give a50% reduction in front brake pressure. The lower front pressure reduces the risk ofwheel lockup in slippery conditions. To return to full front brake pressure; press thetop of the switch.

6. Retarder Selection Switch - Allows the operator to select which retarder isemployed when using the retarder control lever.Pressed at top = Disc BrakePressed at bottom = Transmission

1163 Left Hand Panel

7 Sidelight and Headlight - Press bottom of switch to the first position to operate

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7. Sidelight and Headlight - Press bottom of switch to the first position to operateside, tail and panel lights. The lights in the other switches will illuminate. Pressswitch to the second position to operate the headlights. To switch lights off; pressthe top of the switch.


9. Warning Light Test Switch - Pressing the switch with the ignition switched onwill illuminate warning lights 1, 2, 3, 4, 5, 9, 10, 11, 12, 17, 18, 20, 22 and 23 and thebuzzer will sound, to provide a bulb and system check. Refer to 'Warning Lights'section on pages 4, 5 and 6 for details. The light in the switch will illuminate with thepanel lights.

10. Master ECM Diagnostic Request/Stop Engine Override Switch - Operatesas a diagnostic request switch when:

a - the engine is not running and ignition is 'On'.

b - the engine is idling and not in an engine protection condition.

Pressing and releasing the switch will flash out the engine codes. Pressing theswitch a second time will stop the engine codes flashing.

Note:Inactive codes are displayed on Check Engine Light and active codes aredisplayed on Stop Engine Light. Code 25 means no codes present.

Operates as a Stop Engine Override Switch when the engine is in a rampdownprotection mode for any of the following:

Low Coolant LevelHigh Coolant TemperatureLow Oil PressureHigh Oil Temperature

1556 Right Hand Panel

TEST

7 8 9 10 11 12

11 Receiver ECM Diagnostic Request Switch - Operates as a diagnostic

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3-

11. Receiver ECM Diagnostic Request Switch Operates as a diagnosticrequest switch when:

a - the engine is not running and ignition is 'On'.

b - the engine is idling and not in an engine protection condition.

Pressing and releasing the switch will flash out the engine codes. Pressing theswitch a second time will stop the engine codes flashing.

Note:Inactive codes are displayed on Check Engine Light and active codes are

displayed on Stop Engine Light. Code 25 means no codes present.


13. Manual Mode Switch -Allows the service technician to change theoperation of the transmission from automatic to manual.Automatic - Normal operation.Manual - Service Functions.

14. Mode Selection Switch -Allows the service technician to select between thetransmission 'POWER' and 'ECONOMY' shift schedules.

VIEW ON FRONT OF INTERFACE BOX

1479

MANUAL AUTO POWER ECONOMY

1413

15. Ignition and Starter Key Switch - The combined switch operates the ignition

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3-12

17

1174

0

1

2

3

15. Ignition and Starter Key Switch The combined switch operates the ignitionand starter motor. The key can only be withdrawn from position '0'.

'0' -Ignition switched off. Disconnects the batteries making all electrical systemsinoperative (with the exception of a supply to the ECM & CEC memory, interior lightand to the radio). This position also cuts off fuel to shut down the engine.

'1' -Turn key clockwise to connect the batteries to the electrical systems.

'2' -Ignition switched on, instruments, gauges and warning lights register asappropriate. All electrical systems are operative. The key must remain in thisposition whilst operating the machine.

'3' -Starter motor operates. The key when released will return to position '2'.

16. Remote Diagnostic Test Point -(Located under the dash panel, on the steeringcolumn mounting bracket). Plug in connector for diagnostic data reader (DDR).

1031 15

1116 16

17. Electric Window Switch - Press bottom of switch to lower window; press topof switch to raise window.

Controls

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3-

340

341

342

343

1

2 44444

3

Controls

Headlight Dipper, DirectionIndicator, Windscreen Wiper/Washerand Horn

1. Headlight Dipper and Flasher:Control downwards = Main Beam

Neutral Position = Dipped BeamControl Upwards = Headlight Flash

2. Direction Indicator:Control rearwards = Left IndicatorsControl forwards = Right Indicators

3. Windscreen Wiper/Washer:Position J = Not usedPosition 0 = Neutral PositionPosition 1 = Wiper Slow Speed

Position 2 = Wiper Fast SpeedRing Pushed = Windscreen Wash

4. Horn:

Button pushed in = Horn Sounds

Heater

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3-14

4 4 4

1 23

1 2 3

1105

1117

Heater

Blower control (2) is rotated to select one of three blower speeds.

Temperature control (1) is rotated to vary heater output temperature. Heateroutput air is unheated with the control turned fully anticlockwise and heated byturning clockwise.

Heater/air conditioner outlets (4) may be adjusted to control air flow output by

opening and closing the control flaps. Air direction can be adjusted by rotatingcomplete outlet.

Air Conditioner

Keep all windows and vents closed.

Blower control (2) is rotated to select one of three blower speeds. The airconditioning will not operate if the blower control is not switched on.

Temperature control (3) adjusts the air conditioner output temperature. Rotating the

control to the right provides maximum cooling.Heater/air conditioner outlets (4) may be adjusted to control air flow output byopening and closing the control flaps. Air direction can be adjusted by rotatingcomplete outlet.

Operator's Seat - Air

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3-

6

1

2

4

3

5

pSuspension

The air seat only reacts when the driversits on the seat. When unoccupied theseat sinks to the lowest position to alloweasier access. The incorporatedsuspension block out maintains seat in

position for driving.

The following is the list of controls toadjust the seat:

1. Height and slope adjustment, front.

2. Height and slope adjustment, rear.

3.Backrest adjustment.

4.Horizontal adjustment.

5.Weight adjustment

6.Air lumber support adjustment. Pressbuttons to inflate or deflate the two aircushions in the back of the seat, to suitthe exact shape of the drivers back.

1650

Seat Belt

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3-16

A 4-Point integrated Harness is installed on the operators seat. The operatorsbelt should be buckled up and adjusted via the lapbelt tension on the sides ofthe seat.

A retractable seat belt installed on the jump seat.The jump seat belt requires noexternal adjustment. Both belts allow freedom of movement for proper

manipulation of all controls.

WARNINGSAlways wear seat belt when operating the machine.

Always check condition of seat belts and mounting hardware beforeoperating the machine.

Any signs of looseness or wear should be reported to your ServiceDepartment or Dealer for repair or replacement immediately.

Replace seat belt at least once every three years, regardless ofappearance.

Do not attempt to adjust seat or seat belt while machine is moving.Loss of control may result. Stop machine; apply brakes; then adjust.

1657 Operators Seatbelt

1656 Pasenger Seatbelt

MACHINE CONTROLS

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Braking

The dual circuit brake system is applied during normal operation by using theService Brake Pedal or, in an emergency, by using the Park/Emergency BrakeControl.

A 'Front Brake Accumulator' warning light and a 'Rear Brake Accumulator' warninglight are located on the instrument panel. If any of these lights illuminate duringoperation, stop the machine, apply the parking brake and do not operate until thefault is corrected.

Service Brake

This is a floor mounted pedal operated by the right foot. Depress the pedal asrequired by speed, load and road conditions to slow or stop the machine. Releasethe pedal as the machine slows until, when stopped, the pedal is depressed justenough to hold it stationary.

Park/Emergency Brake

Pushing the control in will apply the spring operated parking brakes within the rearbrake assemblies and the service brakes at all wheels. The parking brake warninglight on the instrument panel will illuminate when the control is pushed in. To releasethe brakes; turn the control clockwise.

The Park/Emergency Brake Control should only be used to stop the machine in anemergency, or, for applying the parking brake once the machine has beenstopped. For normal braking the service brake pedal should be employed.

WARNINGAlways apply the parking brake before leaving the operator's seat.

251

1106

Retarder

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3-18

This control lever (1) is used to apply retardation to the truck. Retardation is theterm used for applying a continuous braking force to hold the truck to a safesteady speed when descending grades.

The retarder is OFF when the lever is fully forward and is APPLIED as the leveris pulled back. Maximum retardation is obtained when the lever is in the fullyback position. The retarder may be used anytime to slow down. If additionalbraking is required apply the service brakes. The retarder is not meant forbringing the machine to a halt, or for sudden deceleration - the service brakesshould be employed for this purpose.

When the retarder is applied, the 'Retarder Indicator Light' on the instrumentpanel will illuminate and an orange coloured warning light at the rear of the truckwill illuminate to warn following vehicles.

Retardation of this truck may be achieved by using the DISC BRAKERETARDER or the TRANSMISSION RETARDER.

Machines fitted with Disc Brake and Transmission Retarders have a 'RetarderSelection Switch' (2). This selects which retarder will be employed when using theretarder control. Pressed at top = Disc Brake, Pressed at bottom = Transmission.Machines which do not have a transmission retarder fitted do not have the selectionswitch fitted.

The operator should select the correct gear range to match the site conditions.Application of the retarder gives the transmission enhanced retardation through 6thand 5th gears until 4th gear is attained.

Note:In order to obtain the maximum retardation and cooling effect duringretardation, the engine speed should be maintained as high as possible without

exceeding the maximum recommendation.

1480

WARNINGDo not use the retarder forparking the vehicle. Only use theparking-emergency brakecontrol for this purpose.

1

2

3

4

5

D

N

R1

R2

1

2

Retarder Operation

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3-

Before the machine crests the top of a grade and starts down, the operatorshould slow the machine with the service brakes and downshift to the gearrange which would be used to ascend the grade. The retarder should be appliedbefore starting the descent. Machine downgrade speed (with the retarderapplied as required) in the gear range selected should be high enough to keepthe engine operating at governed speed with the throttle closed (operator's footoff the accelerator pedal). This will ensure maximum oil circulation and cooling. Ifthe rate of descent is too slow, the transmission should be upshifted to the nexthighest gear range. If the rate of descent is too fast, the gear range selected istoo high and the operator must slow the machine by using the service brakes,then downshift into a lower gear range which will allow a safe descent andefficient retarder operation.

Oil Temperature - Disc Brake

The disc brake hydraulic temperature warning light on the instrument panel willilluminate and an electric horn will sound if the oil flowing through the disc brakeassemblies overheats. If alarm is activated, reduce downgrade travel speed. If the

trouble persists, stop the machine and have the fault corrected.

Oil Temperature - Transmission

During normal operation the transmission oil temperature gauge should read in thegreen zone. However, during transmission retarder operation oil temperature canenter the yellow 'RETARDER ON' zone but should not enter the red zone. Do notallow the temperature to stay at or near the top of the yellow zone for more than 3minutes. Reduce downgrade travel speed to avoid the oil overheating and possibledamage to the transmission.

WARNINGGreat care should be used ifapplying the retarder when roadsurfaces are slippery. Retarderbraking effect will occur only atthe driving axle and could make

vehicle control difficult.

Engine

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3-20

Electronic Foot Pedal

The electronic foot pedal provides an electronic signal to the engine's fuelcontrol system in proportion to the degree of pedal actuation.

Note:The engine MUST be started with the foot 'OFF' the electronic foot pedal.

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 problemdevelops. The DDEC system also takes action to prevent damage to the engineand, provides the serviceman with diagnostic capabilities so that problems can becorrected quickly and easily.

WARNINGBefore any welding is done on a machine equipped with the DDEC IV

system, disconnect the following in this order: Battery earth cable,battery supply cable, alternator earth cables, alternator supply cables,transmission connector, ECM interface harness connectors (30 pin RHS),ECM powerharness connectors (5 pin RHS), ECM engine to transmissiondatalink connectors (6 pin RHS), ECM sensor harness connectors (30 pinLHS) and ECM injector harness connectors (5 pin LHS - 2 connectors)(Note: this engine is equipped with 2 ECMs). Turn off ignition key switchto isolate the batteries before disconnecting any components.

After welding connect all of the above in the reverse order.

255

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3-21557

1 - Electronic Control Module (ECM)2 - Programmable Read Only Memory (PROM)3 - Electronic Unit Injectors (EUI)

4 - Electronic Foot Pedal5 - 'Stop' Light6 - 'Check' Light

7 - Diagnostic Test Point8 - Diagnostic Switches

STOP

TEST

4

5

6

7

3

1,2

8

DDEC IV - Description

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3-22

1. Electronic Control Module (ECM) -Receives electronic inputs from the driveras well as from sensors that provide information electronically, such as oil pressureand temperature and intake manifold pressure. This information is used to controlboth 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 theEEPROM. This information controls the horsepower rating, torque curve, maximumengine speed and engine protection devices. The ECM processes this informationand sends electronic signals to the Electronic Unit Injectors (EUI) where the preciseamount of fuel is injected into the engine.

3. Electronic Unit Injectors (EUI) -The EUI is a lightweight, compact unit thatinjects diesel fuel directly into the combustion chamber. The amount of fuel injectedand the beginning of injection timing is determined by the ECM. The ECM sends acommand 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.

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 enginesensors as they will burn out. Before removing injectors, the fuel passages must beblown out to prevent fuel flow from entering the cylinder head.

DDEC IV - Operation

Th DDEC t t f 24 lt l H i th t f l

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3-2

The DDEC system operates from a 24 volt supply. However, in the event of a lossof power supply, the system will operate at reduced voltage. At reduced voltage theelectronic control system will detect a malfunction and the check engine light on thedash panel will illuminate.

At this point the ECM will go into backup control and a change in engine operationwill be noticed. The engine will operate only at reduced rev/min until the battery

voltage reaches a point where it will no longer function and the engine will shutdown. The machine can still be operated when the check engine light is illuminated,however, the fault should be diagnosed and corrected at the earliest possibleopportunity.

Note:When the stop engine light on the dash panel illuminates, the computer hasdetected a major malfunction in the engine that requires immediate attention. It is theoperators responsibility to shut down the engine to avoid serious damage.

The machine is equipped with the DDEC engine protection system, which recordsthe stop engine malfunction in the ECM. The stop engine and check engine lightsilluminate when the engine protection system is initiated. The engine will immediatelyreduce to 70% of the available torque. Rampdown then commences over a 30second period and reduces the engine to 40% of the available torque.

To allow for the possibility of the engine protection system being activated while themachine is operating in a critical situation, a stop engine override switch is provided.If the switch is pressed and released during rampdown, the 30 second timer willreset, restoring torque to the level immediately following illumination of the stopengine and check engine lights. The switch must be pressed and released again toobtain 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 ofapproximately 15 to 20 seconds.

Note:The ECM will record the number of times the override is activated after thefault occurs. Available Torque is the actual torque available from the engine when

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3-24

q q gthe 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 activation of theengine protection system unless the problem has been diagnosed and corrected.

Conditions that will cause the Stop Engine Light to come on are; Low Coolant Level,High Coolant Temperature, Low Oil Pressure and High Oil Temperature.

Whenever the check engine light or stop engine light comes on, the DDECcomputer will determine where the problem is and will store this information in itsmemory. If the malfunction is intermittent, the lights will come on and go off as thecomputer senses the changing engine condition.

A special diagnostic data reader (DDR) is available that can be plugged into theengine computer memory to extract information related to the cause of the problem.Once the malfunction has been corrected, the DDEC system will return the engineto normal operation. The DDR can now distinguish between active codes and thosestored in the historic code memory. The malfunction code recorded in the ECMmemory will remain until it is erased by a technician.

When the engine is not running and the ignition is on, or, the engine is idling and notin an engine protection condition, engine faults can be diagnosed by the operator.Pressing and releasing the diagnostic request switch will cause the check enginelight 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 systemsare operating correctly. Pressing the switch a second time will stop the enginecodes flashing. Refer to 'DDEC IV Diagnostic Codes' table for other codedescriptions.

Note:Only one light will be flashing at any one time. When code flashing is initiated,

the active codes (or code 25) will be flashed on the stop engine light, then theinactive codes (or code 25) will be flashed on the check engine light. When all of theinactive codes have been flashed, the process of flashing the codes will repeat untilthe conditions for code flashing are no longer satisfied.

WARNINGS

The operator of a DDEC-equipped vehicle must notattempt to use or read a DDR ofany kind while the vehicle isoperating. Doing so can result in

loss of control, which may causevehicle damage and may resultin personal injury.

When engine orelectronics system diagnosis isrequired on a DDEC-equippedvehicle, this must be done by aperson other than the operator.The operator must maintain

control of the moving vehiclewhile the assistant performs thediagnosis.

DDEC IV DIAGNOSTIC CODES

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3-2

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 low11 187 - 7 VSG switch system not responding12 187 - 3 VSG sensor high13 111 - 4 Coolant level sensor input voltage low13 111 - 6 Add coolant level sensor input voltage low14 52 - 3 Intercooler coolant temperature sensor input voltage high14 110 - 3 Coolant temperature sensor input voltage high

14 175 - 3 Oil temperature sensor input voltage high15 52 - 4 Intercooler coolant temperature sensor input voltage low15 110 - 4 Coolant temperature sensor input voltage low15 175 - 4 Oil temperature sensor input voltage low16 111 - 3 Coolant level sensor input voltage high16 111 - 5 Add coolant level sensor input voltage high17 72 - 3 Throttle plate position sensor input voltage high17 51 - 3 Throttle position sensor input voltage high18 72 - 4 Bypass position sensor input voltage low18 51 - 4 Throttle plate position sensor input voltage low21 91 - 3 TPS input voltage high22 91 - 4 TPS input voltage low23 174 - 3 Fuel temperature sensor input voltage high23 - 65 3 Oxygen content circuit input voltage high24 174 - 4 Fuel temperature sensor input voltage low


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3-26


24 - 65 4 Oxygen content circuit input voltage low25 - - - Reserved for 'No Codes'26 - 25 1 Auxiliary shutdown #1 active26 - 61 11 Auxiliary shutdown #2 active27 171 - 3 Ambient air temperature sensor input voltage high (Release 2.00

or later only)27 172 - 3 Air temperature sensor input voltage high27 105 - 3 Intake manifold temperature sensor input voltage high28 171 - 4 Ambient air temperature circuit failed low (Release 2.00 or later

only)28 172 - 4 Air temperature sensor input voltage low28 105 - 4 Intake manifold temperature sensor input voltage low31 - 51 3 Aux. output #3 open circuit (high side) - S331 - 51 4 Aux. output #3 short to ground (high side) - S3

31 - 51 7 Aux. output #3 mechanical system fail - S331 - 52 3 Aux. output #4 open circuit (high side) - T331 - 52 4 Aux. output #4 short to ground (high side) - T331 - 52 7 Aux. output #4 mechanical system fail - T332 - 238 4 SEL open circuit32 - 238 3 SEL short to battery (+)32 - 239 3 CEL short to battery (+)32 - 239 4 CEL open circuit33 102 - 3 Turbo boost pressure sensor input voltage high34 102 - 4 Turbo boost pressure sensor input voltage low35 100 - 3 Oil pressure sensor input voltage high35 19 - 3 High range oil pressure sensor input voltage high36 100 - 4 Oil pressure sensor input voltage low36 19 - 4 High range oil pressure sensor input voltage low37 94 - 3 Fuel pressure sensor input voltage high


DDEC C d #

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3-2


37 18 - 3 High range fuel pressure sensor input voltage high37 95 - 3 Fuel restriction sensor input voltage high38 94 4 Fuel pressure sensor input voltage low38 18 - 4 High range fuel pressure sensor input voltage low38 95 - 4 Fuel restriction sensor input voltage low41 - 21 0 Too many SRS (missing TRS)42 - 21 1 Too few SRS (missing SRS)43 111 - 1 Coolant level low44 52 - 0 Intercooler coolant temperature high44 110 - 0 Coolant temperature high44 172 - 0 Air inlet temperature high44 175 - 0 Oil temperature high44 105 - 0 Intake manifold temperature high45 100 - 1 Oil pressure low

45 19 - 1 High range oil pressure low46 168 - 1 ECM battery voltage low46 - 232 1 Sensor supply voltage low47 94 - 0 Fuel pressure high47 102 - 0 Turbo boost pressure high47 106 - 0 Air inlet pressure high47 164 - 0 Injection control pressure high47 18 - 0 High range fuel pressure high48 18 - 1 High range fuel pressure low48 94 - 1 Fuel pressure low48 106 - 1 Air inlet pressure low48 164 - 1 Injection control pressure low52 - 254 12 A/D conversion fail53 - 253 2 Non-voilatile checksum incorrect53 - 253 12 EEPROM write error


DDEC Code #

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3-28


53 - 253 13 Out of calibration54 84 - 12 Vehicle speed sensor fault55 - 231 12 J1939 data link fault55 - 248 8 Proprietary datad link fault (Master)

55 - 248 9 Proprietary datad link fault (Receiver)56 - 250 12 J1587 data link fault57 - 249 12 J1922 data link fault58 92 - 0 Torque overload61 - xxx 0 Injector xxx response time long62 - 26 3 Aux. output #1 short to battery (+) - F362 - 26 4 Aux. output #1 open circuit - F362 - 40 3 Aux. output #2 short to battery (+) - A262 - 40 4 Aux. output #2 open circuit - A262 - 53 3 Aux. output #5 short to battery (+) - W3

62 - 53 4 Aux. output #5 open circuit - W362 - 54 3 Aux. output #6 short to battery (+) - X362 - 54 4 Aux. output #6 open circuit - X362 - 55 3 Aux. output #7 short to battery (+) - Y362 - 55 4 Aux. output #7 open circuit - Y362 - 56 3 Aux. output #8 short to battery (+) - A162 - 56 4 Aux. output #8 open circuit - A162 - 26 7 Aux. output #1 mechanical system not responding properly - F362 - 40 7 Aux. output #2 mechanical system not responding properly - A262 - 53 7 Aux. output #5 mechanical system not responding properly - W362 - 54 7 Aux. output #6 mechanical system not responding properly - X362 - 55 7 Aux. output #7 mechanical system not responding properly - Y362 - 56 7 Aux. output #8 mechanical system not responding properly - A163 - 57 3 PWM #1 short to battery (+)63 - 57 4 PWM #1 open circuit


DDEC Code #

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63 - 58 3 PWM #2 short to battery (+)63 - 58 4 PWM #2 open circuit63 - 59 3 PWM #3 short to battery (+)63 - 59 4 PWM #3 open circuit

63 - 60 3 PWM #4 short to battery (+)63 - 60 4 PWM #4 open circuit63 - 57 0 PWM #1 above normal range63 - 57 1 PWM #1 below normal range63 - 58 0 PWM #2 above normal range63 - 58 1 PWM #2 below normal range63 - 59 0 PWM #3 above normal range63 - 59 1 PWM #3 below normal range63 - 60 0 PWM #4 above normal range63 - 60 1 PWM #4 below normal range

64 103 - 8 Turbo speed sensor input failure64 103 - 0 Turbo overspeed65 51 - 0 Throttle plate position above normal range65 51 - 1 Throttle plate position below normal range65 51 - 2 Throttle plate position erratic65 51 - 7 Throttle plate not responding65 107 - 3 Air filter restriction sensor voltage high65 107 - 4 Air filter restriction sensor voltage low66 - 76 0 Engine knock level above normal range66 - 76 3 Engine knock level sensor input voltage high66 - 76 4 Engine knock level sensor input voltage low66 - 76 7 Engine knock level sensor not responding66 - 99 3 Oil filter restriction sensor voltage high66 - 99 4 Oil filter restriction sensor voltage low67 109 - 3 Coolant pressure sensor input voltage high


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67 109 - 4 Coolant pressure sensor input voltage low67 106 - 3 Air inlet pressure sensor input voltage high67 106 - 4 Air inlet pressure sensor input voltage low67 20 - 3 High range coolant pressure sensor input voltage high

67 20 - 4 High range coolant pressure sensor input voltage low68 - 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 short72 84 - 0 Vehicle overspeed72 84 - 11 Vehicle overspeed (absolute)72 - 65 0 Oxygen content too high72 - 65 1 Oxygen content too low73 - 151 14 ESS transmission stuck in gear73 - 226 11 Transmission neutral switch failure (ESS Transmission)

73 - 227 2 Aux. analog input data erratic, intermittent, or incorrect (ESStransmission)73 - 227 3 Aux. analog input #1 voltage high (ESS transmission)73 - 77 0 Gas valve position above normal range73 - 77 1 Gas valve position below normal range73 - 77 3 Gas valve position input voltage high73 - 77 4 Gas valve position input voltage low73 - 77 7 Gas metering valve not responding73 107 - 0 Air filter restriction high74 99 - 0 Oil filter restriction high74 70 - 4 Optimized idle safety loop short to ground

75 168 - 0 ECM battery voltage high75 - 232 0 Sensor supply voltage high76 121 - 0 Engine overspeed with engine brake81 - 20 3 Timing actuator (dual fuel) input voltage high


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81 98 - 3 Oil level sensor input voltage high81 101 - 3 Crankcase pressure sensor input voltage high81 164 - 3 Injection control pressure circuit voltage high81 173 - 3 Exhaust temperature sensor input voltage high

82 - 20 4 Timing actuator (dual fuel) input voltage low82 98 - 4 Oil level sensor input voltage low82 101 - 4 Crankcase pressure sensor input voltage low82 164 - 4 Injection control pressure circuit voltage low82 173 - 4 Exhaust temperature sensor input voltage low83 98 - 0 Oil level high83 101 - 0 Crankcase pressure high83 173 - 0 Exhaust temperature high83 173 - 4 Exhaust temperature sensor input voltage low83 73 - 0 Pump pressure high

84 98 - 1 Oil level low84 101 - 1 Crankcase pressure low85 190 - 0 Engine overspeed86 73 - 3 Pump pressure sensor input voltage high86 108 - 3 Barometric pressure sensor input voltage high87 73 - 4 Pump pressure sensor input voltage low87 108 - 4 Barometric pressure sensor input voltage low88 109 - 1 Coolant pressure low88 20 - 1 High range coolant pressure low89 95 - 0 Fuel restriction high89 111 - 12 Maintenance alert coolant level fault

Steering

The steering wheel position can be adjusted as required for the most convenient

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operating position. To adjust, pull out adjustment lock and tilt steering wheel up ordown as desired; release lever to lock adjustment.

The steering system provides full-time hydraulic power with a continuous-runningpump and a pressurized accumulator. The accumulator helps maintain a constantflow of hydraulic power to operate the steering cylinders.

To steer the front wheels, rotate the steering wheel in the desired direction to therequired radius of turn. The front wheels will turn only as the steering wheel isturned and at a rate of turning directly proportional to steering wheel speed. Thefront wheels will stop and hold position when the steering wheel is stopped. Toreturn the front wheels to the straight ahead position or to the opposite direction, turnthe steering wheel in the opposite direction.

WARNINGIn the event of loss of steering pump output pressure, a fully- pressurized

accumulator provides a maximum of two lock to lock turns of the frontwheels. A red warning light on the instrument panel illuminates and abuzzer sounds when steering pressure falls below 83 bar (1 200 lbf/in). Ifthis warning light illuminates, indicating a loss of steering power, themachine must be stopped immediately and no further operationattempted until the fault is corrected.The accumulator slowly bleeds down after engine shut-off to preventaccidental steering. However, accumulator pressure should be dissipatedafter engine shut-off by turning the steering wheel in both directions toavoid accidental steering during bleed down.

Improper steering control unit repair or hose connections can causesudden and forceful steering wheel movement when engine is started.Keep hands off steering wheel when starting engine.

1118

1109

Transmission

This machine is equipped with an CEC (Commercial Electronic Control) shiftt t t th t i i Th CEC hift t ti ll it th

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system, to operate the transmission. The CEC shift system continually monitors thetransmission and shift system electrical components and warns the operator whena problem develops. It also takes action to prevent damage to the transmission, andprovides the serviceman with diagnostic capabilities so that problems can becorrected quickly and easily.

WARNING

Before any welding is done on a machine equipped with a CEC shiftsystem, disconnect battery cables from terminal posts (ground cablefirst) and electrical connections at the engine and transmission ECUs toavoid damage to electrical components. Turn off ignition key switch toisolate the batteries before disconnecting any components.

In addition, CEC provides the following systems designed to protect the operatorand mechanical components:

REVERSE INHIBIT - Prevents gear selection if engine is operating at more than20% throttle.

HOIST INTERLOCK PRESSURE SWITCH - The ECU will shift the transmissionfrom Reverse to Neutral if the body control lever is moved to the 'Raise' position.When this circuit has been activated, moving the transmission shift lever to Neutral,then re-selecting Reverse, will engage Reverse gear whilst the body is held in the'Raise' position. This feature is only operational in the normal automatic drivingmode, either power or economy. It is not activated during the manual mode.

WARNINGThe standard procedure for raising the body must still be adhered to.

BODY UP INTERLOCK - When the body is raised, the CEC system will onlyallow the transmission to operate in First gear. This feature is only operational inthe normal automatic driving mode, either power or economy. It is not activated

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g p yduring the manual mode.

PARKING BRAKE INTERLOCK - If the parking brake is applied while thetransmission is in Neutral, the CEC system will prevent a shift out of Neutral toprotect the brake components. If the parking brake is applied while the transmission

is in gear, the parking brake interlock will not function and normal shifts will occur.

LOCK-IN-GEAR - The lock-in-gear feature is designed to protect the transmissionfrom damage should wheel spinning or lockup occur due to poor traction or panicbraking. The ECU will delay making a shift for several seconds and then, if thecondition fails to correct itself, locks in gear and prevents any further shifting. TheCheck Trans and Do Not Shift warning lights will both come on. If this occurs, theECU must be reset before normal operation may be resumed.

To reset the ECU if the transmission has locked in gear because of wheel spinningor a panic stop, stop the machine, select 'Neutral', apply the parking brake, and shut

down the engine. Wait ten seconds, then restart the engine. Select 'Reverse', then'Neutral'. The Check Trans and Do Not Shift warning lights should go 'Off'.

COLD WEATHER STARTS - During cold weather starts, if the transmissiontemperature is below -24C (-10F) the Do Not Shift and Check Trans warninglights will illuminate and the ECU will prevent the transmission from being shifted outof Neutral. Between -24C (-10F) and -7C (19F) the lights will go out and theECU will only permit operation in First or Reverse gears. Above -7C (19F),normal operation will be permitted.

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VIEW ON FRONT OFINTERFACE BOX

1. Electronic Control Unit (ECU)2. Interface Box3. Gear Shift Selector

4. Mode Selection Switch5. Manual Mode Switch6. Manual Mode Warning Light

7. Check Trans Warning Light8. In-converter Indicator Light9. Digital Data Line

Description and Operation

1. Electronic Control Unit (ECU) -Contains an electronic microcomputer. TheECU receives information in the form of electronic signals from switches and

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ECU receives information in the form of electronic signals from switches andsensors, processes the information, and sends electronic signals to theappropriate solenoids which control the transmission.

2. Interface Box -Contains fuses and relays.

3. Gear Shift Selector - The shift selector is a remote mounted lever type. Thegear shift selector is connected to the ECU by a wiring harness. The shift leverhas 6 forward ranges and 2 reverse ranges, as well as a neutral position.

WARNINGDo not allow the vehicle to coast in Neutral. This practice can result insevere transmission damage.

The shift selector has a single digit LED display, that during normal operation

will display the gear selected (Not gear attained). Diagnostic information can bedisplayed on the single digit LED display by pressing the diagnostic displaybutton. There is a hold override button that must be pressed when shiftingbetween R, N and D. The hold override button is released when desiredselector position is reached. The selector lever can move freely between D andthe number ranges without pressing the hold override button.The transmission upshifts and downshifts automatically between first range andthe highest range selected on the range selector in direct response to throttleposition and transmission output speed.

When reverse range is selected the 'Reverse Alarm' sounds and the 'ReverseLight' illuminates at the rear of the truck. This feature warns personnel to theimmediate rear of the truck that the operator has shifted the transmission toreverse.

Gear Shift Selector1476

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R

MODE

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R2

When drive (D) is selected, the transmission automatically upshifts anddownshifts through all six forward ranges as required by loads and travelspeeds. Selecting a lower range (4th, 3rd etc.) limits the highest range to whichth t i i ill t ti ll hift

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the transmission will automatically upshift.

If a lower range is selected while moving forward, the transmission automaticallydownshifts sequentially to the selected lower range at maximum controlledengine 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) andaccelerate the engine to the machine load and speed requirements. Thetransmission will automatically upshift from 1st through 6th ranges as travelspeed increases.

With the throttle fully depressed, and the Mode Selection Switch in the 'POWER'position, the transmission upshifts to the next higher range when the engineattains maximum rated speed, since maximum power train output is needed

under this condition. At lower throttle settings where minimum power trainperformance is required, the transmission will upshift to the next higher range atless than maximum rated engine speed.

Upgrades or soft spots might slow travel speed, even at full throttle, requiringtransmission downshifts to maintain maximum powertrain performance. Whenthis occurs, the transmission downshifts automatically.

Shift the transmission to the next lowest range if transmission 'Hunting' or 'ShiftCycling' occurs.

When temporarily stopped, such as for yielding the right-of-way to a loadedmachine, the transmission can be left in the selected range and the machineheld stationary with the service brakes.

When stopped for a more extended period with the engine left running, however,shift the transmission to Neutral to avoid unnecessary heat buildup, and applythe parking brake.

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WARNINGAlways select Neutral and apply the parking brake before leaving theoperators seat.

4. Mode Selection Switch - Gives the option to select between transmission'POWER' and 'ECONOMY' shift schedules. The transmission must be in Neutralbefore the switch will function.

The transmission torque converter is equipped with a lockup clutch which, whenengaged by the ECU, locks the converter pump and turbine together as a singleunit and allows power to be transmitted mechanically from the engine directly tothe transmission gearing on a 1 to 1 ratio. When the lockup clutch isdisengaged, the torque converter acts as a fluid coupling, multiplying torquewhen engine speed is significantly higher than transmission output shaft speed.

When the Mode Selection Switch is in the 'POWER' position, the ECU controlsoperation of the lockup clutch according to signals received by the throttleposition sensor (giving engine speed as a percent of throttle), the transmissionoutput shaft speed sensor, and range selector. The ECU may delay applicationof the lockup clutch and allow torque multiplication by the torque converter totake place until a balance is achieved between engine speed and transmissionoutput shaft speed before activating the lockup clutch.

Power versus Economy Mode

The POWER mode is designed for applications involving heavy loads and hillyduty cycles where performance rather than fuel economy is of prime importance.

The ECONOMY mode is designed for applications involving lighter loads and

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level duty cycles or where fuel economy is more important than performance.

In the ECONOMY mode, the ECU controls operation of the lockup clutch with atimed preprogrammed schedule where in Second through Sixth gears the

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timed, preprogrammed schedule where in Second through Sixth gears thelockup clutch is disengaged only long enough to allow the torque converters fluidcoupling to absorb shift shock. Otherwise, the lockup clutch is engaged and notorque multiplication takes place in Second through Sixth gears.

5. Manual Mode Switch - The manual mode facility is designed as a ServiceTechnician facility to allow stall checks and clutch pressure checks to beimplemented by Service Personnel, and permit movement of the vehicle, ifnecessary, to a repair area. With the manual mode switch in the 'On' position,the body up interlock and hoist interlock pressure switch mechanisms aredisengaged.

WARNING

This allows unauthorised selection of reverse or any forward gear with

the body raised, constituting a safety hazard. Operators must not usethe manual mode facility when working the vehicle! It is recommendedthat the mode selection key is removed from the unit and retained in asafe place until required by Service personnel.

Note:The manual mode can only be used if the mode selection switch is in thePower position and the transmission is in neutral.

WARNING

Do not operate engine for more than 30 seconds at full throttle withtransmission in gear and output stalled as this will result in severeoverheat damage to the transmission.


WARNING

The manual mode is not intended to be used for normal

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The manual mode is not intended to be used for normaloperations. The machine should only be driven at very low speeds infirst or reverse gears if the manual mode is activated, or damage to thetransmission may result.

6. Manual Mode Warning Light - This light is located on the front face of theCEC2 interface box. The Manual Mode Warning Light illuminates to alert theoperator when the transmission has been switched to operate in the manualmode. The light should be 'Off' during normal operation.

7. Check Trans Warning Light -Illuminates to alert of a minor fault in thetransmission shift system or abnormal transmission temperature. The warninglight will come 'On' when the ignition keyswitch is turned to position '1' to providea bulb and system check and should go 'Off' a few seconds after the engine isstarted and the transmission oil pressure rises.

The check trans warning light will come 'On' during operation if the ECU hasdetected a minor fault in an electrical component or abnormal transmission oiltemperature. If transmission oil temperature is too high, stop the machine, selectNeutral (N), and increase engine speed to allow a greater flow of oil to the oilcooler until oil temperature drops to normal operating range. In most cases, aminor fault triggering the check trans warning light will not prevent normaloperation from continuing but, depending on the nature of the problem, the ECUcould take action to protect the transmission from damage, such as preventingoperation in high gear ranges. If the check trans warning light comes 'On', havethe problem diagnosed and corrected at the earliest opportunity.

8. In-convertor Indicator Light -Illuminates when the transmission is in torqueconverter drive. It goes 'Off' when Lockup is engaged. In order to avoidunnecessary waste of fuel, if traffic or other road conditions permit, the operator

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should modify throttle position, or gear held to achieve a steady road speed withthe

Documents

TR70 OHE789