Terex TA9P Tier 4 Final User manual

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

Terex Construction
C e n t r a l B o u l e v a r d
Prologis Park
Coventry
CV6 4BX
England
[phone]
[phone]
Email:[email protected]
www.terex.com
Serial Number
Year of Construction
Date of Delivery
Dealer Stamp
Notice

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Record of Revisions
Record of Revisions
* The “Stop-Start” is patent applied for under UK Patent Application Number 1512731.9
Revision
Number Reason for Change Date
1.0 Original Issue 1-May-2015
1.1 Technical Data Section Revised 1-November-2015
1.2 Revised Weights Added 1-January-2016
1.3 TA 9P, 10 &10P version added also “Stop-Start”* option 1-February-2016
1.4 TA9S and TA9SP Swivel Skip Version Added 1-March-2016

Record of Revisions
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Table of Contents
Table of Contents
1 Introduction
1.1 Important Information ................................................................. 1.1
1.2 Safety Alert System .................................................................... 1.1
1.3 Intended Use .............................................................................. 1.1
1.4 Operations Manual ..................................................................... 1.1
1.5 Identification Plate ...................................................................... 1.2
1.6 Warranty Registration ................................................................. 1.3
1.7 Warranty...................................................................................... 1.3
1.8 Service and Replacement Parts Enquiries ................................. 1.3
1.9 Official Documents European Community Only ......................... 1.4
(1) CE mark ................................................................................. 1.4
1.10 California Proposition 65 ............................................................ 1.6
1.11 Bulletin Compliance .................................................................... 1.6
1.12 Contacting the Manufacturer ...................................................... 1.6
1.13 Transfer of Machine ownership .................................................. 1.7
2 Safety
2.1 Safety Alert System .................................................................... 2.1
2.2 ANSI Hazard Classification System ........................................... 2.1
2.3 Personal Protective Equipment (PPE) ....................................... 2.2
2.4 General Safety Information ........................................................ 2.4
2.5 Seat Belt ..................................................................................... 2.6
2.6 ROPS ......................................................................................... 2.6
2.7 Lockout and Tag Out .................................................................. 2.7
2.8 Hydraulic Fluid ............................................................................ 2.7
2.9 Fluid Levels ................................................................................ 2.7
2.10 Battery Electrolyte ...................................................................... 2.7
(1) Skin Exposure ........................................................................ 2.7
(2) Eye Contact ........................................................................... 2.7
(3) Battery Charging .................................................................... 2.7
(4) Frozen Battery Electrolyte ..................................................... 2.7
2.11 Fires ........................................................................................... 2.8
2.12 Water Cooled Engines ............................................................... 2.8
2.13 Lubricants ................................................................................... 2.8
(1) New Oil .................................................................................. 2.8
(2) Old Oil .................................................................................... 2.8
(3) First Aid - Oil .......................................................................... 2.9
2.14 Oil or Fuel Spillage ..................................................................... 2.9
2.15 Gradients .................................................................................... 2.9
(1) Ascending or Descending ...................................................... 2.9
(2) Maximum Gradient .............................................................. 2.10
(3) Crossing a Slope ..................................................................... 2.10
2.16 Responsibilities ........................................................................ 2.10
2.17 Overturning ............................................................................... 2.11
2.18 Safety Signs ............................................................................. 2.11
(1) Safety Sign Symbols ............................................................ 2.12
(2) Safety Sign Location - ISO .................................................. 2.14

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(3) Safety Sign Location - ANSI .................................................2.16
3 Technical Data
3.1 Dimensions .................................................................................3.1
(1) TA 9, TA9P & TA10P .............................................................3.1
3.2 Dimensions ..................................................................................3.2
(1) TA9S & TA9SP .......................................................................3.2
3.3 Turning Circle .............................................................................3.3
3.4 Data ............................................................................................3.4
3.5 Noise Emissions .........................................................................3.6
3.6 Vibration Levels ..........................................................................3.6
4 Description
4.1 TA 9, TA9P & TA10P Dumper .....................................................4.1
4.2 TA9S & TA9SP Dumper .............................................................4.2
4.3 Description...................................................................................4.2
(1) Skip ........................................................................................4.2
(2) Engine ....................................................................................4.2
(3) Chassis ..................................................................................4.3
(4) Steering ..................................................................................4.3
(5) Transmission ..........................................................................4.3
(6) Braking System ......................................................................4.3
(7) Electrical System ....................................................................4.3
4.4 Skip .............................................................................................4.3
(1) Raised Skip ............................................................................4.4
4.5 Chassis .......................................................................................4.4
4.6 Hydraulic System ........................................................................4.4
4.7 Battery Isolator ............................................................................4.5
(1) Operation ...............................................................................4.5
4.8 Circuit Breaker ............................................................................4.6
4.9 Audible Warning .........................................................................4.6
4.10 Control Panel and Switch Functions ...........................................4.7
(1) Multi Function LCD Display .....................................................4.9
(2) Warning Lights ......................................................................4.10
(3) Control Panel Symbols.......................................................... 4.12
(4) Switch Operation................................................................... 4.13
4.11 Engine Ignition Switch ..............................................................4.13
4.12 “Stop-Start” Function - Optional on TA9 ...................................4.13
(1) Stop Function ........................................................................4.14
(2) Start Function........................................................................ 4.14
4.13 Forward/Reverse Switch - “Synchro Shuttle” Transmission ......4.15
4.14 Highway Lighting (When Fitted) ................................................4.16
(1) Direction Indicators ..............................................................4.16
(2) Brake Lights ..........................................................................4.16
(3) Front Light Unit .....................................................................4.16
(4) Rear Light Unit .....................................................................4.17
(5) Registration Plate Lights ......................................................4.17
4.15 Obstruction Beacon ..................................................................4.17
4.16 Foot Brake and Throttle Pedals ................................................4.18

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4.17 Gear Selector Lever “Synchro-Shuttle” Machines .................... 4.19
4.18 Gear Change - “Power Shift” Machines .................................... 4.20
4.19 Parking Brake ........................................................................... 4.21
4.20 Skip Control Lever..................................................................... 4.22
4.21 Tow Hitch ................................................................................. 4.22
4.22 12v Accessory Socket ............................................................... 4.23
5 Transportation
5.1 Transporting by Rail ................................................................... 5.1
5.2 Loading on to a Trailer or Lorry Using Ramps ........................... 5.1
5.3 Articulation Lock ......................................................................... 5.2
5.4 Tie Down Points ......................................................................... 5.2
(1) Forward Tip Machines ............................................................ 5.3
(2) Swing Skip Machines.............................................................. 5.3
(3) Rear Tie Down........................................................................ 5.4
5.5 Tie Down .................................................................................... 5.4
6 Initial Setup and Adjustments
6.1 Delivery Checks ......................................................................... 6.1
6.2 Setup .......................................................................................... 6.1
6.3 Start Up ...................................................................................... 6.2
7 Standard Operating Procedures
7.1 Pre Start Checks ........................................................................ 7.1
7.2 Machine Access ......................................................................... 7.1
7.3 Seat ............................................................................................ 7.2
(1) Seat Adjustment .................................................................... 7.2
(2) Weight Adjustment ................................................................. 7.3
(3) Back Rest Angle Adjustment ................................................. 7.3
(4) Seat belt ................................................................................. 7.4
7.4 To Start the Engine .................................................................... 7.5
7.5 To Stop the Engine ..................................................................... 7.6
7.6 To Move the Machine - “Synchro-Shuttle Transmission ............ 7.6
(1) Moving Off ............................................................................. 7.6
(2) To Change Gear .................................................................... 7.6
(3) To Stop the Machine .............................................................. 7.7
7.7 To Move the Machine - “Power Shift Transmission..................... 7.8
(1) Moving Off .............................................................................. 7.8
(2) To Select Reverse .................................................................. 7.8
(3) To Stop the Machine............................................................... 7.9
7.8 Gradients .................................................................................... 7.9
7.9 Loading the Skip ......................................................................... 7.9
7.10 Skip Operation .......................................................................... 7.10
(1) To Tip the Load - Forward Tip Machines ............................. 7.10
(2) To Lower the Skip ................................................................ 7.11
(3) To Tip the Load - Swing Skip Machines .............................. 7.11
(4) To Lower the Skip ................................................................ 7.11
(5) To Rotate and Tip the Skip .................................................. 7.12
(6) To Lower the Skip ................................................................ 7.12

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(7) To Return the Skip to the Ahead (Travelling) Position .........7.12
7.11 Parking the Machine After Use .................................................7.12
8 Emergency Operating Procedures
8.1 Running Out of Fuel on a Slope ................................................. 8.1
8.2 To Lower the Skip with the Engine “Dead” ..................................8.1
8.3 “Jump Starting” a Machine ..........................................................8.1
9 Maintenance and Lubrication
9.1 General Information ....................................................................9.1
9.2 Maintenance Notes .....................................................................9.1
9.3 Cleaning The Machine ................................................................9.2
(1) Safety Signs ...........................................................................9.2
9.4 Battery Disposal ..........................................................................9.2
9.5 Hydraulic Oil Under Pressure .....................................................9.2
9.6 Skip Support ...............................................................................9.3
(1) Skip Support ...........................................................................9.3
9.7 Articulation Lock .........................................................................9.4
(1) To Fit the Articulation Lock .....................................................9.4
9.8 ROPS..........................................................................................9.5
9.9 Floor Plate Removal ....................................................................9.5
9.10 Engine Coolant ...........................................................................9.6
(1) To Check the Coolant Level ...................................................9.6
(2) To Add Coolant ......................................................................9.6
9.11 Engine Oil ...................................................................................9.7
(1) To Check the Engine Oil Level ...............................................9.7
(2) To Add Oil ..............................................................................9.8
9.12 Synchro Shuttle Gearbox ............................................................9.9
(1) To Check the Level .............................................................9.10
(2) To Add Oil ............................................................................9.10
9.13 Power Shift Gearbox..................................................................9.10
(1) To Check the Level .............................................................9.11
(2) To Add Oil ............................................................................9.11
9.14 Hydraulic System ......................................................................9.12
(1) To Check the Hydraulic Oil Level .........................................9.12
(2) To Add Hydraulic Oil ............................................................9.13
(3) Hydraulic Hoses ....................................................................9.13
9.15 Fuel System .............................................................................. 9.13
(1) To Add Fuel ..........................................................................9.14
9.16 Braking System .........................................................................9.14
(1) Brake Arrangement ..............................................................9.14
(2) To Add Fluid .........................................................................9.15
(3) Parking Brake Test................................................................9.15
9.17 Fuses and Relays ......................................................................9.16
(1) Normal Machines ..................................................................9.16
(2) Power Shift and “Stop-Start” Machines .................................9.17
9.18 Air Cleaner.................................................................................9.18
9.19 Maintenance Schedule .............................................................9.19
9.20 Fluids and Lubricants ................................................................9.21
(1) Engine Oil .............................................................................9.21

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(2) Gearbox ............................................................................... 9.21
(3) Transfer Box ........................................................................ 9.21
(4) Axles .................................................................................... 9.21
(5) Brake Reservoir ................................................................... 9.22
(6) Hydraulic System ................................................................. 9.22
(7) Engine Coolant .................................................................... 9.22
(8) Fuel System ......................................................................... 9.22
(9) Grease ................................................................................. 9.22
9.21 Fluid Capacities ........................................................................ 9.22
10. Troubleshooting
10.1 General Troubleshooting .......................................................... 10.1
(1) Engine will not start .............................................................. 10.1
(2) “Low” engine oil pressure light comes on ............................ 10.1
(3) “High” coolant temperature light comes on .......................... 10.1
(4) Loss of coolant ..................................................................... 10.1
10.2 Electrical Troubleshooting ........................................................ 10.1
(1) Circuit breaker keeps “tripping out”. ..................................... 10.1
(2) System Dead ....................................................................... 10.1
(3) Charge warning light remains On with engine running ........ 10.1
(4) Lights and direction indicators do not work .......................... 10.2
10.3 Hydraulic Troubleshooting ........................................................ 10.2
(1) No Pressure ......................................................................... 10.2
(2) Machine will not steer .......................................................... 10.2
(3) Skip will not tip or rotate ....................................................... 10.2
11. Recovery
11.1 In the Event of a Breakdown .................................................... 11.1
12 Storage, Decommissioning and Disposal
12.1 Long Term Storage .................................................................. 12.1
12.2 Decommissioning ..................................................................... 12.1
12.3 Recommissioning ..................................................................... 12.1
(1) If stored for more than a period of 6 months:- ..................... 12.2
12.4 Disposal .................................................................................... 12.2
12.5 Disposal of Used Batteries ....................................................... 12.2
13 Glossary of Terms
Appendix 1 - Electrical Diagrams
Appendix 2 - Hydraulic Diagrams
Appendix 3 - Fuel System Diagram

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Introduction 1
1Introduction
1.1 Important Information
TEREX appreciates your choice of our product for your application. Our number one priority is
user safety which is best achieved by our joint efforts. We feel you can make a major contribution
to safety if, you as the machines user:
• Comply with all the relevant National Laws and Local Regulations.
• Read, Understand and Follow the instructions in this and any other manuals supplied with this
machine.
• Use Good, Safe Work Practices in a common sense way.
• Only Use Trained Operators to operate the machine who are directed by informed and
knowledgeable supervision. The operator of this machine must be a competent person who
has received thorough training in the use of this type of equipment.
If there is anything in this manual which is not clear or there is information which you think should
be added, contact the Manufacturers Service Department who will deal with your problem or
request.
Machine LEFT and RIGHT HAND. All references in this manual to LEFT and RIGHT are as
viewed from the Operating Position (Operators Seat) with Operator facing the skip.
We reserve the right to make improvements to these machines without incurring any need to
change these operating instructions.
Any modification to this machine which has not been approved by the Manufacturer in writing is
prohibited and immediately invalidates the Manufacturers warranty.
1.2 Safety Alert System
The Safety Alert System identifies important safety messages in this manual. When you see this
symbol, adhere to all safety messages that follow to avoid possible injury or death.
1.3 Intended Use
The machine has been designed and tested to carry out the function of transporting various free
flowing materials. If used correctly, it will provide an effective means of transportation and meet
the appropriate performance standards and regulations.
This machine is not suitable for under ground working or use in hazardous environments.
Use of this product in any other way is prohibited and contrary to its intended use
1.4 Operations Manual
This manual is a guide to the safe operation of the machine and the layout and position of all
controls. It also contains details of checks and procedures within the scope of the operator to
keep the machine in a safe and serviceable condition.
This manual is not a training manual. Contact your local dealer or representative for details of
suitable training courses.

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Any person who intends to use this equipment must read this operations manual carefully before
operating the machine.
Make sure this operations manual is kept with the machine at all times and is in good condition
- replace the manual immediately if it becomes dirty, damaged or has been lost. The manual
holder is located in the back of the seat (Figure 1.1) and is lockable.
Replacement or additional copies of this publication can be ordered from your dealer.
Figure 1.1 - Operations Manual Location
1.5 Identification Plate
The Vehicle Identification Number is recorded on a plate (Figure 1.2) located on the right hand
side of the rear chassis frame.
Figure 1.2 - Vehicle Identification Number Plate Location
1. VIN Plate
You are advised to keep a record of your machines VIN number and the information recorded on
the plate in a safe place.
COV00001
1
COV00510A
1

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Introduction 1
.
Figure 1.3 - Vehicle Identification Plate Information
1. Company Address
2. Vehicle Identification Number
3. Machine Model
4. Operating Mass
5. Maximum Payload
6. Engine Power
7. Year Of Manufacture
8. Model Year
9. Bar Code
1.6 Warranty Registration
Your dealer will have registered you as the owner with Terex at the time of sale. Should you have
any queries please consult your dealer in the first instance.
1.7 Warranty
Full terms and conditions of the machines warranty will be found in the warranty certificate
included in or accompanying this manual.
1.8 Service and Replacement Parts Enquiries
Please state the vehicle type and the Vehicle Identification Number (VIN) when making enquiries
or orders and in all written correspondence.
Terex United GB Ltd, Central Boulevard, Prologis Park, Coventry, CV6 4BX, England
VIN NUMBER:
OPERATNG MASS:
kgPAYLOAD:
kg
MODEL:
ENGINE POWER: kW
YEAR OF MANUFACTURE:
MODELYEAR:
8001-1567
1
2
3
4
5
6
7
8
9
COV 00030-2

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1.9 Official Documents European Community Only
(1) CE mark
The Machinery Safety directive is intended to harmonise all the machinery safety regulations
throughout the community so that there will be no technical barriers to trade.
Compliance with the essential safety requirements of the EEC directives 2006/42/EC
(machinery), 2000/14/EC (Noise) and 2004/108/EC, permits companies to CE mark their
products.
The directive affects almost every equipment supplier and user in the community and in
particular, applies to this type of machine.
The regulations require that potential hazards from machinery are properly addressed and
guarded against.
The EC declaration of conformity is a requirement of CE marking. The declaration for this
machine (Figure 1.4) follows.

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Introduction 1
Figure 1.4 - Copy of CE Certificate
TEREX
Contents of the EC Declaration of Conformity
2006/42/EC Machinery Directive
Manufacturer: Terex GB Limited
Central Boulevard
Prologis Park
Keresley End
Coventry
CV6 4BX
United Kingdom
Name of Person to Compile Technical File: Steve Price
Address of Person to Compile Technical File: Terex GB Ltd
Generic Denomination: Compact Dumper
Machine Function: Earth-moving machinery
Model / Type : TA9. TA9P, TA9S TA0SP
TA10P
Serial/VIN number
Commercial Name: Same as Model /Type
Terex GB Limited hereby declares that the above piece of machinery is in conformity with the relevant provisions of the
Machinery Directive 2006/42/ EC
Terex GB Limited hereby declares that the above piece of machinery is in conformity with the provisions of the following
other EC-directives: Noise - Equipment Used Outdoors (2000/14/EC), Emissions - Non-Road Engines (97/68/EC) and
Electromagnetic Compatibility (2004/108/EC).
Terex GB Limited hereby declares that the following European standards have been used:
EN474-1 & EN474-6
Place of Issue: Coventry, United Kingdom
Date of Issue:
Empowered signatory
Neal Nowick
General Manager

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1.10 California Proposition 65
California (USA) state law stipulates that the manufacturers of machines operated within its
borders must provide a clear warning to customers regarding exposure to substances commonly
associated with the machine that are recognized by the state as harmful. Terex complies with
this requirement by providing the following information.
1.11 Bulletin Compliance
• You must take action and comply with any safety bulletins transmitted to you by your dealer or
by Terex.
• Make sure the details of ownership of the machine are recorded by your dealer and the
information is accurate and up to date. Failure to do so may result in critical safety information
being withheld.
• Bulletins can only be issued to the recorded owner or keeper of the equipment. It is your
responsibility to make sure that your dealer or Terex has your correct details.
• If you are the new owner contact your local dealer with your details and quote the machines
VIN number to make sure you receive any future bulletins or updates.
1.12 Contacting the Manufacturer
At times it may be necessary to contact the manufacturer of this machine. You must supply the
Model and VIN Number of the machine together with your name and contact details.
You must contact Terex for:-
• For any product modifications to your machine.
• To report an accident involving Terex equipment.
• Product applications and safety.
• Standards and regulations compliance.
• To report change of ownership or ownership details (if not reported to a Terex dealer).
California
Proposition 65
Warning: This product contains and/or emits lead and
lead compounds, diesel engine exhaust, and used engine
oil, chemicals known to the state of California to cause
cancer
California
Proposition 65
Warning: This product contains and/or emits lead, lead
compounds and carbon monoxide chemicals known to
the state of California to cause birth defects or other
reproductive harm

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Introduction 1
1.13 Transfer of Machine ownership
If you sell or otherwise dispose of your machine you must tell your dealer or otherwise Terex.:-
• The name and address of the new owner
• The model and VIN number of the machine
• The date of transfer or disposal.

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Safety 2
2 Safety
This manual is designed as a guide to the Machines Controls, Operation and Maintenance. IT IS
NOT A TRAINING MANUAL
2.1 Safety Alert System
The Safety Alert Symbol is used to alert you to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible injury or death
2.2 ANSI Hazard Classification System
(1) Only Applicable to ANSI Safety Signs)
ANSI safety signs are only fitted to machines used in the US, Canada, Australia and New
Zealand
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
All are used as attention getting devices on safety signs fixed to the machinery to assist in
potential hazard recognition and prevention
bDANGER
DANGER - (Always used with a safety alert symbol and white letters on a red background)
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
bWARNING
WARNING - (Always used with a safety alert symbol and black letters on an orange background)
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
bCAUTION
CAUTION - (Always used with a safety alert symbol and black letters on a yellow background)
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

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(2) Property Damage
(3) Procedure
2.3 Personal Protective Equipment (PPE)
The following symbols indicate the personal protective equipment that must be used at all times
when operating this equipment. Operators must not wear rings, scarves, open jackets and must
make sure that all loose clothing is tightly secured. Long hair must be restrained.
NOTICE
NOTICE - (Used without a safety alert symbol and white italic letters on a blue background) Is
used to address practices not related to personal injury
PROCEDURE
PROCEDURE - (Used without a safety alert symbol and black letters on a green background).
This indicates a procedure that must be followed step by step for safe operation. Make sure all
safety notes have been considered before beginning the procedure.
Protective
Helmet
A protective
helmet must
be worn at all
times to
prevent injury
from falling
objects
Safety Boots Safety boots
must be worn
at all times
when
operating this
equipment
Ear Defenders Ear protection
must be worn
at all times
when
operating or
near this
equipment
Safety
Glasses
Safety
glasses must
be worn at all
times to
prevent eye
injury from
flying objects
High Visibility
Clothing
High visibility
clothing must
be worn at all
times when
operating this
equipment.
Seat Belt The seat belt
must be worn
at all times
when
operating this
equipment