Terex Ta300 tier2 User manual

ARTICULATED

TRUCKS

MaintenanceManual

Product Number: TELA1109

IssueDate:07-Feb-2017

Language:English(en)

RevisionNo:1.1

ReferenceNo:15504870

OriginalInstructions

©TEREXTRUCKS2017 ©TEREXTRUCKS2017

TA300Tier2

07-Feb-2017

Page2

Revision1.1MaintenanceManual

TA300Tier2

RecordofRevisions

RevisionNo.ReasonforChangeDate

1.0Issue1.0ofT erexTrucksMaintenanceManual23-Feb-2016

1.1

Chapter3–T echnicalData,Section3.1

Dimensions

Sectionrevised.

Chapter3–T echnicalData,Section3.5

HydraulicSystem

Sectionrevised.

Chapter3–TechnicalData,Section3.6Electrical

System

Sectionrevised.

Chapter3–TechnicalData,Section3.11Vehicle

Weights

Sectionrevised.

Chapter5–Engine,Section5.16Exhaust

System.

Updatedsectionadded.

AppendixB–HydraulicSystemSchematic

Diagram

Newappendixadded.

AppendixC–CerticateofConformity.

Appendixremoved.

07-Feb-2017

RecordofRevisions

Find manuals at https://best-manuals.com

MaintenanceManual

TA300Tier2

Revision1.107-Feb-2017

Page1

TableofContent

TableofContent......................................................................................................1

1Introduction.................................................................................................1-1

1.1MaintenanceManualInformation...................................................................1-2

1.2SafetyInformation..........................................................................................1-2

(1)Proposition65Warnings............................................................................1-2

1.3IdenticationPlate..........................................................................................1-3

1.4IntendedUse..................................................................................................1-3

1.5ProhibitedUse................................................................................................1-3

1.6Warranty.........................................................................................................1-4

1.7Copyright........................................................................................................1-4

1.8TheftDeterrentPractices...............................................................................1-5

2Safety...........................................................................................................2-1

2.1SafetyAlertSymbol........................................................................................2-2

2.2GeneralSafety...............................................................................................2-2

(1)ImportantSafetyNotice.............................................................................2-3

(2)HazardClassications...............................................................................2-3

(3)DescriptionofSafetySymbols...................................................................2-4

2.3PositionofSafetyDecalsontheMachine......................................................2-5

2.4PersonalSafety............................................................................................2-12

(1)ReadandUnderstandthisMaintenanceManualandAllSafety

Signs........................................................................................................2-12

(2)PersonalProtectiveEquipment...............................................................2-12

2.5WorkAreaSafety.........................................................................................2-13

(1)GeneralWorkAreaGuidelines................................................................2-13

(2)MeasuresforProtectionAgainstLightning..............................................2-15

(3)TransportationSafety..............................................................................2-15

(a)Roading...............................................................................................2-15

(b)ArticulationandOscillationLock.........................................................2-16

(c)MachineLiftingPrecautions................................................................2-16

(d)MachineTieDownPrecautions..........................................................2-17

(4)OperationSafety......................................................................................2-18

(a)Pre-Starting.........................................................................................2-18

(b)Starting................................................................................................2-18

(c)Operating............................................................................................2-19

(5)ElectricalSafety.......................................................................................2-21

(6)MaintenanceSafety.................................................................................2-22

(a)BodyProp...........................................................................................2-23

2.6MirrorsandCCTV........................................................................................2-25

2.7WheelsandTires.........................................................................................2-28

2.8LubricationandServicing.............................................................................2-29

3TechnicalData.............................................................................................3-1

3.1Dimensions....................................................................................................3-2

3.2CarryingCapacity...........................................................................................3-3

3.3OperatingTemperature..................................................................................3-3

3.4MechanicalSystem........................................................................................3-4

(1)Engine.......................................................................................................3-4

3.5HydraulicSystem...........................................................................................3-5

3.6ElectricalSystem............................................................................................3-5

TableofContent

Find manuals at https://best-manuals.com

07-Feb-2017

Page2

Revision1.1MaintenanceManual

TA300Tier2

3.7Standards.......................................................................................................3-7

3.8VibrationDataforOffHighwayArticulatedDumpTrucks...............................3-8

3.9GuidelinesForUseAndWorkingConditionsOfEarth-MovingMachineryT o

ReduceVibrationLevels................................................................................3-9

3.10ServiceCapacities.......................................................................................3-10

3.11VehicleWeights............................................................................................3-10

3.12Towing..........................................................................................................3-12

3.13MachineComponentsSpecications...........................................................3-13

(1)WheelsandTires.....................................................................................3-13

(2)Transmission...........................................................................................3-14

(3)Axles........................................................................................................3-15

(4)Suspension..............................................................................................3-15

(5)Body........................................................................................................3-15

(6)Brakes.....................................................................................................3-16

(7)Steering...................................................................................................3-16

(8)BodyHoist...............................................................................................3-16

4Maintenance................................................................................................4-1

4.1MaintenanceandInspectionPlan..................................................................4-2

(1)MaintenanceSafety...................................................................................4-2

(2)MaintenanceSchedules............................................................................4-3

(a)Every10HoursofOperation................................................................4-3

(b)AfterFirst10HoursofOperationorRebuiltComponents....................4-4

(c)Every50HoursofOperation................................................................4-4

(d)Every250HoursofOperation..............................................................4-5

(e)AfterFirst250HoursofOperationorRebuiltComponents..................4-7

(f)Every500HoursofOperation..............................................................4-8

(g)AfterFirst500HoursofOperationorRebuiltComponents..................4-9

(h)Every1000HoursofOperation..........................................................4-10

(i)Every2000HoursofOperation..........................................................4-12

(j)Every4000HoursofOperation..........................................................4-14

(k)Every6000HoursofOperation..........................................................4-14

4.2Non-scheduledMaintenance.......................................................................4-15

4.3AirConditionCommissioningProcedure.....................................................4-16

4.4LubricationSystem.......................................................................................4-17

(1)RecommendedLubricants.......................................................................4-17

(a)SpecicInformationonLubrication.....................................................4-18

(2)LubricationPoints....................................................................................4-19

5Engine..........................................................................................................5-1

5.1Description.....................................................................................................5-2

5.2Operation.......................................................................................................5-4

5.3Removal.........................................................................................................5-5

5.4Installation......................................................................................................5-8

5.5S6EngineManagementSystem(EMS)......................................................5-10

5.6ECU/TCUDiagnosticScreen.......................................................................5-11

5.7FaultCodes..................................................................................................5-12

5.8Cleaning.......................................................................................................5-21

5.9DriveBelts....................................................................................................5-22

(1)DriveBeltMaintenance...........................................................................5-22

(2)DriveBeltRemoval..................................................................................5-23

TableofContent

Find manuals at https://best-manuals.com

MaintenanceManual

TA300Tier2

Revision1.107-Feb-2017

Page3

(3)DriveBeltInstallation...............................................................................5-25

5.10Starting.........................................................................................................5-26

5.11Stopping.......................................................................................................5-27

5.12Oil–Drain/Replenish...................................................................................5-28

(1)Replenish/Check.....................................................................................5-28

5.13OilFilter–Replacement...............................................................................5-29

5.14CentrifugalOilFilter.....................................................................................5-30

5.15AirCleaner...................................................................................................5-34

(1)Description...............................................................................................5-35

(2)AirCleanerRemoval...............................................................................5-36

(3)AirCleanerInstallation............................................................................5-36

(4)AirCleanerFilterRemoval......................................................................5-37

(5)AirCleanerFilterInstallation...................................................................5-37

5.16ExhaustSystem...........................................................................................5-38

(1)ExhaustandMounting.............................................................................5-38

(2)Description...............................................................................................5-39

(3)Removal..................................................................................................5-40

(a)ExhaustFrontSectionPipe................................................................5-40

(b)ExhaustRearSectionPipe.................................................................5-41

(c)ExhaustMiddleSectionPipe..............................................................5-41

(d)SilencertoDiverterBoxExhaustPipe................................................5-42

(e)StackPipe...........................................................................................5-42

(f)Silencer...............................................................................................5-43

(4)Installation...............................................................................................5-44

(a)ExhaustMiddleSectionPipe..............................................................5-44

(b)ExhaustRearSectionPipe.................................................................5-45

(c)ExhaustFrontSectionPipe................................................................5-45

(d)StackPipe...........................................................................................5-46

(e)SilencertoDiverterBoxExhaustPipe................................................5-46

(f)Silencer...............................................................................................5-47

6Transmission...............................................................................................6-1

6.1Transmission..................................................................................................6-2

6.2Description.....................................................................................................6-3

6.3TransmissionMounting..................................................................................6-3

6.4TransmissionT emperaturesandPressures...................................................6-4

6.5SwitchesandSensors....................................................................................6-5

6.6Operations....................................................................................................6-14

(1)EST-37AutomaticShiftTransmission.....................................................6-14

(2)KickdownFacility.....................................................................................6-16

(3)VTS-3ShiftController..............................................................................6-17

(4)StallTest..................................................................................................6-18

(5)NormalModeofOperationDisplay.........................................................6-18

(6)DiagnosticModeofOperationDisplay....................................................6-19

(7)Retarder...................................................................................................6-20

(8)DisplayDuringDiagnosticOperation.......................................................6-21

(9)DescriptionofFaultCodesforErgo-Control............................................6-24

(10)MeasuringResistanceatActuator/SensorsandCable...........................6-52

6.7Removal.......................................................................................................6-53

6.8Disassembly.................................................................................................6-57

TableofContent

Find manuals at https://best-manuals.com

07-Feb-2017

Page4

Revision1.1MaintenanceManual

TA300Tier2

6.9Inspection.....................................................................................................6-58

6.10Assembly......................................................................................................6-59

6.11Installation....................................................................................................6-60

6.12Maintenance.................................................................................................6-63

(1)TransmissionOilCoolerMaintenance.....................................................6-63

(2)PeriodicInspections................................................................................6-63

(3)OilLevelCheck.......................................................................................6-64

(4)ColdOilLevelCheck-EngineOff...........................................................6-64

(5)ColdOilLevelCheck-EngineRunning..................................................6-65

(6)HotOilLevelCheck-EngineRunning....................................................6-65

(7)ToppingUpOil.........................................................................................6-65

(8)OilandFilterChange...............................................................................6-66

6.13AEBStarter..................................................................................................6-67

(1)AEBStarterProcedure............................................................................6-67

6.14ServiceTools................................................................................................6-68

7Drivelines.....................................................................................................7-1

7.1Description.....................................................................................................7-2

7.2FrontDrivelinesandMounting.......................................................................7-3

7.3RearDrivelinesandMounting........................................................................7-6

7.4Removal.........................................................................................................7-7

(1)FrontDrivelines.........................................................................................7-7

(2)RearDrivelines..........................................................................................7-8

7.5UniversalJoint................................................................................................7-9

(1)Disassembly..............................................................................................7-9

(2)Inspection..................................................................................................7-9

(3)Assembly.................................................................................................7-10

7.6Installation....................................................................................................7-11

(1)FrontDrivelines.......................................................................................7-11

(2)RearDrivelines........................................................................................7-12

7.7DrivelineDiagnosisChart.............................................................................7-13

7.8ServiceTools................................................................................................7-13

8AxleGroup..................................................................................................8-1

8.1AxleGroup(Hub)-FrontAxle........................................................................8-3

(1)FrontAxleMultiDiscBrakes.....................................................................8-5

(2)Operation...................................................................................................8-5

(3)RemovalandDisassembly........................................................................8-6

(4)Inspection..................................................................................................8-9

(5)AssemblyandInstallation........................................................................8-10

(6)Maintenance............................................................................................8-20

(a)PlanetaryOilChange..........................................................................8-21

(7)AxleDiagnosis.........................................................................................8-22

(8)SpecialTorqueSpecications..................................................................8-23

(9)SpecialTools...........................................................................................8-23

(10)FabricatedTools......................................................................................8-24

8.2AxleGroup(Hub)-RearAxle......................................................................8-26

(1)RearAxleMultiDiscBrakes....................................................................8-28

(2)Operation.................................................................................................8-28

(3)RemovalandDisassembly......................................................................8-29

(4)Inspection................................................................................................8-31

TableofContent

Find manuals at https://best-manuals.com

MaintenanceManual

TA300Tier2

Revision1.107-Feb-2017

Page5

(5)AssemblyandInstallation........................................................................8-32

(6)Maintenance............................................................................................8-39

(a)PlanetaryOilChange..........................................................................8-40

(b)BleedingtheBrakes............................................................................8-41

(7)AxleDiagnosis.........................................................................................8-42

(8)SpecialTorqueSpecications..................................................................8-43

(9)SpecialTools...........................................................................................8-43

(10)FabricatedTools......................................................................................8-44

8.3DifferentialDriveHead-Front......................................................................8-46

(1)Description...............................................................................................8-47

(2)Removal..................................................................................................8-48

(3)Installation...............................................................................................8-50

(4)Disassembly............................................................................................8-50

(5)Inspection................................................................................................8-51

(6)Assembly.................................................................................................8-52

(7)Maintenance............................................................................................8-58

(8)SpecialTools...........................................................................................8-58

(9)DifferentialDiagnosis...............................................................................8-59

8.4DifferentialDriveHead-CentreAxle...........................................................8-60

(1)Description...............................................................................................8-62

(2)Removal..................................................................................................8-62

(3)Installation...............................................................................................8-63

(4)Disassembly............................................................................................8-64

(5)Inspection................................................................................................8-65

(6)Assembly.................................................................................................8-66

(7)DifferentialDiagnosis...............................................................................8-71

(8)Maintenance............................................................................................8-72

(9)SpecialTools...........................................................................................8-72

(10)SpecialTorqueSpecications..................................................................8-72

8.5DifferentialLockControls.............................................................................8-73

(1)DescriptionandOperation.......................................................................8-74

(a)Ergo-Traction......................................................................................8-77

(2)RemovalandDisassembly......................................................................8-78

(3)AssemblyandInstallation........................................................................8-79

(4)PressureChecks.....................................................................................8-80

(5)Maintenance............................................................................................8-81

(6)SpecialTools...........................................................................................8-81

8.6WheelRimandTire......................................................................................8-82

(1)DescriptionandOperation.......................................................................8-83

(2)PreparationforServicing.........................................................................8-83

(3)RemovingTireandRimAssemblyfromMachine....................................8-84

(4)DismountingTirefromRim......................................................................8-85

(5)Inspection................................................................................................8-87

(6)MountingTireonRim..............................................................................8-88

(7)MountingTireandRimAssemblyonMachine........................................8-89

(8)NitrogenTireInation..............................................................................8-90

(a)NitrogenTireInationKit....................................................................8-91

(b)Re-InationofaMountedTire............................................................8-92

(9)TireExplosionHazard.............................................................................8-93

(10)TireandWheelRimMaintenance...........................................................8-94

TableofContent

Find manuals at https://best-manuals.com

07-Feb-2017

Page6

Revision1.1MaintenanceManual

TA300Tier2

(11)TireCare..................................................................................................8-95

(12)TubelessTireLeakDiagnosis.................................................................8-97

(13)SpecialTorqueSpecications..................................................................8-97

(14)TirePressures.........................................................................................8-98

(15)ServiceTools...........................................................................................8-98

9FuelSystem.................................................................................................9-1

9.1FuelSystem...................................................................................................9-2

9.2Description.....................................................................................................9-4

9.3Operation.......................................................................................................9-5

9.4Removal.........................................................................................................9-6

9.5Disassembly...................................................................................................9-9

9.6Assembly........................................................................................................9-9

9.7Installation....................................................................................................9-10

9.8CleanlinessRequirement.............................................................................9-11

9.9Maintenance.................................................................................................9-12

(1)FuelFilter.................................................................................................9-12

(a)Removal..............................................................................................9-12

(b)Installation...........................................................................................9-12

(2)FuelFillerCap.........................................................................................9-13

(a)Removal..............................................................................................9-13

(b)Installation...........................................................................................9-13

(3)BleedingtheFuelSystem........................................................................9-14

(4)SpecialTools...........................................................................................9-15

9.10Troubleshooting............................................................................................9-16

(1)SDP3FuelSystemT ests.........................................................................9-20

9.11ElectronicFootPedal...................................................................................9-21

(1)Description...............................................................................................9-22

(2)Removal..................................................................................................9-23

(3)Installation...............................................................................................9-24

10HydraulicSystem......................................................................................10-1

10.1MainHydraulicValve....................................................................................10-2

(1)Description...............................................................................................10-2

(2)Removal................................................................................................10-11

(3)Disassembly..........................................................................................10-13

(4)Assembly...............................................................................................10-15

(5)Installation.............................................................................................10-17

(6)IntegralValveTighteningT orques.........................................................10-19

10.2HydraulicTank............................................................................................10-22

(1)Description.............................................................................................10-23

(2)Operation...............................................................................................10-24

(3)Removal................................................................................................10-25

(4)Inspection..............................................................................................10-26

(5)Assembly...............................................................................................10-26

(6)Installation.............................................................................................10-27

10.3MainHydraulicPump.................................................................................10-28

(1)Description.............................................................................................10-31

(2)Operation...............................................................................................10-32

(3)PressureRegulator................................................................................10-33

(a)UnregulatedCondition......................................................................10-33

TableofContent

Find manuals at https://best-manuals.com

MaintenanceManual

TA300Tier2

Revision1.107-Feb-2017

Page7

(b)RegulatedCondition.........................................................................10-34

(c)Stand-byCondition...........................................................................10-35

(4)Removal................................................................................................10-36

(5)Disassembly..........................................................................................10-37

(a)PressureRegulatorDisassembly......................................................10-38

(6)Assembly...............................................................................................10-39

(a)PressureRegulatorAssembly..........................................................10-40

(7)Installation.............................................................................................10-41

(8)PressureChecks...................................................................................10-42

(9)Troubleshooting.....................................................................................10-42

(10)PumpSettingProcedure.......................................................................10-43

(a)DifferentialPressureSetting.............................................................10-43

(b)PumpDeliveryPressureSetting.......................................................10-45

(11)Lubrication.............................................................................................10-46

(12)PumpWearLimits.................................................................................10-46

(13)SpecialTools.........................................................................................10-46

(14)SpecialTorqueSpecications................................................................10-46

10.4Maintenance...............................................................................................10-47

(1)CheckingOilLevel.................................................................................10-47

(2)ReplacingHydraulicOil.........................................................................10-48

(3)ReplacingBreather................................................................................10-48

(4)ReplacingFilterElement.......................................................................10-49

(5)TransmissionCoolerFanDriveTroubleshooting..................................10-50

11SteeringSystem........................................................................................11-1

11.1SteeringSystemSchematic.........................................................................11-2

(1)Description...............................................................................................11-4

(2)DiagnosticTestPoint...............................................................................11-5

(3)Operation.................................................................................................11-6

(a)PriorityFunction..................................................................................11-6

(b)PriorityFlowControlT oSteering........................................................11-6

(c)EmergencySteering...........................................................................11-7

(d)SteeringPressureSetting...................................................................11-8

(4)FillingandBleedingtheSteeringSystem................................................11-9

(5)HydraulicOil..........................................................................................11-10

(6)Maintenance..........................................................................................11-10

(7)ServiceTools.........................................................................................11-10

(8)O-RingFaceSeals(ORFS)....................................................................11-11

(9)SteeringSystemTroubleShooting........................................................11-12

11.2SteeringValve............................................................................................11-13

(1)Description.............................................................................................11-14

(2)Operation...............................................................................................11-15

(3)Removal................................................................................................11-16

(4)Disassembly..........................................................................................11-18

(5)Inspection..............................................................................................11-21

(6)Assembly...............................................................................................11-22

(7)Installation.............................................................................................11-26

(8)SpecialTorqueSpecications................................................................11-27

(9)SteeringControlDiagnosis....................................................................11-27

(10)SpecialTools.........................................................................................11-27

TableofContent

Find manuals at https://best-manuals.com

07-Feb-2017

Page8

Revision1.1MaintenanceManual

TA300Tier2

11.3SteeringCylinder........................................................................................11-28

(1)Operation...............................................................................................11-28

(2)Removal................................................................................................11-29

(3)Disassembly..........................................................................................11-30

(4)Inspection..............................................................................................11-32

(5)Assembly...............................................................................................11-33

(6)Installation.............................................................................................11-34

(7)Maintenance..........................................................................................11-35

(8)SpecialTorqueSpecications................................................................11-35

(9)SpecialTools.........................................................................................11-35

12BodySystem.............................................................................................12-1

12.1BodySystemSchematic..............................................................................12-2

(1)Description...............................................................................................12-3

(2)BodyControlLever..................................................................................12-3

(3)BodyCylinders........................................................................................12-3

(4)Accumulators...........................................................................................12-3

(5)Operation.................................................................................................12-4

(6)LoweringTheBody..................................................................................12-5

(7)EmergencyBodyLoweringProcedure,FollowingLossOfHydraulicAnd

ElectricalPower.......................................................................................12-6

(8)ResettingMainHydraulicValveAfterHydraulicAndElectricalPowerIs

Restored..................................................................................................12-8

(9)CheckingSystemPressures...................................................................12-8

(10)CheckingtheMainBodySystemPressure.............................................12-9

(11)CheckingthePilotControlPressure......................................................12-11

(12)O-RingFaceSeals(ORFS)...................................................................12-12

(13)HydraulicOil..........................................................................................12-13

(14)ServiceTools.........................................................................................12-13

(15)BodySystemTroubleShooting.............................................................12-14

12.2BodyControlLever....................................................................................12-18

(1)DescriptionandOperation.....................................................................12-18

(2)Maintenance..........................................................................................12-19

(3)Troubleshooting.....................................................................................12-20

(4)SpecialTools.........................................................................................12-20

12.3BodyCylinder.............................................................................................12-21

(1)Description.............................................................................................12-22

(2)Removal................................................................................................12-23

(3)Disassembly..........................................................................................12-24

(4)Inspection..............................................................................................12-25

(5)Assembly...............................................................................................12-26

(6)Installation.............................................................................................12-27

(7)Maintenance..........................................................................................12-28

(8)SpecialTorqueSpecications................................................................12-28

(9)SpecialTools.........................................................................................12-28

13BrakingSystem.........................................................................................13-1

13.1BrakingSystemSchematic..........................................................................13-3

(1)Description...............................................................................................13-4

(2)ServiceBrakes........................................................................................13-4

(3)ParkingBrake..........................................................................................13-5

TableofContent

Find manuals at https://best-manuals.com

MaintenanceManual

TA300Tier2

Revision1.107-Feb-2017

Page9

(a)ParkingBrake-Maintenance..............................................................13-5

(b)ParkingBrake-PadReplacement......................................................13-6

(4)HydraulicTank.........................................................................................13-8

(5)MainHydraulicPump..............................................................................13-8

(6)ParkingBrakePressureSwitch...............................................................13-8

(7)BrakeCircuitPressureSwitches.............................................................13-8

(8)BrakeAccumulators................................................................................13-9

(9)BrakeTreadleValve................................................................................13-9

(10)AdvancedEngineBraking.......................................................................13-9

(11)Operation...............................................................................................13-10

(a)BrakeCharging.................................................................................13-10

(b)BrakeApply.......................................................................................13-10

(c)Park/EmergencyBrakeFunction......................................................13-11

(12)CheckingSystemPressures.................................................................13-13

(13)BleedingtheBrakingSystem................................................................13-16

(14)O-RingFaceSeals(ORFS)...................................................................13-16

(15)HydraulicOil..........................................................................................13-16

(16)ServiceTools.........................................................................................13-17

(a)Multi-Gauge......................................................................................13-17

(b)Non-contactInfraredThermometer...................................................13-17

(c)O'RingFaceSeals(ORFS)-SealKit..............................................13-17

(17)BrakingSystemTroubleShooting.........................................................13-18

13.2Accumulator...............................................................................................13-21

(1)Description.............................................................................................13-22

(2)Operation...............................................................................................13-23

(3)Testing...................................................................................................13-24

(a)TestingtheChargingValveForLeakage..........................................13-24

(b)TestingthePrechargePressure........................................................13-25

(4)ChargingtheAccumulator.....................................................................13-27

(5)DischargingNitrogen.............................................................................13-28

(6)Removal................................................................................................13-29

(7)Disassembly..........................................................................................13-30

(8)Inspection..............................................................................................13-31

(9)Assembly...............................................................................................13-32

(10)Installation.............................................................................................13-33

(11)Maintenance..........................................................................................13-34

(12)SpecialTorqueSpecications................................................................13-34

(13)SpecialTools.........................................................................................13-34

(14)AmbientTemperature-NitrogenPre-ChargePressure........................13-35

13.3TreadleValve.............................................................................................13-36

(1)Description.............................................................................................13-37

(2)Operation...............................................................................................13-38

(3)RebuildCriteria......................................................................................13-40

(4)Removal................................................................................................13-41

(5)Disassembly..........................................................................................13-43

(6)Assembly...............................................................................................13-45

(7)Installation.............................................................................................13-47

(8)CheckingSystemPressures.................................................................13-48

(9)SpecialTools.........................................................................................13-49

(10)TreadleValveTroubleshooting..............................................................13-50

TableofContent

07-Feb-2017

Page10

Revision1.1MaintenanceManual

TA300Tier2

(11)SpecialTorqueSpecications................................................................13-52

13.4ParkingBrakeandMounting......................................................................13-53

(1)DescriptionandOperation.....................................................................13-55

(2)Removal................................................................................................13-56

(3)Disassembly..........................................................................................13-57

(4)Inspection..............................................................................................13-58

(5)Assembly...............................................................................................13-59

(6)Installation.............................................................................................13-60

(7)SpecialTools.........................................................................................13-62

(8)SpecialTorqueSpecications................................................................13-62

14ElectricalSystem......................................................................................14-1

14.1CircuitDiagrams...........................................................................................14-3

14.2MainControllerUnitMCU............................................................................14-8

(1)Description...............................................................................................14-8

(2)OperatingStates....................................................................................14-10

(3)MCUErrorCodes..................................................................................14-11

(4)Removal................................................................................................14-15

(5)Installation.............................................................................................14-17

(6)Programming.........................................................................................14-18

(7)Diagnostics............................................................................................14-21

(8)SpecialTools.........................................................................................14-36

14.3TransmissionControllerUnit-TCU............................................................14-37

(1)Description.............................................................................................14-38

(2)Removal................................................................................................14-39

(3)Installation.............................................................................................14-40

(4)Diagnostics............................................................................................14-40

14.4DashboardDisplay.....................................................................................14-41

(1)Removal................................................................................................14-42

(2)Installation.............................................................................................14-43

(3)Programming.........................................................................................14-44

(4)Diagnostics............................................................................................14-46

14.5S6EngineManagementSystem................................................................14-46

(1)Diagnostics............................................................................................14-47

(2)ScaniaDiagnos&ProgrammerSDP3..................................................14-48

14.6PrintedCircuitBoard..................................................................................14-52

(1)Removal................................................................................................14-53

(a)Disassembly......................................................................................14-54

(b)Assembly..........................................................................................14-54

(2)Installation.............................................................................................14-55

14.7DC/DCConvertor.......................................................................................14-56

(1)Removal................................................................................................14-57

(2)Installation.............................................................................................14-58

14.8BatteryBoxAssembly................................................................................14-59

(1)Description.............................................................................................14-61

(2)Removal................................................................................................14-62

(3)Disassembly..........................................................................................14-64

(4)Assembly...............................................................................................14-64

(5)Installation.............................................................................................14-65

(6)Battery...................................................................................................14-66

TableofContent

MaintenanceManual

TA300Tier2

Revision1.107-Feb-2017

Page11

(a)Removal............................................................................................14-67

(b)Installation.........................................................................................14-68

(c)BatteryMaintenance.........................................................................14-69

(7)FuseBox...............................................................................................14-70

(a)Removal............................................................................................14-71

(b)Installation.........................................................................................14-72

14.9ControlsandInstruments...........................................................................14-73

(1)Displays.................................................................................................14-74

(a)FunctionalDescription......................................................................14-75

(b)Menus...............................................................................................14-79

(c)Switches............................................................................................14-86

(d)Controls.............................................................................................14-91

(2)SwitchesandSensors...........................................................................14-93

(a)Description........................................................................................14-94

15Chassis......................................................................................................15-1

15.1Frames.........................................................................................................15-2

(1)Description...............................................................................................15-6

(2)InspectionandMaintenance....................................................................15-7

15.2ArticulationandOscillationPivot..................................................................15-9

(1)DescriptionandOperation.....................................................................15-11

(2)Thru-DriveDriveshaft............................................................................15-11

(a)RemovalandDisassembly...............................................................15-12

(b)Inspection..........................................................................................15-13

(c)AssemblyandInstallation.................................................................15-14

(3)ArticulationComponents.......................................................................15-18

(a)DisconnectingFrontandRearFrames.............................................15-19

(b)Disassembly......................................................................................15-20

(c)Inspection..........................................................................................15-21

(d)Assembly..........................................................................................15-22

(e)ConnectingFrontandRearFrames.................................................15-25

(f)FinalAssembly..................................................................................15-26

(4)OscillationComponents.........................................................................15-27

(a)DisconnectingFrontandRearFrames.............................................15-28

(b)Disassembly......................................................................................15-30

(c)Inspection..........................................................................................15-31

(d)Assembly..........................................................................................15-32

(e)ConnectingFrontandRearFrames.................................................15-34

(5)FinalAssembly......................................................................................15-35

(6)Maintenance..........................................................................................15-37

(a)Every50Hours.................................................................................15-37

(b)Every250Hours...............................................................................15-38

(7)SpecialTools.........................................................................................15-39

(8)SpecialTorqueSpecications................................................................15-39

15.3HoodandMounting....................................................................................15-40

(1)Removal................................................................................................15-42

(2)Installation.............................................................................................15-43

(3)Maintenance..........................................................................................15-44

(4)SpecialTools.........................................................................................15-44

15.4FendersandMounting...............................................................................15-45

TableofContent

07-Feb-2017

Page12

Revision1.1MaintenanceManual

TA300Tier2

(1)Removal................................................................................................15-47

(a)FenderAssemblyLH........................................................................15-47

(b)FenderAssemblyRH........................................................................15-47

(2)Installation.............................................................................................15-48

(a)FenderAssemblyLH........................................................................15-48

(b)FenderAssemblyRH........................................................................15-49

16SuspensionSystem..................................................................................16-1

16.1FrontSuspension(IFS)................................................................................16-2

(1)Description...............................................................................................16-7

(2)Removal..................................................................................................16-7

(3)Disassembly............................................................................................16-9

(4)Assembly...............................................................................................16-11

(5)Installation.............................................................................................16-13

(6)Maintenance..........................................................................................16-16

(7)SpecialTools.........................................................................................16-16

(8)SpecialTorqueSpecications................................................................16-17

16.2RearSuspension........................................................................................16-18

(1)Description.............................................................................................16-19

(2)Removal................................................................................................16-20

(3)Installation.............................................................................................16-23

(4)Maintenance..........................................................................................16-26

(5)ServiceTools.........................................................................................16-26

(6)SpecialTorqueSpecications................................................................16-26

17CoolingSystem.........................................................................................17-1

17.1CoolingSystem............................................................................................17-2

(1)Description...............................................................................................17-2

(2)Operation.................................................................................................17-3

(3)CoolantConditionCheck.........................................................................17-5

(4)CleaningtheCoolingSystem..................................................................17-5

(a)DrainingtheCoolingSystem..............................................................17-6

(b)External-CleaningtheRadiatorandCAC.........................................17-7

(c)Internal-RemovingOilandGrease...................................................17-7

(5)RecommendedCoolants.........................................................................17-7

(a)FillingCoolant.....................................................................................17-8

(6)SpecialTools...........................................................................................17-9

(7)AdequateCorrosionProtection...............................................................17-9

(8)RecommendedAntifreezes.....................................................................17-9

(9)CoolingSystemDiagnosisChart...........................................................17-10

17.2RadiatorandMounting...............................................................................17-11

(1)Description.............................................................................................17-13

(2)Removal................................................................................................17-13

(3)Disassembly..........................................................................................17-17

(4)Inspection..............................................................................................17-18

(5)Assembly...............................................................................................17-18

(6)Installation.............................................................................................17-19

(7)Cleaning................................................................................................17-20

(a)InternalCleaning-WaterTubes.......................................................17-20

(b)ExternalCleaning..............................................................................17-21

(8)Maintenance..........................................................................................17-21

TableofContent

MaintenanceManual

TA300Tier2

Revision1.107-Feb-2017

Page13

(9)SpecialTools.........................................................................................17-21

17.3TransmissionOilCooler.............................................................................17-22

(1)DescriptionandOperation.....................................................................17-23

(2)Removal................................................................................................17-24

(3)Disassembly..........................................................................................17-28

(4)Assembly...............................................................................................17-29

(5)Installation.............................................................................................17-30

(6)Cleaning................................................................................................17-31

(a)ExternalCleaning..............................................................................17-31

(b)InternalCleaning-Tubes..................................................................17-31

(7)ServiceTools.........................................................................................17-32

17.4HydraulicOilCooler...................................................................................17-33

(1)DescriptionandOperation.....................................................................17-34

(2)Removal................................................................................................17-35

(3)Disassembly..........................................................................................17-39

(4)CleaningandInspection........................................................................17-40

(5)Assembly...............................................................................................17-41

(6)Installation.............................................................................................17-42

(7)Maintenance..........................................................................................17-43

(8)ServiceTools.........................................................................................17-43

18OperatorsCompartment..........................................................................18-1

18.1CabandMounting........................................................................................18-2

(1)Description...............................................................................................18-3

(2)Removal..................................................................................................18-5

(3)Installation...............................................................................................18-7

(4)TiltingtheCab..........................................................................................18-8

(5)LoweringtheCab....................................................................................18-9

(6)MirrorArms............................................................................................18-10

(a)Removal............................................................................................18-10

(b)Installation.........................................................................................18-10

(7)ReplacingGlass....................................................................................18-11

(a)WaterLeaks......................................................................................18-11

(8)Maintenance..........................................................................................18-11

(9)ServiceTools.........................................................................................18-11

18.2DriverSeatandMounting..........................................................................18-12

(1)Description.............................................................................................18-13

(2)SeatAdjustment....................................................................................18-14

(3)Operation...............................................................................................18-15

(4)Removal................................................................................................18-16

(5)Disassembly..........................................................................................18-17

(a)HorizontalShockAbsorber...............................................................18-17

(b)VerticalShockAbsorber....................................................................18-18

(c)Compressor......................................................................................18-19

(d)LevelController.................................................................................18-20

(6)Inspection..............................................................................................18-21

(7)Assembly...............................................................................................18-21

(8)Installation.............................................................................................18-22

(9)Maintenance..........................................................................................18-23

(10)SpecialTorqueSpecications................................................................18-23

TableofContent

07-Feb-2017

Page14

Revision1.1MaintenanceManual

TA300Tier2

18.3InstructorSeatandMounting.....................................................................18-24

(1)Description.............................................................................................18-24

(2)RemovalandDisassembly....................................................................18-26

(3)InstallationandAssembly......................................................................18-27

(4)Maintenance..........................................................................................18-27

18.4AirConditioning..........................................................................................18-28

(1)Description.............................................................................................18-28

(2)Removal................................................................................................18-31

(3)Installation.............................................................................................18-36

(4)Maintenance..........................................................................................18-38

(a)DischargingtheSystem....................................................................18-41

(b)ChargingtheSystem........................................................................18-43

(c)FinalChargingOftheSystem...........................................................18-44

(5)AirConditioningRe-StartProcedure.....................................................18-44

(6)Troubleshooting.....................................................................................18-45

(a)AirConditioningTroubleshooting......................................................18-46

(7)SpecialTools.........................................................................................18-48

19Body...........................................................................................................19-1

19.1BodyandMounting......................................................................................19-2

(1)Description...............................................................................................19-3

(2)Operation.................................................................................................19-3

(3)Removal..................................................................................................19-4

(4)Installation...............................................................................................19-6

(5)BodyShimmingProcedure......................................................................19-7

(6)Maintenance............................................................................................19-7

(7)SpecialTools...........................................................................................19-7

(8)ChainOperatedT ailgateOption..............................................................19-8

(a)TailgateRemoval................................................................................19-9

(b)TailgateInstallation...........................................................................19-11

(c)TailgateMaintenance........................................................................19-13

20Storage,DecommissioningandDisposal..............................................20-1

20.1Storage.........................................................................................................20-2

20.2Disposal.......................................................................................................20-5

21Miscellaneous...........................................................................................21-1

21.1Welding........................................................................................................21-2

(1)GeneralWeldingProcedure....................................................................21-3

21.2ServiceTools................................................................................................21-4

21.3AxleBoltandNutT orqueSpecications......................................................21-5

21.4StandardBoltandNutT orqueSpecications...............................................21-7

AppendixAElectricalSchematicDiagrams....................................................A-1

AppendixBHydraulicSystemSchematicDiagram........................................B-1

BrakePedal-DetailedView...........................................................................B-3

GlossaryofTerms

Index

TableofContent

MaintenanceManual

TA300Tier2

Revision1.107-Feb-2017

Page1-1