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.
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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
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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
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(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
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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
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(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
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(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
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(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
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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
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