Related Manuals for Terex TR45
Summary of Contents for Terex TR45
- Page 1 TR45/60 TR45/60 Operation - Safety - Maintenance Operation - Safety - Maintenance https://www.besttruckmanuals.com/...
- Page 2 SPECIFY - SPECIFY - PART NUMBER 15275741 PART NUMBER 15275741 TECHNICAL PUBLICATIONS DEPARTMENT TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED TEREX EQUIPMENT LIMITED MOTHERWELL, SCOTLAND ML1 5RY MOTHERWELL, SCOTLAND ML1 5RY Ref No. OHE 817-839 July 2003 Ref No. OHE 817-839 July 2003...
- Page 3 ONLY TRAINED Y TRAINED PERSONNEL SHOULD PERSONNEL SHOULD BE ALLOWED TO OPERA ALLOWED TO OPERATE THIS V TE THIS VEHICLE EHICLE The operator is responsible and must be The operator is responsible and must be familiar with the contents of the Operator's familiar with the contents of the Operator's Handbook and any local regulations prior to Handbook and any local regulations prior to...
- Page 4 https://www.besttruckmanuals.com/...
- Page 5 CALIFORNIA CALIFORNIA Proposition 65 Warnings Proposition 65 Warnings WARNING: WARNING: Diesel engine exhaust and Diesel engine exhaust and some of its constituents are known to the some of its constituents are known to the State of California to cause cancer, birth State of California to cause cancer, birth defects, and other reproductive harm.
- Page 6 SPARE PARTS STATEMENT SPARE PARTS STATEMENT When carrying out repairs, alterations or fitting attachments, it is important that only genuine spare parts are When carrying out repairs, alterations or fitting attachments, it is important that only genuine spare parts are used to ensure the operating safety of the machine is not impaired.
- Page 7 EC DECLARATION OF CONFORMITY EC DECLARATION OF CONFORMITY MANUFACTURERS NAME AND FULL MANUFACTURERS NAME AND FULL ADDRESS ADDRESS TEREX EQUIPMENT LIMITED, TEREX EQUIPMENT LIMITED, MOTHERWELL, MOTHERWELL, SCOTLAND, SCOTLAND, ML1 5RY ML1 5RY D D E E S S C C R R I I P P T T I I O O N N O O F F M M A A C C H H I I N N E E R R Y Y...
- Page 8 SPARE PARTS STATEMENT SPARE PARTS STATEMENT When carrying out repairs, alterations or fitting attachments, it is important that only gen When carrying out repairs, alterations or fitting attachments, it is important that only genuine spare parts are uine spare parts are used to ensure the operating safety of the used to ensure the operating safety of the machine is not impaired.
- Page 9 EC DECLARATION OF CONFORMITY EC DECLARATION OF CONFORMITY MANUFACTURERS NAME AND FULL MANUFACTURERS NAME AND FULL ADDRESS ADDRESS TEREX EQUIPMENT LIMITED, TEREX EQUIPMENT LIMITED, MOTHERWELL, MOTHERWELL, SCOTLAND, SCOTLAND, ML1 5RY ML1 5RY D D E E S S C C R R I I P P T T I I O O N N O O F F M M A A C C H H I I N N E E R R Y Y...
- Page 10 SPARE PARTS STATEMENT SPARE PARTS STATEMENT When carrying out repairs, alterations or fitting attachments, it is important that only gen When carrying out repairs, alterations or fitting attachments, it is important that only genuine spare parts are uine spare parts are used to ensure the operating safety of the used to ensure the operating safety of the machine is not impaired.
- Page 11 CAL DATA Warning Warning Lights Lights .............. 3-4 Engine Engine Operation....... Operation....... 4-6 Technical Technical Data - T Data - TR45 R45 ..........9-3 Instruments Instruments ................ 3-7 Starting Starting the the Engine Engine ....
- Page 12 TR45 and TR60 Trucks. parking procedures for the TR45 and TR60 Trucks. Look for this symbol to point out important safety precautions. It means: Look for this symbol to point out important safety precautions.
- Page 13 WARNING WARNING These trucks are equipped with These trucks are equipped with cylinders containing compressed cylinders containing compressed nitrogen gas. Transportation of these trucks by any method may nitrogen gas. Transportation of these trucks by any method may require a special permit from the appropriate authority of the country require a special permit from the appropriate authority of the country involved.
- Page 14 Truck Identification Truck Identification While reading this handbook you will While reading this handbook you will notice references to controls and notice references to controls and equipment which may not be found on equipment which may not be found on all trucks.
- Page 15 Theft Deterrent Practices Theft Deterrent Practices General General The owner/operator should take the following precautions to discourage The owner/operator should take the following precautions to discourage theft, to aid theft, to aid in the recovery in the event that the truck is stolen, or to reduce vandalism. in the recovery in the event that the truck is stolen, or to reduce vandalism.
- Page 16 Actions to Aid in Recovery of Actions to Aid in Recovery of Stolen Trucks Stolen Trucks In the event of theft, immediately notify In the event of theft, immediately notify the law enforcement authorities having the law enforcement authorities having jurisdiction.
- Page 17 2 - Safety Precautions 2 - Safety Precautions https://www.besttruckmanuals.com/...
- Page 18 SAFETY PRECAUTIONS SAFETY PRECAUTIONS General General Read t Read this Ope his Operator rator’s Han ’s Handbook a dbook and lea nd learn the rn the opera operating ch ting charact aracteristi eristics and cs and limitations of the machine. Know what operating clearances the machine limitations of the machine.
- Page 19 Clean Clean any mu any mud, gr d, grease o ease or oil r oil from from contro controls, h ls, handrai andrails, la ls, ladders dders and de and decks. cks. Lash necessary tools securely and remove all loose items before operating Lash necessary tools securely and remove all loose items before operating machine.
- Page 20 Preventing Fire Hazards Preventing Fire Hazards General Fire Precautions General Fire Precautions Make s Make sure ma ure machine chine has fi has fire ext re extinguis inguisher an her and that d that it is a it is accessi ccessible an ble and fully d fully...
- Page 21 Shut Shut off en off engine a gine and use nd use extra extra cautio caution if en n if engine i gine is hot w s hot when re hen refuelli fuelling. Ground the hose spout to prevent sparks when spout is touched to fuel tank Ground the hose spout to prevent sparks when spout is touched to fuel tank filler tube.
- Page 22 Alway Always disc s disconnect onnect batter batteries an ies and alt d alternato ernator lea r leads bef ds before c ore carryin arrying out g out any welding on the machine. welding on the machine. Never Never check b check batter attery charg...
- Page 23 Pre-Starting Pre-Starting If en If engine i gine is to b s to be star e started an ted and run d run indoor indoors, ens s, ensure p ure proper roper ventil ventilation ation to to remove deadly exhaust gases. remove deadly exhaust gases.
- Page 24 Operating Operating Ensur Ensure all e all cab g cab glass, lass, mirro mirrors an rs and ligh d light len t lenses ar ses are cle e clean dur an during ma ing machine chine operation for maximum visibility. operation for maximum visibility.
- Page 25 Use e Use extrem xtreme cauti e caution and on and turn turn on ligh on lights at ts at night night or wh or when fog en fog, dust , dust or sim or similar ilar hazards limit visibility. Do not overdrive your headlights. hazards limit visibility.
- Page 26 Roading Roading Matc tch sp h spee eed to d to ro road c ad con ondi diti tion ons. s. Yield Yield the r the right o ight of way f way when when requir required. O ed.
- Page 27 Lubrication and Servicing Lubrication and Servicing Do no Do not allo t allow una w unauthor uthorized p ized personn ersonnel to el to servic service or m e or maintai aintain this n this machin machine. e. Study the Operator’s Handbook and Service Manual before starting, Study the Operator’s Handbook and Service Manual before starting, operating or servicing this machine.
- Page 28 Wheels and Tyres Wheels and Tyres If tyres on a machine were inflated at the factory with dry nitrogen gas, the tyre If tyres on a machine were inflated at the factory with dry nitrogen gas, the tyre walls will be marked 'N' and the following factory installed decal will be found walls will be marked 'N' and the following factory installed decal will be found mounted on either side of the cab platform and the body.
- Page 29 Avoid Tyre Explosion Hazard Avoid Tyre Explosion Hazard AT LEAST 460 m AT LEAST 460 m AT LEAST 15 m (50 ft) AT LEAST 15 m (50 ft) (1 500 ft) (1 500 ft) WARNING WARNING Whenever a machine’s tyre(s) is (are) exposed Whenever a machine’s tyre(s) is (are) exposed to to excessive heat such as a machine fire or extremely excessive heat such as a machine fire or extremely...
- Page 30 Decals and Instruction Plates Decals and Instruction Plates Decals and instruction plates fitted to Decals and instruction plates fitted to these machines may vary from country these machines may vary from country to country to suit local needs. These to country to suit local needs.
- Page 31 1. 1. Alternator Precautions Alternator Precautions 2. 2. CEC (ATEC) Welding Warning CEC (ATEC) Welding Warning 1 1 5 5 1 1 7 7 1 1 4 4 3. 3. Engine Instructions Engine Instructions 4. 4. Body Control Lever Positions Body Control Lever Positions 2, 3, 4, 5, 6, 7 2, 3, 4, 5, 6, 7...
- Page 32 2-16 2-16 https://www.besttruckmanuals.com/...
- Page 33 3 - Controls and Operating 3 - Controls and Operating https://www.besttruckmanuals.com/...
- Page 34 1477 1477 https://www.besttruckmanuals.com/...
- Page 35 CONTROLS AND INSTRUMENTS CONTROLS AND INSTRUMENTS 1. 1. Face Vent/ Face Vent/Side Windo Side Window Demister w Demister 20. . Reta Retarder Cont rder Control 2. 2. Warn Warning L ing Lights ights 21. . Igniti Ignition and Starter Key Switc on and Starter Key Switch h 3.
- Page 36 BASIC DATA BASIC DATA Warning Lights Warning Lights 1. Alternator Charging (Red) - 1. Alternator Charging (Red) - Illuminates to indicate when the Illuminates to indicate when the alternator is not charging. alternator is not charging. 2. Engine Water Temperature (Red) - 2.
- Page 37 accumulator. Stop the machine if this light illuminates and do not operate until the accumulator. Stop the machine if this light illuminates and do not operate until the fault is corrected. fault is corrected. 11. Low Steering Pressure (Red) - 11.
- Page 38 23. Transmission Oil Filter Restriction (Amber) - 23. Transmission Oil Filter Restriction (Amber) - Illuminates when the filter is Illuminates when the filter is restricted, indicating that a filter change is required. Transmission will not upshift restricted, indicating that a filter change is required. Transmission will not upshift from first gear while this light is illuminated.
- Page 39 Instruments Instruments 1. Tachometer/Hourmeter - 1. Tachometer/Hourmeter - Driven Driven from the engine ECM, the tachometer from the engine ECM, the tachometer indicates the engine speed in indicates the engine speed in RPM x100 RPM x100 revolutions per minute.
- Page 40 5. Transmission Oil Pressure 5. Transmission Oil Pressure Gauge - Gauge - Indicates transmission clutch Indicates transmission clutch application oil pressure. The reading application oil pressure. The reading will vary during shifts and with varying will vary during shifts and with varying speeds and loads.
- Page 41 Switches Switches 1. Hazard Warning Lights - 1. Hazard Warning Lights - Press bottom of switch to make turn indicators flash Press bottom of switch to make turn indicators flash simultaneously as hazard warning lights. The light in the switch and direction simultaneously as hazard warning lights.
- Page 42 7. Sidelight and Headlight - 7. Sidelight and Headlight - Press bottom of switch to the first position to operate Press bottom of switch to the first position to operate side, tail and panel lights. The lights in the other switches will illuminate. Press side, tail and panel lights.
- Page 43 13. Manual Mode Switch - 13. Manual Mode Switch - Allows the service technician to change the Allows the service technician to change the operation of the transmission from automatic to manual. operation of the transmission from automatic to manual. Automatic - Normal operation.
- Page 44 17. Electric Window Switch - 17. Electric Window Switch - Press Press bottom of switch to lower window; bottom of switch to lower window; press top of switch to raise window. press top of switch to raise window. 1174 1174 Controls...
- Page 45 Heater Heater Blower control (2) is rotated to select one of three blower speeds. Blower control (2) is rotated to select one of three blower speeds. Temperature control (1) is rotated to vary heater output temperature. Heater Temperature control (1) is rotated to vary heater output temperature. Heater ...
- Page 46 Operator's Seat - Air Operator's Seat - Air Suspension Suspension The air seat only reacts when the driver The air seat only reacts when the driver sits on the seat. When unoccupied sits on the seat. When unoccupied the seat sinks to the lowest position to seat sinks to the lowest position to allow easier access.
- Page 47 Seat Belt Seat Belt Retractable seat belts are installed on both operators seat and jump seat. The Retractable seat belts are installed on both operators seat and jump seat. The seat belts require no external adjustment and allow freedom of movement for seat belts require no external adjustment and allow freedom of movement for proper manipulation of all controls.
- Page 48 MACHINE CONTROLS MACHINE CONTROLS Braking Braking The dual circuit brake system is applied during normal operation by using the The dual circuit brake system is applied during normal operation by using the Service Brake Pedal or, in an emergency, by Service Brake Pedal or, in an emergency, by using the Park/Emergency Brake using the Park/Emergency Brake Control.
- Page 49 Retarder Retarder This control lever (1) is used to apply retardation to the truck. Retardation is the This control lever (1) is used to apply retardation to the truck. Retardation is the term used for applying a continuous braking force term used for applying a continuous braking force to hold the truck to a safe steady to hold the truck to a safe steady speed when descending grades.
- Page 50 Retarder Operation Retarder Operation Before the machine crests the top of a grade and starts down, the operator Before the machine crests the top of a grade and starts down, the operator WARNING WARNING should slow the machine with the service brakes and downshift to the gear should slow the machine with the service brakes and downshift to the gear Great care should be used if Great care should be used if...
- Page 51 Engine Engine Electronic Foot Pedal Electronic Foot Pedal The electronic foot pedal provides an electronic signal to the engine's fuel The electronic foot pedal provides an electronic signal to the engine's fuel control system in proportion to the degree of pedal actuation. control system in proportion to the degree of pedal actuation.
- Page 52 STOP STOP TEST TEST 1 1 - Ele - Electroni ctronic Co c Control ntrol Module Module (ECM) (ECM) 4 4 - El - Elect ectron ronic F ic Foot oot Ped Pedal al 7 7 - ' - 'Fl Flui uid' d' Li Ligh ght t 2 2 - Progr - Programmabl...
- Page 53 QUANTUM Electronic Fuel System - Description QUANTUM Electronic Fuel System - Description 1. Electronic Control Module (ECM) - 1. Electronic Control Module (ECM) - Receives electronic inputs from the driver Receives electronic inputs from the driver as well as from sensors that provide information electronically, such as well as from sensors that provide information electronically, such as oil pressure as oil pressure and temperature and intake manifold pressure.
- Page 54 QUANTUM Electronic Fuel System - Operation QUANTUM Electronic Fuel System - Operation When the 'Stop' light on the dash panel illuminates, the computer has detected a When the 'Stop' light on the dash panel illuminates, the computer has detected a major malfunction in the engine that requires immediate attention.
- Page 55 A special diagnostic data reader (INSITE) is available that can be plugged into A special diagnostic data reader (INSITE) is available that can be plugged into the engine computer memory to extract information related to the cause of the the engine computer memory to extract information related to the cause of the problem.
- Page 56 ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES E E r r r r o o r r C C o o d d e e D D e e s s c c r r i i p p t t i i o o n n F F a a u u l l t t L L a a m m p p 1 1 1 1 1 1 E E C C M M H H a a r r d d w w a a r r e e I I n n t t e e r r n n a a l l F F a a i i l l u u r r e e - - M M i i s s s s i i o o n n d d i i s s a a b b l l i i n n g g...
- Page 57 ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES E E r r r r o o r r C C o o d d e e D D e e s s c c r r i i p p t t i i o o n n F F a a u u l l t t L L a a m m p p 2 2 5 5 9 9 F F u u e e l l S S h h u u t t o o f f f f S S o o l l e e n n o o i i d d - - F F u u e e l l s s h h u u t t o o f f f f v v a a l l v v e e s s t t u u c c k k o o p p e e n n...
- Page 58 Steering Steering The steering wheel position can be adjusted as required for the most convenient The steering wheel position can be adjusted as required for the most convenient operating position. To adjust, pull out adjustment lock and tilt steering wheel up operating position.
- Page 59 Transmission Transmission This machine is equipped with an CEC (Commercial Electronic Control) shift This machine is equipped with an CEC (Commercial Electronic Control) shift system, to operate the transmission. The CEC shift system continually monitors the system, to operate the transmission. The CEC shift system continually monitors the transmission and shift system electrical components and warns the operator when transmission and shift system electrical components and warns the operator when a problem develops.
- Page 60 BODY UP INTERLOCK - When the body is raised, the CEC system will only BODY UP INTERLOCK - When the body is raised, the CEC system will only allow the transmission to operate in First gear. This feature is only operational in allow the transmission to operate in First gear.
- Page 61 1 1 2 2 3 3 4 4 VIEW ON FRONT OF VIEW ON FRONT OF 5 5 D D N N INTERFACE BOX INTERFACE BOX R R 1 1 R R 2 2 MANUAL AUT MANUAL AUT POWER POWER...
- Page 62 Description and Operation Description and Operation 1. Electronic Control Unit (ECU) - 1. Electronic Control Unit (ECU) - Contains an electronic microcomputer. The Contains an electronic microcomputer. The ECU receives information in the form of electronic signals from switches and ECU receives information in the form of electronic signals from switches and sensors, processes the information, and sends electronic signals to the sensors, processes the information, and sends electronic signals to the...
- Page 63 through all six forward ranges as required by loads and travel speeds. Selecting through all six forward ranges as required by loads and travel speeds. Selecting a lower range (4th, 3rd etc.) limits the highest range to which the transmission a lower range (4th, 3rd etc.) limits the highest range to which the transmission will automatically upshift.
- Page 64 WARNING WARNING Always select Neutral and apply the parking brake before leaving the Always select Neutral and apply the parking brake before leaving the operator’s seat. operator’s seat. 4. Mode Selection Switch - 4. Mode Selection Switch - Gives the option to select between transmission Gives the option to select between transmission MANU MANUAL AUTO...
- Page 65 timed, preprogrammed schedule where in Second through Sixth gears the timed, preprogrammed schedule where in Second through Sixth gears the lockup clutch is disengaged only long enough to allow the torque converter’s lockup clutch is disengaged only long enough to allow the torque converter’s fluid coupling to absorb shift shock.
- Page 66 WARNING WARNING The manual mode is not intended to The manual mode is not intended to be used for normal be used for normal operations. The machine should only be driven at very low speeds in operations. The machine should only be driven at very low speeds in first or reverse gears if the manual mode is activated, or damage to the first or reverse gears if the manual mode is activated, or damage to the transmission may result.
- Page 67 should modify throttle position, or gear held to achieve a steady road speed with should modify throttle position, or gear held to achieve a steady road speed with the torque converter lockup engaged (Indicator Light 'Off'). The Lockup relay in the torque converter lockup engaged (Indicator Light 'Off').
- Page 68 Retrieving Diagnostic Codes Retrieving Diagnostic Codes Diagnostic fault codes can be retrieved from the CEC2 system using the gear Diagnostic fault codes can be retrieved from the CEC2 system using the gear shift selector or by plugging in the diagnostic data reader (DDR). To obtain shift selector or by plugging in the diagnostic data reader (DDR).
- Page 69 CEC2 DIAGNOSTIC CODES CEC2 DIAGNOSTIC CODES M M a a i i n n C C o o d d e e S S u u b b C C o o d d e e D D e e s s c c r r i i p p t t i i o o n n C C h h e e c c k k T T r r a a n n s s L L i i g g h h t t 1 1 3 3 1 1 2 2...
- Page 70 CEC2 DIAGNOSTIC CODES CEC2 DIAGNOSTIC CODES M M a a i i n n C C o o d d e e S S u u b b C C o o d d e e D D e e s s c c r r i i p p t t i i o o n n C C h h e e c c k k T T r r a a n n s s L L i i g g h h t t 3 3 6 6 0 0 0 0...
- Page 71 Body Control Body Control The lever to the left of the operator’s seat controls the hydraulic valve which The lever to the left of the operator’s seat controls the hydraulic valve which operates the body hoist cylinders. The four operating positions of the lever from operates the body hoist cylinders.
- Page 72 Raising the Body Raising the Body Before raising the body, allow the engine to slow to idle, make sure the rear Before raising the body, allow the engine to slow to idle, make sure the rear wheels are on firm level ground, shift the transmission to Neutral and hold the wheels are on firm level ground, shift the transmission to Neutral and hold the machine stationary by applying the brakes with the Parking-Emergency brake machine stationary by applying the brakes with the Parking-Emergency brake...
- Page 73 4 - Operating The Truck 4 - Operating The Truck https://www.besttruckmanuals.com/...
- Page 74 OPERATING THE TRUCK OPERATING THE TRUCK ENGINE ENGINE RADIATOR AND COOLING RADIATOR AND COOLING Pre-Starting Inspection Pre-Starting Inspection Check oil level. Check for Check oil level. Check for LINES LINES leaks. leaks. Check for leaks. Check for leaks. * Before the engine is started ensure the * Before the engine is started ensure the machine is ready for operation.
- Page 75 Component Checks Component Checks 1. Engine - 1. Engine - With the engine off, check With the engine off, check oil level. The oil level should be oil level. The oil level should be between the lower and upper marks between the lower and upper marks on the dipstick.
- Page 76 7. Body and Disc Brake Cooling 7. Body and Disc Brake Cooling Tank - Cold Oil Level - Tank - Cold Oil Level - The bottom The bottom sight gauge should show full. Add sight gauge should show full. Add fluid, if low.
- Page 77 Suspension Ride Struts Suspension Ride Struts Suspension ride struts are oiled and charged with nitrogen to ensure optimum ride comfort. However, ride struts may have Suspension ride struts are oiled and charged with nitrogen to ensure optimum ride comfort. However, ride struts may have been lowered during transportation of the machine.
- Page 78 Engine Operation Engine Operation Note: Note: The electronic controlled engine will override the electronic foot pedal The electronic controlled engine will override the electronic foot pedal position until the engine is warmed up to the correct operating temperature. The position until the engine is warmed up to the correct operating temperature.
- Page 79 Starting the Engine Starting the Engine Attention to the warning lights and Attention to the warning lights and instruments when starting the engine, instruments when starting the engine, MODE MODE and operating, will help the operator and operating, will help the operator monitor the machine systems and monitor the machine systems and...
- Page 80 7. 7. Turn key further clockwise against Turn key further clockwise against spring pressure to position '3' to crank spring pressure to position '3' to crank the engine. Release the key as soon as the engine. Release the key as soon as RPMx100 RPMx100 the engine starts firing.
- Page 81 Starting the Engine with Jumper Cables Starting the Engine with Jumper Cables WARNING WARNING Hazardous hydrogen gas and sulphuric acid. Check for required voltage Hazardous hydrogen gas and sulphuric acid. Check for required voltage and polarity connections to discharged batteries. Excessive booster and polarity connections to discharged batteries.
- Page 82 Pre-Operating Checks Pre-Operating Checks Make sure all cab glass, mirrors and lights are clean. Test all controls to ensure Make sure all cab glass, mirrors and lights are clean. Test all controls to ensure they are functioning properly. Select 'REVERSE' momentarily on the transmission they are functioning properly.
- Page 83 WARNING WARNING Make sure the area around the machine is clear of Make sure the area around the machine is clear of personnel and personnel and obstructions before carrying out these checks. obstructions before carrying out these checks. If the machine moves during these checks, If the machine moves during these checks, stop the machine, apply the stop the machine, apply the...
- Page 84 Driving and Stopping Driving and Stopping Before driving off observe all Before driving off observe all instruments and warning lights. All instruments and warning lights. All MODE MODE instruments should operate in their instruments should operate in their normal range and all warning lights normal range and all warning lights should be out except possibly the...
- Page 85 5. Release the service brake, apply 5. Release the service brake, apply the accelerator and move off. the accelerator and move off. 6. To stop the machine release the 6. To stop the machine release the accelerator and depress the service accelerator and depress the service brake pedal.
- Page 86 Stopping the Engine Stopping the Engine 1. Make sure the parking-emergency 1. Make sure the parking-emergency brake control is in the 'PARK' position. brake control is in the 'PARK' position. 2. Make sure the transmission is in 2.
- Page 87 5. Turn the steering wheel in both directions to dissipate the pressure in the 5. Turn the steering wheel in both directions to dissipate the pressure in the steering accumulator to prevent accidental steering during bleed down. steering accumulator to prevent accidental steering during bleed down. 1109 1109 6.
- Page 88 Parking Parking When parking the machine overnight, or for an extended period, the following When parking the machine overnight, or for an extended period, the following procedure in addition to that given in 'Stopping the Engine' will help maintain it in procedure in addition to that given in 'Stopping the Engine' will help maintain it in good condition for subsequent use: good condition for subsequent use:...
- Page 89 5 - Working the Truck 5 - Working the Truck https://www.besttruckmanuals.com/...
- Page 90 WORKING THE TRUCK WORKING THE TRUCK Off-highway trucks are used on a variety of hauling jobs, from mine overburden Off-highway trucks are used on a variety of hauling jobs, from mine overburden removal to dam building. Every truck operation, regardless of the type of job, can removal to dam building.
- Page 91 the truck is usually backed into the loading position with this method, the the truck is usually backed into the loading position with this method, the operator must be alert and careful while backing. operator must be alert and careful while backing. For fastest, most accurate loading when being loaded by a front end loader, the For fastest, most accurate loading when being loaded by a front end loader, the truck operator should spot his machine on the most level area and at an angle to...
- Page 92 Hauling Hauling While travelling the haul road, always maintain a safe speed for the haul road While travelling the haul road, always maintain a safe speed for the haul road conditions and grades. Never allow the machine to move or coast with the conditions and grades.
- Page 93 Dumping Dumping The dumping operation usually depends upon the type of material being hauled. The dumping operation usually depends upon the type of material being hauled. TWO MINIMUM TWO MINIMUM For instance, overburden and other waste material is usually dumped over a For instance, overburden and other waste material is usually dumped over a spoil bank or piled into large mounds.
- Page 94 can be pushed over the edge later. can be pushed over the edge later. Before raising the body, make sure the rear wheels are on firm level ground. If Before raising the body, make sure the rear wheels are on firm level ground. If one wheel is higher than the other, a twisting strain is imposed upon the body one wheel is higher than the other, a twisting strain is imposed upon the body hinge pins, hoists and chassis.
- Page 95 Empty Return Empty Return Make sure the body is completely lowered, the body control lever is in the Make sure the body is completely lowered, the body control lever is in the 'FLOAT' position, and the transmission is shifted to the correct range before 'FLOAT' position, and the transmission is shifted to the correct range before releasing the brakes and moving away from the dump site.
- Page 96 https://www.besttruckmanuals.com/...
- Page 97 6 - Roading 6 - Roading https://www.besttruckmanuals.com/...
- Page 98 ROADING ROADING WARNING WARNING These machines are equipped with These machines are equipped with cylinders containing compressed cylinders containing compressed nitrogen gas. Transportation of these machines by any method may nitrogen gas. Transportation of these machines by any method may require a special permit from the appropriate authority of the country require a special permit from the appropriate authority of the country involved.
- Page 99 Inspection Inspection Perform all pre-starting and post-starting checks described in this Handbook. Pay Perform all pre-starting and post-starting checks described in this Handbook. Pay particular attention to the function of all instruments and lights, and make any particular attention to the function of all instruments and lights, and make any repairs necessary.
- Page 100 In Case of Trouble In Case of Trouble If trouble develops en route, move machine off the road at the first safe parking If trouble develops en route, move machine off the road at the first safe parking place, and shut off the engine.
- Page 101 7 - Moving Disabled Truck 7 - Moving Disabled Truck https://www.besttruckmanuals.com/...
- Page 102 MOVING DISABLED TRUCK MOVING DISABLED TRUCK Any unusual power train noises noted while operating the truck should be Any unusual power train noises noted while operating the truck should be reported to those responsible for maintenance. Should the power train, hydraulic reported to those responsible for maintenance.
- Page 103 If the parking brake must be released, but the engine cannot be operated to If the parking brake must be released, but the engine cannot be operated to provide the required hydraulic power needed to release the brake, refer to the provide the required hydraulic power needed to release the brake, refer to the machine service manual Section 165-0030, for parking brake release with machine service manual Section 165-0030, for parking brake release with...
- Page 104 https://www.besttruckmanuals.com/...
- Page 105 8 - Lubrication and Servicing 8 - Lubrication and Servicing https://www.besttruckmanuals.com/...
- Page 106 SAFETY PRECAUTIONS SAFETY PRECAUTIONS Do not allow unauthorized personnel to service or maintain this truck. Study the Do not allow unauthorized personnel to service or maintain this truck. Study the Operator’s Handbook and Maintenance Manual before starting, operating or Operator’s Handbook and Maintenance Manual before starting, operating or servicing this truck.
- Page 107 LUBRICATION AND SERVICING LUBRICATION AND SERVICING WARNING WARNING These trucks are equipped with engine and transmission oil pans which These trucks are equipped with engine and transmission oil pans which permit operation at maximum gradeability as permit operation at maximum gradeability as designated in the designated in the 'Performance Data' section of the relevent Sales Specification Sheet.
- Page 108 1 1 6 6 2 2 1 1 5 5 8 8 2 2 6 6 1 1 0 0 2 2 8 8 2 2 1 1 2 2 2 2 1 1 9 9 1 1 2 2 2 2 1 1 2 2 5 5...
- Page 109 LUBRICATION AND SERVICE CHART LUBRICATION AND SERVICE CHART I I n n t t e e r r v v a a l l R R e e f f . . N N o o . . o o f f H H o o u u r r s s P P o o i i n n t t s s I I d d e e n n t t i i f f i i c c a a t t i i o o n n S S e e r r v v i i c c e e I I n n s s t t r r u u c c t t i i o o n n s s P P o o i i n n t t s s L L u u b b r r i i c c a a n n t t S S e e r r v v i i c c e e / / Q Q u u a a n n t t i i t t i i e e s s...
- Page 110 LUBRICATION AND SERVICE CHART LUBRICATION AND SERVICE CHART (CONTINUED) (CONTINUED) I I n n t t e e r r v v a a l l R R e e f f . . N N o o . . o o f f H H o o u u r r s s P P o o i i n n t t s s I I d d e e n n t t i i f f i i c c a a t t i i o o n n S S e e r r v v i i c c e e I I n n s s t t r r u u c c t t i i o o n n s s P P o o i i n n t t s s L L u u b b r r i i c c a a n n t t S S e e r r v v i i c c e e / / Q Q u u a a n n t t i i t t i i e e s s...
- Page 111 LUBRICATION AND SERVICE CHART (Continued) LUBRICATION AND SERVICE CHART (Continued) I I n n t t e e r r v v a a l l R R e e f f . . N N o o . . o o f f H H o o u u r r s s P P o o i i n n t t s s I I d d e e n n t t i i f f i i c c a a t t i i o o n n S S e e r r v v i i c c e e I I n n s s t t r r u u c c t t i i o o n n s s...
- Page 112 MISCELLANEOUS SERVICING MISCELLANEOUS SERVICING WHEN REQUIRED WHEN REQUIRED Seat Belts - Seat Belts - Inspect seat belts and replace if damaged. Inspect seat belts and replace if damaged. Note: Note: Replace seat belts at least once every three years, regardless of Replace seat belts at least once every three years, regardless of appearance.
- Page 113 Steering, Braking and Body Hoist Systems - Steering, Braking and Body Hoist Systems - Check for correct operation of Check for correct operation of all systems before operating the truck. all systems before operating the truck. Steering Filter - Steering Filter - Check steering filter restriction warning light with the truck Check steering filter restriction warning light with the truck empty, brakes released, oil at normal operating temperature, engine operating at...
- Page 114 Note: Note: The fan belt is maintained to the correct belt tension by a spring loaded The fan belt is maintained to the correct belt tension by a spring loaded idler arm, therefore, there is no need to check or adjust belt tension. idler arm, therefore, there is no need to check or adjust belt tension.
- Page 115 EVERY 2 000 HOURS OF OPERATION EVERY 2 000 HOURS OF OPERATION Steering Filter - Steering Filter - Clean filter housing and install new element when indicated, Clean filter housing and install new element when indicated, or after 2 000 hours of operation, whichever comes first. or after 2 000 hours of operation, whichever comes first.
- Page 116 SERVICE C SERVICE C APACITIES APACITIES Service Capacities Service Capacities R R e e f f . . T T R R 4 4 5 5 T T R R 6 6 0 0 P P o o i i n n t t s s I I d d e e n n t t i i f f i i c c a a t t i i o o n n L L u u b b r r i i c c a a n n t t l l i i t t r r e e s s U U S S g g a a l l...
- Page 117 RECOMMENDED LUBRICANTS RECOMMENDED LUBRICANTS C C O O M M P P O O N N E E N N T T L L U U B B R R I I C C A A N N T T V V I I S S C C O O S S I I T T Y Y ( ( S S e e e e N N o o t t e e 1 1 * * ) ) E E n n g g i i n n e e E E n n g g i i n n e e o o i i l l w w i i t t h h 1 1 .
- Page 118 RECOMMENDED LUBRICANTS (Continued) RECOMMENDED LUBRICANTS (Continued) C C O O M M P P O O N N E E N N T T L L U U B B R R I I C C A A N N T T V V I I S S C C O O S S I I T T Y Y ( ( S S e e e e N N o o t t e e 1 1 ) ) R R i i d d e C e Cy y l l i i n n d d e e r r s s...
- Page 119 9 - Technical Data 9 - Technical Data https://www.besttruckmanuals.com/...
- Page 120 4 060 4 060 Max. Max. (13-4) (13-4) 1 195 1 195 Body Body Mulden- Mulden- (3-11) (3-11) Depth Depth tiefe tiefe 3 800 3 800 (12-6) (12-6) 3 530 3 530 (11-7) (11-7) (2-8) (2-8) (1-6) (1-6) 1 520...
- Page 121 TECHNICAL DATA TR45 TECHNICAL DATA TR45 Speeds With Standard Differential Speeds With Standard Differential ENGINE ENGINE Forward Forward Make/Model Make/Model ................ Cummi Cummins ns QSK1 QSK19-C52 9-C525 5 G G e e a a r r Type Type ..
- Page 122 Rear: Rear: Variable rate nitrogen/oil cylinders with A-frame Variable rate nitrogen/oil cylinders with A-frame Front Bra Front Brake Circui ke Circuit Pressur t Pressure e ......159 bar (2 300 lbf/in 159 bar (2 300 lbf/in²) ²) linkage and lateral stabilizer bar.
- Page 123 STEERING SYSTEM STEERING SYSTEM Control Valve Control Valve ..........Servo Servo Controlled, Controlled, Open Open Centre Centre Independent hydrostatic steering with closed-centre Independent hydrostatic steering with closed-centre Body Body Raise Raise Time Time ....................13 13 Seconds Seconds steering valve, accumulator and pressure compensating steering valve, accumulator and pressure compensating...
- Page 124 SERVICE CAPACITIES SERVICE CAPACITIES VEHICLE WEIGHTS (MASS) VEHICLE WEIGHTS (MASS) Engine Crankcase and Filters Engine Crankcase and Filters ...... 55 litres 55 litres (14.5 U (14.5 US gal) S gal) Transmission and Filters Transmission and Filters ..........
- Page 125 TR60 T TR60 Technical echnical Data Data On Following Page On Following Page https://www.besttruckmanuals.com/...
- Page 126 4 470 4 470 (14-8) (14-8) 1 425 1 425 Body Body (4-8) (4-8) Depth Depth (14-0) (14-0) 4 270 4 270 3 950 3 950 (12-11) (12-11) (3-1) (3-1) (2-0) (2-0) 1 380 1 380 Vehicle Clearance Diameter (SAE) 21 m Vehicle Clearance Diameter (SAE) 21 m (68-10) (68-10) (4-6)
- Page 127 TECHNICAL DATA TR60 TECHNICAL DATA TR60 ENGINE ENGINE reverse. Automatic converter lockup action in all speed reverse. Automatic converter lockup action in all speed Make/Model Make/Model ............... . Cummi Cummins ns QSK1 QSK19-C65 9-C650 0 ranges.
- Page 128 SUSPENSION SUSPENSION Accumulators: Accumulators: Front: Front: King pin strut type independent front wheel suspension King pin strut type independent front wheel suspension Nitrogen Nitrogen Precharge P Precharge Pressure ressure ........55 bar 55 bar (800 lbf/in²) (800 lbf/in²) by self-contained, variable rate, nitrogen/oil cylinders.
- Page 129 STEERING SYSTEM STEERING SYSTEM Control Valve Control Valve ..........Servo Servo Controlled, Controlled, Open Open Centre Centre Independent hydrostatic steering with closed-centre Independent hydrostatic steering with closed-centre Body Body Raise Raise Time Time ....................13 13 Seconds Seconds steering valve, accumulator and pressure compensating steering valve, accumulator and pressure compensating...
- Page 130 SERVICE CAPACITIES SERVICE CAPACITIES Vehicle Weights (Mass) Vehicle Weights (Mass) Engine Crankcase and Filters Engine Crankcase and Filters ...... 55 litres 55 litres (14.5 U (14.5 US gal) S gal) Transmission and Filters Transmission and Filters ........
- Page 131 10 - 10 - Symbol Identification Symbol Identification https://www.besttruckmanuals.com/...
- Page 132 SYMBOL IDENTIFICATION SYMBOL IDENTIFICATION These pages explain the meaning of symbols that may appear on your machine. These pages explain the meaning of symbols that may appear on your machine. B B a a s s i i c c S S w w i i t t c c h h H H o o u u r r m m e e t t e e r r U U n n l l o o c c k k...
- Page 133 E E n n g g i i n n e e B B a a s s i i c c T T r r a a n n s s m m i i s s s s i i o o n n M M i i n n i i m m u u m m ' ' O O f f f f ' ' T T r r a a n n s s m m i i s s s s i i o o n n...
- Page 134 H H o o t t H H e e a a t t i i n n g g L L i i g g h h t t F F l l o o o o d d H H o o r r n n Hydraulic Hydraulic...
- Page 135 H H e e a a t t e e r r P P a a r r k k i i n n g g L L o o w w S S t t e e e e r r i i n n g g B B o o d d y y ' ' H H o o l l d d ' ' B B r r a a k k e e P P r r e e s s s s u u r r e e...
- Page 136 L L i i f f t t P P o o i i n n t t C C l l u u t t c c h h 'Disengage' 'Disengage' D D o o N N o o t t L L i i f f t t B B r r a a k k e e Applied - Applied -...
- Page 137 Notes Notes 10-7 10-7 https://www.besttruckmanuals.com/...
- Page 138 NOTES NOTES 10-8 10-8 https://www.besttruckmanuals.com/...
- Page 139 NOTES NOTES 10-9 10-9 https://www.besttruckmanuals.com/...
- Page 140 NOTES NOTES 10-10 10-10 https://www.besttruckmanuals.com/...
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