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Summary of Contents for Terex TR45
- Page 1 TR45 Off-Highway Trucks Service Manual TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED, MOTHERWELL, SCOTLAND, ML1 5RY REF. NO. SM754/781 SM 1606 Rev 2 02-02...
- Page 2 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
- Page 3 TEREX SERVICE DEPARTMENT TEREX Equipment Limited, Motherwell, Scotland ML1 5RY Tel. (0698) 732121 Tlx. 77141 Fax. (0698) 734046 TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. (918) 446-5581 Fax. (918) 446-9752 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
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Page 5: Important Safety Notice
WARNING Never use parts which are altered, modified, or weakened in operation. This can seriously jeopardize the integrity of the machine and could result in property damage or serious personal injury. SM 222 Rev 1 9-93 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... - Page 6 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
- Page 7 TABLE OF CONTENTS Section No. Description SM No. GENERAL INFORMATION 0000 TR45 Off-Highway Truck 1608 CHASSIS 0010 Chassis, Hood and Fenders 1570 ENGINE 0030 Engine and Mounting 1571 0050 Air Cleaner 1572 0130 Power Takeoff 1296 TRANSMISSION 0010 Transmission and Mounting...
- Page 8 Air Conditioning and Mounting 1620 BODY 0010 Body and Mounting 1610 MISCELLANEOUS 0020 Lubrication System 1611 0070 Service Tools 1621 0080 Standard Bolt and Nut Torque Specifications 1238 0090 Unit Storage 1239 SM 1607 Rev 2 02-02 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
- Page 9 GENERAL INFORMATION - TR45 Off-Highway Truck Section 000-0000 SM - 2014 4 060 (13-4) 1 195 Body (3-11) Depth 3 800 (12-6) 3 530 (11-7) (2-11) (1-9) 1 440 Vehicle Clearance Diameter (SAE) 21m (69ft) (4-9) 7 455 (24-6) 2 710 (8-11)
- Page 10 General Information - TR45 Off-Highway Truck Section 000-0000 DRIVE AXLE Parking Heavy duty axle with single reduction spiral bevel gear Application of rear brakes by springs in brake disc pack. differential, full floating axle shafts, and planetary reduction Hydraulically released.
- Page 11 General Information - TR45 Off-Highway Truck Section 000-0000 ELECTRICAL Typical Noise Levels Type ..........24 Volt, Negative Ground Operator Ear (ISO 6394) ..........80 dbA Battery ..Two, 12 Volt, 165 Ah each, Maintenance Free Accessories ..............24 Volt *Exterior Sound Rating (SAE J88 JUN 86) ....88 dbA Alternator ..............
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Page 13: Installation
Using a suitable lifting device, align the component to to relieve pressure in the steering circuit. Block all road wheels. be installed in position on the chassis. Secure the component securely to the chassis with mounting hardware removed during removal. SM 1570 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... -
Page 14: Maintenance
Successfully welded repairs will depend to a great To keep rust and corrosion to a minimum, periodic extent upon the use of the proper equipment, materials painting of abrasions and other exposed metal areas on the frame is highly recommended. SM 1570 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... - Page 15 49 - Bolt 37 - Lockwasher 12 - Washer 24 - Nut 50 - Hardened Washer 25 - Washer 38 - Washer 51 - Nut Fig. 3 - Exploded View of Fenders and Mounting SM 1570 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
- Page 16 2 - RH Step Assembly 5 - Step 9 - Locknut 13 - Nut 3 - Plate 6 - Bolt 10 - Nut 14 - Hardened Washer Fig. 4 - Exploded View of Ladders and Handrails SM 1570 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
- Page 17 2 - Cover Plate 5 - Bolt 8 - Grille 12 - Hardened Washer 3 - Washer 6 - Nut 9 - Bolt 13 - Plate Fig. 5 - Radiator Guard and Mounting SM 1570 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
- Page 18 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
- Page 19 (6) at the front of engine (1) and a passage in the filter adaptor and into the elements. two rear mounts (5). Rubber isolation mounts (12) Impurities are filtered out as the oil passes through the SM 1571 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
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Page 20: Cooling System
Note: The electronically controlled engine will override problems can be corrected quickly and easily. the electronic foot pedal position until the engine is SM 1571 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... - Page 21 SM 1571 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
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Page 22: Operation
If the malfunction System Diagnostic Codes' table for fault code descriptions. is intermittent, the lights will come on and go off as the computer senses the changing engine condition. SM 1571 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... - Page 23 Blowby Pressure, Engine Protection - Blowby pressure high Amber Blowby Pressure Sensor - Component shorted high Yellow Blowby Pressure Sensor - Component shorted low Yellow Engine Speed Sensor - Engine speed signals do not match SM 1571 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
- Page 24 SM 1571 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
- Page 25 (4). 3. Inspect engine damper (16) and flange coupling (19) 7. Loosen alternator mounting bolt (62) to allow slack for damage and repair or replace as required. in 'V' belts. Remove 'V' belts. SM 1571 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
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Page 26: Installation
(55) clockwise until the correct 101 - 126 Nm (75 - 93 lbf ft). tension is obtained (refer to 'Drive Belt Adjustments'). When correct tension is obtained tighten locknut (54). SM 1571 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... -
Page 27: Every 250 Hours
Section 210-0000, with the filter. If not, remove it from the filter adaptor. COOLING SYSTEM. 2. Clean the filter adaptor with a clean, lint free cloth. SM 1571 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... -
Page 28: Lubrication System
0.81 mm (0.032 in) of their specified centre distances. 4. Repeat step 3 for second fuel filter. 5. Start the engine and check for leaks. If any leaks are noted, have them corrected. SM 1571 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... -
Page 29: Special Tools
FIG. NO. ITEM NO. ITEM NAME lbf ft Bolt Bolt Bolt 81 - 95 60 - 70 Bolt 81 - 95 60 - 70 Fan Hub Mounting Bolts 101 - 126 75 - 93 SM 1571 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... - Page 30 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
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Page 31: Engine Air Cleaner
Refer to allowable limit. When air restriction levels are reached, SM 1572 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... -
Page 32: Air Cleaner Assembly
The elements should not be serviced on Note: Air cleaner body (1) should be thoroughly the basis of visual observation as this would lead to SM 1572 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... -
Page 33: Primary Element
1. Release latches (5) on cover assembly (4) and 9. Install primary element (2) in air cleaner body (1). remove cover assembly from air cleaner body (1). SM 1572 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... -
Page 34: Secondary Element
As a dry air cleaner element becomes loaded with general service tools required. These tools are dust, the vacuum on the engine side of the air cleaner available from your dealer. SM 1572 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... -
Page 35: Description And Operation
PTO cover (29) so that the pump can be installed in 1. Remove locknut (16) and hardened washer (19) the same position at installation. from driveshaft (15). Pull yoke (22) from driveshaft (15). 6. With suitable blocking or lifting equipment, support SM 1296 2-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... - Page 36 DO NOT spin bearings with compressed air. Inspect bearing bores 7. Pull bearings (10 & 11) from flywheel cover case for out of roundness. Replace bearings, if required. (1) with a suitable bearing puller. SM 1296 2-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
- Page 37 5. Start the engine and bring oil to correct operating install snap rings (17). temperature. Check for leaks and correct as necessary. 6. Install new oil seal (9) into centre bore in PTO 6. Remove wheel blocks from all road wheels. SM 1296 2-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
- Page 38 These tools are available from To drain: Remove drain plug (6) from flywheel cover your dealer. SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft Locknut 950 - 1 085 700 - 800 SM 1296 2-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
- Page 39 Operation of the transmission is by driven by the pump. The stator is the reaction (torque the Commercial Electronic Control (CEC) Shift System, multiplying) element. SM 1612 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606...
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Page 40: Transmission Oil Cooler
However, during transmission retarder operation oil temperature can enter the yellow 'Retarder 3. Block all road wheels. On' zone but should not enter the red zone. SM 1612 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1606... - Page 41 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...
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