PDF Operation Safety Maintenance Manual Terex TR45 TR60 Dump Truck - 520 KB
This is the official Operation, Safety, and Maintenance Manual for the Terex TR45 and TR60 dump trucks.
It provides operators with vital information on safe operating procedures and daily maintenance checks.
Understanding the content of this manual is key to preventing accidents and ensuring the long-term reliability of your heavy-duty equipment.
It's a fundamental resource for both new and seasoned operators.
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TR45/60
Operation - Safety - Maintenance
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CONTENTS
1. INTRODUCTION 3. CONTROLS AND OPERATING 5. WORKING THE TRUCK
Introduction ........................................ 1-2 (Cont) Working the Truck .............................. 5-2
Safety Precautions ............................ 1-2 Machine Controls ............................ 3-16 Loading ........................................... 5-2
Machine Identification ........................ 1-4 Braking .......................................... 3-16 Hauling ............................................ 5-4
Theft Deterrent Practices .................. 1-5 Service Brake ............................ 3-16 Dumping ......................................... 5-5
Park/Emergency Brake ............. 3-16 Empty Return ................................. 5-7
2. SAFETY PRECAUTIONS Retarder ..................................... 3-17
General .............................................. 2-2 Engine ........................................... 3-19 6. ROADING
Vehicle Lifting Precautions ................ 2-3 Electronic Foot Control .............. 3-19 Roading .............................................. 6-2
Vehicle Tie Down Precautions .......... 2-3 Quantum Fuel System ............... 3-19 General .......................................... 6-2
Preventing Fire Hazards .................... 2-4 Description ................................. 3-21 Preparation Prior to Roading ......... 6-2
Mounting and Dismounting ................ 2-6 Operation .................................... 3-22 In Case Of Trouble ........................ 6-4
Pre-Starting ........................................ 2-7 Steering ......................................... 3-26
Starting ............................................... 2-7 Transmission ................................ 3-27 7. MOVING DISABLED TRUCK
Operating ........................................... 2-8 Description and Operation ......... 3-30 Moving Disabled Truck ...................... 7-2
Roading ............................................ 2-10 General Operation ..................... 3-35
Lubrication and Servicing ................ 2-11 Body Control ................................. 3-36 8. LUBRICATION AND SERVICING
Wheels and Tyres ............................ 2-12 Raising the Body ........................ 3-37 Safety Precautions ............................ 8-2
Avoid Tyre Explosion Hazard .......... 2-13 Lowering the Body ..................... 3-37 Lubrication and Servicing .................. 8-3
Decals and Instruction Plates .......... 2-14 Lubrication and Service Chart ........... 8-5
4. OPERATING THE TRUCK Miscellaneous Servicing .................... 8-8
3. CONTROLS AND OPERATING Pre-Starting Inspection ...................... 4-2 Service Capacities ........................... 8-12
Controls and Instruments .................. 3-3 Component Checks ........................... 4-3 Recommended Lubricants .............. 8-13
Basic Data ......................................... 3-4 Suspension Ride Struts .................... 4-5
Warning Lights ............................... 3-4 Engine Operation ............................... 4-6 9. TECHNICAL DATA
Instruments .................................... 3-7 Starting the Engine ............................ 4-7 Technical Data - TR45 ....................... 9-3
Switches ......................................... 3-9 Starting the Engine with Technical Data - TR60 ....................... 9-8
Controls ........................................ 3-12 Jumper Cables .............................. 4-9
Heater .......................................... 3-13 Pre-Operating Checks .................... 4-10 10. SYMBOL IDENTIFICATION
Air Conditioner .............................. 3-13 Brake Function Checks .................. 4-10
Operator's Seat - Driving and Stopping ....................... 4-12
Air Suspension ......................... 3-14 Stopping the Engine ........................ 4-14
Seat Belt ....................................... 3-15 Parking ............................................. 4-16
1-1
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* Shut off engine and use extra caution if engine is hot when refuelling.
Ground the hose spout to prevent sparks when spout is touched to fuel tank
filler tube.
* Never smoke while checking or adding fuel or other fluids or handling fluid
containers and hoses.
* Use care and do not stand downwind when adding fuel or other flammable
fluids to tanks and reservoirs to avoid fluids being blown or splashed onto
clothing.
* Close fuel tank shut-off valves, if used, before servicing fuel system.
* When preparing machines or components for storage, seal and tape all
openings and close containers tightly to seal in all volatile inhibitor fluids and
compounds used.
* Follow manufacturer’s recommendations when handling and using engine-
starting fluids and disposing of spent containers. Do not puncture or burn
empty containers. These fluids are explosive and highly flammable.
Electrical Hazard Precautions
* Never smoke or allow open flames or sparks near batteries.
* Leave battery box open when charging batteries in machine for adequate
ventilation of explosive gas (hydrogen) produced.
* Always disconnect batteries before repairing electrical system to avoid
danger of fire-causing sparks. Disconnect battery ground cable first and
reconnect last.
2-5
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1. Alternator Precautions
15 16 17 14 2. CEC (ATEC) Welding Warning
3. Engine Instructions
14 13
4. Body Control Lever Positions
2, 3, 4, 5, 6, 7 8 9 13 5. Retarder Positions
6. CEC (ATEC) Switches
12 18 7. Pre-operating Instructions
8. Acoustic Foam Precautions
11
9. Pre-operating Instructions
1 10 10. Hydraulic Oil Decal
11. Sight Gauge Plate
12. Hydraulic Oil Pressure Plate
13. Anti-Syphon Instructions
14. Instruction Plate
15. Hydraulic Oil Level
16. Instruction Decal
17. Hydraulic Oil Level
18. Lubrication Chart
19. Pressure Test Points
20. Accumulator Charging Instructions
21. Accumulator Precautions
22. Pressure Test Points
25 24 22, 23 20, 21 19 23. Pressure Test Points
24. Ride Strut Pressure Warning
25. Machine Serial Plate
660
2-15
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Switches
1 2 3 4 5 6
1. Hazard Warning Lights - Press bottom of switch to make turn indicators flash
simultaneously as hazard warning lights. The light in the switch and direction
indicator warning light on the right hand dash panel will flash. To switch hazard lights
off; press the top of the switch.
2. Position not used.
(0)
HAZARD 50%
3. Position not used.
1163 Left Hand Panel 4. Position not used.
5. Front Brake Pressure Reduction (Optional) - Press bottom of switch to give a
50% reduction in front brake pressure. The lower front pressure reduces the risk of
wheel lockup in slippery conditions. To return to full front brake pressure; press the
top of the switch.
6. Retarder Selection Switch (Optional on TR45) - Allows the operator to select
which retarder is employed when using the retarder control lever.
Pressed at top = Disc Brake
Pressed at bottom = Transmission
Note: Machines which do not have a transmission retarder fitted do not have the
selection switch fitted.
3-9
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Engine
Electronic Foot Pedal
The electronic foot pedal provides an electronic signal to the engine's fuel
control system in proportion to the degree of pedal actuation.
Note: The electronic controlled engine will override the electronic foot pedal position
until the engine is warmed up to the correct operating temperature. The engine
MUST be started with the foot 'OFF' the electronic foot pedal.
255
QUANTUM Electronic Fuel System
This machine is equipped with the Quantum Electronic Fuel System, an electronic
engine control system, which continually monitors the engine and warns the
operator when a problem develops. The system also takes action to prevent
damage to the engine and, provides the serviceman with diagnostic capabilities so
that problems can be corrected quickly and easily.
WARNING
Before any welding is done on a machine equipped with the Quantum
Electronic Fuel System, disconnect the following in this order: Battery
earth cable, battery supply cable, alternator earth cables, alternator
supply cables, transmission connector, ECM interface harness connector
(30 pin RHS), ECM powerharness connector (5 pin RHS) and ECM sensor
harness connector (30 pin LHS). Turn off ignition key switch to isolate the
batteries before disconnecting any components.
After welding connect all of the above in the reverse order.
3-19
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7
3 8
1
2
3
4
D
5
VIEW ON FRONT OF
N
R1
R2 INTERFACE BOX
9 5 6 4
1 MANUAL AUTO POWER ECONOMY
2
1. Electronic Control Unit (ECU) 4. Mode Selection Switch 7. Check Trans Warning Light
2. Interface Box 5. Manual Mode Switch 8. In-converter Indicator Light
3. Gear Shift Selector 6. Manual Mode Warning Light 9. Digital Data Line
1488 3-29
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4 - Operating The Truck
4-1
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WARNING
Make sure the area around the machine is clear of personnel and
obstructions before carrying out these checks.
If the machine moves during these checks, stop the machine, apply the
parking brake and do not operate until the fault is corrected.
Note: The following checks are NOT intended to measure maximum brake
holding ability. If NEW brake pads are fitted, they MUST be burnished as per the
manufacturers recommendations before carrying out the checks.
Service Brake Holding Ability Check
Depress the service brake pedal and select 1st gear on the transmission shift
selector. Pull the park/emergency brake control out to release the brakes.
Depress accelerator control and accelerate engine to 1 350 rev/min. The
machine should not move. Decelerate engine, shift transmission to 'NEUTRAL'
and apply the parking brake before releasing the service brake.
Emergency Brake Holding Ability Check
Depress the service brake pedal, release the park/emergency brakes, select first
gear, apply the park/emergency brakes and release the service brake pedal.
Depress accelerator control and accelerate engine to 1 350 rev/min. The
machine should not move. Decelerate engine and shift transmission to 'NEUTRAL'.
Note: Brake holding effort required to hold a machine static at a specific engine
speed, can vary from machine to machine due to differences in engine
performance, powertrain efficiency, etc., as well as differences in brake holding
ability.
Note: As an indication of system deterioration, the engine speed at which point
the machine moved, with the service or emergency brakes applied, can be
compared against the engine speed your machine was able to hold to on a
previous check.
4-11
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Dumping
The dumping operation usually depends upon the type of material being hauled.
TWO MINIMUM
For instance, overburden and other waste material is usually dumped over a
spoil bank or piled into large mounds. The dumping on a job of this type might be
controlled by a dump 'SPOTTER', 'FLAGMAN' or 'BANKSMAN' or second person
who directs the truck to its dumping area. The 'SPOTTER' is needed due to the
limited rear visibility the operator has with a loaded truck of this size. While
backing to dump, the operator must watch the 'SPOTTER' at all times and follow
his direction. Under no circumstances should the operator leave his seat to gain
088 Safety First better visibility while backing. Always remain seated to maintain maximum
machine control.
Mineral ores, blasted rock etc., are usually dumped into a hopper or crusher
where it is processed before shipment. When dumping into a hopper, the
operator, in order to avoid excess wear on the tyres, must avoid hitting the
protecting rail at the hopper. If a DRIVEOVER HOPPER is used, the operator
must avoid rubbing the tyre inner sidewalls.
When hauling dirt or rock from a borrow pit into a fill area such as an earth-fill
dam, the load is usually dumped in a string with other loads and the loads
089 Avoid Obstacles smoothed out with a crawler tractor. When dumping on a fill of this type, the
operator usually works alone and picks his own dumping place. To save
bulldozer work and cleaning up, the load should be dumped as close as possible
to the preceding load. The operator should pull past the preceding load, turn in
line with the string and back his truck until it is within a few feet of the last load.
This assures that the load will fall in the right place.
No matter what kind of job the operator is working, there are a few things which
are common to all jobs and which the operator should observe -
When dumping over a spoil bank without a 'SPOTTER', know how close the
machine can safely approach the edge under all weather conditions. If in doubt
090 Watch Spotter as to dumping safety, dump the load a safe distance from the edge so that it 5-5
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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
machine service manual Section 165-0030, for parking brake release with
auxiliary hydraulic power source. See WARNING on previous page.
Connect a suitable towing bar to one of the lugs on the front bumper of the
disabled machine and reverse another machine, in a straight and in-line
manoeuvre, towards the disabled machine. Connect the opposite end of the
towing bar to the towing point on the rear axle of the recovery machine and
ensure that it is securely locked.
Note: An alternative method of towing a disabled machine is by connecting an
A-Frame arrangement to the lugs on the front bumper of the disabled machine
and the towing point of the recovery machine.
To prevent possible damage to the transmission, the towing speed should never
exceed 10 km/h (6.2 mile/h) and the distance towed should not be longer than
10 km (6.2 miles).
WARNING
If using a chain or cable, be sure it is strong enough for the expected
load and properly secured.
When pulling, take up the slack slowly to avoid jerking. A chain or
cable which fails under load can cause serious injury. Stand clear. Do
not pull through a kinked chain or cable. Do not pull or tow unless the
operator’s compartment is guarded against or out of reach of a
whipping chain or cable. Attach only to the towing points. Failure to
follow these instructions could cause serious injury or death.
7-3
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Steering, Braking and Body Hoist Systems - Check for correct operation of all
systems before operating the truck.
Steering Filter - Check steering filter restriction warning light with the truck
empty, brakes released, oil at normal operating temperature, engine operating at
1 500 rev/min and while turning the steering wheel at one turn/sec. If the warning
light illuminates, the filter element should be replaced.
Rear Disc Brake Filter(s) -
Replace element(s) when indicator shows oil at the replace element level.
AFTER FIRST 150 HOURS OF OPERATING NEW OR REBUILT
COMPONENTS
Transmission - Drain oil, replace filters and refill.
Differential - Drain oil and refill.
Planetaries - Drain oil and refill.
EVERY 250 HOURS OF OPERATION
Oil Can Points - Oil accelerator linkage, hinges, and other working parts with
engine oil.
Coolant Additive - Check and replenish DCA4 concentration as described in
Section 210-0000, COOLING SYSTEM, in the Maintenance Manual.
Coolant Filter(s) - Replace coolant filter(s) if required. When testing the DCA4
concentration, depending on the level of DCA4, the coolant filter(s) may not
necessarily have to be changed. Refer to Section 210-0010, COOLING
SYSTEM, in the Maintenance Manual.
Cooling Fan - Visually check the fan for cracks, loose rivets, and bent or loose
blades. Check fan mounting and tighten if required. Replace any fan that is
damaged. 8-9
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STEERING SYSTEM Control Valve ...................... Servo Controlled, Open Centre
Independent hydrostatic steering with closed-centre Body Raise Time ............................................... 13 Seconds
steering valve, accumulator and pressure compensating Body Lower Time ................................................. 9 Seconds
piston pump.
ELECTRICAL
Accumulator provides uniform steering regardless of engine
speed. In the event of loss of engine power it provides steering of Type ............................................. 24 Volt, Negative Ground
approximately two lock-to-lock turns. A low pressure indicator Battery ......... Two, 12 Volt, 165 Ah each, Maintenance Free
light warns of system pressure below 83 bar (1 200 lbf/in²). Accessories ............................................................... 24 Volt
Steering meets ISO 5010, SAE J53. Alternator .................................................................. 70 Amp
Starter ........................................................................ 8.9 kW
System Pressure .................................. 159 bar (2 300 lbf/in²)
Relief Pressure ..................................... 207 bar (3 000 lbf/in²) BODY
Steering Cylinders ...................... Double Acting, Single Stage Longitudinal 'V' type floor with integral transverse box-
Accumulator: section stiffeners. The body is exhaust heated and rests on
Oil Capacity .................................. 14.0 litres (3.70 US gal) resilient impact absorption pads.
Nitrogen Precharge Pressure ................. 55 bar (800 lbf/in²)
Steering Angle (Left and Right) ......................................... 39° Body wear surfaces are high hardness (360-440 BHN)
Pump: abrasion resistant steel. Yield strength of plates 1 000 MPa
Type ......................................................................... Piston (145 000 lbf/in²).
Capacity at 2 100 rev/min .......... 1.4 litres/s (22 US gal/min)
Plate Thicknesses:
BODY HYDRAULICS Floor ........................................................... 19 mm (0.75 in)
Two body hoist cylinders are mounted between the frame rails. Side ............................................................ 10 mm (0.39 in)
Cylinders are two-stage with power down in the second stage. Front, lower ................................................ 10 mm (0.39 in)
System Relief Pressure ..................... 190 bar (2 750 lbf/in²) ROPS Cabguard SAE J1040 Feb 86. ISO 3471
Pump:
Type ........................................................................... Gear Volumes:
Capacity at 2 100 rev/min . 227 litres/min (60 US gal/min) Struck (SAE) .......................................... 19.6 m³ (25.6 yd³)
Heaped 2:1 (SAE) .................................. 26.0 m³ (34.0 yd³)
9-5