Terex TR45 User manual

SM 1606 Rev 2 02-02
TR45
Off-Highway Trucks
Service Manual
TECHNICAL PUBLICATIONS DEPARTMENT
TEREX EQUIPMENT LIMITED,
MOTHERWELL, SCOTLAND, ML1 5RY
REF. NO. SM754/781

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TEREX SERVICE DEPARTMENT
PURPOSE:
To advise potentially hazardous condition.
DETAIL:
It has been brought to our attention that 'Viton' material used in manufacture of oil seals and 'O' rings, produces
a highly corrosive acid (Hydrofluoric) when subjected to temperatures above 315° C.
The resulting contamination can have extreme consequences on human tissue since it is almost impossible to
remove after contact.
We therefore recommend the following procedure when it is necessary to inspect any equipment that has been
subjected to a high temperature i.e. fire.
a. Visually inspect for any gaskets or seals which have suffered from heat; they will appear black and sticky.
b. If this is affirmed - Do Not Touch
c. Make enquiries to ascertain the material composition. Any Fluoro-elastomer (Viton, Fluorel or Tecmoflon)
should be considered dangerous but natural rubber and nitrile are non-hazardous.
d. If Fluoro-elastomer seals have been used, then the affected area MUST be decontaminated before
undertaking further work.
e. Disposable Heavy Duty Gloves (Neoprene) MUST be worn and the affected area decontaminated by
washing thoroughly with Limewater (Calcium Hydroxide solution).
f. Any cloths, residue and gloves used MUST be safely discarded after use.
Note: Burning of the discarded items is NOT RECOMMENDED, except in an approved incineration process
where the gaseous products are treated by alkaline scrubbing.
Service
Information
Alert
DATE: April 1994 B168
MODEL: General
SUBJECT: VITON 'O' RINGS AND SEALS (FLUORO-ELASTOMERS) - SAFETY HAZARDS
TEREX Equipment Limited, Motherwell, Scotland ML1 5RY Tel. [phone] Tlx. 77141 Fax. [phone]
TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. [phone] Fax. [phone]
The information contained within this
Alert must not be made available to
third parties not authorised to receive it.
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SM 222 Rev 1 9-93
Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service
procedures recommended and described in this publication, are effective methods for performing service
operations. Some of these service operations require the use of tools specially designed for the purpose.
The special tools should be used when, and as recommended.
It is important to note that this publication contains various WARNINGS and NOTES which should be
carefully read in order to minimize the risk of personal injury to personnel, or the possibility that improper
service methods will be followed which may damage the vehicle or render it unsafe. It is also important to
understand these WARNINGS and NOTES are not exhaustive. It is not possible to know, evaluate and
advise the service trade of ALL conceivable ways in which service might be carried out, or, of the
possible hazardous consequences of each way. Consequently, no such broad evaluation has been
undertaken. Accordingly, anyone who uses a service procedure, or tool, which is not recommended, must
first satisfy themselves thoroughly that neither their safety, nor vehicle safety, will be jeopardized by the
service method he/she selects.
Two types of heading are used in this manual to attract your attention.
1. WARNING - This symbol is used when an operating procedure, practice, etc., which, if not correctly
followed could result in personal injury or loss of life. Look for this symbol to point out important safety
precautions. It means - ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
2. Note - This is used when an operating procedure, practice, etc., which, if not strictly observed, could result in
damage to or destruction of equipment.
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.
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SM 1607 Rev 2 02-02 1
TABLE OF CONTENTS
Section No. Description SM No.
000 GENERAL INFORMATION
0000 TR45Off-HighwayTruck 1608
100 CHASSIS
0010 Chassis, Hood and Fenders 1570
110 ENGINE
0030 EngineandMounting 1571
0050 Air Cleaner 1572
0130 Power Takeoff 1296
120 TRANSMISSION
0010 Transmission and Mounting 1612
0070 Commercial Electronic Control (CEC) Shift System 1575
0070 Commercial Electronic Control 2 (CEC2) 2128
0090 Power Takeoff 1178
0100 Transmission Oil Filter 1576
130 DRIVELINE
0010 Front Driveline - Pre June 1998 Production 1180
0010 Front Driveline - From June 1998 Production 1577
0020 Rear Driveline - Pre June 1998 Production 1311
0020 Rear Driveline - From June 1998 Production 1578
140 FRONT AXLE
0040 Wheel, Rim and Tyre 1303
160 REAR AXLE
0020 Differential 1298
0030 Axle Group 1299
0050 Wheel, Rim and Tyre 1300 Rev 1
165 BRAKE PARTS
0020 Brake Parts - Front Axle 1186
` 0030 Brake Parts - Rear Axle 1301
180 SUSPENSION SYSTEM
0030 Ride Cylinder - Front 1584
0050 Ride Cylinder - Rear 1302
190 CIRCUIT DIAGRAMS
0000 CircuitDiagrams 1585
0270 Switches and Sensors 1586
200 FUEL SYSTEM
0010 Fuel Tank and Mounting 1587
0040 Fuel Lines 1195
0051 Electronic Foot Pedal 1196
210 COOLING SYSTEM
0000 Cooling System 1305
0040 Radiator,Header Tank and Mounting 1613
0050 Disc Brake Oil Cooler 1589
0060 Transmission Oil Cooler 1590
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SM 1607 Rev 2 02-02
2
* * * *
TABLE OF CONTENTS
Section No. Description SM No.
220 STEERING SYSTEM
0000 Steering System Schematic 1591
0040 Steering and Brake Control Tank 1592
0050 Steering Pump 1204
0080 Accumulator 1205
0090 Steering Valve 1206
0110 Double Relief Valve 1208
0120 Steering Cylinder and Linkage 1304
0130 Accumulator Valve 1209
0150 SteeringFilter 1593
230 BODY SYSTEM
0000 Body System Schematic 1594 Rev 1
0040 Body and Disc Brake Cooling Tank 1595
0050 TandemPump 1213
0060 Body Control Valve 1596 Rev 1
0081 Body Control Joystick 1597
0090 Kick-over Valve 1218
0120 Relief Valve 1598
0121 Pilot Supply Valve 1599
0130 BodyCylinder 1221
250 BRAKING SYSTEM
0000 Braking System Schematic 1222
0050 Brake Manifold Valve 1223
0060 Accumulator 1600
0070 TreadleValve 1225
0090 Directional Control Valve 1226
0100 Monoblock Brake Valve 1227
0130 Retarder Control Valve 1609
0140 Shuttle Valve 1229
260 OPERATORS COMPARTMENT
0010 Cab and Mounting 1602
0110 Passenger Seat and Mounting 1603
0130 Air Conditioning and Mounting 1620
270 BODY
0010 Body and Mounting 1610
300 MISCELLANEOUS
0020 Lubrication System 1611
0070 Service Tools 1621
0080 Standard Bolt and Nut Torque Specifications 1238
0090 Unit Storage 1239
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Section 000-0000
1
SM160812-98
GENERAL INFORMATION - TR45 Off-Highway Truck
ENGINE
Make/Model ................................... Cummins QSK 19-C525
Type .................... 4 Cycle, Turbocharged/Low Temperature
Aftercooled. Electronic Management.
Gross Power at 2 100 rev/min ......392 kW (525 hp, 532 PS)
Net Power at 2 100 rev/min ..........370 kW (495 hp, 502 PS)
Note: Power ratings to SAE J1995 Jun 90. Engine
emission meets USA EPA/CARB MOH 40 CFR 89 and
proposedEUnon-roadmobilemachinerydirective.
Maximum Torque .............................. 2 407 Nm (1 775 lbf ft)
at 1 300 rev/min
Number of Cylinders/Configuration .........................6, in line
Bore x Stroke ........................ 159 x 159 mm (6.25 x 6.25 in)
Total Displacement ..............................18.9 litres (1 150 in³)
Starting...................................................................... Electric
Maximum Speed, Full Load ............................ 2 100 rev/min
Maximum Speed, No Load ............................. 2 300 rev/min
Idle Speed................................................... 700/750 rev/min
Safe Operating Angle .................................. 30°/60% Grade
TRANSMISSION
Make/Model ................................................. Allison M5600A
Automatic electronic control with soft shift feature.
Remote mounted in the frame. Integral torque converter
and planetary gearing. Six speeds forward, two reverse.
Automaticconverter lockupactionin allspeed ranges.
Downshiftinhibitor.
Fig. 1 - Machine Dimensions
Speeds With Standard Differential
Forward
Gear 1 2 3 4 5 6
Ratio 4.00 2.68 2.01 1.35 1.00 0.67
km/h 10.0 14.5 19.5 29.0 39.0 60.0
mile/h 6.0 9.0 12.0 18.0 24.5 36.0
Reverse
Gear 1 2
Ratio 5.12 3.46
km/h 7.5 11.5
mile/h 4.5 7.0
SM - 2014
2 350 (7-9) 3 940 (12-11) 2 410 (7-11)
8 700 (28-7)
585 (1-11)
15˚ 3 430
(11-3)
7 455
(24-6)
4 700 
(15-5)
5 485 
(18-0)
7 120
(23-4)
58˚
3 855
(12-8)
430
(1-5)
Vehicle Clearance Diameter (SAE) 21m (69ft)
3 530
(11-7)
3 800
(12-6)
4 060
(13-4)
Max
Body
Depth

1 195 
(3-11)
1 440 
(4-9)
885
(2-11) 525
(1-9)
2 710 (8-11)
3 980 (13-1)
4 240 (13-11)
Optional
Spillguard
4 630 (15-2)
4 370 (14-4)
4 525
(14-10)
4 245
(13-11)
4 135
(13-7)
585
(1-11)
2 685 (8-10)
3 325 (10-11)
3 965 (13-0)
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Section 000-0000
General Information - TR45 Off-Highway Truck
SM160812-982
DRIVE AXLE
Heavy duty axle with single reduction spiral bevel gear
differential, full floating axle shafts, and planetary reduction
at each wheel.
Ratios: Standard Optional
Differential ............................................. 3.15:1 3.73:1
Planetary ............................................... 5.66:1 5.66:1
TotalReduction.................................... 17.83:1 21.11:1
SUSPENSION
Front:Kingpinstrut typeindependentfront wheelsuspension
byself-contained,variablerate,nitrogen/oilcylinders.
Rear:Variableratenitrogen/oilcylinderswithA-framelinkage
andlateralstabilizerbar.
MaximumStrutStroke
Front........................................................... 251 mm(9.9 in)
Rear ........................................................... 182mm (7.2in)
MaximumRearAxleOscillation ....................... ± 6.5 Degrees
WHEELS AND TYRES
Wheel Rim Width .......................................................... 13 in
Wheel Rim Width (Optional) ......................................... 15 in
Standard Tyres (Front & Rear) ..............18.00 R33 ** Radial
Optional Tyres (Front & Rear) ...............21.00 R35 ** Radial
Note: It is recommended that for tyres both listed and
unlisted, the user should consult the tyre manufacturer and
evaluate all job conditions in order to make the proper
selection.
BRAKES
Service
All hydraulic brake system. Transmission mounted pressure
compensatingpump provideshydraulic pressurefor brakes
andsteering.Independent circuitsfront andrear. Eachcircuit
incorporatesanitrogen/hydraulicaccumulatorwhichstores
energyto provideconsistentbraking response.
Front Brake Circuit Pressure ................ 159 bar(2 300lbf/in²)
Rear Brake Circuit Pressure ....................52 bar (750 lbf/in²)
Accumulators:
NitrogenPrecharge Pressure ................. 55bar(800lbf/in²)
Front:
Type............................... Dry Disc with 1 calliper per wheel
DiscDiameter .......................................... 660mm(25.5in)
PadArea,Total ..................................... 1 395 cm²(216 in²)
Rear:
Type..................Oilcooled,multiple frictiondiscs(14 total),
completelysealedfromdirtandwater.
Braking Surface, Total ....................38 310 cm² (5 938 in²)
Cooling Flow, Max. .......... 553 litres/min (146 US gal/min)
Parking
Application of rear brakes by springs in brake disc pack.
Hydraulically released.
Hold-off Pressure ..................................83 bar (1 200 lbf/in²)
Retardation
Modulated lever control of rear disc pack.
Retarder Actuation Pressure ......... up to 33 bar (480 lbf/in²)
Emergency
Push button solenoid control applies service and parking
brakes.Automaticallyapplies whenengine isswitchedoff.
Parking brake applies should system pressure fall below a
predeterminedlevel.
Brakes conform to ISO 3450, SAE J1473 OCT 90.
STEERING SYSTEM
Independenthydrostaticsteeringwithclosed-centresteering
valve,accumulatorandpressurecompensatingpistonpump.
Accumulatorprovidesuniformsteeringregardlessofengine
speed. In the event of loss of engine power it provides
steering of approximately two lock-to-lock turns. A low
pressure indicator light warns of system pressure below
83 bar (1 200 lbf/in²). Steering meets ISO 5010, SAE J53.
System Pressure................................ 159 bar (2 300 lbf/in²)
Relief Pressure ...................................207 bar (3 000 lbf/in²)
Steering Cylinders ................... Double Acting, Single Stage
Accumulator:
Oil Capacity .................................. 14.0 litres (3.70US gal)
NitrogenPrecharge Pressure .................55bar (800lbf/in²)
SteeringAngle(LeftandRight) .........................................39°
Pump:
Type......................................................................... Piston
Capacity at 2 100 rev/min ..........1.4 litres/s (22 US gal/min)
BODY HYDRAULICS
Twobody hoistcylinders aremounted betweenthe frame
rails. Cylinders are two-stage with power down in the
second stage.
System Relief Pressure ..................... 190 bar (2 750 lbf/in²)
Pump:
Type........................................................................... Gear
Capacity at 2 100 rev/min.............................227 litres/min
(60 US gal/min)
Control Valve ...................... Servo Controlled, Open Centre
Body Raise Time................................................ 13 Seconds
Body Lower Time ................................................. 9 Seconds
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