Best Terex TR60 Off-Highway Truck Service Repair Manual
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🏷️ Basic Information Identification Make: Terex Model: TR60 Off-Highway Truck Model Variant: Articulated Dump Truck Intended Use: Heavy construction, mining, and quarrying operations Generation Generation Designation: Not explicitly defined, but represents a specific generation of Terex articulated dump trucks Codes Product Code: Likely specific to the manufacturer's internal coding, not publicly stated in product name 👋 Introduction Market Position Market Position: The Terex TR60 is positioned as a robust and reliable articulated dump truck for demanding off-highway applications. It competes in the heavy-duty construction and mining equipment sector, offering a balance of payload capacity, maneuverability, and durability. Competitive Analysis Competitive Analysis: Competes with other major manufacturers of articulated dump trucks such as Caterpillar (e.g., 730, 735 series), John Deere, Volvo CE, Komatsu, and Bell Equipment. Key differentiators often include engine choice, transmission performance, hydraulic responsiveness, and overall build quality for harsh environments. Key Features Key Features: High payload capacity (60-ton class), robust drivetrain for all-terrain operation, advanced hydraulic systems for steering and braking, operator comfort features, durable chassis and body construction, efficient engine options, designed for extreme operating conditions. 📋 Manual Details Coverage Areas Coverage Areas: Comprehensive coverage for Terex TR60 Off-Highway Truck, including all major systems and components. Specific model year coverage might vary based on the manual's edition, but generally covers the TR60 throughout its production run or a significant portion thereof. Page Count Page Count: Typically 500+ pages, indicative of the complexity and depth of coverage for heavy equipment. Manual Type Manual Type: Service Repair Manual / Workshop Manual Language Language: English Format Format: Digital (PDF) - Searchable and Printable 📖 Manual Coverage Systems Covered Systems Covered: Engine (e.g., Cummins, Caterpillar), Transmission (e.g., Allison automatic), Powertrain, Hydraulic System (steering, braking, hoist), Electrical System (12V/24V), Chassis, Suspension, Steering, Braking System, HVAC System, Operator Cabin, Body and Frame, Cooling System, Fuel System, Exhaust System, Drivetrain (differentials, axles, driveshafts), Wheels and Tires. Procedures Included Procedures Included: Routine maintenance, scheduled servicing, troubleshooting guides, diagnostic procedures, component removal and installation, disassembly and assembly of major components, repair instructions, torque specifications, electrical schematics, hydraulic schematics, inspection procedures, special tool requirements, safety precautions. Technical Depth Technical Depth: In-depth technical detail suitable for professional mechanics and experienced technicians. Covers everything from basic fluid checks to complete engine overhauls and complex hydraulic system diagnostics. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: High-resolution, suitable for printing. Includes clear diagrams, schematics, and photographs. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Primary Engine: Typically powered by a high-horsepower diesel engine from manufacturers like Cummins or Caterpillar. Specific models vary by production year and region, but common engines include Cummins QSX15 or Caterpillar C15. Performance Gross Horsepower: Generally in the range of 500-600 HP (approx. 373-447 kW), depending on engine option and configuration. Peak Torque: Typically exceeding 1500 lb-ft (approx. 2034 Nm), providing substantial power for hauling heavy loads in challenging conditions. Fuel System Fuel System Type: Commonly utilizes a high-pressure common rail (HPCR) direct injection system for optimal fuel efficiency and emissions control. Fuel Type: Diesel Cooling System Cooling System Type: Water-cooled, typically with a large-capacity radiator and fan for sustained operation under heavy load and high ambient temperatures. Emissions Controls Emissions Controls: May include Exhaust Gas Recirculation (EGR), Diesel Particulate Filters (DPF), and Selective Catalytic Reduction (SCR) systems, depending on the model year and emissions regulations. 🔧 Transmission Standard Transmission Type: Heavy-duty, electronically controlled automatic transmission, commonly from Allison Transmission. Optional Optional Transmission: Less common, but some models might have alternative transmission options or configurations depending on specific market demands. Features Transmission Features: Features include multiple forward and reverse gears (e.g., 6 or 7 forward gears), torque converter with lock-up, electronic shift control, and integrated retarder for downhill braking assistance. Fluid Type Transmission Fluid Type: Typically requires a specialized synthetic automatic transmission fluid (ATF), such as Allison TES 295 or equivalent, ensuring optimal performance and longevity in heavy-duty applications. Fluid Capacity Transmission Fluid Capacity: Approximately 20-30 liters (5.3-7.9 US gallons), varies by specific model and transmission housing. 📐 Dimensions Exterior Overall Length: Approx. 9-10 meters (29.5-32.8 ft) Overall Width: Approx. 3.5-4 meters (11.5-13.1 ft) Overall Height: Approx. 3.5-4 meters (11.5-13.1 ft) Cargo Payload Capacity: 60 US tons (approx. 54.4 metric tons) Body Volume Heaped: Approx. 45-55 cubic yards (34.4-42.0 cubic meters) Weights Operating Weight: Typically in the range of 45-55 tons (approx. 99,000-121,000 lbs / 45,000-55,000 kg) Gvw Gross Vehicle Weight: Exceeds 100 tons (220,000 lbs / 100,000 kg), including payload. Wheelbase Articulation Angle: Typically around 50 degrees, enabling excellent maneuverability in confined spaces. 🛡️ Safety Features Ratings Safety Ratings: Not applicable in the traditional sense for consumer vehicles. Safety focuses on structural integrity, operator protection, and operational stability in extreme conditions. Manual will detail safety features and...
Heavy construction, mining, and quarrying operations
Generation
Generation Designation:
Not explicitly defined, but represents a specific generation of Terex articulated dump trucks
Codes
Product Code:
Likely specific to the manufacturer's internal coding, not publicly stated in product name
👋 Introduction
Market Position
Market Position:
The Terex TR60 is positioned as a robust and reliable articulated dump truck for demanding off-highway applications. It competes in the heavy-duty construction and mining equipment sector, offering a balance of payload capacity, maneuverability, and durability.
Competitive Analysis
Competitive Analysis:
Competes with other major manufacturers of articulated dump trucks such as Caterpillar (e.g., 730, 735 series), John Deere, Volvo CE, Komatsu, and Bell Equipment. Key differentiators often include engine choice, transmission performance, hydraulic responsiveness, and overall build quality for harsh environments.
Key Features
Key Features:
High payload capacity (60-ton class), robust drivetrain for all-terrain operation, advanced hydraulic systems for steering and braking, operator comfort features, durable chassis and body construction, efficient engine options, designed for extreme operating conditions.
📋 Manual Details
Coverage Areas
Coverage Areas:
Comprehensive coverage for Terex TR60 Off-Highway Truck, including all major systems and components. Specific model year coverage might vary based on the manual's edition, but generally covers the TR60 throughout its production run or a significant portion thereof.
Page Count
Page Count:
Typically 500+ pages, indicative of the complexity and depth of coverage for heavy equipment.
Manual Type
Manual Type:
Service Repair Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF) - Searchable and Printable
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine (e.g., Cummins, Caterpillar), Transmission (e.g., Allison automatic), Powertrain, Hydraulic System (steering, braking, hoist), Electrical System (12V/24V), Chassis, Suspension, Steering, Braking System, HVAC System, Operator Cabin, Body and Frame, Cooling System, Fuel System, Exhaust System, Drivetrain (differentials, axles, driveshafts), Wheels and Tires.
Procedures Included
Procedures Included:
Routine maintenance, scheduled servicing, troubleshooting guides, diagnostic procedures, component removal and installation, disassembly and assembly of major components, repair instructions, torque specifications, electrical schematics, hydraulic schematics, inspection procedures, special tool requirements, safety precautions.
Technical Depth
Technical Depth:
In-depth technical detail suitable for professional mechanics and experienced technicians. Covers everything from basic fluid checks to complete engine overhauls and complex hydraulic system diagnostics.
📊 Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Print Quality:
High-resolution, suitable for printing. Includes clear diagrams, schematics, and photographs.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Primary Engine:
Typically powered by a high-horsepower diesel engine from manufacturers like Cummins or Caterpillar. Specific models vary by production year and region, but common engines include Cummins QSX15 or Caterpillar C15.
Performance
Gross Horsepower:
Generally in the range of 500-600 HP (approx. 373-447 kW), depending on engine option and configuration.
Peak Torque:
Typically exceeding 1500 lb-ft (approx. 2034 Nm), providing substantial power for hauling heavy loads in challenging conditions.
Fuel System
Fuel System Type:
Commonly utilizes a high-pressure common rail (HPCR) direct injection system for optimal fuel efficiency and emissions control.
Fuel Type:
Diesel
Cooling System
Cooling System Type:
Water-cooled, typically with a large-capacity radiator and fan for sustained operation under heavy load and high ambient temperatures.
Emissions Controls
Emissions Controls:
May include Exhaust Gas Recirculation (EGR), Diesel Particulate Filters (DPF), and Selective Catalytic Reduction (SCR) systems, depending on the model year and emissions regulations.
🔧 Transmission
Standard
Transmission Type:
Heavy-duty, electronically controlled automatic transmission, commonly from Allison Transmission.
Optional
Optional Transmission:
Less common, but some models might have alternative transmission options or configurations depending on specific market demands.
Features
Transmission Features:
Features include multiple forward and reverse gears (e.g., 6 or 7 forward gears), torque converter with lock-up, electronic shift control, and integrated retarder for downhill braking assistance.
Fluid Type
Transmission Fluid Type:
Typically requires a specialized synthetic automatic transmission fluid (ATF), such as Allison TES 295 or equivalent, ensuring optimal performance and longevity in heavy-duty applications.
Fluid Capacity
Transmission Fluid Capacity:
Approximately 20-30 liters (5.3-7.9 US gallons), varies by specific model and transmission housing.
Typically in the range of 45-55 tons (approx. 99,000-121,000 lbs / 45,000-55,000 kg)
Gvw Gross Vehicle Weight:
Exceeds 100 tons (220,000 lbs / 100,000 kg), including payload.
Wheelbase
Articulation Angle:
Typically around 50 degrees, enabling excellent maneuverability in confined spaces.
🛡️ Safety Features
Ratings
Safety Ratings:
Not applicable in the traditional sense for consumer vehicles. Safety focuses on structural integrity, operator protection, and operational stability in extreme conditions. Manual will detail safety features and procedures.
Active Features
Active Safety Features:
Advanced braking systems (e.g., multi-disc wet brakes, hydraulic retarder), sophisticated drivetrain management for traction control, rollover protection structures (ROPS), falling object protection structures (FOPS) for the cab.
Passive Features
Passive Safety Features:
Reinforced operator cab, seat belts, emergency stop buttons, fire suppression systems (optional), high-visibility lighting, mirrors, and cameras.
💡 Technology Features
Infotainment
Infotainment System:
Minimalist by consumer vehicle standards. Focus is on operational displays. May include a basic radio, siren, and warning systems. The manual covers the electrical interfaces for these.
Driver Assistance
Driver Assistance Systems:
Includes functional systems like onboard diagnostics (OBD) for engine and transmission management, payload monitoring systems, and potentially camera systems for improved visibility. The manual details diagnostic readouts and system checks.
Connectivity
Connectivity Features:
Primarily focused on diagnostic ports (e.g., J1939 for engine/transmission data) for connection to external diagnostic tools and fleet management systems. No consumer-oriented infotainment connectivity.
Controls
Operational Controls:
Includes hydrostatic power steering, transmission selector lever, throttle, brake pedal, retarder control, hoist control lever, and auxiliary function controls. The manual explains the operation and maintenance of these controls.
🔧 Maintenance
Service Intervals
Service Intervals:
The manual details specific service intervals based on operating hours. Typical intervals include: Daily inspections (pre-start checks), 250-hour services (lubrication, filter checks), 500-hour services (fluid changes, more thorough inspections), 1000-hour services (major component checks, system analysis), and annual/2000-hour major services.
Fluid Specifications
Engine Oil Type:
Typically SAE 15W-40 heavy-duty diesel engine oil meeting API CJ-4 or newer specifications (e.g., CK-4).
Coolant Type:
Ethylene glycol-based antifreeze/coolant with extended life additives, typically a 50/50 mix with deionized water. Specifications might align with CAT ELC or equivalent heavy-duty coolant.
Hydraulic Fluid Type:
Typically a high-quality hydraulic fluid meeting ISO VG 32 or VG 46 specifications, suitable for heavy-duty hydraulic systems operating under high pressure and temperature variations.
Brake Fluid Type:
Heavy-duty hydraulic brake fluid, often DOT 4 or equivalent, used in a dedicated brake system reservoir.
Known Issues
Common Wear Items:
Wear items include brake pads and discs, tires, suspension pivot bushings, hydraulic hoses and seals, and body wear plates. The manual will guide on inspection and replacement of these components.
Common Potential Issues:
Potential issues can include hydraulic leaks due to high operating pressures, electrical system faults in harsh environments, drivetrain component wear (e.g., differentials, final drives), and engine cooling system performance. The manual provides diagnostics for these.
Lubrication
Greasing Points:
Numerous greasing points on articulation joints, steering linkages, suspension components, hoist cylinder pivots, and driveshaft U-joints. The manual specifies interval and grease type.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Terex Corporation has a long history in the construction and mining equipment industry, known for producing heavy-duty machinery. Terex mining products often leverage engineering from acquired companies, contributing to a rich heritage of rugged equipment.
Model Evolution
Model Evolution:
The TR60 is part of Terex's lineage of articulated dump trucks. Evolution typically involves powertrain upgrades for efficiency and emissions, improvements in hydraulic systems, enhanced operator comfort, and structural reinforcements to meet evolving industry demands and regulatory standards.
Production
Production Locations:
Terex mining and heavy equipment have been manufactured at various global sites, with specific locations for articulated dump trucks potentially including facilities in North America and Europe. Precise locations may vary by model year.
Typical Production Years:
The TR60 model line has been produced over a significant period, with various iterations and updates throughout the 2000s and into the 2010s. Specific model year coverage depends on the manual edition.
🏆 Awards & Recognition
Recognitions
Industry Recognitions:
Terex equipment is generally recognized for its durability and performance in the heavy-duty sector. Specific awards for the TR60 model might relate to operational efficiency or innovative features within the construction equipment industry.
Ratings
Durability Ratings:
While not formal consumer ratings, Terex products are evaluated by fleet managers and operators for their longevity and reliability in demanding conditions. Manual provides maintenance to ensure these ratings.
Certifications
Manufacturing Certifications:
Manufacturing facilities typically adhere to ISO 9001 for quality management systems and may hold other environmental and safety certifications relevant to heavy manufacturing.
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