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Product Training
Rigid Dump Truck (R.D.T.)
TR45 : TR60 : TR70 : TR100

Routine Service

070907

TEREX CENTRE OF EXCELLENCE

TEREX Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
United Kingdom
1 Technical Online Assistance; http://constructionsupport.terex.com
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General Safety Precautions

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General Safety Precautions

Proper service and repair is important to the safe, reliable
operation of all motor vehicles. Detailed service procedures are
recommended and described in various TEREX publications i.e.;
 Maintenance Manuals
 Operators Handbook
 Parts Book
These publications offer 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 these publications contain various
WARNINGS and NOTES which should be carefully read in order to
minimise the risk of personal injury, or the possibility that improper
service methods will be followed which may damage the vehicle or
render it unsafe.
All trucks are installed with warning and instruction decals. These
decals also offer guidance towards the safe service, maintenance
and operation of the TEREX truck.

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Safety Precautions
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SAFETY IS UP TO YOU
YOU CAN PREVENT SERIOUS INJURY OR DEATH

GOOD SAFETY PRACTICE PROTECTS YOU AND OTHERS AROUND YOU

BE OBSERVANT - BE ALERT - BE AWARE

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Safety Precautions
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Safety When Servicing
 Service and maintenance work not carried out
correctly can be dangerous to yourself and others.
 Always attach a 'DO NOT OPERATE' or similar
warning sign to the ignition switch or a prominent
control before cleaning, lubricating or servicing the
vehicle.
 Never allow anyone to work on the vehicle while it is
moving. Make sure there is no one on the vehicle
before working on it.
 Do not work under or near an unblocked or
unsupported body. Always use the body safety pins.
 Do not work under or near any unblocked or
unsupported linkage, part or vehicle.
 Block wheels from rotating when working in and
around and under the truck.

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Safety Precautions
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Safety When Servicing

 Always relieve stored pressure before servicing any
pressurised system. Follow the procedures and safety
precautions detailed in the relevant Maintenance Manual
section.

 Be alert to high pressure fluid leaks. Stop Truck, Relieve

Stored Pressure and Fix Failure.

 When changing oil in the engine, transmission and

hydraulic systems, or removing hydraulic lines,
remember that the oil may be hot and can cause
burns to unprotected skin.

 When working on or around exhaust components,

remember that the components may be hot and can
cause burns to unprotected skin.

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Welding Precautions
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MAKING WELD REPAIRS

BEFORE WELDING ON TRUCK;

• TURN KEY-SWITCH OFF
• TURN MASTER SWITCH OFF
DISCONNECT;
• BATTERY SUPPLY & EARTH CABLES
• ALTERNATOR EARTH & SUPPLY CABLES
• TRANSMISSION ECU
• ENGINE ECM
• OPTIONS ie. REAR VIEW TV, LUBE SYSTEMS etc.

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Welding Precautions
MAKING WELD REPAIRS 7

Weld Repair Close To Earth Cable

Weld Repair Not Close

7 To Earth Cable
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Jump Starting Precautions

Starting the Engine with Jumper Cables 8

WARNING
Hazardous hydrogen gas and sulphuric acid. Check for required voltage and
polarity connections to discharged batteries. Excessive booster voltage and/or
incorrect jumper cable connections, open flame, lighted cigar, or other
ignition source can cause battery explosion/fire. Keep all sources of ignition
away from batteries. Do not lean over batteries, and, wear eye protection at
all times to prevent personal injury.

Do not jump start a vehicle by using arc welding equipment.

Currents and voltages are dangerously high and cannot be sufficiently
reduced to make the method safe.
Note: Be sure machines are not touching each other. Use cables that are equal to cable size on
the machine. Booster battery should be the same specification as discharged battery.
If jumper cables are used to start an engine, be sure to follow this procedure:
Connect one end of a jumper cable, usually coloured red, to the discharged battery 'POSITIVE'
(+) post. Connect the other end of the same cable to the 'POSITIVE' (+) post on the booster or
charged battery.
Connect one end of the second cable, usually coloured black, to the 'NEGATIVE’ (-) post of the
booster battery. Connect the other end of the 'NEGATIVE' (-) cable to machine frame for
grounding so that if a spark occurs, it is away from battery fumes (explosive hydrogen).
Check for cause of failure on the dead battery.
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Routine Service and Maintenance

Lubrication And Servicing 9

Lubrication is an essential part of preventive maintenance. It is important that the instructions

regarding types of lubricants and the frequency of their application be followed to prolong the
useful life of the machine. Periodic lubrication of moving parts reduces to a minimum the
possibility of mechanical failures.

Thoroughly clean all fittings, caps, plugs etc., to prevent dirt from entering the system while
servicing.

Lubricants must be at operating temperature when draining.

Do not operate any system unless oil level is within the operating range as indicated on oil
level dip stick, sight gauge or level plug.

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Pre-Operational Checks
Pre-Operational Checks 10

• Before the engine is started ensure the machine is ready for operation.
• The machine should be in a level position to permit accurate checking of fluid
quantities in the engine and other components.
• Make sure parking brake is set and block wheels if necessary to prevent
accidental movement of the machine while checking component levels.
• Test all lights and horn for proper operation.
• Walk around the machine and carry out the Inspections and Component
Checks described in the drawing on the following pages.

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Pre-Operational Checks
Pre-Operational Checks 11

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Routine Service and Maintenance

Initial/Routine Maintenance 12

Wheel Rim Nuts - After first 10 hours of operation re-torque nuts to recommended
torque rating. Check torque every 50 hours(weekly) there after.

AFTER FIRST 150 HOURS OF OPERATING NEW OR REBUILT COMPONENTS

Transmission - Drain oil and refill (Non TranSynd RD filled transmissions only)
replace filter (All Oil Types) clean internal filter and finger magnet.

Differentials - Drain oil and refill to level plug.

Planetaries - Drain oil and refill to level plug.

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Routine Service and Maintenance

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Routine Service and Maintenance

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Routine Service and Maintenance

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Routine Service and Maintenance

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EO - Engine Oil. Refer to 'Recommended

Reference point from
Lubrication/Service
Layout Drawing
Lubricants' and 'Engine Oil Drain Intervals'.
HO - Hydraulic Transmission Oil. Refer to Refers to notes within the
'Recommended Lubricants'. Operator Handbooks and
Maintenance Manual
EPL - Extreme Pressure Gear Lubricant spec.
Lubrication and Servicing
MIL-L-2105D.
Sections.
EP, NLGI - Extreme Pressure Lithium No. 2 Grease
Serv Man. Refers to
(without 'Molybdenum').
Maintenance Manual
PAG Oil - Polyalklene Glycol (PAG) Compressor section/chapter.
Lubricating Oil - Low Viscosity (ISO46). Tightening torque values
can also be listed.

All change and service periods are recommendations based on average operating conditions. Lubricants showing evidence of
excessive heat, oxidation or dirt should be changed more frequently to prevent these conditions. Lubricant change and service
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periods must be established on the basis of individual job conditions.
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TranSynd RD Specific Servicing

(Transmission Oil)
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TranSynd RD Specific Servicing

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Typical Service Capacities –

Based on TR45/TR60
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Typical Recommended Lubricants

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Oil Type Summary

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Oil Drain Summary

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Engine Oil
250 Hours
500 Hours (TR70) All change and service periods are
Transmission Oil (EO) recommendations based on average
1000 Hours operating conditions.
TranSynd RD
4000 Hours DRAIN INTERVALS ARE
RECOMMENDATIONS ONLY.
Final Drives
1500 Hours Lubricant and service periods must be
Hydraulic Oils established on the basis of individual
2000 Hours work conditions, utilizing oil sampling.
Rear Brake Packs
2000 Hours

Complete drain recommended after first 150 hours of operation.

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S.O.S. Scheduled Oil Sampling

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Recommendations;
• Use SOS to monitor condition & maintenance
requirements of your equipment.
• SOS taken when oil is warm & particles suspended.
Ensuring sample is representative of oil
compartment.
• When using drain stream for SOS, do not collect
from initial or final draining.

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Front Suspension
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HEIGHT (Reference only)

TR35 140-146mm (5.5-5.75”)
TR40 165-171mm (6.5-6.75”)
TR45 165-171mm (6.5-6.75”)
TR60 165-171mm (6.5-6.75”)
TR70 155-162mm (6.12-6.38”)
TR100 155-162mm (6.12-6.38”)

CHARGE
TR35 11.7 bar (170 PSI) TR60 13.8 bar (200 PSI)
TR40 13.8 bar (200 PSI) TR70 17.2 bar (250 PSI)
TR45 13.8 bar (200 PSI) TR100 16.3 bar (240 PSI)
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Rear Suspension
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HEIGHT (reference only)

TR35 365mm (14.38”)
TR40 556mm (21.88”)
TR45 556mm (21.88”)
TR60 505mm (19.88”)
TR70 374-381mm (14.75-15.00”)
TR100 378-385mm (14.88-15.12”)

CHARGE
Standard Rock Standard Rock
TR35 5.5 bar (80 PSI) 7 bar (100 PSI) TR60 8.3 bar (120 PSI) 9 bar (130 PSI)
TR40 7 bar (100 PSI) 7.6 bar (110 PSI) TR70 8.3 bar (120 PSI) 9 bar (130 PSI)
TR45 7 bar (100 PSI) 7.6 bar (110 PSI) TR1008.3 bar (120 PSI) 9.6 bar (140 PSI)
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