Terex TR60 Off-Highway Truck Maintenance Manual – Complete PDF Guide

Description

Terex TR60 Off-Highway Truck Maintenance Manual

When you need to keep a 54,430 kg payload haul truck running safely and efficiently, having the correct service data is not optional. This Terex TR60 Off-Highway Truck Maintenance Manual (Document SM1564 Rev 3) is your complete, single-source reference for routine maintenance, component removal, disassembly, inspection, assembly, and installation procedures. Whether you are a fleet maintenance manager, a field technician, or a heavy equipment mechanic, this manual provides the exact specifications and step-by-step instructions required to service the TR60 correctly the first time.

File Details

• Manual Type: Maintenance Manual
• Brand: Terex
• Model: TR60 Off-Highway Truck
• Engine: Cummins QSK19-C650 (4 Cycle, Turbocharged/Low Temperature Aftercooled)
• Transmission: Allison M6600AR
• Document Number: SM1564 Rev 3
• Language: English
• File Format: PDF
• Page Count: 526 pages

Chapters Covered

• 000 General Information
• 0010 Welding Procedure
• 100 Chassis, Hood and Fenders
• 110 Engine and Mounting
• 120 Transmission and Mounting
• 130 Driveline
• 140 Front Axle
• 160 Rear Axle
• 165 Brake Parts
• 180 Suspension System
• 190 Circuit Diagrams
• 200 Fuel System
• 210 Cooling System
• 220 Steering System
• 230 Body System
• 250 Braking System
• 260 Operators Compartment
• 270 Body and Mounting
• 300 Miscellaneous

General Information and Specifications

This opening section lays the foundation for every job that follows. You will find the complete machine dimensions, weight distributions for empty and loaded conditions, and the essential service capacities, including 66 litres for the engine crankcase, 85 litres for the transmission, and a 606-litre fuel tank. It also details the Cummins QSK19-C650 engine specifications, the Allison M6600AR transmission gear ratios, and critical operating parameters such as the 30%/60% safe operating grade.

Engine, Chassis, and Cooling

Detailed procedures guide you through the removal and installation of the hood, fenders, and the massive Cummins QSK19 engine. You will find the exact torque specifications for engine mounts, the complete air cleaner assembly service procedure, and the full cooling system schematic. This chapter also covers the replacement of the radiator, header tank, and both the disc brake and transmission oil coolers, ensuring your TR60 stays within its required operating temperature range.

Transmission, Driveline, and Axles

The Allison M6600AR transmission requires precise handling. This manual provides the full removal, disassembly, assembly, and installation sequence, along with the complete Commercial Electronic Control (CEC) Shift System description and troubleshooting codes. The driveline section covers universal joint and slip joint service with specific torque values. Moving to the axles, you get the complete differential overhaul procedure, including pinion cage and ring gear adjustments, backlash tolerances, and the planetary gear assembly procedures for the rear axle.

Braking and Steering Systems

Safety is paramount on a machine this size. The braking section thoroughly documents the front and rear brake systems, including the removal and installation of the brake pads, calipers, and the massive oil-cooled disc brakes. It covers the treadle valve, monoblock brake valve, accumulators (with their 55 bar nitrogen precharge), and the complete bleeding procedure. The steering section provides the hydrostatic steering schematic, steering pump overhaul, double relief valve adjustment, and the removal and installation of the steering cylinders and linkage.

Body System and Hydraulics

From the tandem pump to the body control joystick, this chapter gives you the hydraulic expertise to maintain the hoist system. You will find the complete removal and installation procedures for the body cylinders, the kick-over valve, the pilot supply valve, and the body control valve, along with the critical pressure test point values you need to diagnose a sluggish or failing hoist system.

Electrical, Cab, and Operator Compartment

With over 50 pages of circuit diagrams, this section is a goldmine for troubleshooting electrical faults. It includes the CEC transmission interface, the Quantum engine ECM interface, and the full electrical schematic with fuse and relay locations. In the operator’s compartment chapter, you will find cab mounting procedures, air conditioning system service (including R-134a charging and leak testing), and seat removal and installation.

Lubrication, Tools, and Specifications

The final section brings together the essential data you will reference daily. It provides the comprehensive lubrication and service chart, which details every grease point, fluid capacity, and service interval from daily checks to the 5,000-hour wheel bearing repack. It also includes standard bolt and nut torque specifications for both imperial and metric fasteners, and a list of the special service tools required for major overhauls.

Why This Manual is Essential for Your TR60

Operating and maintaining a Terex TR60 without the factory-specified procedures is a gamble that can lead to catastrophic component failure, costly downtime, and compromised safety. This manual gives you the exact torque values, wear limits, pressure readings, and step-by-step disassembly sequences that Terex engineers designed for this machine. From diagnosing a fault code in the CEC shift system to correctly shimming the differential or bleeding the brake accumulators, you have the information at your fingertips to complete the job with confidence. Delivered instantly as a high-quality PDF, this manual can be viewed on any device, printed for the shop floor, and searched for the specific procedure you need. No shipping, no waiting—just the professional-grade maintenance data you need to keep your TR60 hauling.

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