Product Training
Rigid Dump Trucks
TR45 : TR60
Cummins QSK19 Tier3
150310
Terex Centre of Excellence
Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
United Kingdom
Technical Online Assistance: [Link]
Engine Specification
2
TR45 TR60
Serial Number Range T881 T882
Cummins Engine QSK19 – C525 QSK19 – C700
Displacement l 18.9 18.9
Gross Power kW 392 522
HP 525 700
Max. Torque @ RPM Nm 2407 @ 1300 2893 @ 1300
lbf ft 1775 @ 1300 2200 @ 1300
Max Speed – Full Load Rev/min 2000 2000
Max Speed – No Load Rev/min 2244 2350
Idle Speed Rev/min 700 / 750 Self Adjusting
Welding Precautions
3
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
• Any other electronic options ie. rear view TV, lube
systems, etc.
Engine Electronic Controls
4
The primary functions of the control
system include fuelling and timing
control. Reducing exhaust emissions
while optimizing engine performance.
It does this from a series of input
signals from various devices e.g.
pressure and temperature sensors,
operator inputs, accelerator pedal etc.
The control system can offer engine
protection, ramping down available
power when an out of range condition
parameter is sensed.
E.C.M.
The control system can be accessed
utilising available diagnostic tools.
Providing fault information, data
logging, parameter adjustment (if
licensed).
Engine Electrical Identification
5
Engine LHS 31 Pin OEM
23 Pin OEM
9 Pin 16 Pin OEM
Diagnostic
E.C.M.
Power
50 Pin 60 Pin
Connector
Engine Electrical Connections
6
Engine Electrical Identification
31-Pin Connector
23-Pin Connector
16-Pin Connector 50-Pin 60-Pin Power
Connector Connector Connector
3 2
4 1
Main Fuse Box
7
F1 F13 F25
K23 K4
K43
K34 K56
F12 F24 F36 K15 K38 K57
Relay Definition
K4 Flasher K15 Dipped Beam K56 Sound Power Body Raise
K23 Ignition K34 Horn K57 Sound Power 1st / Rev Gr.
K38 Main Beam K43 Radio
Start Circuit
8
To Battery Charge Lamp
Ignition Key Switch
Master Disconnect Relay
Neutral Start Relay
Starter
Alternator
Motor
Relay
Battery Starter
Motor
Battery
Power Module
9
Disconnect Relay
K59 K23
F40 Ignition
F41
K2 Master
F42 K23
F43 Engine
Timer
F44 Relay
K23
Trans.
Power Module –
Mounted on Battery Box
E.C.M. Power
10
See Page 11 for location.
To 9 pin Diagnostic Connector
Terex Power Module
To 9 pin Diagnostic Connector
50 Pin Connector
3 2
16 Pin OEM Connector
50-Pin 60-Pin Power 4 1
Connector Connector Connector Power Connector
E.C.M. Inline Power Fuses
11
2 x 10 amp power fuses mounted on
side of interface connectors. Rear
LHS of engine.
Diagnostic / Soundpower Circuit
12
Body Proxy
Sw.
S68
S68
Sound Power Bridge
S68 Diagnostic Request
S68 Diagnostic Scroll
Accelerator Pedal
H2 Definitions
M Engine Stop Lamp
Idle Validation Sw.
P Engine Check Lamp
R Engine Protection
Tachometer
Lamp
Engine Gauges / Senders
13
P2
P5 Engine Oil P4
P5
Pressure
Gauge
P3
P3 Coolant
Temperature
Gauge
P2 Tachometer
P4 Fuel Level
B22 – Lube Oil Filters
Gauge
B22 Engine Oil
Pressure
Sender
B2 Coolant
Temperature
Sender
B8 Fuel Level
Sender
B2 – Thermostat Housing
(P2) Tachometer Calibration
14
Tachometer Calibration Input
TR45 12.00 Pulses
TR60 12.00 Pulses
The tachometer when installed as new or replaced will
require calibration prior to being put to work. PULSE
On the rear of the tachometer there is a pressure pad.
1. Hold down pressure pad.
2. Turn on ignition - Do not start engine.
3. Hold pressure pad until the word ‘PULSE’ appears
on the tachometer display.
4. Release pressure pad and a calibration figure will be
displayed, similar to above.
5. Each digit will flash for 4-5 seconds each, prior to
advancing to the next digit.
6. To alter a digit, press the pressure pad.
7. Once calibration is complete, turn off ignition.
Can-Bus Communication
15
37
46
47 50 Pin
Engine Mounted 9 Pin
B
Engine LHS
Connector (Cummins A
Provided) E
D
C
B
A
E 3 pin Can-Bus Interface connector (not
D schematically shown). Refer to page 17
C for Engine/Transmission Interface.
Transmission ECU
9 Pin Diagnostic Connector
16
A – Ground
B – System Voltage
C – CAN + (High) J1939 Datalink Supply
D – CAN – (Low) J1939 Datalink Return
E – CAN Shield
F–
G–
H–
System Checks;
Voltage across A – B = System Voltage 24V J
Resistance Across C – D = 60 Ω
Can-Bus Communication
17
Located behind 16 pin OEM
engine connector.
3 pin Can-Bus engine /
transmission interface.
Terminating at transmission
ECU – Shifter Connector(S)
pins 12(G), 13(R), 29(B).
Insite Diagnostic Tool
18
9 PIN DIAGNOSTIC CONNECTION - FRONT OF
INSTRUCTOR SEAT
INSITE KIT 15500623
INCLUDES INSITE PROGRAM & INLINE
CONNECTOR
INSITE SPARES
Insite Software CD-ROM 15501453
Inline Connector Interface 15501478
PC/Inline Interface Cable 15501479
Inline Interface/Vehicle Cable(9) 15501480
Inline Interface/Vehicle Cable(6) 15500716
Quickcheck Diagnostic Tool
19
Quickcheck KIT 15501303
Includes Handheld and Cables
Quickcheck Software 15503659
On Board Diagnostics / Warnings
20
On Board Diagnostics
Extensive Fault Detection Fault Capability
Flash Out Fault Codes
Fault Lamps Located on Dash
Engine Protection De-Rate System
Diagnostic button (S68) activates diagnostic
mode. Diagnostic scroll button (S68) is used to S68
scroll backwards and forward through mulit-
S68
diagnostic codes. Press top top of switch (S68)
will advance to next active code, pressing
bottom of button (S68) will go back to previous
active code.
On Board Display
1. Alternator Charging Lamp (Red)
2. Engine Water Temperature (Red)
3. Engine Water Level (Amber)
4. Air Restriction Lamp (Amber)
5. Engine Oil Pressure Lamp (Red)
6. Engine Stop Lamp (Red)
7. Engine Warning Lamp (Amber)
8. Engine Protection Lamp (Amber)
On Board Diagnostics / Warnings
21
Cummins On Board Diagnostics
Flash Out Engine Fault Codes
Amber Lamp - Soft Codes
Red Lamp - Hard (Critical) Codes
Flash Sequence:
1 FLASH
2 FLASHES 3 FLASHES 5 FLASHES
SHORT PAUSE SHORT PAUSE
1 FLASH
Example; CODE 235
Retrieving Diagnostics / Warnings
22
ECM will detect fault on engine
Either engine warning or stop lamp will illuminate depending on severity of fault
Select diagnostic request switch
The amber warning lamp will flash once(1) followed by the fault code flashed out on the red
stop lamp. The amber warning light will then flash once(1) when fault code is complete.
This sequence will continue until the diagnostic scroll switch is selected. Pushing the top of the
switch will advance to the next fault code. Pushing the bottom of the switch will return to the
previous fault code.
If only 1 fault code is active, the system will continuously display the same fault code.
Press diagnostic request switch to exit diagnostic mode.
Engine Protection
23
The machine is equipped with an engine protection derate
system.
The ’Protection' light (8) illuminates when the engine
protection derate system is initiated.
The engine power and speed will be gradually reduced
depending on the level of severity of the out-of-range
condition.
The ’Protection' light (8) will start to flash if the out-of-range
condition continues to get worse. The operator MUST shut
down the engine to avoid serious damage.
Faults for Protection activation:
• Low coolant level
• High coolant temperature
• Idle validation/throttle pedal switch mismatch
• High intake manifold temperature
• Low oil pressure
• High fuel rail pressure
Engine Mounted Sensors
24
1. Intake manifold temperature sensor
2. Intake manifold pressure sensor
3. Barometric pressure sensor
4. Engine oil rifle pressure sensor
5. Engine crankshaft speed/position sensor
6. Fuel delivery pressure sensor
7. Engine fuel temperature sensor
8. Fuel pump pressurizing assembly
9. Injector metering rail pressure sensor
10. Engine camshaft speed/position sensor
11. Engine coolant temperature sensor
12. Intake manifold port.
Pressure Sensor – 3 wire Temperature Sensor – 2 wire
Sensors Specifications
25
Engine Oil Rifle Pressure 1 Sensor - Torque = 14 N•m [124 in-lb]
Pressure (kPa) Pressure [psia] Pressure (inHg) Voltage (VDC)
0 0 0 0.21 to 0.79
103 15 31 0.90 to 1.10
172 25 51 1.17 to 1.52
345 50 102 1.83 to 2.50
517 75 153 2.59 to 3.41
689 100 204 3.43 to 4.25
827 120 244 4.09 to 4.91
Intake Manifold 1 Pressure Sensor (Torque = 14 N•m [124 in-lb])
Pressure (kPa) Pressure [psia] Pressure [inHg] Voltage (VDC)
0 0 0 0.22 to 0.80
103 15 31 1.23 to 1.40
207 30 61 1.97 to 2.27
310 45 92 2.71 to 3.16
414 60 122 3.45 to 4.04
519 75 153 4.20 to 4.92
Conversions
1 lb/in2 (psi) = 6.9 kPa 1 bar = 100 kPa 1 bar = 14.5 lb/in2 (psi)
Sensors Specifications
26
All Temperature Sensors (Torque = 15 N•m [133 in-lb])
Temperature (°C) Temperature [°F] Resistance (Ohms)
0 32 30K to 36K
25 77 9K to 11K
50 122 3K to 4K
75 167 1350 to 1500
100 212 600 to 675
Barometric Pressure Sensor - Torque = 23 N•m [204 in-lb]
Pressure (kPa) Pressure (psia) Pressure (inHg) Voltage (VDC)
45 6.50 13 0.32 to 0.69
69 10 20 1.72 to 2.23
90 13 27 2.96 to 3.52
103 15 31 3.72 to 4.45
110 16 33 4.14 to 4.87
Fuel Delivery Pressure Sensor
Pressure (kPa) Pressure [psia] Pressure [inHg] Voltage (VDC)
103 15 31 0.50
552 80 163 1.61
1034 150 305 2.80
1379 200 407 3.65
1724 250 509 4.50
Injector Metering Rail 1 Pressure Sensor
Pressure (kPa) Pressure [psia] Pressure [inHg] Voltage (VDC)
0 0 0 0.50
50,000 7,252 14,765 1.50
100,000 14,504 29,530 2.50
150,000 21,756 44,295 3.50
200,000 29,008 59,060 4.50
Electrical Checks
27
Voltage Checks (DC) – Key On
Check across appropriate terminals in parallel to the circuit.
Continuity (Bleep)
Resistance Checks (Ω) – Key Off DO NOT USE
Check across appropriate terminals
Resistance
Continuity Checks – Key Off – Use Resistance.
It is recommended Not To Use Continuity (Bleep) Test. Voltage
Internal voltages within ECM are limited to 5 V. Most multi-
meters contain a 9 V battery. Voltage spikes could
permanently damage ECM.
Red
O.L. = Open Circuit Lead
1Ω = Continuity or Short Circuit for
Current
To check a particular meter for correct readings;
Hold leads apart – reading = Open Circuit
Touch leads together – reading = Continuity or S.C.
Current Checks (Amps) – Key On
Ensure red lead is located in correct meter port.
Connect the meter in series with the circuit at the point
where you wish to measure (This will mean breaking the
circuit). It must be on the SUPPLY line.
Fuel Lines – Fuel Pre-Filter
28
Suction
Pressure
Return
Delivery Fuel Return Fuel
Manifold Delivery
To Manifold
Injector
Housing
Main
Fuel Fuel Pre-Filter
Pump Special Collar Vent/Cap Wrench
15503453
Fuel
Pre-
Filter Drain Daily
Replace Element 250 hrs
Fuel Lines - Engine
29
Service Schedule
30
Recommended Service Intervals
Daily / 10 hrs
• Check Oil Level – Add if low
• Engine Fuel Pre-Filter – Drain Water and Sediment
250 hrs
• Oil Filters – Replace
• Fuel Filter – Replace
• Engine Fuel Pre-Filter - Replace
• Coolant Filter – Check DCA4 Additive, replace if required.
• Engine Oil – Drain & Re-fill
• Crank Case Breather – Clean
1500 hrs
• Valve Adjustment – Check and adjust if required.
• Fan Hub - Lubricate
6000 hrs
• Coolant – Drain, Flush and Re-Fill
Service Schedule
31
Engine Oil Type
Engine Engine oil with 1.00% sulphated ash is recommended. Ambient Temp Recommendation
Sulphated ash must not exceed 1.85% limit. 0° C and above SAE 20W-40
API code CH-4, ACEA-E5. -10° C and above SAE 15W-40
-25° to 35° C SAE 10W-30
Engine Crank Case & Filters 55 litres
12.1 UK gal
14.5 US gal
Valve Adjustment (Tier3 Electronic Injector)
Initial Set; Exhaust Intake
0.69mm (0.027”) 0.36mm (0.014”)
Recheck Limits; 0.61 – 0.762 mm 0.28 - 0.43 mm
(0.025 – 0.030”) (0.011 – 0.017”)
Coolant Additive Checks
Refer to service manual section 210-000 for detailed procedures
DCA4 Test Kit - 15269814
Always refer to latest and appropriate service / maintenance documentation for correct procedures.
32
Terex Equipment Limited
Motherwell, ML1 5RY
Scotland
+44 (0)1698 732121
+44 (0)1698 734046
Web
[Link]
Technical Online Assistance
[Link]
