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150310
TR45 TR60
Serial Number Range T881 T882
23 Pin OEM
E.C.M.
Power
50 Pin 60 Pin
Connector
Engine Electrical Connections
6
Engine Electrical Identification
31-Pin Connector
23-Pin Connector
3 2
4 1
Main Fuse Box
7
F1 F13 F25
K23 K4
K43
K34 K56
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
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
50 Pin Connector
3 2
16 Pin OEM Connector
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
B2 – Thermostat Housing
(P2) Tachometer Calibration
14
37
46
47 50 Pin
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
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
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
Flash Sequence:
1 FLASH
1 FLASH
Example; CODE 235
Retrieving Diagnostics / Warnings
22
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
Pressure
Return
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
Always refer to latest and appropriate service / maintenance documentation for correct procedures.
32
Web
www.terex.com