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TR100
Mining Truck
Maintenance Manual
TECHNICAL PUBLICATIONS DEPARTMENT
TEREX EQUIPMENT LIMITED,
MOTHERWELL, SCOTLAND, ML1 5RY
REF. NO. SM755/783
SM 1616 Rev 1 11-00
Related Manuals for Terex TR100
Summary of Contents for Terex TR100
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Page 1
TR100 Mining Truck Maintenance Manual TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED, MOTHERWELL, SCOTLAND, ML1 5RY REF. NO. SM755/783 SM 1616 Rev 1 11-00… -
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Page 3: Important Safety Notice
WARNING Never use parts which are altered, modified, or weakened in operation. This can seriously jeopardize the integrity of the machine and could result in property damage or serious personal injury. SM 222 Rev 1 9-93 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF…
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Page 4
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Page 5
TEREX SERVICE DEPARTMENT TEREX Equipment Limited, Motherwell, Scotland ML1 5RY Tel. (0698) 732121 Tlx. 77141 Fax. (0698) 734046 TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. (918) 446-5581 Fax. (918) 446-9752 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 6
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Page 7
TABLE OF CONTENTS Section No. Description SM No. GENERAL INFORMATION 0000 TR100 Off-Highway Truck 1618 Rev 1 CHASSIS 0010 Chassis, Hood and Fenders — Pre January 2000 Production 1622 0010 Chassis, Hood and Fenders — From January 2000 Production 1898… -
Page 8
Body and Mounting 1653 Rev 1 MISCELLANEOUS 0020 Lubrication System 1654 Rev 1 0070 Service Tools 1662 Rev 1 0080 Standard Bolt and Nut Torque Specifications 1238 0090 Unit Storage 1239 SM 1617 Rev 1 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 9
GENERAL INFORMATION — TR100 Mining Truck Section 000-0000 SM — 2034 1 635 Body (5-4) Depth 5 150 (16-11) 4 730 (15-6) 1 220 (4-0) (2-7) 1 755 (5-9) 8 960 Vehicle Clearance Diameter (SAE) 24.5 m (80 ft) 3 420 (11-3) -
Page 10
General Information — TR100 Mining Truck Section 000-0000 Parking DRIVE AXLE Application of rear brakes by springs in brake disc pack. Heavy duty axle with full floating axle shafts, single reduction spiral bevel gear differential and planetary Hydraulically released. reduction at each wheel. -
Page 11
General Information — TR100 Mining Truck Section 000-0000 BODY SERVICE CAPACITIES Longitudinal ‘V’ type floor with integral transverse box- Engine Crankcase and Filters ..134 litres (35.4 US gal) section stiffeners. The body is exhaust heated and rests on Transmission and Filters ….. 100 litres (26 US gal) resilient impact absorption pads. -
Page 12
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Page 13: Installation
Using a suitable lifting device, align the component to pressure in the steering circuit. Block all road wheels. be installed in position on the chassis. Secure the component securely to the chassis with mounting hardware removed during removal. SM 1622 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF…
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Page 14: Maintenance
As a general rule however, if parts are twisted, bent or pulled apart, or After welding, reconnect all of the above in the a frame is bent or twisted, no welding should be done reverse order. SM 1622 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF…
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Page 15: Special Tools
SERVICE TOOLS for part numbers of general service tools required. These tools are available from your dealer. If painting of the actual frame of the unit is required, SM 1622 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF…
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Page 16
20 — Panel Assembly — LH 28 — Nut 6 — Nut 14 — Step Assembly 21 — Panel Assembly — RH 29 — Hardened Washer 7 — Locknut Fig. 4 — Exploded View of Ladders and Handrails SM 1622 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 17
8 — Bolt 10 — Bolt 3 — Grille — Top 6 — Button Plug 11 — Hardened Washer 9 — Hardened Washer Fig. 5 — Exploded View of Radiator Guard and Mounting SM 1622 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 18
13 — Mudguard 3 — Bar 7 — Nut 11 — Angle Support 14 — Bracket 4 — Bar 8 — Flap 12 — Bar 15 — Hardened Washer Fig. 6 — Mudguards SM 1622 12-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 19
Block all road Using a suitable lifting device, align the component to wheels. be installed in position on the chassis. Secure the component securely to the chassis with mounting hardware removed during removal. SM 1898 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 20
As a general rule however, if parts are twisted, bent or pulled apart, or After welding, reconnect all of the above in the a frame is bent or twisted, no welding should be done reverse order. SM 1898 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 21
SERVICE TOOLS for part numbers of general necessary. service tools required. These tools are available from your dealer. If painting of the actual frame of the unit is required, SM 1898 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
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17 — Step Assembly — RH 26 — ‘U’ Bolt & Nut 9 — Step Assembly 18 — Hoodside — LH 37 — Hardened Washer 27 — Bolt Fig. 4 — Exploded View of Ladders and Handrails SM 1898 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
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8 — Bolt 10 — Bolt 3 — Grille — Top 6 — Button Plug 11 — Hardened Washer 9 — Hardened Washer Fig. 5 — Exploded View of Radiator Guard and Mounting SM 1898 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 24
4 — Bolt 13 — Mudflap — RH 9 — Mudflap — LH 17 — Flap 5 — Bolt 14 — Angle Support 10 — Angle Support 18 — Flap Fig. 6 — Mudguards SM 1898 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 25
There are two starter motors mounted at the rear right engine manufacturers service manual. hand side of the engine, one of which is a prelube starter motor. SM 1655 Rev 1 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 26
(39). Tie hose assemblies (36 & 37) and it can cause serious damage to the skin away from engine (1) to prevent fouling during engine removal. and eyes. SM 1655 Rev 1 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 27: Power Take-Off
Support (5) assembly can be removed by removing ‘Maintenance’. bolts (4). 5. Refer to the Engine Service Manual for additional 27. If it is necessary to remove crossmember (6) from engine disassembly/assembly, repair, adjustment and tune-up procedures. SM 1655 Rev 1 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF…
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Page 28
(1) assembly in 6. Secure support (5) assembly to engine (1) with bolts the frame. (4). Secure rear mounts (15) to engine (1) with bolts (14 & 23) and hardened washers (12). SM 1655 Rev 1 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 29: Cooling System
Tighten mounting clamps securely. 33. Ensure the parking brake is applied and remove wheel blocks from road wheels. 22. Install exhaust tubes on the engine turbochargers and tighten mounting clamps securely. SM 1655 Rev 1 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF…
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Page 30: Lubrication System
The lack of lubrication during the delay until the filters are pumped full of oil is harmful to the Install new fuel filters (28) on the filter head and tighten engine. SM 1655 Rev 1 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF…
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Page 31: Service Tools
These tools are Add oil as necessary to bring the level to the high (H) available from your dealer. mark on dipstick (44). SM 1655 Rev 1 11-00 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF…
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Page 32
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Page 33: Engine Air Cleaner
Refer to allowable limit. When air restriction levels are reached, SM 1246 2-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF…
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Page 34
(4) is not broken. If vacuator valve (6) is lost or damaged, WARNING replace it to maintain pre-cleaner efficiency and normal Always shutdown the engine before servicing filter element service life. air cleaner. SM 1246 2-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 35: Air Cleaner Assembly
Mark each first one or two cleanings. After that, the life of the cleaned element to show total cleanings to date. element will gradually decrease with each cleaning; SM 1246 2-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF…
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Page 36: Secondary Element
3. Keep new or cleaned filter elements on hand for numbers of service tools referenced in this section and replacement to prevent unnecessary downtime of the general service tools required. These tools are vehicle. available from your dealer. SM 1246 2-98 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF…
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Page 37: Description And Operation
Block all road wheels. 8. With suitable blocking or lifting equipment, support 3. Disconnect driveline from yoke (5) at PTO the tandem pump before loosening attaching nuts. SM 1656 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF…
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Page 38
(1) with a suitable bearing puller. (6, Fig. 2) from driveshaft (15). Pull yoke (5, Fig. 2) from driveshaft (15). 8. If required, note locations and remove dowel pins (2) from flywheel cover case (1). SM 1656 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 39
4. Inspect flywheel cover case (1) and PTO cover (6) secured and of adequate capacity to do the job for cracks. If either flywheel cover case (1) or PTO safely. cover (6) are damaged, both parts must be replaced as an assembly. SM 1656 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF… -
Page 40: Oil Level Check
(1, Fig. 1) and drain oil into a suitable match marks inscribed during disassembly. container. Reinstall drain plug (14) securely when draining is complete. Note: Tighten all fasteners to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS. SM 1656 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF…
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Page 41
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Table of Contents for Terex TR100:
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Section 110-0050 Engine — Air Cleaner 2 SM 1246 2-98 SM — 1693 ‘Measuring Air Restriction’. Safety element (3) is installed in each air cleaner assembly inside of primary element (2). This element increases the reliability of the air cleaner’s protection of the engine from airborne dirt. It protects the engine from dirt admitted by a damaged primary element (2), or dirt that might be dropped into the air cleaner as
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Chassis — Chassis, Hood and Fenders Section 100-00100 4 SM 1898 11-00 SM — 2386 1 — Bolt 2 — Bolt 3 — Bolt 4 — Hardened Washer 5 — Bolt 6 — Nut 7 — Locknut 8 — Hardened Washer 9 — Step Assembly 10 — Rung 11 — Hardened Washer 12 — Hardened Washer 13 — Rubber Strip 14 — Hardened Washer 15 — Bolt 16 — Step Assembly — LH 17 — Step Assembly — RH 18 — Hoodside — LH 19 — Hoodside — RH 20 — Panel Assembly — LH 21 — Panel Assembly — RH 22 — Bumper Extension — LH 23 — Bumper Assembly — RH 24 — Bracket 25 — Bracket 2
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SM 1617 Rev 1 11-00 1 TABLE OF CONTENTS Section No. Description SM No. 000 GENERAL INFORMATION 0000 TR100 Off-Highway Truck 1618 Rev 1 100 CHASSIS 0010 Chassis, Hood and Fenders — Pre January 2000 Production 1622 0010 Chassis, Hood and Fenders — From January 2000 Production 1898 110 ENGINE 0030 Engine and Mounting 1655 Rev 1 0050 Air Cleaner 1246 0130 Power Takeoff 1656 120 TRANSMISSION 0010 Transmission and
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3 Section 110-0130 SM 1656 1-99 Engine — Power Takeoff SM — 2044 5. Visually check oil seal lip contact surfaces on driveshaft (15) and yoke (5, Fig. 2) for nicks, dents, scratches, wear, or corrosion. Replace as necessary. ASSEMBLY Numbers in parentheses refer to Figs. 3, unless otherwise specified. Note: Prior to assembly, lubricate all seal lips and surfaces
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4 Section 110-0130 Engine — Power Takeoff SM 1656 1-99 1. If removed, install dowel pins (2) in flywheel cover case (1), as noted at disassembly. 2. If removed, install breather assembly (10, Fig. 2) in PTO cover (6). 3. Install new oil seal (5) in centre bore of flywheel cover case (1) so that it is flush with flywheel cover case (1) face. See Fig. 1. Note: When installing new oil seals, install them with the oil lip (larger of the two lips with the sp
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Section 000-0000 General Information — TR100 Mining Truck SM 1618 Rev 1 11-00 2 Parking Application of rear brakes by springs in brake disc pack. Hydraulically released. Hold-off Pressure …………………………….83 bar (1 200 lbf/in²) Retardation Modulated lever control of rear disc pack. Retarder Actuation Pressure ……… up to 33 bar (480 lbf/in²) Emergency Push button solenoid control applies service and parking brakes. Automatically applies when engine is switched off. Parking brake applies should system pressure fall below a p
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1 Section 110-0130 SM 1656 1-99 DESCRIPTION AND OPERATION Numbers in parentheses refer to Fig. 1. The function of the power takeoff (PTO), as the name implies, is to provide the means of mounting and driving auxiliary components. The tandem gear pump for the disc brake cooling system is mounted on the left hand side of the PTO cover (6) and its input shaft is meshed with the internal splines in the hub of driven gear (12). Refer to Section 250-0055, TANDEM PUMP. The main hydraulic pum
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SM 1655 Rev 1 11-00 Engine — Engine and Mounting Section 110-0030 2 6. If the vehicle is equipped with an air conditioning system, evacuate refrigerant from the system and disconnect lines at the compressor. Refer to Section 260-0130, AIR CONDITIONING. 7. Place a suitable container under the engine drain port, remove drain plug and drain the oil. After draining, reinstall drain plug in the engine sump and tighten securely. 8. With suitable containers in position, open drain cocks and drain coola
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Section 110-0050 1 SM 1246 2-98 ENGINE — Air Cleaner SM — 1532 DESCRIPTION Numbers in parentheses refer to Fig. 1, unless otherwise specified. There are three, dual dry element type air cleaner assemblies mounted on the platform to the right hand side of the cab. Air cleaner assemblies prolong engine life by removing grit, dust and water from the air as it enters the engine. Grit and dust combined with engine oil, forms a highly abrasive compound which can destroy the engine in a comp
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Section 110-0050 Engine — Air Cleaner 4 SM 1246 2-98 8. After primary element (2) is thoroughly dried, inspect for damage or ruptures, especially close to the end caps. To detect paper ruptures, place a bright light bulb inside the element and rotate element slowly. Inspection of element on the outside will disclose any holes where concentrated light shines through. Even the smallest hole will pass dust to the engine and may result in costly engine repairs. 9. Install primary element (2) in air cleaner body (1). 10. Install cover assembly (4) on air cleaner body (1) a
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SM 1655 Rev 1 11-00 Engine — Engine and Mounting Section 110-0030 4 INSTALLATION Numbers in parentheses refer to Fig. 1. Note: Tighten all fasteners without special torques specified to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS. WARNING To prevent personal injury and property damage, be sure lifting device is properly secured and of adequate capacity to do the job safely. 1. Position spacer (47) and fan (48)
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Chassis — Chassis, Hood and Fenders Section 100-00100 2 SM 1622 12-98 MAINTENANCE Inspection Inspect the frame and attached parts at intervals not exceeding 250 hours for cracked or broken welds and bending/twisting of the frame. Any defects found should be repaired before they progress into major failures. Contact your dealer for recommended weld and repair instructions. Welding Note: It is important that the electrical connections are disconnected in the following order to prevent damage to the electrical components: a. Disconnect
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Chassis — Chassis, Hood and Fenders Section 100-00100 6 SM 1898 11-00 SM — 2388 1 — Mudguard 2 — Bar 3 — Bar 4 — Bolt 5 — Bolt 6 — Lockwasher 7 — Nut 8 — Hardened Washer 9 — Mudflap — LH 10 — Angle Support 11 — Angle Support 12 — Angle Support 13 — Mudflap — RH 14 — Angle Support 15 — Bar 16 — Bar 17 — Flap 18 — Flap Fig. 6 — Mudguards * * * * 5 6 7 15 17 2 4 5 6 6 7 10 11 9 3 1 5 6 7 4 8 13 14 6 5 2 18 7 6 5 16 7 6 5 1 3 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF
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Chassis — Chassis, Hood and Fenders Section 100-00100 2 SM 1898 11-00 MAINTENANCE Inspection Inspect the frame and attached parts at intervals not exceeding 250 hours for cracked or broken welds and bending/twisting of the frame. Any defects found should be repaired before they progress into major failures. Contact your dealer for recommended weld and repair instructions. Welding Note: It is important that the electrical connections are disconnected in the following order to prevent damage to the electrical components: a. Disconnect battery equalizer
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[Page 1] Terex TR100 TR100 Mining Truck Maintenance Manual TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED, MOTHERWELL, SCOTLAND, ML1 5RY REF. NO. SM755/783 SM 1616 Rev 1 11-00 |
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[Page 2] Terex TR100 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF |
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[Page 3] Terex TR100 SM 222 Rev 1 9-93 Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service procedures recommended and described in this publication, are effective methods for performing service operations. Some of the… |
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[Page 4] Terex TR100 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF |
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[Page 5] Terex TR100 TEREX SERVICE DEPARTMENT PURPOSE: To advise potentially hazardous condition. DETAIL: It has been brought to our attention that ‘Viton’ material used in manufacture of oil seals and ‘O’ rings, produces a highly corrosive acid (Hydr… |
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[Page 6] Terex TR100 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF |
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[Page 7] Terex TR100 SM 1617 Rev 1 11-00 1 TABLE OF CONTENTS Section No. Description SM No. 000 GENERAL INFORMATION 0000 TR100 Off-Highway Truck 1618 Rev 1 100 CHASSIS 0010 Chassis, Hood and Fenders — Pre January 2000 Production 1622 0010 Chassis, Hood and Fenders — From… |
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[Page 8] Terex TR100 SM 1617 Rev 1 11-00 2 * * * * TABLE OF CONTENTS Section No. Description SM No. 220 STEERING SYSTEM 0000 Steering System Schematic 1661 0040 Steering and Brake Control Tank 1638 0050 Steering Pump 1639 0080 Accumulator 1205 0090 Steering V… |
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[Page 9] Terex TR100 Section 000-0000 1 SM 1618 Rev 1 11-00 GENERAL INFORMATION — TR100 Mining Truck SM — 2034 TRANSMISSION Make/Model ………………………………….Allison DP-8963 CEC Automatic electronic control with soft shift feature. Remote mounted in the … |
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[Page 10] Terex TR100 Section 000-0000 General Information — TR100 Mining Truck SM 1618 Rev 1 11-00 2 Parking Application of rear brakes by springs in brake disc pack. Hydraulically released. Hold-off Pressure …………………………….83 bar (1 200 lbf/in²) Reta… |
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[Page 11] Terex TR100 Section 000-0000 3 SM 1618 Rev 1 11-00 General Information — TR100 Mining Truck BODY Longitudinal ‘V’ type floor with integral transverse box- section stiffeners. The body is exhaust heated and rests on resilient impact absorption pads. Bod… |
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[Page 12] Terex TR100 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF |
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[Page 13] Terex TR100 Section 100-0010 1 SM 1622 12-98 SM — 1585 CHASSIS — Chassis, Hood and Fenders REMOVAL WARNING To prevent personal injury and property damage, be sure wheel chocks, blocking materials and lifting equipment are properly secured and of adequate capacit… |
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[Page 14] Terex TR100 Chassis — Chassis, Hood and Fenders Section 100-00100 2 SM 1622 12-98 MAINTENANCE Inspection Inspect the frame and attached parts at intervals not exceeding 250 hours for cracked or broken welds and bending/twisting of the frame. Any defects found sh… |
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[Page 15] Terex TR100 Section 100-0010 3 SM 1622 12-98 Chassis — Chassis, Hood and Fenders 1 — Fender Extension 2 — Fender Assembly — LH 3 — Fender Assembly — RH 4 — Platform Assembly — RH 5 — Front Crossmember 6 — Rear Crossmember 7 — Cover Plate 8 — Mudguard 9 — Mudguar… |
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[Page 16] Terex TR100 Chassis — Chassis, Hood and Fenders Section 100-00100 4 SM 1622 12-98 SM — 2036 5 8 8 6 1 11 7 21 19 17 1 10 12 7 15 23 12 1 13 14 4 9 7 1 11 7 12 27 28 29 226 25 15 13 14 22 1 11 7 7 12 3 12 1 18 16 20 12 1 7 11 1 7 11 1 27 28 29 2 24 26 1 — Bolt 2 … |
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[Page 17] Terex TR100 Section 100-0010 5 SM 1622 12-98 Chassis — Chassis, Hood and Fenders SM — 1589 Fig. 5 — Exploded View of Radiator Guard and Mounting 1 — Radiator Guard 2 — Grille — Bottom 3 — Grille — Top 4 — Clamp 5 — Clip 6 — Button Plug 7 — Bolt 8 — Bolt 9 — Hard… |
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[Page 18] Terex TR100 Chassis — Chassis, Hood and Fenders Section 100-00100 6 SM 1622 12-98 SM — 2037 1 — Mudguard 2 — Bolt 3 — Bar 4 — Bar 5 — Bolt 6 — Lockwasher 7 — Nut 8 — Flap 9 — Mudflap — LH 10 — Support Bar 11 — Angle Support 12 — Bar 13 — Mudguard 14 — Bracket 15… |
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[Page 19] Terex TR100 Section 100-0010 1 SM 1898 11-00 SM — 2387 CHASSIS — Chassis, Hood and Fenders REMOVAL WARNING To prevent personal injury and property damage, be sure wheel chocks, blocking materials and lifting equipment are properly secured and of adequate capacit… |
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[Page 20] Terex TR100 Chassis — Chassis, Hood and Fenders Section 100-00100 2 SM 1898 11-00 MAINTENANCE Inspection Inspect the frame and attached parts at intervals not exceeding 250 hours for cracked or broken welds and bending/twisting of the frame. Any defects found sh… |
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[Page 21] Terex TR100 Section 100-0010 3 SM 1898 11-00 Chassis — Chassis, Hood and Fenders 1 — Fender Extension 2 — Fender Assembly — LH 3 — Fender Assembly — RH 4 — Platform Assembly — RH 5 — Front Crossmember 6 — Rear Crossmember 7 — Cover Plate 8 — Mudguard 9 — Mudguar… |
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[Page 22] Terex TR100 Chassis — Chassis, Hood and Fenders Section 100-00100 4 SM 1898 11-00 SM — 2386 1 — Bolt 2 — Bolt 3 — Bolt 4 — Hardened Washer 5 — Bolt 6 — Nut 7 — Locknut 8 — Hardened Washer 9 — Step Assembly 10 — Rung 11 — Hardened Washer 12 — Hardened Washer 13 -… |
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[Page 23] Terex TR100 Section 100-0010 5 SM 1898 11-00 Chassis — Chassis, Hood and Fenders SM — 1589 Fig. 5 — Exploded View of Radiator Guard and Mounting 1 — Radiator Guard 2 — Grille — Bottom 3 — Grille — Top 4 — Clamp 5 — Clip 6 — Button Plug 7 — Bolt 8 — Bolt 9 — Hard… |
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[Page 24] Terex TR100 Chassis — Chassis, Hood and Fenders Section 100-00100 6 SM 1898 11-00 SM — 2388 1 — Mudguard 2 — Bar 3 — Bar 4 — Bolt 5 — Bolt 6 — Lockwasher 7 — Nut 8 — Hardened Washer 9 — Mudflap — LH 10 — Angle Support 11 — Angle Support 12 — Angle Support 13 — M… |
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[Page 25] Terex TR100 1 SM 1655 Rev 1 11-00 Section 110-0030 ENGINE — Engine and Mounting SM — 1592 65 4 7 8 10 11 9 12 13 48 47 46 45 24 27 28 30 29 26,3 LHS 2,3 RHS 1 7 8 12 23 12 14 15 9 13 54 55 53 52 51 50 49 21,22 18 19,20,16 44 20,19,17 21 22 35 36 38 39,40,41 43 3… |
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[Page 26] Terex TR100 SM 1655 Rev 1 11-00 Engine — Engine and Mounting Section 110-0030 2 6. If the vehicle is equipped with an air conditioning system, evacuate refrigerant from the system and disconnect lines at the compressor. Refer to Section 260-0130, AIR CONDITIONIN… |
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[Page 27] Terex TR100 3 SM 1655 Rev 1 11-00 Section 110-0030 Engine — Engine and Mounting the chassis, remove disc brake oil cooler and transmission oil cooler from crossmember (6) first. Refer to Section 210-0050, DISC BRAKE OIL COOLER, and, Section 210-0060, TRANSMISSIO… |
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[Page 28] Terex TR100 SM 1655 Rev 1 11-00 Engine — Engine and Mounting Section 110-0030 4 INSTALLATION Numbers in parentheses refer to Fig. 1. Note: Tighten all fasteners without special torques specified to standard torques listed in Section 300-0080, STANDARD BOLT AND N… |
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[Page 29] Terex TR100 5 SM 1655 Rev 1 11-00 Section 110-0030 10. Secure support (5) assembly to crossmember (6) with bolts (7) and hardened washers (8). Secure rear mounts (15) to chassis mounts with bolts (7), hardened washers (8) and locknuts (13). 11. Connect front dri… |
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[Page 30] Terex TR100 SM 1655 Rev 1 11-00 Engine — Engine and Mounting Section 110-0030 6 MAINTENANCE Numbers in parentheses refer to Fig. 1, unless otherwise specified. Every 10 Hours (Daily) General — Visually check the engine for leaks, loose or damaged parts, worn or … |
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[Page 31] Terex TR100 7 SM 1655 Rev 1 11-00 Section 110-0030 Engine — Engine and Mounting Apply a thin film of clean lubricating oil to the gasket surface of the new filters and fill the filters with clean lubricating oil specified in Section 300-0020, LUBRICATION SYSTEM…. |
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[Page 32] Terex TR100 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF |
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[Page 33] Terex TR100 Section 110-0050 1 SM 1246 2-98 ENGINE — Air Cleaner SM — 1532 DESCRIPTION Numbers in parentheses refer to Fig. 1, unless otherwise specified. There are three, dual dry element type air cleaner assemblies mounted on the platform to the right hand sid… |
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[Page 34] Terex TR100 Section 110-0050 Engine — Air Cleaner 2 SM 1246 2-98 SM — 1693 ‘Measuring Air Restriction’. Safety element (3) is installed in each air cleaner assembly inside of primary element (2). This element increases the reliability of the air cleane… |
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[Page 35] Terex TR100 Section 110-0050 3 SM 1246 2-98 Check condition of clamps (10 & 11, Fig. 3), hump hoses (8 & 9, Fig. 3) and plenum chamber (1, Fig. 3). Tighten/replace as necessary. Air Cleaner Assembly Numbers in parentheses refer to Fig. 1, unless otherwis… |
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[Page 36] Terex TR100 Section 110-0050 Engine — Air Cleaner 4 SM 1246 2-98 8. After primary element (2) is thoroughly dried, inspect for damage or ruptures, especially close to the end caps. To detect paper ruptures, place a bright light bulb inside the element and rotate… |
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[Page 37] Terex TR100 1 Section 110-0130 SM 1656 1-99 DESCRIPTION AND OPERATION Numbers in parentheses refer to Fig. 1. The function of the power takeoff (PTO), as the name implies, is to provide the means of mounting and driving auxiliary components. The tandem gear pump… |
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[Page 38] Terex TR100 2 Section 110-0130 Engine — Power Takeoff SM 1656 1-99 Remove nuts and lockwashers from tandem pump mounting studs and secure pump clear of PTO assembly (1). 9. Match mark engine flywheel housing and flywheel cover case (1, Fig. 1) so that PTO assemb… |
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[Page 39] Terex TR100 3 Section 110-0130 SM 1656 1-99 Engine — Power Takeoff SM — 2044 5. Visually check oil seal lip contact surfaces on driveshaft (15) and yoke (5, Fig. 2) for nicks, dents, scratches, wear, or corrosion. Replace as necessary. ASSEMBLY Numbers in parent… |
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[Page 40] Terex TR100 4 Section 110-0130 Engine — Power Takeoff SM 1656 1-99 1. If removed, install dowel pins (2) in flywheel cover case (1), as noted at disassembly. 2. If removed, install breather assembly (10, Fig. 2) in PTO cover (6). 3. Install new oil seal (5) in c… |
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[Page 41] Terex TR100 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com |