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TEREX Equipment Limited Operations Manual

15504845

Original Operating Instructions

OHE783

Related Manuals for Terex TR100

Summary of Contents for Terex TR100

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TEREX Equipment Limited Operations Manual 15504845 Original Operating Instructions OHE783…
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TEREX Equipment Limited Operator Handbook TEREX Equipment Limited Operator Handbook Re-order Issued by; Customer Support Department Terex Equipment Limited Newhouse Industrial Estate Motherwell, ML1 5RY Scotland Tel; +44 (0) 1698 732121 Fax; +44 (0) 1698 503210 http//:constructionsupport.terex.com www.terex.com OHE783 (CEC2)
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This Handbook is provided as a guide to familiarize the operator and serviceman with the controls, recommended inspections, start-up, operating, shutdown and parking procedures for a TR100 Rigid Truck. Look for the safety alert symbol to point out important safety precautions. It…
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Introduction 1991 INTENDED USE OF MACHINE This product and its approved attachments are primarily intended to be used as described in this manual. Use of this product in any other way is prohibited and contrary to its intended use. Hazard Classification Multi-tier hazard classification system is used to communicate potential personal injury hazards.
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Introduction There is a dealer serving every part of the world where these products are sold. Your dealer is ready to provide you with any additional information needed and should be consulted for additional publications for this machine. THEFT DETERRENT PRACTICES General The owner/operator should take the following precautions to discourage theft, to aid in the recovery in the event that the machine is stolen, or to reduce vandal-…
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ONLY TRAINED COMPETENT PERSONNEL SHOULD BE ALLOWED TO OPERATE THIS VEHICLE The operator is responsible and must be familiar with the contents of the Operator’s Handbook and any Local / National regulations prior to operating this vehicle.
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CALIFORNIA Proposition 65 Warnings WARNING: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. WARNING: Battery posts, terminals and related accessories contain lead lead compounds, chemicals known to the State of California to cause cancer…
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SPARE PARTS STATEMENT When carrying out repairs, alterations or fitting attachments, it is important that only genuine spare parts are used to ensure the operating safety of the machine is not impaired. It is only by using genuine parts that the technical requirements stipulated by the manufacturer can be maintained.
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Motherwell, Scotland. ML1 5RY 2006/42/EC DESCRIPTION OF MACHINERY: MAKE: TEREX MODEL/DESIGNATION: TR100 Rigid Truck INSPECTOR: UNIT SERIAL NUMBER: WE DECLARE THAT THE ABOVE MACHINERY FULFILS ALL THE RELEVANT PROVISIONS OF THE ABOVE DIRECTIVES FULL QUALITY ASSURANCE (Annex X): CERTIFICATE NUMBER: LRQ 0925301/A L.R.Q.A.
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SPARE PARTS STATEMENT When carrying out repairs, alterations or fitting attachments, it is important that only genuine spare parts are used to ensure the operating safety of the machine is not impaired. It is only by using genuine parts that the technical requirements stipulated by the manufacturer can be maintained.
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Motherwell, Scotland. ML1 5RY 2006/42/EC DESCRIPTION OF MACHINERY: MAKE: TEREX MODEL/DESIGNATION: TR100 Rigid Truck INSPECTOR: UNIT SERIAL NUMBER: WE DECLARE THAT THE ABOVE MACHINERY FULFILS ALL THE RELEVANT PROVISIONS OF THE ABOVE DIRECTIVES FULL QUALITY ASSURANCE (Annex X): CERTIFICATE NUMBER: LRQ 0925301/A L.R.Q.A.
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SPARE PARTS STATEMENT When carrying out repairs, alterations or fitting attachments, it is important that only genuine spare parts are used to ensure the operating safety of the machine is not impaired. It is only by using genuine parts that the technical requirements stipulated by the manufacturer can be maintained.
Page 17: Table Of Contents

CONTENTS 1. INTRODUCTION Introduction Safety Precautions Intended use of machine Hazard Classification Machine Identification Theft Deterrent Practices 2. SAFETY PRECAUTIONS General Vehicle Lifting Precautions Vehicle Tie Down Precautions Preventing Fire Hazards Mounting and Dismounting Pre-Starting Starting Operating Roading 2-10 Lubrication and Servicing 2-10 Scrapping of Machine 2-11…
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Moving Disabled Truck 8. LUBRICATION AND SERVICING Safety Precautions Lubrication and Servicing Lubrication and Service Chart Miscellaneous Servicing Service Capacities Recommended Lubricants Air Conditioning Re-start Procedure 8-10 Tyre Pressure 8-10 9. TECHNICAL DATA Technical Data — TR100 10.SYMBOL IDENTIFICATION 10-3…
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Page 21: Introduction

This manual is provided as a guide to familiarize the operator and serviceman with the controls, recommended inspections, start-up, operating, shutdown and parking procedures for a TR100 Rigid Truck. Safety alert symbol Look for the safety alert symbol to point out important safety precautions. It…
Page 22: Intended Use Of Machine

Introduction MOT00440 INTENDED USE OF MACHINE This machine and its approved attachments are primarily intended to be used as described in this manual. Use of this machine in any other way is prohibited and contrary to its intended use. Hazard Classification Multi-tier hazard classification system is used to communicate potential personal injury hazards.
Page 23: Theft Deterrent Practices

Introduction There is a dealer serving every part of the world where these machines are sold. Your dealer is ready to provide you with any additional information needed and should be consulted for additional manuals for this machine. THEFT DETERRENT PRACTICES General The owner/operator should take the following precautions to discourage theft, to aid in the recovery in the event that the machine is stolen, or to reduce vandal-…
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2 — Safety…
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Safety SAFETY The machine should be properly operated and maintained to keep it in safe, efficient operating condition. Be sure that all controls are free of mud, grease, or other matter that might cause slips hazardous to the operator, serviceman, or other personnel or equipment.
Page 28: Safety Precautions

Safety SAFETY PRECAUTIONS General Read this Operator’s Handbook and learn the operating characteristics and limitations of the vehicle. Know what operating clearances the vehicle requires. Read and understand all the safety signs prior to • operation. • If the safety signs are obstructed by dirt or debris, clean them using mild soap and water prior to operation.
Page 29: Vehicle Lifting Precautions

Safety Vehicle Lifting Precautions Prior to lifting, the vehicle should be parked on a level surface, wheels blocked. The vehicle should be lifted using a spreader bar if possible. Lift using FOUR slings from the lifting points provided at the bumper end of the chassis and at the rear of the body.
Page 30: Preventing Fire Hazards

Safety PREVENTING FIRE HAZARDS General Fire Precautions Make sure the vehicle has a fire extinguisher and that it is accessible and fully charged (Not furnished with the vehicle). Never use an open flame as a light anywhere on, or around, the vehicle. Clean all dirt, oil, grease and other fluids from systems and components to minimize fire hazards and aid in spotting loose or leaking lines, fittings etc..
Page 31: Mounting And Dismounting

Safety Electrical Hazard Precautions Never smoke or allow open flames or sparks near batteries. Leave battery box open when charging batteries in the vehicle for adequate ventilation of explosive gas (hydrogen) produced. Always disconnect batteries before repairing electrical system to avoid danger of fire-causing sparks.
Page 32: Pre-Starting

Safety Pre-Starting If engine is to be started and run indoors, ensure proper ventilation to remove deadly exhaust gases. Always perform ‘Pre-Starting Inspection’ instructions described on page 4-3 to ensure the vehicle is ready for operation. Always walk around the vehicle to make sure no-one is working on, underneath or close to the vehicle before starting the engine or operating the vehicle.
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Safety Sound horn before starting engine or beginning to move the vehicle; two blasts for forward and three blasts for reverse. Watch for ground crew and other personnel on foot. Sound horn as a warning before setting the vehicle in motion and when approaching ground crew.
Page 34: Roading

Safety Roading Match speed to road conditions. Yield the right of way when required. Obey the rules of the road. Stay as close to the side of the road as possible. Pass other equipment only when the road is clear and enough room / space to pass and reserve power is available.
Page 35: Scrapping Of Machine

Safety Always use a self-attaching chuck with a long airline, and, stand to one side while the tyre is inflating. Refer to Section 160-0050, WHEEL RIM AND TYRE in the Maintenance Manual. Ensure any lifting devices are adequate for the job which they are intended. Scrapping the Machine At the end of its life, the machine should be disassembled by a competent person using safe working prctices, wearing the…
Page 36
Safety Installation and Adjustment of Mirrors and CCTV The operator must survey their surroundings before entering the machine, and check their field of vision prior to and during operation of the machine. All mirrors must be adjusted when installed, and prior to operating the machine, to achieve optimum visibility and thus minimize the risk of injury to themself and others.
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Safety 2063 2064 2065 When the three loose mirrors (F, G and H) have been fitted, the machine has a total of eight mirrors, designated A to H respectively, and positioned generally as illustrated. The area surrounding the machine is to be considered as two distinct fields of view, illustrated below as areas 1 to 8 in the immediate vicinity, and areas 9 to 15 at a radius of 12 m from the operator when seated.
Page 38
Safety Installation of Mirrors A and B and Associated Brackets Mirrors A and B and are supplied fitted, on brackets folded into the handrails. They must be installed by the customer in the positions defined by the illustration below. Mirror A is to be installed on the upper vertical extension immediately above the upper hand-rail.
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Safety Installation of Bracket for Mirror H The bracket provided for the mounting of mirror H is supplied as a loose item, and must be installed by the customer in the position defined by the illustration below. 2073 MIRROR ATTACHMENT POSITION Ref.
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Safety Visibility 2067 4 280 1000 1000 1000 The visibility for this vehicle at a 1m area boundary from the outside surface of the vehicle at a height no greater than 1.5 m is shown in the diagram above. The hatched area (A) shows the area where the operator’s view is blocked by part of the machine, when mirrors and other CCTV visual aids are installed and adjusted correctly, when viewing from the operator’s seating position.
Page 41: Cctv

Safety CCTV 2062 Some machines are fitted with CCTV cameras at the rear, and a CCTV monitor in the cab for viewing the CCTV images. Operate the CCTV system in accordance with the manufacturer’s instructions, provided in the cab. Option with Addition of Ground Level 2069 Isolation Switch Some machines are fitted with a ground level isolation…
Page 42: Wheels And Tyres

Safety Wheels and Tyres If tyres on the vehicle were inflated at the factory with dry nitrogen gas, the tyre walls will be marked ‘N’ and the following factory installed decal will be found mounted on the fenders. NOTICE TYRES ON THIS VEHICLE ARE FACTORY INFLATED WITH DRY NITROGEN. IT IS RECOMMENDED THAT DRY NITROGEN BE USED EXCLUSIVELY FOR ALL TYRE PRESSURE ADJUSTMENTS AS WELL AS INFLATION OF REPLACEMENT TYRES.
Page 43: Avoid Tyre Explosion Hazard

Safety AVOID TYRE EXPLOSION HAZARD Whenever a vehicle’s tyre(s) is (are) exposed to excessive heat, such as a vehicle fire or extremely hot brakes, the hazard of a subsequent violent tyre explosion must be recognized. All nearby persons must avoid approaching the vehicle, so as not to be physically endan- gered in the event of an explosion of the tyre and rim parts.
Page 44: Decals And Instruction Plates

Safety DECALS AND INSTRUCTION PLATES Decals and instruction plates fitted to vehicles may vary from country to 4, 5 country to suit local needs. These pages contain a brief description and the 2, 3 location of the decals and instruction 8, 9 plates that may appear on your vehicle.
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Body Control (1897) TR60 101 200 lb ( 46 000 kg ) TR70 116 850 lb ( 53 000 kg ) Hand Lamp (1964) TR100 159 500 lb ( 72 500 kg ) 15335767 Safety Lift Instruction (1900) 15335731 Transmission Retarder…
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4.57m ( 15′ 0″ ) TR100 4.85m ( 15′ 11″ ) 15303454 Vehicle Height (1965) TEREX EQUIPMENT LIMITED 15331024 NEWHOUSE INDUSTRIAL ESTATE MOTHERWELL, SCOTLAND. ML1 5RY. Power Module (1969) MODEL NO. / MODELL MODELE No. / No. DE MODELO PRODUCT IDENTIFICATION NO. / FAHRGESTELL — NR No.
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Safety 15342619 Fuse/Relay Chart (2195) 15335803 Fuse/Relay Chart (1927) 2-23…
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Safety SAFETY DECAL SET ISO STANDARD ROPS FOPS lb MAX. kg MAX. TEREX No. 15335811 ROPS and FOPS, See handbook for procedure (1931) PSI / BAR 15336277 Suspension Strut (2198) 15335771 Gradeability Chart, TR35 (1910) 15335820 15335785 Hydraulic Oil Sight…
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Gradeability chart, TR70 (1916) 15335749 Crush Hazard, Install support before servicing (1908) 15335778 Gradeability chart, TR100 (1918) 15335789 15335792 Caution Cab Foam, Do not weld or burn cab Rim clamps, See handbook for procedure structure unless foam is removed (1920)
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Do not repair. Unauthorised modification will void certification. Tighten fastners MANUFACTURED FOR/BY TEREX EQUIPMENT LTD. — SCOTLAND periodically. 15335812 ROPS and FOPS (1932) SAFETY DECAL SET ANSI STANDARD WARNING WARNING TR35 Crush Hazard.
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Select the correct 15335863 injury. gear for the gradient you are on. Warning Back Alarm 15335784 (1924) Decline Warning TR100 (1919) OPTIONAL ADDITIONAL SAFETY DECALS KEEP CLEAR ITEMS 1, 2 AND 3 FITTED TO RHS OF TRUCK ONLY Additional Safety Decals (2070)
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Page 53: Controls And Operating

3 — Controls and Operating…
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Page 55: Controls And Instruments

Controls and Operating CONTROLS AND INSTRUMENTS 4 5 6 10 11 12 13 1622 Face Vent/Side Window Demister Steering Wheel Warning Lights Steering Wheel Adjustment Lock Tachometer/Hourmeter Headlight Dipper, Engine Water Temperature Gauge Direction Indicator, Engine Oil Pressure Gauge Windscreen Wiper/Washer and Fuel Gauge Horn Control Warning Lights…
Page 56: Basic Data

5. Engine Oil Pressure (Red) Illuminates when the engine oil pressure drops below the safe operating pressure. 6. Engine Stop Light (Red) Not currently used on TR100. 7. Engine Warning Light (Yellow) Not currently used on TR100. 8. Engine protection Fluid Light (Amber) Not currently used on TR100.
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Controls and Operating 10. Rear Brake Accumulator Pressure (Red) Illuminates to warn of low pressure in the rear brake system accumulator. Stop the machine if this light illuminates and do not operate until the fault is corrected. 11. Low Steering Pressure (Red) Illuminates when the steering system oil pressure drops below 83 bar (1200 lbf/in²).
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Controls and Operating 24. Engine Overspeed (Red) Illuminates to alert the operator when the transmission ECU detects an engine speed of 2550 rev/min. NOTE : For further information on items 21 and 24, refer to ‘Transmission’section on pages 3-23 and 3-24.
Page 59: Instruments

Controls and Operating INSTRUMENTS 1. Tachometer/Hourmeter Indicates the engine speed in revolutions per minute. The needle shows the variations in engine operating speed. RPM x100 Never accelerate the engine to speeds indicated by the red zone on the dial face. A digital hourmeter is incorporated in the tachometer to record total hours of engine operation.
Page 60: Switches

Controls and Operating SWITCHES 1. Hazard Warning Lights Press bottom of switch to make turn indicators flash simultaneously as hazard warning lights. The light in the switch and direction indicator warning light on the dash panel will flash. To switch hazard lights off; press the top of the switch.
Page 61
Controls and Operating 15. Ignition and Starter Key Switch The combined switch operates the ignition, pre-lube motor and starter motor. The key can only be withdrawn from position ‘0’. ‘0’ — Ignition switched off. Disconnects the batteries making all electrical systems inoperative (with the exception of a supply to the transmission ECU memory, interior light and to the radio).
Page 62: Controls

Controls and Operating CONTROLS Headlight Dipper, Direction Indicator, Windscreen Wiper/Washer and Horn 1. Headlight Dipper and Flasher: Control Downwards = Main Beam Neutral Position = Dipped Beam Control Upwards = Headlight Flash 2. Direction Indicator: Control Rearwards = Left Indicators Control Forwards = Right Indicators 3.
Page 63: Operator’s Seat — Air Suspension

Controls and Operating 4. Repeatedly switch the air conditioning on and off for at least 1 minute. This should be at least 12 repetitions. 5. Commissioning the air conditioning unit is complete and ready for use. NOTE : Follow the instructions given above, otherwise the machine may be damaged.
Page 64: Seat Belt

Controls and Operating NOTE : If the horizontal slide become loose, adjustment can be achieved by tightening of two gold coloured grub screws on the right- hand side of the slide plate, the access to which requires logitudinal movement of the seat to align access holes. Tighten the grub screws by ¼…
Page 65
Controls and Operating Always wear the seat belt when operating the machine. Always check condition of seat belts and mounting hardware before operating the machine. Any signs of looseness or wear should be reported to your Mainenance Department or Dealer for repair or replacement imme- diately.
Page 66: Machine Controls

Controls and Operating MACHINE CONTROLS Braking The dual circuit brake system is applied during normal operation by using the Service Brake Pedal or, in an emergency, by using the Parking/Emergency Brake Control. A ‘Front Brake Accumulator’ warning light and a ‘Rear Brake Accumulator’ warning light are located on the instrument panel.
Page 67: Retarder

Controls and Operating Retarder This control lever (1) is used to apply retardation to the truck. Retardation is the term used for applying a continuous braking force to hold the truck to a safe steady speed when descending grades. The retarder is OFF when the lever is fully forward and is APPLIED as the lever is pulled back.
Page 68
Controls and Operating Retarder Operation Before the machine crests the top of a grade and starts down, the operator should slow the machine with the service brakes and downshift to the gear range which would be used to ascend the grade. The retarder should be applied before starting the descent.
Page 69: Engine

Controls and Operating ENGINE Accelerator This is a floor mounted pedal operated by the right foot. Press the pedal down as required, to increase fuel flow to accelerate the engine. NOTE : Do not place the engine under full load at full speed immediately after starting.
Page 70: Steering

Controls and Operating Steering The steering wheel position can be adjusted as required for the most convenient operating position. To adjust, pull out adjustment lock and tilt steering wheel up or down as desired; release lever to lock adjustment. The steering system provides full-time hydraulic power with a continuous running pump and a pressurized accumulator.
Page 71: Transmission

Controls and Operating Transmission This machine is equipped with a CEC (Commercial Electronic Control) shift sys- tem, to operate the transmission. The CEC shift system continually monitors the transmission and shift system electrical components and warns the operator when a problem develops. It also takes action to prevent damage to the transmission, and provides the serviceman with diagnostic capabilities so that problems can be corrected quickly and easily.
Page 72
Controls and Operating LOCK-IN-GEAR The lock-in-gear feature is designed to protect the transmission from damage should wheel spinning or lockup occur due to poor traction or panic braking. The ECU will delay making a shift for several seconds and then, if the condition fails to correct itself, locks in gear and prevents any further shifting.
Page 73: Description And Operation

Controls and Operating VIEW ON FRONT OF INTERFACE BOX MANUAL AUTO POWER ECONOMY 1. Electronic Control Unit (ECU) 7. Check Trans Warning Light 4. Mode Selection Switch 2. Interface Box 8. In-converter Indicator Light 5. Manual Mode Switch 3. Gear Shift Selector 9.
Page 74
Controls and Operating The transmission provides six forward ranges, one reverse range and a neutral position. The transmission upshifts and downshifts automatically between first range and the highest range selected on the range selector in direct response to throttle position and transmission output speed. When reverse range is selected the ‘Reverse Alarm’ sounds and the ‘Reverse Light’ illuminates at the rear of the truck.
Page 75
Controls and Operating 4. Mode Selection Switch Gives the option to select between transmission ‘POWER’ and ‘ECONOMY’ shift schedules. The transmission must be in Neutral before the switch will function. The transmission torque converter is equipped with a lockup clutch which, MANUAL AUTO POWER ECONOMY when engaged by the ECU, locks the converter pump and turbine together as…
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Controls and Operating 6. Manual Mode Warning Light This light is located on the front face of the CEC-2 Interface Box. The warning light lluminates to alert the operator when the transmission has been switched to operate in the manual mode. The light should be ‘Off’ during normal operation.
Page 77: General Transmission Operation

Controls and Operating GENERAL TRANSMISSION OPERATION Watch for wide deviations from normal readings on the transmission oil temperature gauge during machine operation. If the transmission oil temperature gauge, on vehicles which do not have a transmission retarder fitted, shows temperature consistently rising above…
Page 78
Controls and Operating CEC2 DIAGNOSTIC CODES Main Code Sub Code Description Check Trans Light ECU input voltage low ECU input voltage high Throttle sensor failed low Throttle sensor failed high Engine speed sensor Turbine speed sensor Output speed sensor Primary shift selector Primary shift selector mode function Secondary shift selector Secondary shift selector mode function…
Page 79: Body Control

Controls and Operating BODY CONTROL The lever to the left of the operator’s seat controls the hydraulic valve which operates the body hoist cylinders. The four operating positions of the lever from front to rear are as follows: ‘LOWER’ — This position provides hydraulic force to power-down the body. It is needed when the body cannot be started downward from the fully raised position by gravity.
Page 80
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Page 81: Operating The Truck

4 — Operating the Truck…
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Page 83: Pre-Starting Inspection

Operating the Truck OPERATING THE TRUCK Pre-Starting Inspection Make sure all safety signs are free of damage, and are fully readable, replace as necessary. 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.
Page 84: Component Checks

Operating the Truck COMPONENT CHECKS 1. Engine With the engine off, check oil level. The oil level should be between the lower and upper marks on the dipstick. Add oil if low. 2. Fuel Pre-filters Drain sediment and water from fuel pre-filters until fuel runs clear. 3.
Page 85
Operating the Truck 6. Fuel Level Gauge Check fuel level. Tank should be filled at end of each shift to prevent condensation. 7. Body and Disc Brake Cooling Hydraulic Tank — Cold Oil Level With the body fully lowered, the oil should be showing between the upper and lower lines on the sight gauge (on tanks with two sight gauges, the bottom gauge should show full).
Page 86: Suspension Ride Struts

Maintenance Manual for full details. Truck TR35 TR40 TR45 TR60 TR70 TR100 Front Ride Struts — bar (lbf/in 11.7 (170) 13.8 (200) 13.8 (200) 13.8 (200) 17.2 (250) 16.3 (240) Height — mm (in) 143 (5.6) 168 (6.6) 168 (6.6) 168 (6.6)
Page 87: Engine Operation

Operating the Truck ENGINE OPERATION NOTICE Do not place engine under FULL LOAD at FULL SPEED IMMEDIATELY after starting. ALWAYS allow the engine to fully circulate lubricate and warm up gradually before operating at full speed and full load. Operate engine at top rated speed when maximum power is needed for the load.
Page 88: Starting The Engine

Operating the Truck STARTING THE ENGINE Attention to the warning lights and instruments when starting the engine, and operating, will help the operator monitor the machine systems and components. 1. Make sure the parking/emergency brake control is in the ‘PARK’ position. 1106 2.
Page 89
Operating the Truck starting sequence. The engine pre-lube motor will run until engine oil pressure of 0.35 — 0.48 bar (5 — 7 lbf/in²) is achieved. This will normally take between 8 -15 seconds, but can take up to 45 seconds in cold climates or with dry filters. After an interval of 3 seconds, the pre-lube motor stops and the engine starter motors engage.
Page 90: Starting The Engine At Low Ambient Temperature

Operating the Truck STARTING THE ENGINE AT LOW AMBIENT TEMPERATURES {Below 0 °C (32 °F)} Follow steps 1 through 5 for ‘Starting the engine’ as described on page 4-8 then proceed as follows: 1. Fill starting aid reservoir if required. To fill, raise the cover of the reservoir and push the filler can, head downwards, firmly over the filler valve of the reservoir.
Page 91: Pre-Operating Checks

Operating the Truck NOTICE Be sure machines are not touching each other. Use cables that are equal to cable size on the machine, for example (1/0) or (2/0). 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.
Page 92: Brake Function Checks

Operating the Truck BRAKE FUNCTION CHECKS In addition to the above checks, the following brake function checks can be carried out to determine if both the service and emergency brake systems are functional before operating the machine. Make sure the area around the machine is clear of personnel and obstructions before carrying out these checks.
Page 93: Driving And Stopping

Operating the Truck DRIVING AND STOPPING Before driving off observe all instruments and warning lights. All instruments should operate in their normal range and all warning lights should be out except possibly the Direction Indicator and Headlight Main Beam warning lights. Make sure the area around the machine is clear of personnel and obstructions before driving off.
Page 94: Stopping The Engine

Operating the Truck To stop the machine release the accelerator and depress the service brake pedal. Release the service brake as the machine slows until, when stopped, the pedal is depressed just enough to hold the machine stationary. When the machine has stopped, shift the transmission to Neutral, apply the parking brake and release the service brake.
Page 95
Operating the Truck Allow the engine to idle 3 — 5 minutes after a full load operation before shutting it off. This allows the engine to cool gradually and uniformly. Turn the steering wheel in both directions to dissipate the pressure in the steering accumulator to prevent accidental steering during bleed down.
Page 96: Parking

Operating the Truck PARKING When parking the machine overnight, or for an extended period, the following procedure in addition to that given in ‘Stopping the Engine’ will help maintain it in good condition for subsequent use: Fill the fuel tank completely, to prevent condensation. If security kit is supplied, keep it locked.
Page 97: Working The Truck

5 — Working the Truck…
Page 98
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Page 99: Loading

Working the Truck WORKING THE TRUCK Off-highway trucks are used on a variety of hauling jobs, from mine overburden MODE MODE removal to dam building. Every truck operation, regardless of the type of job, can be divided into four phases; loading, hauling, dumping and the empty return. Note: After coming to a stop for loading or unloading the truck, shifting the transmission to «NEUTRAL»…
Page 100
Working the Truck The following precautions should be observed when approaching the loading area and while being loaded — Avoid rocks and other shovel spillage that can needlessly damage 2043 Watch Other Trucks tyres or other truck components. Allow the cleanup machine sufficient time to clear up such debris.
Page 101: Hauling

Working the Truck Hauling While travelling the haul road, always maintain a safe speed for the haul road conditions and grades. Never allow the machine to move or coast with the transmission in ‘NEUTRAL’! Maintain Safe Speed When approaching downgrades, select the proper transmission range and use the retarder and service brakes as required to maintain safe descent speed without over-speeding the engine or gaining excess travel speed.
Page 102: Dumping

Working the Truck Dumping The dumping operation usually depends upon the type of material being hauled. For instance, overburden and other waste material is usually dumped over a spoil bank or piled into large mounds. The dumping on a job of this type might be controlled by a dump ‘SPOTTER’, ‘FLAGMAN’ or ‘BANKSMAN’ or second person who directs the truck to its dumping area.
Page 103: Empty Return

Working the Truck NOTICE Before raising the body, make sure the rear wheels are on firm level ground. If one wheel is higher than the other, a twisting strain is im- posed upon the body hinge pins, hoists and chassis. Stop the ma- chine, allow the engine to slow to idle, shift the transmission to ‘NEU- TRAL’ and apply the brakes with the Spotting Brake control to hold the machine stationary.
Page 104
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Page 105: Roading

6 — Roading…
Page 106
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Page 107: General

Roading ROADING These machines are equipped with cylinders containing compressed nitrogen gas. Transportation of these machines by any method may require a special permit from the appropriate authority of the coun- try involved. Consult your Dealer for details. General ‘ROADING’ (operating a truck over public highways) requires special care and attention.
Page 108: In Case Of Trouble

Roading Clean all glass and adjust the seat for proper operation of all controls. Check all lights and other controls for proper operation. Make sure the truck body is empty, fully lowered and the body control lever is in the ‘FLOAT’ position. Note: Make sure the body control lever is in the ‘FLOAT’ position.
Page 109: Moving Disabled Truck

7 — Moving a Disabled Truck…
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Page 111: Moving Disabled Truck

Moving a Disabled Truck MOVING DISABLED TRUCK Any unusual power train noises noted while operating the truck should be reported to those responsible for maintenance. Should the power train, hydraulic or electrical systems fail, the machine should be stopped and shut down immediately until suitable repairs can be made.
Page 112
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Page 113: Lubrication And Servicing

8 — Lubrication and Servicing…
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Page 115
Lubrication and Servicing SAFETY PRECAUTIONS Do not allow unauthorized personnel to service or maintain this machine. Study the Operator’s Handbook and Maintenance Manual before starting, operating or servicing this machine. Always follow procedures and safety precautions detailed in the Maintenance Manual. Always attach a ‘DO NOT OPERATE’ or similar warning sign to ignition switch or a control before cleaning, lubricating or servicing the machine.
Page 116
Lubrication and Servicing LUBRICATION AND SERVICING units which are TranSynd RD filled may result in damage to the transmission. These trucks are fitted with engine and transmission oil pans which permit Trucks filled with Allison TranSynd RD oil should operation at maximum gradeability as only be filled with TranSynd RD oil at drain and designated in the ‘Performance Data’…
Page 117: Lubrication And Service Chart

Lubrication and Servicing 16 21 5 8 26 10 28 21 22 19 12 26 8 10 28 4 20 2 3 15 25 18 17 1582 LUBRICATION AND SERVICE CHART Interval Ref. No. of Hours Points Identification Service Instructions Points Lubricant Service/Quantities Engine Check oil level.
Page 118
Lubrication and Servicing LUBRICATION AND SERVICE CHART (Continued) Interval Ref. No. of Hours Points Identification Service Instructions Points Lubricant Service/Quantities Engine Fuel Filters Replace filters. Maintenance Manual 110-0030 Engine Coolant Additive Check DCA concentration and replenish. DCA4 See Page 8-7 Engine Coolant Filter(s) Replace filter(s) if required.
Page 119: Miscellaneous Servicing

Lubrication and Servicing RECOMMENDED LUBRICANTS- (TranSynd RD Specific) COMPONENT LUBRICANT VISCOSITY (See Note 1*) Temp Recommendation Transmission TranSynd RD Allison Transmission Oil -35° C SAE 0W-30 or TranSynd RD Minimum operating Temperatures (without -30º C SAE 0W-20 (Arctic) preheat) -28º C DEXRON-III -20º…
Page 120: Service Capacities

Maintenance Procedures should be carried out in conjunction with any additional procedures in the relevant manufacturers ‘Operation and Maintenance Manual’, at the intervals specified. SERVICE CAPACITIES Ref. TR100 Points Identification Lubricant litres US gal Engine Crankcase and Filters EO 35.4…
Page 121: Recommended Lubricants

Lubrication and Servicing Note: Capacities given are approximate. Work to dipstick, sight gauges or level plugs. Use table in conjunction with ‘Recommended Lubricants’ table. Note: *Use of the correct transmission oil type is essential to prevent damage to the transmission and maintain correct operation.
Page 122: Air Conditioning Re-Start Procedure

Tyre pressure should be recalculated if not shown for a particular truck. Contact TEREX for assistance. The tyre inflation pressures listed are manufacturers’ recommendations for G.V.W. travelling at maximum speed. TEREX advise that operators check tyre inflation pressures with tyre manufactures to ensure correct setting for each particular…
Page 123: Technical Data

9 — Technical Data…
Page 124
Technical Data This Page Intentionally Left Blank…
Page 125: Technical Data Tr100

Technical Data TECHNICAL DATA TR100 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) (29-5) 5 080 (16-8)
Page 126
Technical Data TRANSMISSION Make/Model …………..Allison H 8610 AR CEC 2 Automatic electronic control with soft shift feature. Remote mounted in the frame with integral TC 890 torque converter and planetary gearing. Six speeds forward, one reverse. Automatic converter lockup action in all speed ranges. Downshift inhibitor. Intregal hydraulic retarder.
Page 127
Technical Data BRAKES Service All hydraulic brake system control. Transmission mounted pressure compensating pump provides hydraulic pressure for brakes and steering. Independent circuits front and rear. Each circuit incorporates a nitrogen accumulator which stores energy to provide consistent braking response. Front Brake Circuit Pressure ………159 bar (2 300 lbf/in²) Rear Brake Circuit Pressure ……….
Page 128
Technical Data Pump: Type ………………Piston Capacity at 2 100 rev/min ……1.57 litres/s (25 US gal/min) BODY HYDRAULICS Two body hoist cylinders are mounted between the frame rails. Cylinders are two-stage with power down in the second stage. System Relief Pressure ……… 190 bar (2 750 lbf/in²) Pump: Type ……………….
Page 129
Rear Ride Strut (Each) ……….18 litres (4.8 US gal) Power Takeoff …………..1.5 litres (0.4 US gal) Air Conditioning Compressor ……… 0.135 litres (0.036 US gal) Sound Power Level ISO6395 TR100 A — Weighted sound power level Lwa in decibels 88.5 dba Uncertainty Kwa, in decibels…
Page 130
Net Weight 68 260 150 490 PAYLOAD, maximum 40 825 90 000 Whole Body Vibration TR100 Maximum Gross Weight* 158 980 350 495 Vibration Emission Value a 0.73m/s FOR UNIT EQUIPPED WITH OPTIONAL BODY Uncertainty K 0.37m/s LINER PLATES: Chassis, with hoists…
Page 131: 10 — Symbol Identification

Symbol Identification 10 — Symbol Identification 10-1…
Page 132
Symbol Identification This Page Intentionally Left Blank 10-2…
Page 133
Symbol Identification SYMBOL IDENTIFICATION These pages explain the meaning of symbols that may appear on your machine. Fast Engine Basic Pressure Warning Symbol Engine Pressurised Air Filter Slow Compartment Pressure Restriction Starter Engine Master Lock Oil Filter Switch Pressure Basic Switch Lock Level…
Page 134
Symbol Identification Low Steering Heater Light Flood Pressure Hydraulic High Speed Coolant Light Low Or Level Conditioner Temperature Beam Low Speed Inside Coolant cold’ Light High Or Level Beam Circulation Body Up Outside Coolant Instrument Panel Light Parking Body ‘Raise’ Lamp Test Brake Cooling…
Page 135
Symbol Identification Trans. Water in Engine Lift Point Oil Temp. Fuel Stop STOP Drop Wait to Trans Oil Temp Do Not Lift Start Over Speed Drop Oil Battery Bowl Pressure Forward power Suspension Engine Reverse Trans. Maintainance Air Filter retarder Engine Transmission Brake…
Page 136
Symbol Identification NOTES 10-6…
Page 137
Symbol Identification NOTES 10-7…
Page 138
Symbol Identification NOTES 10-8…

Источник

Terex TR100: Available Instructions

Note for Owners:

Guidesimo.com webproject is not a service center of Terex trademark and does not carries out works for diagnosis and repair of faulty Terex TR100 equipment. For quality services, please contact an official service center of Terex company. On our website you can read and download documentation for your Terex TR100 device for free and familiarize yourself with the technical specifications of device.

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Источник

Самосвал Terex ТR 100. Руководство — часть 1

Ðàçäåë 000-0000

SM 1618 Ðåä. 3 07-11

ÎÁÙÈÅ ÑÂÅÄÅÍÈß — êàðüåðíûé ñàìîñâàë

ÎÁÙÈÅ ÑÂÅÄÅÍÈß — êàðüåðíûé ñàìîñâàë TR100

TR100

SM — 2034

ÊÎÐÎÁÊÀ ÏÅÐÅÄÀ×

Èçãîòîâèòåëü/ìîäåëü

……….

Allison H 8610 AR CEC 2

Àâòîìàòè÷åñêîå ýëåêòðîííîå óïðàâëåíèå

ñ ôóíêöèåé ïëàâíîãî ïåðåêëþ÷åíèÿ ïåðåäà÷.

Âûíåñåíà íà ðàìó, ñî âñòðîåííûì

ãèäðîòðàíñôîðìàòîðîì TC 890 è ïëàíåòàðíîé

ïåðåäà÷åé. Øåñòü ñêîðîñòåé ïðè äâèæåíèè

ïåðåäíèì õîäîì, îäíà ñêîðîñòü ïðè äâèæåíèè

çàäíèì õîäîì. Àâòîìàòè÷åñêàÿ áëîêèðîâêà êîðîáêè

ïåðåäà÷ âî âñåõ èíòåðâàëàõ ñêîðîñòåé.

Áëîêèðîâêà ïîíèæåíèÿ ïåðåäà÷è. Ãèäðàâëè÷åñêèé

ðåòàðäåð.

Ðèñ. 1 — Ðàçìåðû ìàøèíû

ÄÂÈÃÀÒÅËÜ

Èçãîòîâèòåëü/ìîäåëü

……………..

Cummins KTA-38-C1050

Òèï

………….

4-òàêòíûé ñ òóðáîíàääóâîì/ñ îõëàæäåíèåì

íàãíåòàåìîãî âîçäóõà

Ïîëíàÿ ìîùíîñòü ïðè 2100 îá/ìèí

…………………

783 êÂò

(1050 ë.ñ., 1094 PS)

Ïîëåçíàÿ ìîùíîñòü ïðè 2100 îá/ìèí

……………..

727 êÂò

(975 ë.ñ., 988 PS)

Ïðèìå÷àíèå.

Ïðèìå÷àíèå. Íîìèíàëüíàÿ ìîùíîñòü ñîãëàñíî

SAE J1995 èþíü 1990 ã. Ïîëåçíàÿ ìîùíîñòü äàíà çà

âû÷åòîì âåíòèëÿòîðà è ãåíåðàòîðà. Äâèãàòåëü íå

òðåáóåò ñíèæåíèÿ íîìèíàëüíûõ õàðàêòåðèñòèê

âïëîòü äî âûñîòû 3050 ì.

Ìàêñèìàëüíûé êðóòÿùèé ìîìåíò

………………….

4631 Íì

ïðè 1300 îá/ìèí

Êîëè÷åñòâî öèëèíäðîâ/êîíôèãóðàöèÿ

…………………

12 B

Äèàìåòð x äëèíà õîäà

……………………………..

159 x 159 ìì

Îáùèé îáúåì

………………………………………………

37,7 ëèòðà

Ïóñê äâèãàòåëÿ

………………………………….

Ýëåêòðè÷åñêèé

Ìàêñèìàëüíàÿ ñêîðîñòü âðàùåíèÿ, ïîëíàÿ íàãðóçêà…

2100 îá/ìèí

Ìàêñèìàëüíàÿ ñêîðîñòü âðàùåíèÿ áåç íàãðóçêè

……….

2400 îá/ìèí

Ñêîðîñòü âðàùåíèÿ íà õîëîñòûõ îáîðîòàõ

….

750 îá/ìèí

Ñêîðîñòè ñî ñòàíäàðòíûì ïëàíåòàðíûì ðåäóêòîðîì

Ïåðåäíèå

Ïåðåäà÷à

×èñëî

4,24

2,32

1,69

1,31

1,00

0,73

êì/÷

8,2

15,0

20,6

26,5

34,8

47,6

ìèëü/÷

5,1

9,3

12,8

16,5

21,6

29,6

Çàäíÿÿ

×èñëî

5,75

êì/÷

6,0

ìèëü/÷

3,8

4825 (15-10)

5935 (19-6)

Опциональный

надставной борт

4850

(15-11)

5235

(17-2)

4700

(15-5)

2945 (9-8)

3760 (12-4)

4570 (15-0)

815 (2-8)

275

(0-11)

755

(2-7)

1635

(5-4)

1220

(4-0)

5080 (16-8)

1755 (5-9)

3420 (11-3)

Макс.

глубина

кузова

4575

(15-0)

Диаметр наименьшей окружности,

огибающей наружные выступающие части автомобиля

при самом крутом повороте (SAE) 24,5 м

3150 (10-4)

4570 (15-0)

3100 (10-2)

10 820 (35-6)

Размеры

мм

4445

(14-7)

6880

(22-7)

8640

(28-4)

6080

(19-11)

8960

(29-5)

660 (2-2)

510

(1-8)

15°

58°

4730

(15-6)

5150

(16-11)

Ðàçäåë 000-0000

Îáùèå ñâåäåíèÿ — êàðüåðíûé ñàìîñâàë

Îáùèå ñâåäåíèÿ — êàðüåðíûé ñàìîñâàë TR100

TR100

SM 1618 Ðåä. 3 07-11

Ïåðåäíèå:

Òèï

………

Ñóõèå äèñêîâûå ñ 1 ñóïïîðòîì íà êîëåñî

Äèàìåòð äèñêà

……………………………………………

965 ìì

Ïëîùàäü íàêëàäêè, îáùàÿ

……………………….

2015 ñì

Çàäíèå:

Òèï

……….

Ñ ìàñëÿíûì îõëàæäåíèåì, ìíîãîäèñêîâûå,

ãåðìåòè÷íî èçîëèðîâàííûå îò ãðÿçè è âëàãè.

Òîðìîçíàÿ ïîâåðõíîñòü, îáùàÿ

……………….

87 567 ñì

Ñòîÿíî÷íûé

Çàäíèå òîðìîçà ïðèâîäÿòñÿ â äåéñòâèå ïðóæèíàìè

â ïàêåòå òîðìîçíûõ äèñêîâ. Ñ ãèäðàâëè÷åñêèì

îòêëþ÷åíèåì.

Äàâëåíèå óäåðæàíèÿ

………………………………………..

83 áàð

Çàìåäëåíèå

Óïðàâëåíèå ïàêåòîì çàäíèõ äèñêîâûõ òîðìîçîâ

ñ ïîìîùüþ ìîäóëèðîâàííîãî ðû÷àãà.

Äàâëåíèå ñðàáàòûâàíèÿ ðåòàðäåðà

…………….

äî 33 áàð

Àâàðèéíûé

Ýëåêòðîìàãíèòíîå óïðàâëåíèå êíîïêè òîðìîçíîé

ñèñòåìû ïðèâîäèò â äåéñòâèå âñïîìîãàòåëüíûé

è ñòîÿíî÷íûé òîðìîç. Ïðè âûêëþ÷åíèè äâèãàòåëÿ

ïðèâîäèòñÿ â äåéñòâèå àâòîìàòè÷åñêè. Ñòîÿíî÷íûé

òîðìîç ñðàáàòûâàåò â òîì ñëó÷àå, åñëè äàâëåíèå

â ñèñòåìå îïóñêàåòñÿ íèæå ïðåäâàðèòåëüíî çàäàííîãî

óðîâíÿ.

Òîðìîçà ñîîòâåòñòâóþò ISO 3450, SAE J1473 OCT 90.

ÑÈÑÒÅÌÀ ÐÓËÅÂÎÃÎ ÓÏÐÀÂËÅÍÈß

Íåçàâèñèìîå ãèäðîñòàòè÷åñêîå ðóëåâîå óïðàâëåíèå,

êëàïàí ðóëåâîãî óïðàâëåíèÿ ñ íà÷àëüíûì îñåâûì

ïåðåêðûòèåì, ãèäðîàêêóìóëÿòîð è ïîðøíåâîé íàñîñ

ñ êîìïåíñàöèåé äàâëåíèÿ.

Àêêóìóëÿòîð îáåñïå÷èâàåò ðàâíîìåðíóþ

óïðàâëÿåìîñòü, íå çàâèñÿùóþ îò îáîðîòîâ äâèãàòåëÿ.

Â ñëó÷àå ïîòåðè ìîùíîñòè äâèãàòåëÿ ãèäðîàêêóìóëÿòîð

îáåñïå÷èâàåò óïðàâëÿåìîñòü ïðèìåðíî íà äâà ïîëíûõ

ïîâîðîòà ðóëåâîãî êîëåñà îò óïîðà äî óïîðà.

Ñâåòîâàÿ èíäèêàöèÿ íèçêîãî äàâëåíèÿ ïðåäóïðåæäàåò

î ïàäåíèè äàâëåíèÿ íèæå 83 áàð. Ðóëåâîå óïðàâëåíèå

ñîîòâåòñòâóåò ISO 5010 è SAE J53.

Äàâëåíèå â ñèñòåìå

……………………………………….

159 áàð

Ðàçãðóçî÷íîå äàâëåíèå

………………………………….

207 áàð

Ðóëåâûå öèëèíäðû

……………………..

Äâîéíîãî äåéñòâèÿ,

îäíîñòóïåí÷àòûå

Ãèäðîàêêóìóëÿòîð:

Êîëè÷åñòâî æèäêîñòè

……………………………..

16,4 ëèòðà

Äàâëåíèå íà÷àëüíîé çàðÿäêè àçîòîì

……………

55 áàð

Óãîë ïîâîðîòà (âëåâî è âïðàâî)

……………………………

39°

Íàñîñ:

Òèï

…………………………………………………………….

Ïîðøåíü

Ïðîèçâîäèòåëüíîñòü ïðè 2100 îá/ìèí

……………

2,0 ë/ñ

ÂÅÄÓÙÈÉ ÌÎÑÒ

Óñèëåííûå ìîñòû ñ ïëàâàþùèìè âàëàìè,

îäíîñòóïåí÷àòûì ñïèðàëüíî-êîíè÷åñêèì

äèôôåðåíöèàëîì è ïëàíåòàðíûì ðåäóêòîðîì

íà êàæäîì êîëåñå.

Ïåðåäàòî÷íûå ÷èñëà:

Ñòàíäàðòíûå Îïöèîíàëüíûå

Äèôôåðåíöèàë

………………………..

2.16:1

Ïëàíåòàðíûé ðåäóêòîð

………….

13.75:1

10.50:1

Îáùåå ïåðåäàòî÷íîå ÷èñëî

ðåäóêòîðà

……………………………….

29.70:1

22.68:1

ÏÎÄÂÅÑÊÀ

Ïåðåäíÿÿ:

Ïåðåäíÿÿ: Íåçàâèñèìàÿ ïîäâåñêà ïåðåäíèõ êîë¸ñ

íà ñòîéêàõ ñ ïîâîðîòíûì êóëàêîì, ñ àâòîíîìíûìè

àçîòíî-ìàñëÿíûìè öèëèíäðàìè ñ ïåðåìåííûìè

õàðàêòåðèñòèêàìè.

Çàäíÿÿ:

Çàäíÿÿ: Àçîòíî-ìàñëÿíûå öèëèíäðû ñ ïåðåìåííûìè

õàðàêòåðèñòèêàìè, A-îáðàçíûì ñî÷ëåíåíèåì

è ñòàáèëèçàòîðîì ïîïåðå÷íûõ êîëåáàíèé.

Ìàêñèìàëüíûé õîä ñòîéêè

Ïåðåäíÿÿ

…………………………………………………….

229 ìì

Çàäíÿÿ

………………………………………………………..

175 ìì

Ìàêñèìàëüíûé óãîë îòêëîíåíèÿ çàäíåãî

ìîñòà ïðè êîëåáàíèÿõ

…………………………..

±7,0 ãðàäóñîâ

ÊÎËÅÑÀ È ØÈÍÛ

Øèðèíà êîëåñíûõ îáîäüåâ

………………………..

19,5 äþéìà

Øèíû (ïåðåäíèå è çàäíèå)

Ñòàíäàðòíûå

…………………….

27.00 R 49** ðàäèàëüíûå

Îïöèîíàëüíûå

………………………….

27.00-49 (48 PR) E-4

Ïðèìå÷àíèå.

Ïðèìå÷àíèå. Êàê â îòíîøåíèè øèí, âêëþ÷åííûõ

â ñïèñîê, òàê è â îòíîøåíèè ëþáûõ äðóãèõ øèí

ðåêîìåíäóåì ïîëüçîâàòåëþ ïðîêîíñóëüòèðîâàòüñÿ

ñ ïðîèçâîäèòåëåì øèí è îöåíèòü âñå óñëîâèÿ ðàáîòû,

÷òîáû ñäåëàòü ïðàâèëüíûé âûáîð.

ÒÎÐÌÎÇÀ

Îáñëóæèâàíèå

Ïîëíîñòüþ ãèäðàâëè÷åñêîå óïðàâëåíèå òîðìîçíîé

ñèñòåìîé. Óñòàíîâëåííûé íà êîðîáêå ïåðåäà÷

ïîðøíåâîé íàñîñ ñ êîìïåíñàöèåé äàâëåíèÿ ñîçäàåò

ãèäðàâëè÷åñêîå äàâëåíèå â òîðìîçíîé ñèñòåìå

è ðóëåâîì óïðàâëåíèè. Íåçàâèñèìûå ïåðåäíèé

è çàäíèé êîíòóðû. Â êàæäîì êîíòóðå ïðåäóñìîòðåí

àçîòíûé àêêóìóëÿòîð, êîòîðûé çàïàñàåò ýíåðãèþ äëÿ

áûñòðîãî òîðìîæåíèÿ.

Äàâëåíèå â ãèäðîñèñòåìå ïåðåäíåãî òîðìîçà

….

159 áàð

Äàâëåíèå â ãèäðîñèñòåìå çàäíåãî òîðìîçà

……..

52 áàð

Ãèäðîàêêóìóëÿòîðû:

Äàâëåíèå íà÷àëüíîé çàðÿäêè àçîòîì

……………

55 áàð

Ðàçäåë 000-0000

SM 1618 Ðåä. 3 07-11

Îáùèå ñâåäåíèÿ — êàðüåðíûé ñàìîñâàë

Îáùèå ñâåäåíèÿ — êàðüåðíûé ñàìîñâàë TR100

TR100

ÃÈÄÐÀÂËÈ×ÅÑÊÀß ÑÈÑÒÅÌÀ ÊÓÇÎÂÀ

Äâà ãèäðîöèëèíäðà îïðîêèäûâàòåëÿ êóçîâà

ðàçìåùåíû ìåæäó ëîíæåðîíàìè. Â äâóõñòóïåí÷àòûõ

ãèäðîöèëèíäðàõ ïðåäóñìîòðåíî âîçâðàòíîå çâåíî íà

âòîðîé ñòóïåíè.

Ðàçãðóçî÷íîå äàâëåíèå â ñèñòåìå

………………….

190 áàð

Íàñîñ:

Òèï

…………………………………………………………..

Ïåðåäà÷à

Ïðîèçâîäèòåëüíîñòü ïðè 2100 îá/ìèí

……………

6,1 ë/ñ

Ðàñïðåäåëèòåëüíûé êëàïàí

………

ñ ñåðâîóïðàâëåíèåì,

îòêðûòûé â ñðåäíåì ïîëîæåíèè

Âðåìÿ îïðîêèäûâàíèÿ êóçîâà

………………

16,3 ñåêóíäû

Âðåìÿ îïóñêàíèÿ êóçîâà

…………………………….

18 ñåêóíä

ÝËÅÊÒÐÎÎÁÎÐÓÄÎÂÀÍÈÅ

Òèï

………

24 Â ñ çàçåìëåííûì îòðèöàòåëüíûì ïîëþñîì

Àêêóìóëÿòîð

………………..

×åòûðå, 12 Â, 210 À-÷ êàæäûé,

íå òðåáóþùèé îáñëóæèâàíèÿ

Íàâåñíîå îáîðóäîâàíèå

………………………………………

24 Â

Ãåíåðàòîð

…………………………………………………………….

70 À

Ñòàðòåð

………………………………………………….

Äâà, 8,9 êÂò

ÊÓÇÎÂ

Äâóñêàòíîå â ïðîäîëüíîì ñå÷åíèè äíèùå

ñ âûïîëíåííûìè çàîäíî ïîïåðå÷íûìè ðåáðàìè

æåñòêîñòè. Êóçîâ îáîãðåâàåòñÿ òåïëîì âûõëîïíûõ

ãàçîâ è óñòàíîâëåí íà óïðóãèõ ïîäóøêàõ, ãàñÿùèõ

óäàðíûå âîçäåéñòâèÿ.

Ïîâåðõíîñòè òðåíèÿ êóçîâà ñäåëàíû èç èçíîñîñòîéêîé

ñòàëè ïîâûøåííîé òâåðäîñòè (360–440 BHN). Ïðåäåë

òåêó÷åñòè ïëèò 1000 ÌÏà.

Òîëùèíà ïëèòû:

Äíèùå

……………………………………………………………

19 ìì

Áîêîâàÿ ñòîðîíà

…………………………………………….

10 ìì

Ïåðåäíÿÿ, íèæíÿÿ

…………………………………………..

10 ìì

Êîçûðåê íàä êàáèíîé ROPS SAE J1040 ôåâðàëü 86.

ISO 3471

Âìåñòèìîñòü:

Ïîãðóçî÷íàÿ (SAE)

……………………………………….

41,6 ì

Íàñûïíîãî ãðóçà â êóçîâå 2:1 ïî âûñîòå (SAE)

…..

57,0 ì

ÑÒÀÍÄÀÐÒÍÛÅ ÓÐÎÂÍÈ ØÓÌÀ

Â ÊÀÁÈÍÅ ÎÏÅÐÀÒÎÐÀ (ISO 6394)

………………….

83 äÁÀ

*ÂÅËÈ×ÈÍÀ ÂÍÅØÍÅÃÎ ØÓÌÀ

(SAE J88 JUN 86)

…………………………………….

93 äÁÀ

*Óêàçàííûé âûøå ðåçóëüòàò ïîëó÷åí äëÿ ðåæèìà,

âûäàþùåãî ìàêñèìàëüíûé óðîâåíü âíåøíåãî

øóìà ïðè èçìåðåíèè è ðàáîòå â ñîîòâåòñòâèè

ñ ïðåäïèñàííûìè ñòàíäàðòíûìè ïðîöåäóðàìè.

Ðåçóëüòàòû ïîêàçàíû äëÿ áàçîâîé êîíôèãóðàöèè.

Ïðèìå÷àíèå.

Ïðèìå÷àíèå. Óðîâåíü âîçäåéñòâèÿ øóìà íà

îïåðàòîðà è íàõîäÿùèéñÿ ðÿäîì ïåðñîíàë ìîæåò

áûòü âûøå, â çàâèñèìîñòè îò óäàëåííîñòè îò

çäàíèé, îòâàëîâ ãðóíòà, ìàøèííîãî îáîðóäîâàíèÿ è

ò.ä. Äëÿ çàùèòû îðãàíîâ ñëóõà ðàáî÷èõ íåîáõîäèìî

èçìåðèòü ôàêòè÷åñêèé óðîâåíü âîçäåéñòâèÿ øóìîì

íà ìåñòå ðàáîò è âûïîëíèòü ïðèìåíèìûå

íîðìàòèâíûå òðåáîâàíèÿ.

ÐÀÁÎ×Àß ÅÌÊÎÑÒÜ

Êàðòåð äâèãàòåëÿ è ôèëüòðû

……………………………

134 ë

Êîðîáêà ïåðåäà÷ è ôèëüòðû

……………………………

100 ë

Ñèñòåìà îõëàæäåíèÿ

………………………………………..

304 ë

Òîïëèâíûé áàê

……………………………………………….

1090 ë

Áàê ãèäðàâëè÷åñêîé ñèñòåìû ðóëåâîãî óïðàâëåíèÿ.61 ë

Ðóëåâîå óïðàâëåíèå

………………………………………….

72 ë

Áàê ãèäðàâëè÷åñêîé æèäêîñòè êóçîâà

è îõëàæäåíèÿ òîðìîçîâ

…………………………………….

297 ë

Ãèäðàâëè÷åñêàÿ ñèñòåìà êóçîâà è îõëàæäåíèÿ

òîðìîçîâ

……………………………………………………………

564 ë

Âñå ïëàíåòàðíûå ðåäóêòîðû êîëåñ

……………………..

57 ë

Äèôôåðåíöèàë

……………………………………………………

61 ë

Öèëèíäðû ïåðåäíåé ñòîéêè (êàæäûé)

………………….

27 ë

Öèëèíäðû çàäíåé ñòîéêè (êàæäûé)

……………………..

18 ë

Îòáîð ìîùíîñòè

………………………………………………..

1.5 ë

Êîìïðåññîð êîíäèöèîíåðà

……………………………

0,135 ë

ÂÅÑ ÀÂÒÎÌÎÁÈËß (ÌÀÑÑÀ)

êã

ôóíòû

Øàññè, ñ îïðîêèäûâàòåëåì

53 240

117 380

êóçîâà

Êóçîâ, ñòàíäàðòíûé

15 380

33 900

Âåñ íåòòî

68 620

151 280

ÃÐÓÇÎÏÎÄÚÅÌÍÎÑÒÜ,

90 720

200 000

ìàêñèìàëüíàÿ

Ìàêñèìàëüíàÿ ïîëíàÿ ìàññà

159 340

351 280

òðàíñïîðòíîãî ñðåäñòâà*

ÄËß ÌÀØÈÍÛ, ÎÁÎÐÓÄÎÂÀÍÍÎÉ

ÄÎÏÎËÍÈÒÅËÜÍÛÌÈ ÏËÈÒÀÌÈ ÎÁØÈÂÊÈ ÊÓÇÎÂÀ:

Øàññè, ñ îïðîêèäûâàòåëåì

53 240

117 380

êóçîâà

Êóçîâ, ñ èçíîñîñòîéêèìè

20 910

46 100

íàêëàäêàìè

Âåñ íåòòî

74 150

163 480

ÃÐÓÇÎÏÎÄÚÅÌÍÎÑÒÜ,

85 190

187 800

ìàêñèìàëüíàÿ

Ìàêñèìàëüíàÿ ïîëíàÿ ìàññà

159 340

351 280

òðàíñïîðòíîãî ñðåäñòâà*

* Ìàêñèìàëüíî äîïóñòèìàÿ ïîëíàÿ ìàññà òðàíñïîðòíîãî

ñðåäñòâà ñ îïöèÿìè, ïðèíàäëåæíîñòÿìè, ïîëíîñòüþ

çàïðàâëåííûì òîïëèâíûì áàêîì è ãðóçîì.

ÐÀÑÏÐÅÄÅËÅÍÈÅ ÂÅÑÀ

Ïåðåäíèé

Çàäíèé

ìîñò

Â íåíàãðóæåííîì ñîñòîÿíèè %

Â íàãðóæåííîì ñîñòîÿíèè %

Раздел 000-0010

SM 2172

01-10

Сварочные работы

ПРЕДУПРЕЖДЕНИЯ

Перед проведением любых сварочных работ

на машине, оснащенной какими-либо

электронными системами, отключите

следующие компоненты (если применимо)

в порядке, указанном ниже. Кабель массы

аккумулятора, плюсовой кабель аккумулятора,

кабели заземления стабилизатора, плюсовые

кабели стабилизатора и электрические

соединения тахометра, ЭБУ коробки передач,

рычаг управления кузовом, ЭБУ гидравлической

системы и перегородки кабины во избежание

повреждения электрических компонентов.

Перед отключением любых компонентов

выключите массу, чтобы изолировать

аккумуляторные батареи. По окончании

сварки подключите указанные выше разъемы

в обратной последовательности.

Перед выполнением любых сварочных работ

убедитесь, что место сварки очищено от

лакокрасочных материалов. Несоблюдение

этого требования может привести к образованию

вредных паров краски.

Примечание.

По возможности всегда прикрепляйте

кабели заземления сварочного аппарата

к свариваемой детали или части рамы.

Для сварочных работ на раме рекомендуется

использовать электродуговую сварку. Поскольку

характер и размер повреждения рамы нельзя

определить заранее, нет единой процедуры ремонта.

В качестве общей рекомендации можно указать, что

в случае скручивания, сгиба или разделения деталей,

а также если рама погнута или скручена, сварочные

работы можно выполнять только после выпрямления

деталей до исходной формы.

Успех сварочных работ во многом зависит от

использования правильного оборудования,

материалов и от квалификации сварщика.

Консультацию по поводу возможности проведения

сварочных работ можно получить в сервисном отделе.

ПРЕДУПРЕЖДЕНИЕ

Наплавной металл и металлы с покрытием

из кадмия, используемые для газовой резки,

образуют не имеющий запаха токсичный дым.

Рекомендованные нормы производственной

гигиены для защиты сварщика от паров кадмия

и оксидов металлов предусматривают

использование в помещении надлежащей

системы вентиляции, специально предназначенной

для сварочных работ. Респиратор (например,

MSA «Gasfoe») с картриджем для дуговой

сварки плавящимся электродом обеспечивает

защиту от кадмия, дыма и оксидов металлов.

Респиратор «Gasfoe» рекомендован Горным

бюро США: Имеющий номер утверждения 23B-10,

он предназначен для защиты от газов, испарений

и/или паров металлов.

Примечание.

Ток от сварочного электрода всегда

проходит по пути наименьшего сопротивления.

Например, если клемма заземления прикреплена

к задней раме, а сварочные работы выполняются на

передней, ток должен проходить через соединение

рам, чтобы цепь сварочного аппарата замкнулась.

Поскольку поворотная рама обеспечивает

наименьшее сопротивление, но не предназначена для

электрического соединения, между подвижными

частями могут возникнуть электронная дуга, которая

приведет к образованию на рабочих поверхностях

сварных точек и увеличить норму износа этих

компонентов.

Общая процедура выполнения сварочных

работ

При ремонте дефектов вне непосредственной

близости от литых изделий из легированных сталей

необходимо придерживаться следующих общих

правил.

1. Удалите трещину методом воздушно-дуговой резки

или расшлифуйте ее до неповрежденного металла.

Если используется метод воздушно-дуговой резки, то

перед резкой нагрейте этот участок до 100°C, отмерив

8–10 см в обе стороны от повреждения. По окончании

резки расшлифуйте это место для удаления тонкого

слоя сажи.

2. Проведите проверку герметичности методом

проникающего красителя, чтобы убедиться, что

трещина полностью удалена.

ОБЩАЯ ИНФОРМАЦИЯ — процедура проведения сварочных работ

Источник

Table of Contents for 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 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 comparatively short period of time. A rubber vacuator valve (6) att
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
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 spring behind it) facing inwar
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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 26 — ‘U’ Bolt & Nut 27 — Bolt 28 — Nut 29 — Harden
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, TRANSMISSION OIL COOLER. 28. With oil coolers removed, remove locknuts (13), hardened washers (12), bolts (10) and hardened washers (11). Remove front crossmember (6) from chassis mounts. 29. If
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. Body wear surfaces are high hardness (360-440 BHN) abrasion resistant steel. Yield strength of plates 1 000 MPa (145 000 lbf/in²). Plate Thicknesses: Floor ………………………………………………… 19 mm (0.75 in) Side ………………………………
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 bo
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 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 this publicatio
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 — Mudguard 10 — Handrail — LH 11 — Handrail — RH 12 — Plate Assembly 13 — Arm 14 — Mirror 15 — Block 16 — Spacer 17 — Spacer 18 — Spacer 19 — Bolt 20 — Hardened Washer 21 — Bolt 22 — Bolt 23
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 37 32 33 34 42 38 31 35 DESCRIPTION Numbers in parentheses refer to Fig. 1. For engine make, model and specification, refer to Section 000-0000, GENERAL INFORMATION. For detailed engine servicing and
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 capacity to do the job safely. To remove any of the components shown in Figs. 1 through 6 (or similar components) the following procedures should be carried out. 1. Position the vehicle in a level work area, appl

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Источник

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Summary of Contents:

[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
…

[Page 2] Terex TR100

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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…

[Page 4] Terex TR100

THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1616.PDF
…

[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…

[Page 6] Terex TR100

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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…

[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…

[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 …

[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…

[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…

[Page 12] Terex TR100

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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…

[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…

[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…

[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 …

[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…

[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…

[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…

[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…

[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…

[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 -…

[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…

[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…

[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…

[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…

[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…

[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…

[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…

[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 …

[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….

[Page 32] Terex TR100

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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…

[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…

[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…

[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…

[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…

[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…

[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…

[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…

[Page 41] Terex TR100

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Summary of Contents for Terex TR100

Page 17: Table Of Contents

Page 21: Introduction

Page 22: Intended Use Of Machine

Page 23: Theft Deterrent Practices

Page 28: Safety Precautions

Page 29: Vehicle Lifting Precautions

Page 30: Preventing Fire Hazards

Page 31: Mounting And Dismounting

Page 32: Pre-Starting

Page 34: Roading

Page 35: Scrapping Of Machine

Page 41: Cctv

Page 42: Wheels And Tyres

Page 43: Avoid Tyre Explosion Hazard

Page 44: Decals And Instruction Plates

Page 53: Controls And Operating

Page 55: Controls And Instruments

Page 56: Basic Data

Page 59: Instruments

Page 60: Switches

Page 62: Controls

Page 63: Operator’s Seat — Air Suspension

Page 64: Seat Belt

Page 66: Machine Controls

Page 67: Retarder

Page 69: Engine

Page 70: Steering

Page 71: Transmission

Page 73: Description And Operation

Page 77: General Transmission Operation

Page 79: Body Control

Page 81: Operating The Truck

Page 83: Pre-Starting Inspection

Page 84: Component Checks

Page 86: Suspension Ride Struts

Page 87: Engine Operation

Page 88: Starting The Engine

Page 90: Starting The Engine At Low Ambient Temperature

Page 91: Pre-Operating Checks

Page 92: Brake Function Checks

Page 93: Driving And Stopping

Page 94: Stopping The Engine

Page 96: Parking

Page 97: Working The Truck

Page 99: Loading

Page 101: Hauling

Page 102: Dumping

Page 103: Empty Return

Page 105: Roading

Page 107: General

Page 108: In Case Of Trouble

Page 109: Moving Disabled Truck

Page 111: Moving Disabled Truck

Page 113: Lubrication And Servicing

Page 117: Lubrication And Service Chart

Page 119: Miscellaneous Servicing

Page 120: Service Capacities

Page 121: Recommended Lubricants

Page 122: Air Conditioning Re-Start Procedure

Page 123: Technical Data

Page 125: Technical Data Tr100

Page 131: 10 — Symbol Identification

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