Page 1 TEREX Equipment Limited Operations Manual 15504845 Original Operating Instructions OHE783...
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Page 3 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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Page 5 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...
Page 6 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.
Page 7 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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Page 9 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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Page 11 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...
Page 12 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 13 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.
Page 14 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 15 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.
Page 16 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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Page 19 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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Page 25 2 - Safety...
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Page 27 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.
Page 33 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.
Page 37 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.
Page 39 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.
Page 40 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.
Page 45 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...
Page 46 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.
Page 47 Safety 15342619 Fuse/Relay Chart (2195) 15335803 Fuse/Relay Chart (1927) 2-23...
Page 48 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...
Page 49 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)
Page 50 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.
Page 51 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
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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.
Page 57 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).
Page 58 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...
Page 76 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.
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Page 81: 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
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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.
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Page 105: Roading
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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
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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.
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Page 113: 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
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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...
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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...
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Terex TR100 Operation Manual

1 Introduction

2 Safety Precautions

3 Controls and Operating

5 Working the Truck

6 Roading

8 Lubrication and Servicing

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