Terex TR40 Service Manual
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Terex TR40 Service Manual

Terex TR40 Service Manual

Off-highway trucks
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TR40
Off-Highway Trucks
Service Manual
TECHNICAL PUBLICATIONS DEPARTMENT
TEREX EQUIPMENT LIMITED,
MOTHERWELL, SCOTLAND, ML1 5RY
REF. NO. SM753/780
SM 1663 REV 1 02/02

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  • Page 1 TR40 Off-Highway Trucks Service Manual TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED, MOTHERWELL, SCOTLAND, ML1 5RY REF. NO. SM753/780 SM 1663 REV 1 02/02...
  • Page 2 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 3 TEREX SERVICE DEPARTMENT TEREX Equipment Limited, Motherwell, Scotland ML1 5RY Tel. (0698) 732121 Tlx. 77141 Fax. (0698) 734046 TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. (918) 446-5581 Fax. (918) 446-9752 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 4 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...

  • Page 5: Important Safety Notice

    WARNING Never use parts which are altered, modified, or weakened in operation. This can seriously jeopardize the integrity of the machine and could result in property damage or serious personal injury. SM 222 Rev 1 9-93 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 6 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 7 TABLE OF CONTENTS Section No. Description SM No. GENERAL INFORMATION 0000 TR40 Off-Highway Truck 1665 CHASSIS 0010 Chassis, Hood and Fenders 1666 ENGINE 0030 Engine and Mounting 1667 0050 Air Cleaner 1668 0130 Power Takeoff 1669 TRANSMISSION 0010 Transmission and Mounting...
  • Page 8 0110 Passenger Seat and Mounting 1603 BODY 0010 Body and Mounting 1675 MISCELLANEOUS 0020 Lubrication System 1670 0070 Service Tools 1684 0080 Standard Bolt and Nut Torque Specifications 1238 0090 Unit Storage 1239 SM 1664 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 9 GENERAL INFORMATION - TR40 Off-Highway Truck Section 000-0000 SM - 2081 4 060 (13-4) 1 120 Body (3-8) 3 800 Depth (12-6) 3 530 (11-7) (2-8) (1-6) 1 520 (5-0) 2 710 (8-11) 7 380 (24-2) 3 900 (12-10) Vehicle Clearance Diameter (SAE) 20m (66ft)
  • Page 10 General Information - TR40 Off-Highway Truck Section 000-0000 DRIVE AXLE Retardation Heavy duty axle with single reduction spiral bevel gear Modulated lever control of rear disc pack. differential, full floating axle shafts, and planetary reduction Retarder Actuation Pressure ..up to 33 bar (480 lbf/in²) at each wheel.
  • Page 11 General Information - TR40 Off-Highway Truck Section 000-0000 BODY *EXTERIOR SOUND RATING Longitudinal 'V' type floor with integral transverse box- (SAE J88 JUN 86) ............90 dbA section stiffeners. The body rests on resilient impact absorption pads. *The above result is for the mode giving the highest exterior...
  • Page 12 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...

  • Page 13: Installation

    Using a suitable lifting device, align the component to to relieve pressure in the steering circuit. Block all road wheels. be installed in position on the chassis. Secure the component securely to the chassis with mounting hardware removed during removal. SM 1666 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...

  • Page 14: Maintenance

    Successfully welded repairs will depend to a great To keep rust and corrosion to a minimum, periodic extent upon the use of the proper equipment, materials painting of abrasions and other exposed metal areas on the frame is highly recommended. SM 1666 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 15 26 - Bolt 8 - Bolt 17 - Bolt 35 - Washer 9 - Lockwire 18 - Locknut 27 - Bolt 36 - Mirror Fig. 3 - Exploded View of Fenders and Mounting SM 1666 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 16 2 - RH Step Assembly 5 - Step 9 - Locknut 13 - Nut 3 - Plate 6 - Bolt 10 - Nut 14 - Hardened Washer Fig. 4 - Exploded View of Ladders and Handrails SM 1666 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 17 2 - Cover Plate 5 - Bolt 8 - Grille 12 - Hardened Washer 3 - Washer 6 - Nut 9 - Bolt 13 - Plate Fig. 5 - Radiator Guard and Mounting SM 1666 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 18 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 19 (3) and a pre-charge coolant filter (4) installed on the safely. right hand side of engine (1). A lube oil bypass filter is mounted off the front left hand of the horse collar. SM 1667 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 20 8. With suitable containers in position, open drain cocks and drain coolant from the radiator and engine 20. Attach suitable lifting equipment to the lifting SM 1667 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 21 (1) in the frame. 3. Inspect engine damper (26) and flange coupling (27) for wear or damage and replace if necessary. 7. Secure engine (1) to front mounting crossmember SM 1667 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 22 Note: Never operate the engine with oil level below 20. Using suitable lifting equipment, install radiator the low (L) or above the high (H) mark on the guard assembly to the frame. Secure with the dipstick. SM 1667 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 23 LUBRICATION SYSTEM. The oil level should be WARNING between the low (L) and high (H) marks on the Avoid direct contact of hot oil with your skin. dipstick. Hot oil can cause serious personal injury. SM 1667 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...

  • Page 24: Alternator Drive Belt

    Turn steering wheel several times to relieve pressure in Note: Lower jam nut (7) on adjusting screw (8) has the steering circuit. Block all road wheels. left hand threads. SM 1667 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...

  • Page 25: Service Tools

    TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft Bolt 39 - 47 29 - 35 Bolt 68 - 81 50 - 60 4, 5 & 6 Capscrew Jam Nut Sump Drain Plug SM 1667 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 26 THIS PAGE IS INTENTIONALLY LEFT BLANK Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...

  • Page 27: Engine Air Cleaner

    Refer to allowable limit. When air restriction levels are reached, SM 1668 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...

  • Page 28: Air Cleaner Assembly

    The elements should not be serviced on Note: Air cleaner body (1) should be thoroughly the basis of visual observation as this would lead to SM 1668 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...

  • Page 29: Primary Element

    To detect paper ruptures, place a bright light bulb inside the element and rotate element slowly. Visually determine the condition of primary element (2) SM 1668 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...

  • Page 30: Secondary Element

    SERVICE TOOLS vehicle. Refer to Section 300-0070, SERVICE TOOLS for part numbers of service tools referenced in this section and general service tools required. These tools are available from your dealer. SM 1668 1-99 Find manuals at http://best-manuals.com/search?&s=TEREX-SM1663.PDF...
  • Page 31 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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