Terex TL100 Wheel Loader Illustrated Parts Catalog Manual – Serial No. TL1002 0372-XXXX

Description

Complete Factory Parts Catalog for Terex TL100 Wheel Loaders

The Terex TL100 Wheel Loader Illustrated Parts Catalog Manual – Serial No. TL1002 0372-XXXX is the definitive reference document for equipment owners, fleet maintenance teams, and professional service technicians. Published by Terex Compact Germany GmbH in Crailsheim under reference number 5780400034 (Revision 1.00, issue date 13-December-2013), this comprehensive manual covers the Terex TL100 articulated wheel loader across its primary production build and specialized factory options, including the 36 km/h high-speed travel version (Schnellfahrausfuehrung). Every single mechanical, structural, hydraulic, and electrical assembly is cataloged with professional exploded-view engineering diagrams paired with precise itemized part tables showing OEM part numbers, official part designations in four languages, required assembly quantities, and critical dimension callouts.

File Details

• Manual Type: Illustrated Parts Catalog (Ersatzteilkatalog / Catalogue pièces / Catálogo de repuestos)
• Brand: Terex
• Model: TL100 Wheel Loader (Standard & 36 km/h High-Speed Travel Configuration)
• Serial Number Coverage: TL1002 0372-XXXX (with sub-assembly breakdowns noting <TL10020161, TL10020162>, <TL1002 0126, and TL1002 0127>)
• Engine Model: TD2011L04W 4-Cylinder Turbocharged Diesel (54 kW / 2200 RPM)
• Reference / Document Number: 5780400034
• Revision Number: 1.00
• Publication / Issue Date: 13-December-2013
• Manufacturer: Terex Compact Germany GmbH, Crailsheim, Germany
• Languages Included: English, German (Deutsch), French (Français), Spanish (Español)
• Page Count: 368 pages
• File Format: High-Quality Printable PDF

Chapters Covered

• 0.000 / 0.100 Inspection Parts: Standard maintenance filters, engine oil filter (5411642211), fuel filter cartridge (5411656301), primary air cartridge (5501660912), safety air cartridge (5501660914), hydraulic tank return filter element (5003820082), breather filter, standard cabin filter (5388665486), charcoal filter option (5388664116), and pollen filter option (5388664117).
• 1.000 / 1.001 Front Chassis: Welded front frame assembly (6406001001), protective lower covers, composite front mudguards, wheel chocks with chassis brackets, work lamp supports, and corrosion-resistant fasteners.
• 1.002 Articulation: Center oscillating articulation pivot joint, central pivot pin (0337006202, 50x556mm), spherical link bearing GE 50 DO 2RS, thrust plates, multi-thickness shimming discs (0.5mm, 1.0mm, 2.5mm), and safety locking pin with retainer chain.
• 1.010 Werkzeug: Factory-supplied hand grease gun (1858000050), high-performance EP2 lubricant cartridges, and 30mm tubular box wrench with tommy bar.
• 2.000 / 2.001 Rear Chassis & Fender: Rear chassis frame (6406005001), molded polyethylene rear fenders, heavy cast counterweights (left 0405006021, right 0405006022), and heavy-duty M16 mounting bolts.
• 2.002 Steps, Cover, Floor Frame Shock Mounting: Operator cabin access steps, Metacone vibration-damping shock rubber mounts (70 Shore), chassis floor brackets, and bottom underplates.
• 2.003 Centralized Lubrication, Oscillating Axle Bearing: Oscillating rear axle pivot pin (0460006016, 70x329mm), grease distribution blocks, high-pressure lubrication lines, bronze bushings, and calibrated shims.
• 2.005 Oil Tank: Hydraulic reservoir assembly (6453013001), tank dipstick (5003648865), filler breather cap, temperature regulator thermostat (5003700046), and suction return filter assembly (5003659215).
• 2.006 Fuel Tank: High-capacity diesel fuel tank (5267010052), electrical fuel level sensor/float transmitter (5755586679, L=450mm), suction tubes, drain valves, and filler strainers.
• 2.007 Engine Cover: Hinged engine hood canopy (5529020130), pneumatic gas strut (5696636571), mounting brackets, mechanical slam latches, soundproofing seals, and brush strips.
• 2.014 Steering Unit: Hydraulic Orbitrol steering control unit (5904662030), adjustable steering column assembly, tilt bellows, and 400mm steering wheel with spinner knob.
• 2.015 Stickers Terex: Machine branding, noise level certification plates (LWA 101 dB), speed restriction badges (20 km/h and 36 km/h), safety and pinch hazard warning decals, and cabin control layout placards.
• 2.020 Operator’s Cab – Glazing: Safety glass windshield, curved rear glass, tinted roof pane, bonded side windows, glazing profiles, rubber weatherstripping, and cabin mounting hardware for standard White and optional Charcoal cabin shells.
• 2.021 / 2.022 Operator’s Cab – Equipment 1 & 2: Internal molded trim linings, rearview mirrors, sun visor, front 800mm pantograph wiper arm and motor, rear wiper motor, interior dome lighting, 12V horn, audio speaker grilles, and radio aerial cable.
• 2.023 Operator’s Cab – Heating: Complete cab heater core assembly (5388665554), multi-directional air vents, intake reduction nozzles, Bowden control cables, and coolant circulation hoses.
• 2.024 / 2.025 Operator’s Cab – Door Right & Door Left: Right and left door frames, door locks, exterior handles, key cylinders, lower fixed door glass, upper fixed windows, and optional sliding window kits.
• 2.027 Air Conditioner: Engine-driven A/C compressor (5169001018, 12V), condenser heat exchanger (5169001017), combination evaporator unit, receiver-drier bottle, pressure switch, and specialized refrigerant hoses.
• 2.030 – 2.037 Operator Seats: Mechanical suspension driver seat (5305661730), canopy seat version (5305661720), MSG95 pneumatic suspension driver seat with lumbar spinal support, and luxury air-ride seat with integrated compressor and seat heating.
• 3.000 / 3.001 Axles, Tires: Drive axle mounting hardware, cardan drive shaft (5200655217), wheel rims (11×20 and 13×20 8-hole), and industrial tire options (12.5-20, 14.5-20, 16/70-20, 335/80 R20, 365/80 R20, 375/75 R20, and 405/70 R20).
• 3.002 – 3.009 Front Axle – 5904661716: Spiral bevel ring and pinion gear set (5904662795), differential cage, multi-disc limited slip / wet service brake pack, axle bridge housing, planetary wheel hub reduction gears, and caliper assemblies.
• 3.010 – 3.016 Rear Axle – 5904661718: Standard rear drive axle carrier, differential gear set, axle housing beam, reduction drop gearbox casing, drive pinions, and wheel hub assemblies.
• 3.020 – 3.037 Axle & Gearbox – 36 Km/H High-Speed Version: High-speed front drive axle, rear axle (5904661720), transfer shift gearbox, electro-hydraulic 2-speed gear shift selector unit (5904662832), and differential components.
• 3.050 / 3.055 Service Brake & Parking Brake: Foot brake pedal assembly (5719660110), master cylinder, fluid reservoir (5650638854), pressure switches, and mechanical handbrake lever (5388665013) with Bowden control cable.
• 4.000 / 4.001 Working Equipment & Loading Equipment: Z-bar kinematics loader frame (6406020001), heavy tilting lever (6453023001), tilt linkage dog-bone, hardened steel pivot pins, composite flanged bushings, and grease fittings.
• 5.000 – 5.020 Work Tools & Attachments: Hydraulic quick-attach hitch frame (6405104000), mechanical quick-mount coupler, general loading buckets (0.80 m³ to 1.00 m³), heavy-duty earth buckets (0.90 m³ to 1.10 m³), light-material high-capacity buckets (1.20 m³ to 1.55 m³), bolt-on reversible cutting edges, weld-on bucket teeth, and pallet fork carriage (6397712000) with lifting hook.
• 6.000 – 6.011 Engine Assembly & Engine Components: Deutz TD2011L04W 4-cylinder engine block, turbocharger (5411663059), cylinder head with multi-thickness head gaskets (1.51mm, 1.61mm, 1.71mm), individual fuel injection pumps, injectors, engine oil pump, starter motor (12V), 95A alternator, coolant pump, exhaust manifold, silencer, and accelerator pedal linkage.
• 6.030 Refueling Pump: Electric 12V 20A diesel fuel transfer pump (5531001001), mounting bracket, reinforced suction hose, foot check valve, and electrical wiring harness with inline 20A fuse.
• 7.000 – 7.050 Hydraulic Installation: Hydrostatic drive circuit with high-pressure lines (4SH NW20), variable displacement pump, Rexroth A6VM80DA2 hydraulic drive motor, steering hydraulics with priority flow divider valve (5606664621), loader lift and tilt lines, pilot control servo lines, and 36 km/h transmission shifting circuits.
• 8.000 – 8.020 Hydraulic Components & Cylinders: HDM19WL/3 main three-spool valve bank (5088081227), pilot control joystick manifolds, hydraulic accumulator (5572100103), twin steering cylinders (Z 70/30, 6500507500), dual loader boom lift cylinders (Z 115/70, 6501238100), bucket dump cylinder (Z 105/50, 6501060000), and quick-coupler locking cylinder (Z 63/50, 6502116100).
• 9.000 – 9.020 Electrical Installation: Front and rear chassis wiring harnesses, operator console switches, central digital instrument cluster (5110662040), main vehicle electronic control module (6451045100), starter battery box with high-current maxi fuses (30A, 50A, 80A), immobilizer anti-theft key lock unit (5050655535), and transmission shift electrics.
• Alphanumeric Parts List: Comprehensive numerical index listing every single part number across the entire catalog with cross-references to chapter sections and page numbers.

Together, these chapters provide parts specialists, field mechanics, and rebuilders with a completely transparent, bolt-by-bolt view of the loader. Rather than guessing component fitment or relying on generalized aftermarket listings, this document shows the exact factory breakdown of every sub-assembly, enabling technicians to identify underlying seals, O-rings, bearings, shims, bushings, and hardware without disassembling the machine prior to ordering.

Powertrain, Axle & Transmission Architecture

The Terex TL100 Wheel Loader utilizes a robust hydrostatic powertrain engineered for high breakout force and smooth tractive effort. This parts catalog covers the hydrostatic pump mounting to the engine flywheel via a Centaflex SAE 6.1/2 flexible coupling (5105660739), supplying flow to the Rexroth A6VM80DA2 variable-displacement drive motor (5364664190). Heavy-duty cardan drive shafts transfer torque directly to the rigid front drive axle and oscillating rear drive axle.

For standard 20 km/h machines, the catalog details the front drive axle (5904661716) and rear drive axle (5904661718). For fast-travel models, Chapter 3.020 through 3.037 provides dedicated coverage for the 36 km/h high-speed version, featuring rear axle 5904661720 with an integrated two-speed mechanical drop gearbox and an electro-hydraulic shift cylinder assembly (5904662832). Both axle configurations include fully detailed spiral bevel gear sets (5904662795), planetary wheel hub reductions with heavy-duty wheel studs (5904662829, M22x1.5), cassette shaft seals, and wet multi-disc brake assemblies with internal and external friction discs. Critical shimming options ranging from 0.1mm up to 2.50mm are cataloged with individual part numbers, allowing mechanics to achieve exact bearing preload and gear lash when rebuilding axle differentials and reduction hubs.

IMAGES PREVIEW

Hydraulic System & Actuator Breakdown

Hydraulic efficiency is central to the performance of the Terex TL100 parts manual, and this catalog documents every line, fitting, valve block, and hydraulic cylinder. The open-center working hydraulic system is powered by a high-output gear pump (5100620029) feeding the primary HDM19WL/3 monoblock directional control valve (5088081227). The catalog provides internal exploded views of the valve block, detailing the main pressure relief valve (5088081186), secondary anti-cavitation/shock valves calibrated for 130 bar, 230 bar, and 280 bar circuits, and pilot operator spool caps.

Steering priority is maintained via a dedicated priority valve (5606664621) directing pressurized oil to the Danfoss-type Orbitrol steering unit (5904662030) and twin steering cylinders (Z 70/30, part 6500507500 with 70mm bore and 30mm rod). For the loader working equipment, the catalog illustrates the dual lifting cylinders (Z 115/70, part 6501238100 with 115mm bore and 70mm piston rod) and the central dumping cylinder (Z 105/50, part 6501060000 with 105mm bore and 50mm rod). Each cylinder section includes an exploded bill of materials detailing cylinder barrels, chrome-plated piston rods, guide bushings, spherical link bearings (such as GE 60 DO 2RS and GE 45 GS 2RS), internal buffer rings, rod seals, double wiper scrapers, and complete factory seal rebuild kits.

Engine Integration, Operator Cab & Electrical Details

Under the engine hood, the catalog details the complete installation of the Deutz TD2011L04W 4-cylinder oil/water-cooled turbocharged diesel engine rated at 54 kW (73.4 HP) at 2200 RPM. Illustrated sub-assemblies include the side-by-side combined cooling radiator (5010672050), rubber vibration mounts, Donaldson cyclonic air cleaner assembly with service restriction indicator switch (5501660960), heavy-duty exhaust muffler, and optional 12V high-flow refueling transfer pump.

For operator comfort and safety, full breakdowns are supplied for the sound-insulated driver cabin (covering models SK31/2 and SK31/3), detailing curved panoramic safety glass panes, door latch mechanisms, and HVAC climate control with A/C compressor and heater matrices. Seating breakdowns encompass standard mechanical seats, canopy-specific seats, and full Grammer MSG95 pneumatic luxury air-suspension driver seats with active spinal lumbar supports and 12V seat heating. The electrical sections catalog complete wiring harnesses for the front chassis, rear chassis, console, and engine bay, along with the dashboard digital instrument display (5110662040), starter relay box, central machine control unit (6451045100), and immobilizer key security system.

The Professional Advantage: Fast, Accurate Parts Identification

Using the genuine Terex TL100 Wheel Loader Illustrated Parts Catalog Manual – Serial No. TL1002 0372-XXXX gives your shop the capability to maintain and repair equipment with 100% factory precision. Whether conducting routine filter servicing, rebuilding worn center articulation pins and link bearings, repacking hydraulic cylinders, or replacing transmission gearing, this manual completely eliminates guesswork. Having access to exact OEM part numbers and exploded schematics ensures that you order the correct parts the very first time, preventing expensive machine downtime, restocking charges, and parts return delays. Delivered as an instant high-resolution digital PDF download, this manual provides immediate lifetime access with zero shipping wait times, allowing you to search on your workshop computer, zoom in on intricate exploded assemblies on your mobile tablet in the field, or print out clean schematic pages for your service binders.