Terex TR100 Mining Truck Maintenance Manual SM1616 Rev 2 – PDF Download

Description

Terex TR100 Mining Truck Maintenance Manual – SM1616 Rev 2

The Terex TR100 Mining Truck Maintenance Manual is a 528-page workshop document covering scheduled maintenance, removal, disassembly, assembly, adjustment, testing and troubleshooting procedures for the TR100 off-highway mining truck. Published under document number SM1616 Rev 2, this PDF delivers the manufacturer’s own service information for the Cummins KTA-38-C1050 powered TR100, arranged section by section under the Terex SM numbering system used by field technicians, mine maintenance crews and independent repair shops.

Rather than a short operator’s booklet or a generic diesel text, this is the full multi-section maintenance manual. It walks through the whole machine – engine mounting, Allison DP-8963 transmission and its CEC Plus II shift system, front and rear drivelines, differential, wheel planetaries, disc and oil-cooled brakes, ride cylinders, cooling circuit, fuel tank, steering circuit, body hoist hydraulics, cab, and the electrical circuits that tie them together.

File Details

• Manual Type: Maintenance / Service Manual
• Brand: Terex
• Model: TR100 Mining Truck
• Document Number: SM1616 Rev 2
• Language: English
• Page Count: 528 pages
• File Format: PDF

Chapters Covered

• General Information – TR100 Off-Highway Truck specifications (SM 1618 Rev 1)
• Welding Procedure (SM 2172)
• Chassis, Hood and Fenders
• Engine and Mounting (SM 1655 Rev 1)
• Air Cleaner (SM 1246)
• Power Takeoff (SM 1656)
• Transmission and Mounting (SM 1623 / SM 1899)
• Commercial Electronic Control (CEC) Shift System (SM 1619 Rev 1)
• Transmission Power Takeoff (SM 1178)
• Transmission Oil Filter (SM 1624)
• Front and Rear Driveline (SM 1657 / SM 1658)
• Front Axle – Wheel, Rim and Tyre (SM 1625 Rev 1)
• Rear Axle – Differential (SM 1626 Rev 1 / SM 1907)
• Rear Axle – Axle Group (SM 1627 Rev 1)
• Rear Axle – Wheel, Rim and Tyre (SM 1628 Rev 1)
• Brake Parts – Front and Rear Axle (SM 1629 / SM 1630)
• Suspension – Front and Rear Ride Cylinders (SM 1631 / SM 1632)
• Circuit Diagrams (SM 1585)
• Switches and Sensors (SM 1633 Rev 1 / SM 2046)
• Fuel Tank and Mounting (SM 1634)
• Cooling System (SM 1263)
• Radiator, Header Tank and Mounting (SM 1635 / SM 1900)
• Disc Brake Oil Cooler (SM 1636)
• Transmission Oil Cooler (SM 1637)
• Steering System Schematic (SM 1661)
• Steering and Brake Control Tank (SM 1638)
• Steering Pump (SM 1639)
• Steering Accumulator (SM 1205)
• Steering Valve (SM 1640 Rev 1)
• Double Relief Valve (SM 1208)
• Steering Cylinder and Linkage (SM 1641 / SM 2047)
• Accumulator Valve (SM 1642)
• Steering Filter (SM 1593)
• Body System Schematic (SM 1646 Rev 1)
• Body and Disc Brake Cooling Tank (SM 1643)
• Main Hydraulic Pump (SM 1644)
• Body Control Valve (SM 1659 Rev 1)
• Body Control Joystick (SM 1277)
• Manifold Relief Valve (SM 1645)
• Pilot Supply Valve (SM 1599)
• Body Cylinder (SM 1279)
• Braking System Schematic (SM 1660 Rev 1)
• Brake Manifold Valve (SM 1647)
• Tandem Pump (SM 1648)
• Brake Accumulator (SM 1600)
• Treadle Valve (SM 1649)
• Directional Control Valve (SM 1226)
• Monoblock Brake Valve (SM 1227 Rev 2)
• Pressure Reducing Valve (SM 2045)
• Retarder Control Valve (SM 1650 Rev 1)
• Shuttle Valve (SM 1229)
• Parking Brake Valve (SM 1651)
• Brake Dump Valve (SM 1652)
• Cab and Mounting (SM 1602 Rev 1)
• Driver Seat and Mounting (SM 1901)
• Passenger Seat and Mounting (SM 1603 / SM 1902)
• Air Conditioning (SM 1903)
• Body and Mounting (SM 1653 Rev 1)
• Lubrication System (SM 1654 Rev 1)
• Service Tools (SM 1662 Rev 1)
• Standard Bolt and Nut Torque Specifications (SM 1238)
• Unit Storage (SM 1239)

Every section follows the same disciplined format: description and operation, removal, disassembly, inspection, assembly, installation, maintenance and – where applicable – diagnosis charts and special torque tables. That structure is what makes the Terex TR100 Maintenance Manual usable both as a one-off repair guide and as an ongoing reference for a workshop running a fleet of TR100 trucks.

What the TR100 Maintenance Manual Covers in Detail

The early sections establish the machine itself. General Information lays out TR100 dimensions, the Cummins KTA-38-C1050 rating, Allison DP-8963 transmission speeds, axle ratios, brake pressures, tyre sizes, service capacities and vehicle weights. The Welding Procedure section then sets out the pre-weld electrical isolation order, cadmium-plated metal warnings, ARC-AIR gouging procedure and the E-7016 electrode specification used for frame repairs.

Chassis, hood, fenders, ladders, handrails, mudguards, radiator guard and mounting hardware all appear as exploded component views with numbered parts lists. Engine and Mounting (SM 1655 Rev 1) covers the removal, disassembly, inspection, assembly and installation sequence for the Cummins KTA-38-C1050 together with its rear mounts, crossmember, fan, coupling and drive flange. Air Cleaner (SM 1246) then deals with the dual dry element assemblies, restriction gauge, primary and safety element servicing and water manometer restriction measurement.

Transmission coverage is extensive. The Transmission and Mounting section handles the Allison DP-8963 with its TC 890 torque converter, lockup clutch, planetary gearing and hydraulic retarder, including a converter stall test procedure and a full mechanical troubleshooting chart. The CEC Shift System section documents the Commercial Electronic Control – components, wiring, ECU operating power, neutral start circuit, reverse alarm, parking brake interlock, body up interlock and every diagnostic trouble code from Code 13 low battery voltage through Code 69 ECU software error.

Driveline, front axle, rear differential, axle group, wheel planetaries and the front and rear wheel, rim and tyre sections handle the mechanical drive path along with tyre dismounting, bead breaking, rim inspection, nitrogen inflation and tyre care procedures. Brake Parts sections (front and rear) cover the disc brake heads, pads, pistons, seals and torque figures, while the Suspension System sections cover front and rear ride cylinders including nitrogen charging and height specification.

Cooling System, Radiator and Header Tank, Disc Brake Oil Cooler and Transmission Oil Cooler form the thermal package. Fuel Tank and Mounting covers tank removal, sender, strainer and the optional fast fuelling system. The Steering System section is one of the largest, with a dedicated schematic section, tank, pump overhaul, accumulator, steering valve, double relief valve, cylinder and linkage and the accumulator valve. The Body System mirrors that depth for the hoist circuit – main hydraulic pump, body control valve, joystick, manifold relief valve, pilot supply valve and body cylinder.

Braking System follows the same pattern: a multi-sheet schematic showing engine shutdown, engine running, service brake, emergency brake, OCDB retarder, transmission retarder and parking brake states, backed up by individual sections on the brake manifold valve, tandem pump, accumulators, treadle valve, directional control valve, monoblock brake valve, pressure reducing valve, retarder control valve, shuttle valve, parking brake valve and brake dump valve. Operators Compartment covers cab, driver seat, passenger seat and air conditioning. Body and Mounting covers the dump body, safety pins, pads and shimming procedure, while Miscellaneous wraps up with the Lubrication System, Service Tools, Standard Bolt and Nut Torque Specifications and Unit Storage.

Who This Manual Is For

This Terex TR100 service manual is aimed at the people who actually keep a TR100 working: mine maintenance technicians, heavy equipment mechanics, fleet supervisors planning overhauls, and owners running a single TR100 in quarry or mine duty. Because it preserves the manufacturer’s own procedures, torque values, tolerances and diagnosis charts, it is the reference a technician reaches for when a fault code is on the CEC display, when the rear brakes need to be rebuilt, when a ride cylinder has to be recharged, or when the body hydraulics have to be stripped down.

Why It Matters to Have This Manual on Hand

Mining trucks like the TR100 are unforgiving of guesswork. Brake pressures, nitrogen pre-charge values, torque values, wear limits and inspection intervals all have real consequences for safety and machine life. The wrong torque on a differential bearing cap, the wrong pre-charge in a steering accumulator, or skipping the correct electrical isolation order before welding can turn a routine job into an expensive failure. Having the manufacturer’s own specifications in front of you – drawn from the same source document used by the dealer network – removes that guesswork.

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Instant PDF Delivery

The Terex TR100 Mining Truck Maintenance Manual SM1616 Rev 2 is delivered as an instant PDF download immediately after checkout. There is no shipping, no waiting for a printed copy to arrive and no dependence on a workshop PC. Read it on a laptop in the office, a tablet on the shop floor, or a phone at the machine. Print the section you need – an exploded view, a torque table, a wiring diagram – and take the paper to the job. Keep the file on your own device and refer back to it every service.