Terex TR100 User manual

TEREX Equipment Limited Operations Manual
Operations Manual
TR100
15504845
OHE783
Original Operating Instructions

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TEREX Equipment Limited Operator Handbook
Operator Handbook
TR100
15504845
OHE783
TEREXEquipmentLimited OperatorHandbookRe-order
Issued by;
Customer Support Department
Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
Scotland
Tel; [phone]
Fax; [phone]
http//:constructionsupport.terex.com
www.terex.com
OHE783 (CEC2)
Re-order Part Number
15504845
This controlled document is the original instruction
and should remain with the vehicle at all times.
Revision: May 2012
Dealer:

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1-1
Introduction
INTRODUCTION
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
means:
ATTENTION! BECOME ALERT! YOUR SAFETY ANDTHE SAFETY OF OTH-
ERS IS INVOLVED!
SAFETY PRECAUTIONS
The machine should be properly operated and maintained to keep it in a 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. Report all malfunctions to those responsible for
maintenance, and, do not operate the equipment until corrected.Normal service
or maintenance performed as required can prevent unexpected and unneces-
sary downtime.
This Handbook describes general inspections, servicing and operation with the
normal safety precautions required for normal servicing and operating condi-
tions. It is not a guide however, for other than normal conditions or situations,
and therefore, servicemen and operators must be safety conscious and alert to
recognize potential servicing or operating safety hazards at all times, and take,
necessary precautions to assure safe servicing and operation of the machine.
WARNING
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 country
involved. Consult your dealer for details.
All information, illustrations and specifications contained in this publication are
based on the latest product information available at the time of publication.The
right is reserved to make changes at any time without notice.
Continuing improvement and advancement of the design may cause changes to
your machine which may not be included in this publication. Each publication is
reviewed and revised, as required, to update and include these changes in later
editions.
This Handbook contains lubrication and routine servicing instructions, most of
which can be performed in the field. Maintenance manuals containing repair/
rebuild procedures can be obtained from your dealer.
Safety alert symbol

1-2
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. The following signal words used with the safety alert symbol
indicate a specific level of severity of the potential hazard. Signal words used
without the safety alert symbol relate to property damage and protection only.
All are used as attention getting devices throughout this handbook as well as on
decals and labels fixed to the machinery to assist in potential hazard
recognition and prevention.
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous
situation which, if not avoided, may result in property damage.
Machine Identification
While reading this handbook you will notice references to controls and equipment
which may not be found on all machines. It is important that you know your
machine and its equipment and how to operate it properly.
Information regarding the machine model, code and chassis serial number is
found on the unit serial number plate on the rear right of the front frame. The
machine model and serial number should always be referenced in any
correspondence with your dealer or factory.
DANGER
WARNING
CAUTION
CAUTION

1-3
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-
ism.
Actions to Discourage Theft and Vandalism
Remove all keys any time the machine is left unattended.
At night lock all doors and attach, secure or lock all anti-vandalism and
anti-theft devices on the machine.
Immobilise the machine by removing a critical electrical or starting system de-
vice.
Upon receipt of a machine, record the machine serial number and the serial
numbers of all major components and attachments. Keep this list up to date and
filed in a safe location for fast retrieval.
Place a decal or notice on the machine stating that all serial numbers are recorded.
Discourage the thief! Inspect the gates and fences of the machinery storage
yard or construction site. Keep machines in well-lit areas and ask the local law
enforcement authorities to make frequent checks around the storage yard or
work site.
Establish liaison with neighbours and ask them to watch equipment left at job
sites and to report any suspicious activities to the local law enforcement au-
thorities.
Make frequent inventories of machines to promptly detect losses or vandalism.
Actions to Aid in Recovery of Stolen Machines
In the event of theft, immediately notify the law enforcement authorities having
jurisdiction. Provide the investigating officer with name, type of equipment, chassis
and serial numbers of major attachments and components. It is helpful to show
the investigating officer an Operator’s Handbook, photographs, and advertising,
to familiarize him with the appearance of the machine.
Report the theft to the insurance company. Provide the model and all serial
numbers.
Report the model and serial numbers of the stolen machine to a dealer handling
the respective line of equipment. Request that the dealer forward this same
information to the equipment manufacturer.

1-4
Introduction
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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
and lead compounds, chemicals
known to the State of California to cause
cancer and reproductive harm.
Wash hands after handling.

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.
If a General Operating Approval is issued for this machine, it may be considered null and void
if non-genuine parts are used.

EC DECLARATION OF CONFORMITY
MANUFACTURERS NAME AND FULL ADDRESS:
Terex Equipment Limited,
Newhouse Industrial Estate,
Motherwell,
Scotland.
ML1 5RY
DESCRIPTION OF MACHINERY:
MAKE: TEREX
2000/14/EC
2004/108/EC
2006/42/EC
Name:
Address:
Paul Douglas,
Newhouse Industrial Estate,
Motherwell, Scotland. ML1 5RY
PERSON AUTHORISED TO COMPILE TECHNICAL FILE DIRECTIVES COMPLIED WITH:
MODEL/DESIGNATION:
UNIT SERIAL NUMBER:
INSPECTOR:
WE DECLARE THAT THE ABOVE MACHINERY FULFILS ALL THE RELEVANT PROVISIONS OF
THE ABOVE DIRECTIVES
FULL QUALITY ASSURANCE (Annex X):
L.R.Q.A. Ltd.,
Hiramford,
Middlemarch Office Village,
Siskin Drive,
Coventry.
CV3 4FJ.
England
NAME: Paul Douglas
General Manager
Motherwell, Scotland
POSITION:
PLACE:
CERTIFICATE NUMBER:
LRQ 0925301/A
FOR AND ON BEHALF OF THE MANUFACTURER:
DATE OF MANUFACTURE:
SIGNATURE:
DATE:
TR100 Rigid Truck

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 byusing genuine parts that the technical requirements stipulated bythe manufacturer
can bemaintained.
If aGeneral Operating Approval is issued for this machine, it may beconsidered null and void
if non-genuine parts are used.

EC DECLARATION OF CONFORMITY
MANUFACTURERS NAME AND FULL ADDRESS:
Terex Equipment Limited,
Newhouse Industrial Estate,
Motherwell,
Scotland.
ML1 5RY
DESCRIPTION OF MACHINERY:
MAKE: TEREX
2000/14/EC
2004/108/EC
2006/42/EC
Name:
Address:
Paul Douglas,
Newhouse Industrial Estate,
Motherwell, Scotland. ML1 5RY
PERSON AUTHORISED TO COMPILE TECHNICAL FILE DIRECTIVES COMPLIED WITH:
MODEL/DESIGNATION:
UNIT SERIAL NUMBER:
INSPECTOR:
WE DECLARE THAT THE ABOVE MACHINERY FULFILS ALL THE RELEVANT PROVISIONS OF
THE ABOVE DIRECTIVES
FULL QUALITY ASSURANCE (Annex X):
L.R.Q.A. Ltd.,
Hiramford,
Middlemarch Office Village,
Siskin Drive,
Coventry.
CV3 4FJ.
England
NAME: Paul Douglas
General Manager
Motherwell, Scotland
POSITION:
PLACE:
CERTIFICATE NUMBER:
LRQ 0925301/A
FOR AND ON BEHALF OF THE MANUFACTURER:
DATE OF MANUFACTURE:
SIGNATURE:
DATE:
TR100 Rigid Truck

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 byusing genuine parts that the technical requirements stipulated bythe manufacturer
can bemaintained.
If aGeneral Operating Approval is issued for this machine, it may beconsidered null and void
if non-genuine parts are used.

CONTENTS
1. INTRODUCTION
Introduction 1-1
Safety Precautions 1-1
Intended use of machine 1-2
Hazard Classification 1-2
Machine Identification 1-2
Theft Deterrent Practices 1-3
2. SAFETY PRECAUTIONS
General 2-4
Vehicle Lifting Precautions 2-5
Vehicle Tie Down Precautions 2-5
Preventing Fire Hazards 2-6
Mounting and Dismounting 2-7
Pre-Starting 2-8
Starting 2-8
Operating 2-8
Roading 2-10
Lubrication and Servicing 2-10
Scrapping of Machine 2-11
Option With Additional Mirrors 2-12
CCTV 2-17
Ground Level Isolation Switch 2-17
Wheels and Tyres 2-18
Avoid Tyre Explosion Hazard 2-19
Decals and Instruction Plates 2-20
3. CONTROLS AND OPERATING
Controls and Instruments 3-3
Basic Data 3-4
Warning Lights 3-4
Instruments 3-7
Switches 3-8
Controls 3-10
Heater 3-10
Air Conditioner 3-10
Operator's Seat - Air Suspension 3-11
Seat Belt 3-12
Machine Controls 3-14
Braking 3-14
Service Brake 3-14
Park/Emergency Brake 3-14
Automatic Spotting Brake 3-14
Retarder 3-15
Engine 3-17
Accelerator 3-17
Steering 3-18
Transmission 3-19
Description and Operation 3-21
General Transmission Operation 3-25
Body Control 3-27
Raising the Body 3-27
Lowering the body 3-27

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CONTENTS
4. OPERATING THE TRUCK
Pre-Starting Inspection 4-3
Component Checks 4-4
Suspension Ride Struts 4-6
Engine Operation 4-7
Starting the Engine 4-8
Starting the Engine at low ambient
Temperature 4-10
Starting the Engine with Jumper Cables 4-10
Pre-Operating Checks 4-11
Brake Function Checks 4-12
Driving and Stopping 4-13
Stopping the Engine 4-14
Parking 4-16
5. WORKING THE TRUCK
Working the Truck 5-3
Loading 5-3
Hauling 5-5
Dumping 5-6
Empty Return 5-7
6. ROADING
Roading 6-3
General 6-3
Preparation Prior to Roading 6-3
In Case Of Trouble 6-4
7. MOVING DISABLED TRUCK
Moving Disabled Truck 7-3
8. LUBRICATION AND SERVICING
Safety Precautions 8-3
Lubrication and Servicing 8-4
Lubrication and Service Chart 8-5
Miscellaneous Servicing 8-7
Service Capacities 8-8
Recommended Lubricants 8-9
Air Conditioning Re-start Procedure 8-10
Tyre Pressure 8-10
9. TECHNICAL DATA
Technical Data - TR100 9-3
10.SYMBOL IDENTIFICATION 10-3

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