Terex TR70 User manual
TEREX SERVICE DEPARTMENT
PURPOSE:
To advise potentially hazardous condition.
DETAIL:
It has been brought to our attention that 'Viton' material used in manufacture of oil seals and 'O' rings, produces a
highly corrosive acid (Hydrofluoric) when subjected to temperatures above 315° C.
The resulting contamination can have extreme consequences on human tissue since it is almost impossible to
remove after contact.
We therefore recommend the following procedure when it is necessary to inspect any equipment that has been
subjected to a high temperature i.e. fire.
a. Visually inspect for any gaskets or seals which have suffered from heat; they will appear black and sticky.
b. If this is affirmed - Do Not Touch
c. Make enquiries to ascertain the material composition. Any Fluoro-elastomer (Viton, Fluorel or Tecmoflon)
should be considered dangerous but natural rubber and nitrile are non-hazardous.
d. If Fluoro-elastomer seals have been used, then the affected area MUST be decontaminated before
undertaking further work.
e. Disposable Heavy Duty Gloves (Neoprene) MUST be worn and the affected area decontaminated by washing
thoroughly with Limewater (Calcium Hydroxide solution).
f. Any cloths, residue and gloves used MUST be safely discarded after use.
Note: Burning of the discarded items is NOT RECOMMENDED, except in an approved incineration process
where the gaseous products are treated by alkaline scrubbing.
Service
Information
Alert
DATE: April 1994 B168
MODEL: General
SUBJECT: VITON 'O' RINGS AND SEALS (FLUORO-ELASTOMERS) - SAFETY HAZARDS
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
The information contained within this
Alert must not be made available to
third parties not authorised to receive it.
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SM 222 Rev 1 9-93
Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service
procedures recommended and described in this publication, are effective methods for performing service
operations. Some of these service operations require the use of tools specially designed for the purpose.
The special tools should be used when, and as recommended.
It is important to note that this publication contains various WARNINGS and NOTES which should be
carefully read in order to minimize the risk of personal injury to personnel, or the possibility that improper
service methods will be followed which may damage the vehicle or render it unsafe. It is also important to
understand these WARNINGS and NOTES are not exhaustive. It is not possible to know, evaluate and
advise the service trade of ALL conceivable ways in which service might be carried out, or, of the
possible hazardous consequences of each way. Consequently, no such broad evaluation has been
undertaken. Accordingly, anyone who uses a service procedure, or tool, which is not recommended, must
first satisfy themselves thoroughly that neither their safety, nor vehicle safety, will be jeopardized by the
service method he/she selects.
Two types of heading are used in this manual to attract your attention.
1. WARNING - This symbol is used when an operating procedure, practice, etc., which, if not correctly
followed could result in personal injury or loss of life. Look for this symbol to point out important safety
precautions. It means - ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
2. Note - This is used when an operating procedure, practice, etc., which, if not strictly observed, could result in
damage to or destruction of equipment.
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.
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SM 1910 Rev 2 02-02 1
TABLE OF CONTENTS
SectionNo. Description SM No.
000 GENERALINFORMATION
0000 TR70Off-HighwayTruck 1911
100 CHASSIS
0010 Chassis,HoodandFenders 1918
110 ENGINE
0030 EngineandMounting 1923
0050 AirCleaner 1925
0130 PowerTakeoff 1914
120 TRANSMISSION
0010 TransmissionandMounting 1932
0070 Commercial Electronic Control (CEC) Shift System 1575 Rev2
0070 CommercialElectronicControl2(CEC2) 2128
0090 PowerTakeoff 1915
0100 Transmission Oil Filter 1931
130 DRIVELINE
0010 FrontDriveline 1577
0020 RearDriveline 1578
140 FRONTAXLE
0040 Wheel,Rim andTyre 2042
160 REARAXLE
0020 Differential 2045
0030 AxleGroup 1184
0050 Wheel,Rim andTyre 2044
165 BRAKEPARTS
0020 Brake Parts - Front Axle 1916
0030 Brake Parts - Rear Axle 2038
180 SUSPENSION SYSTEM
0030 Ride Cylinder-Front 1912
0050 RideCylinder-Rear 2033
190 CIRCUITDIAGRAMS
0000 CircuitDiagrams 1924
0270 SwitchesandSensors 2032 Rev1
200 FUEL SYSTEM
0010 FuelTank,Lines andMounting 1927
0051 Electronic Foot Pedal 2031
210 COOLINGSYSTEM
0040 Radiator,HeaderTankandMounting 2034
0050 Disc Brake Oil Cooler 2035
0060 TransmissionOilCooler 2036
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SM 1910 Rev 2 02-02
2
* * * *
TABLE OF CONTENTS
SectionNo. Description SM No.
220 STEERING SYSTEM
0000 Steering System Schematic 1591
0040 SteeringandBrakeControlTank 1592
0050 SteeringPump 1639
0080 Accumulator 1205
0090 SteeringValve 2027
0110 DoubleReliefValve 1208
0120 SteeringCylinderandLinkage 2028
0130 AccumulatorValve 1209
0150 SteeringFilter 1593
230 BODY SYSTEM
0000 Body System Schematic 1929Rev 1
0040 Body and Disc Brake Cooling Tank 1928
0050 TandemPump 1213
0060 BodyControl Valve 2029Rev1
0081 Body Control Joystick 1597
0110 Manifold Relief Valve 1645
0121 Pilot Supply Valve 1599
0130 BodyCylinder 1930
250 BRAKINGSYSTEM
0000 Braking System Schematic 2039Rev 1
0050 BrakeManifoldValve 2040
0060 Accumulator 1600
0070 TreadleValve 1225 Rev1
0090 DirectionalControlValve 1226
0100 MonoblockBrakeValve 1227Rev2
0110 PressureReducingValve(Optional) 2041
0130 RetarderControlValve 1601Rev1
0140 Shuttle Valve 1229
260 OPERATORSCOMPARTMENT
0010 CabandMounting 1602 Rev1
0090 DriverSeatandMounting 1901
0110 PassengerSeatandMounting 1902
0130 AirConditioningandMounting 2043
270 BODY
0010 BodyandMounting 1917
300 MISCELLANEOUS
0020 LubricationSystem 2030
0070 Service Tools 2037Rev 1
0080 StandardBoltand NutTorque Specifications 1238
0090 UnitStorage 1239
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Section 000-0000
1
SM 1911 7-00
GENERAL INFORMATION -TR70 Off-Highway Truck
SM - 2409
ENGINE
Make/Model .................................... Detroit Diesel 12V 2000
Type ............................. 4 Cycle, Turbocharged/Aftercooled.
Electronic Management
Gross Power @ 2 100 rev/min.................................. 567 kW
(760 hp, 770 PS)
Net Power @ 2 100 rev/min..................................... 522 kW
(700 hp, 710 PS)
Note: Power ratings to SAE J1995 Jun 95. Engine
emission meets USA EPA/CARB MOH 40 CFR 89 and
EU NRMM (non-road mobile machinery directive).
Maximum Torque ...3 118 Nm (2 300 lbf ft) @ 1 200 rev/min
Number of Cylinders/Configuration ..............................12, V
Bore x Stroke ........................ 130 x 150 mm (5.11 x 5.91 in)
Total Displacement ................................. 24 litres (1 464 in³)
Starting...................................................................... Electric
Maximum Speed, Full Load ............................ 2 100 rev/min
Maximum Speed, No Load ............................. 2 250 rev/min
Idle Speed.......................................................... 750 rev/min
Safe Operating Angle .................................. 30°/60% Grade
TRANSMISSION
Make/Model .............................................. Allison M6600AR
automatic electronic control with soft shift feature.
Remote mounted in the frame. Integral TC 682 torque
converter and planetary gearing. Six speeds forward, two
reverse. Automatic converter lockup action in all speed
ranges. With body up, gear range is limited to 1st forward
only. Downshift inhibitor. Intregal hydraulic retarder.
Fig. 1 - Machine Dimensions
Speeds With 24.00 R 35 Tyres
Forward
Gear 1 2 3 4 5 6
Ratio 4.00 2.68 2.01 1.35 1.00 0.67
km/h 9.5 14.2 18.9 28.2 38.1 57.0
mile/h 5.9 8.8 11.8 17.5 23.7 35.5
Reverse
Gear 1 2
Ratio 5.12 3.46
km/h 7.4 11.0
mile/h 4.6 6.8
4 420 (14-6)
3 660 (12-0)
2 970 (9-9)
5 290 (17-4)
4 940 (16-2)
2 995 (9-10)
4 445 (14-7)
Dimensions in mm (ft-in)
2 490 (8-2) 4 470 (14-8) 2 945 (9-8)
9 905 (32-6)
8 380
(27-6)
3 940
(12-11)
4 270
(14-0)
Vehicle Clearance Diameter (SAE) 22.4 m (73-6)
Max
Body
Depth
1 500
(4-11)
1 536
(5-0)
1080
(3-6) 610
(2-0)
460 (1-6)
685 (2-3)
3 785
(12-5)
6 200
(20-4)
6 580
(21-7)
8 380
(27-6)
59˚
15˚
4 190
(13-9)
4 570
(15-0)
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Section 000-0000
General Information - TR70 Off HighwayTruck
SM 1911 7-00
2
DRIVE AXLE
Heavy duty axle with single reduction spiral bevel gear
differential, full floating axle shafts, and planetary reduction
at each wheel.
Ratios: Standard Optional
Differential....................................... 3.73:1 3.15:1
Planetary......................................... 5.80:1 5.80:1
Total Reduction............................. 21.63:1 18.27:1
SUSPENSION
Front: King pin strut type independent front wheel
suspension by self-contained, variable rate, nitrogen/oil
cylinders.
Rear: Variable rate nitrogen/oil cylinders with A-frame
linkage and lateral stabilizer bar.
Maximum Strut Stroke
Front .......................................................235 mm (9.25 in)
Rear ..........................................................193 mm (7.6 in)
Maximum Rear Axle Oscillation..................... ± 7.5 Degrees
WHEELS AND TYRES
Wheel Rim Width .......................................................... 17 in
Standard Tyres (Front & Rear) ..............24.00 R 35** Radial
Optional Tyres (Front & Rear) ............ 24.00-35 (48 PR) E-3
Note: It is recommended that for tyres both listed and
unlisted, the user should consult the tyre manufacturer and
evaluate all job conditions in order to make the proper
selection.
BRAKES
Service
All hydraulic brake system. 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 ............. 110 bar (1 600 lbf/in²)
Rear Brake Circuit Pressure ....................52 bar (750 lbf/in²)
Accumulators:
Nitrogen Precharge Pressure...............55 bar (800 lbf/in²)
Front:
Type............................ Dry Disc with 2 callipers per wheel
Disc Diameter ............................................710 mm (28 in)
Pad Area, Total.................................... 2 788 cm²(432 in²)
Rear:
Type...............................Oil cooled, multiple friction discs,
completely sealed from dirt and water.
Braking Surface, Total ..................67 390 cm² (10 445 in²)
Parking
Application of rear brakes by springs in brake disc pack.
Hydraulically released.
Hold-off Pressure ..................................83 bar (1 200 lbf/in²)
Retardation
Modulated lever control of rear disc pack.. 670 kW (900 hp)
continuous.
Retarder Actuation Pressure ......... up to 33 bar (480 lbf/in²)
Emergency
Push button solenoid control applies service and parking
brakes. Automatically applies when engine is switched off.
Parking brake applies should system pressure fall below a
predetermined level.
Brakes conform to ISO 3450, SAE J1473 OCT 90.
STEERING SYSTEM
Independent hydrostatic steering with closed-centre
steering valve, accumulator and pressure compensating
piston pump.
Accumulator provides uniform steering regardless of engine
speed. In the event of loss of engine power it provides
steering of approximately two lock-to-lock turns.
A low pressure indicator light warns of system pressure
below 83 bar (1 200 lbf/in²). Steering meets SAE J53.
Relief Pressure ...................................210 bar (3 000 lbf/in²)
Steering Cylinders ................... Double Acting, Single Stage
Accumulator:
Nitrogen Precharge Pressure...............55 bar (800 lbf/in²)
Steering Angle (Left and Right) .......................................42°
Pump:
Type......................................................................... Piston
Capacity at 2 100 rev/min..... 1.75 litres/s (32 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........................................................................... Gear
Capacity at 2 100 rev/min..................................6.1 litres/s
(97 US gal/min)
Control Valve ...................... Servo Controlled, Open Centre
Body Raise Time................................................ 13 Seconds
Body Lower Time ............................................ 11.5 Seconds
ELECTRICAL
Type ............................................. 24 Volt, Negative Ground
Battery......... Two, 12 Volt, 165 Ah each, Maintenance Free
Accessories................................................................ 24 Volt
Alternator ..................................................................70 Amp
Starter ........................................................................... 9 kW
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Section 000-0000
3
SM 1911 7-00
General Information - TR70 Off-HighwayTruck
BODY
Longitudinal 'V' type floor with integral transverse box-
section stiffeners. The body is exhaust heated and rests on
resilient impact absorption pads.
Body floor wear surfaces are high hardness (450 BHN)
abrasion resistant steel. Yield strength of plates 1 200 MPa
(174 000 lbf/in²). All other wear surfaces are high hardness
(360-440 BHN) abrasion resistant steel. Yield strength of
plates 1 000 MPa (145 000 lbf/in²).
Plate Thicknesses:
Floor ......................................................... 19 mm (0.75 in)
Side .......................................................... 10 mm (0.39 in)
Front, lower............................................... 10 mm (0.39 in)
ROPS Cabguard SAE J1040 Feb 86. ISO 3471
Volumes:
Struck (SAE)............................................... 29 m³ (38 yd³)
Heaped 2:1 (SAE) ................................ 41.5 m³ (54.3 yd³)
SERVICE CAPACITIES
Engine Crankcase and Filters............... 94 litres (25 US gal)
Transmission and Filters.................... 85 litres (22.5 US gal)
Cooling System ................................ 236 litres (62.3 US gal)
Fuel Tank .......................................... 938 litres (248 US gal)
Steering Hydraulic Tank ....................... 61 litres (16 US gal)
Steering System................................. 92 litres (24.3 US gal)
Body and Brake Cooling Tank ............ 258 litres (68 US gal)
Body and Brake Cooling System ...... 432 litres (114 US gal)
Planetaries (Total) ............................. 43 litres (11.4 US gal)
Differential.......................................... 52 litres (13.7 US gal)
Front Ride Strut (Each) ........................ 25 litres (6.6 US gal)
Rear Ride Strut (Each)......................... 21 litres (5.5 US gal)
Power Takeoff........................................... 4 litres (1 US gal)
Air Conditioning Compressor...... 0.135 litres (0.036 US gal)
Typical Noise Levels
Operator Ear (ISO 6394)............................................ 81 dbA
*Exterior Sound Rating (SAE J88 JUN 86)................ 91 dbA
* - The above result is for the mode giving the highest
exterior sound level when measured and operated as per
the prescribed procedures of the standard. Results shown
are for the vehicle in base configuration.
Note: Noise Level Exposure to the operator and bystander
personnel may be higher depending upon proximity to
buildings, rock piles, machinery etc.. The actual job site
Noise Level Exposure must be measured and applicable
regulations complied with in respect to Employee Hearing
Protection.
* * * *
Vehicle Weights (Mass) kg lb
Chassis, with hoists 36 190 79 780
Body, standard 11 500 25 350
Net Weight 47 690 105 140
PAYLOAD, maximum 65 000 143 300
Maximum Gross Weight* 112 690 248 440
FOR UNIT EQIPPED WITH OPTIONAL HARD ROCK
BODY:
Chassis, with hoists 36 190 79 780
Body, with wear plates 16 450 36 270
Net Weight 52 640 116 050
PAYLOAD, maximum 60 050 132 390
Maximum Gross Weight* 112 690 248 440
* Maximum permissable gross vehicle weight with options,
attachments, full tank and payload.
WEIGHT DISTRIBUTION Front Axle Rear Axle
Empty % 48 52
Loaded % 34 66
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Section100-0010
1
SM 1918 7-00
CHASSIS - Chassis, Hood and Fenders
REMOVAL
WARNING
To prevent personal injury and property
damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
To remove any of the components shown in
Figs. 1, 2, 3, 4 or 5 (or similar components) the
following procedures should be carried out.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine.
2. Turn steering wheel in both directions several times
to relieve pressure in the steering circuit. Block all road
wheels.
3. Attach a suitable lifting device to the component and
remove mounting hardware. Remove the component
from the vehicle.
INSTALLATION
Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
WARNING
To prevent personal injury and property
damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
Using a suitable lifting device, align the component to
be installed in position on the chassis. Secure the
component securely to the chassis with mounting
hardware removed during removal.
11
1014
12
13
2
5
4
1
3
8
7
6
9
8
7
6
Fig. 1 - Exploded View of Chassis and Guards
1 - Frame Assembly
2 - Bushing
3 - Engine Guard
4 - Transmission Guard
5 - Bolt
6 - Nut
7 - Lockwasher
8 - Washer
9 - Bolt
10 - Washer
11 - Bolt
12 - Hardened Washer
13 - Locknut
14 - Spring Disc
SM - 2511
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Chassis - Chassis, Hood and Fenders
Section100-0010
2SM 1918 7-00
SM - 2554MAINTENANCE
Inspection
Inspect the frame and attached parts at intervals not
exceeding 250 hours for cracked or broken welds and
bending/twisting of the frame. Any defects found
should be repaired before they progress into major
failures. Contact your dealer for recommended weld
and repair instructions.
Welding
Note: It is important that the electrical connections are
disconnected in the following order to prevent damage
to the electrical components:
a. Disconnect battery equalizer ground cables.
b. Disconnect battery cables from terminal posts
(ground cable first).
c. Disconnect battery equalizer positive cables.
d. Disconnect electrical connections at the ECU.
After welding, reconnect all of the above in the reverse
order.
WARNING
Welding and flame cutting cadmium plated
metals produce odourless fumes which are
toxic. Recommended industrial hygiene
practice for protection of the welding operator
from the cadmium fumes and metallic oxides
requires enclosure ventilation specifically
designed for the welding process. A
respiratory protective device such as the
M.S.A. 'Gasfoe' respirator with G.M.A. cartridge
will provide protection against cadmium,
fumes and metallic oxides. The 'Gasfoe'
respirator has been approved by the U.S.
Bureau of Mines: Approval number 23B-10,
and is designed to protect against gases,
vapours, and/or metal fumes.
Electric arc welding is recommended for all chassis
welding. Since the nature and extent of damage to the
frame cannot be predetermined, no definite repair
procedure can be established. As a general rule
however, if parts are twisted, bent or pulled apart, or a
frame is bent or twisted, no welding should be done
until the parts are straightened or realigned.
Successfully welded repairs will depend to a great
extent upon the use of the proper equipment, materials
and the ability of the welder. The Service Department
can be consulted regarding the feasibility of welding
repairs.
Painting
A check of the condition of the paint should be made
approximately twice a year and chassis repainted if
necessary.
WARNING
Welding, burning, heating or dressing surfaces
previously painted using polyurethane paint
produces fumes which are toxic. Surfaces
must be prepared using paint stripper prior to
area being reworked. Recommended Industrial
Hygiene and Safety Rules should be be
followed for protection of the welding operator
from fumes.
If painting of the actual frame of the unit is required,
thoroughly clean the areas to be painted. Apply a
primer coat of red oxide and then a finish coat of
polyurethaneenamel.
To keep rust and corrosion to a minimum, periodic
painting of abrasions and other exposed metal areas
on the frame is highly recommended.
Fig. 2 - Exploded View of Hood and Mounting
1
3
5
24
5
1 - Hood Assembly
2 - Plate
3 - Bolt
4 - Bolt
5 - Hardened Washer
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Section100-0010
3
SM 1918 7-00
Chassis - Chassis, Hood and Fenders
Fig. 3 - Exploded View of Fenders and Mounting
6
7
11
7
12
11
7
12
8
16 11
18
2
17
19
18
12
11
712
9
13
14
4
3
5
1
4
3
20
10
19
7
12
11
7
12
191812
24
23 15 22
21
11
18
SM - 2555
1 - Front Crossmember Assembly
2 - Rear Crossmember Assembly
3 - Bolt
4 - Hardened Washer
5 - Platform & Cover Assembly
6 - Bolt
7 - Hardened Washer
8 - Platform LHS
9 - Fender Assembly LH
10 - Fender Assembly RH
11 - Bolt
12 - Locknut
13 - Bolt
14 - Snubbing Washer
15 - Handrail & Kickstrip Assembly
16 - Handrail Assembly LH
17 - Kickstrip
18 - Hardened Washer
19 - Bolt
20 - Platform Extension
21 - Bolt
22 - Hardened Washer
23 - Mirror
24 - Mirror Wide Angle
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Chassis - Chassis, Hood and Fenders
Section100-0010
4SM 1918 7-00
SM - 2513
1 - LH Step Assembly
2 - RH Step Assembly
3 - Bolt
4 - Washer
5 - Nut
6 - Step
7 - Bolt
8 - Washer
9 - Locknut
Fig. 4 - Exploded View of Ladders and Handrails
1
2
3
4
4
5
3
4
4
5
3
4
4
5
3
4
4
5
6
7889
6
7889
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Chassis - Chassis, Hood and Fenders
Section100-0010
6SM 1918 7-00
SM - 2557
1 - Mudflap Front
2 - Angle Bracket
3 - Angle Bracket
4 - Plate
5 - Mudflap
6 - Angle Bracket
7 - Clamp Plate
8 - Mudflap
9 - Clamp Plate
10 - Bolt
11 - Lockwasher
12 - Nut
13 - Plate
14 - Plate
15 - Mudflap RH Front
16 - Bracket Assembly
17 - Backing Strip
18 - Mudflap RH Rear
19 - Backing Strip
20 - Bracket Assembly
21 - Bolt
22 - Locknut
23 - Hardened Washer
24 - Bolt
25 - Plate Assembly LH
26 - Plate Assembly RH
27 - Mudguard Plate LH
28 - Mudguard Plate RH
29 - Mudflap LH
30 - Mudflap RH
Fig. 6 - Exploded View of Mudflaps and Mounting
* * * *
10
10
11
11
12
12
6
7
5
8
10 9
12 11
21
21
23
23
22
22
1011 28
11
10
30
24
23
16
15
19
22 1921
1110
26
9810
1112
2119
19
19
19
19
23 22 24
23
20
1110
1011
18
1
14
13
10 1112
29
11
10
1110
25 4
3
2
10
11
12
12
11
10
4
27
17
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Section 110-0030
SM19237-00 1
ENGINE - Engine and Mounting
SM - 2465
DESCRIPTION
Numbers in parentheses refer to Fig. 1.
For engine make, model and specification, refer to
Section 000-0000, GENERAL INFORMATION. For
engine servicing and repair data refer to the engine
manufacturers service manual.
The engine is mounted to the frame by mounting
crossmember (13) and two mounting brackets (9) at
the front of engine (1) and two rear mounts (21).
Rubber isolation mounts (17 & 22) through engine
mounts provide sufficient flexibility to absorb varying
engine vibration and torsional loads.
There are three full-flow oil filters (2) mounted on the
right hand side of engine (1) in a downward position.
The filters are of the throw away, spin-on type. Oil
supplied by the engine oil pump passes through oil
filters (2) before reaching the various moving parts of
engine (1). The oil is forced by pump pressure
through a passage in the filter adaptor and into the
Fig. 1 - Engine and Mounting
1 -Engine
2 - Oil Filter
3 - Primary Fuel Filter
4 -Secondary Fuel Filter
5 - Fan Belt
6 -Thermostat
7 -ThermostatSeal
8 - Gasket
9 - Front Mounting Bracket
10 - Bolt
11 - Bolt
12 -Lockwasher
13 -MountingCrossmember
14 - Bolt
15 -Washer
16 - Nut
17 - Isolation Mount
18 -SnubbingWasher
19 - Bolt
20 - Locknut
21 -Rear MountingBracket
22 - Isolation Mount
23 -SnubbingWasher
24 - Bolt
25 - Locknut
1
2
6
8
7
6
8
4
3
21
21
11
12
1210 24
23
22
25
13
20
17
18
19
12
16
9
1210
14
15
9
5
LIFTING POINTS
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Section 110-0030
Engine - Engine and Mounting
SM19237-002
elements. Impurities are filtered out as the oil passes
through the elements and out through another
passage in the filter adaptor.
There are four spin-on type fuel filters mounted on
the right hand side of engine (1), two primary fuel
filters (3) and two secondary fuel filters (4). Primary
fuel filters (3) are in the fuel flow and act as strainers
and secondary fuel filters (4) filter the fuel after
having passed through primary fuel filters (3).
DETROITDIESEL ELECTRONIC
CONTROL (DDEC)
Description
Refer to Fig. 2.
WARNING
Before any welding is done on a machine
equipped with the DDEC IV system,
disconnect the following in this order:
Battery earth cable, battery supply cable,
alternator earth cables, alternator supply
cables, transmission connector, ECM interface
harness connectors (30 pin RHS), ECM
powerharness connectors (5 pin RHS), ECM
engine to transmission datalink connectors (6
pin RHS), ECM sensor harness connectors (30
pin LHS) and ECM injector harness connectors
(5 pin LHS - 2 connectors) (Note: this engine
is equipped with 2 ECMs). Turn off ignition
key switch to isolate the batteries before
disconnecting any components.
After welding connect all of the above in the
reverse order.
The engine is equipped with DDEC IV which which
continually monitors the engine and warns the
operator when a problem develops. The DDEC IV
system also takes action to prevent damage to the
engine and, provides the serviceman with diagnostic
capabilities so that problems can be corrected
quickly and easily.
1. Electronic Control Module (ECM) - Receives
electronic inputs from the driver as well as from
mounted sensors that provide information
electronically, such as oil pressure and temperature
and intake manifold pressure. This information is
used to control both the quantity of fuel injected and
injectiontiming.
2. Programmable Read Only Memory (PROM) -
Located in the ECM and encoded with the operating
software. Additional information is programmed into
the EEPROM. This information controls the
horsepower rating, torque curve, maximum engine
speed and engine protection devices. The ECM
processes this information and sends electronic
signals to the Electronic Unit Injectors (EUI) where the
precise amount of fuel is injected into the engine.
3. Electronic Unit Injectors (EUI) - The EUI is a
lightweight, compact unit that injects diesel fuel directly
into the combustion chamber. The amount of fuel
injected and the beginning of injection timing is
determined by the ECM. The ECM sends a command
pulse which activates the injector solenoid.
The EUI performs four functions:
a - Creates the high fuel pressure required for efficient
injection.
b - Meters and injects the exact amount of fuel
required to handle the load.
c - Atomizes the fuel for mixing with the air in the
combustion chamber.
d - Permits continuous fuel flow for component cooling.
Electronic unit injectors are self compensating and
virtually eliminate engine tune-ups.
Note: Never apply 12 V directly to terminals on the
injector or engine sensors as they will burn out. Before
removing injectors, the fuel passages must be blown
out to prevent fuel flow from entering the cylinder
head.
4. Electronic Foot Pedal - The electronic foot pedal
provides an electrical signal to the engine's fuel
control system in proportion to the degree of pedal
actuation.
Note: The engine MUST be started with foot 'OFF'
the electronic foot pedal.
5. Stop Engine Light - When the 'Stop Engine' light
comes on, the computer has detected a major
malfunction in the engine that requires immediate
attention. It is the operators responsibility to shut
down the engine to avoid serious damage.
6. Check Engine Light - When the 'Check Engine'
light comes on, the computer has detected a fault in
the engine. The fault should be diagnosed and
corrected at the earliest opportunity.
Find manuals at http://best-manuals.com/search?&s=TEREX-SM1909
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