Volvo TEREX TR100 User manual

© TEREX TRUCKS 2019
RIGID TRUCKS
Maintenance Manual
Product Identification: TELR7831
Issue Date:
Language:
Revision No:
Reference No:
Original Instructions
01-AUG-2019
English (en)
1.3
15272903
TR100
TRUCKS
MOT05113

Volvo Construction Equipment Haulers Ltd
Newhouse Industrial Estate
Motherwell, ML1 5RY
United Kingdom
Tel: [phone]
Fax: [phone]
www.terextrucks.com
Product Identification Number
Year of Construction
Date of Delivery
Dealer Stamp
Notice
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For further information on the subject matter detailed within this Maintenance Manual,
please refer to Terex Trucks Operators Manuals and Illustrated Parts Catalouges.
Alternatively, please contact;
Technology Department
Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
Tel; [phone]
Fax; [phone]
The illustrations, technical information, data and descriptive text in this manual, to the
best of our knowledge, is correct at the time of issue. The right to change specifications,
equipment and maintenance instructions at any time without notice, is reserved as part
of the Terex Trucks policy of continuous development and improvement of the product.
No part of this publication may be reproduced, transmitted in any form - electronic,
mechanical, photocopying, recording, translating or by any other means without prior
permission of Technology Department - Terex Trucks.
Please refer to Terex Trucks Specification Sheets or consult Factory Representatives to
ensure that information is current.
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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.
IMPORTANT SAFETY NOTICE
I Safety Alert Symbol
The safety alert symbol is used to alert you to a potential personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
Hazard Classification
A 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 manual as well as on deals and labels fixed to the machinery
to assist in potential hazard recognition and prevention.
I DANGER
I WARNING
I CAUTION
CAUTION
DANGER indicates an imminent 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 hazard-
ous situation which, if not avoided, may result in property damage.
I WARNING
Never use parts which are altered, modified, or weakened in operation. This can seriously jeopardise the
integrity of the machine and could result in property damage or serious personal injury.
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SM1617 Rev 26 07-19 5
TABLE OF CONTENTS
Section No. Description SM No.
000 GENERAL INFORMATION
0000 TR100 Off-Highway Truck 1618 Rev 6
0010 Welding Procedure 2172
100 CHASSIS
0010 Chassis, Hood and Fenders 1898 Rev 1
110 ENGINE
0030 Engine and Mounting 1655 Rev 2
0050 Air Cleaner 1246
0130 Power Takeoff 1656 Rev 2
120 TRANSMISSION
0010 Transmission and Mounting 1899 Rev 2
0072 Commercial Electronic Control (CEC5) 2579
0090 Power Takeoff 1178 Rev 1
0100 Transmission Oil Filter 1624 Rev 1
130 DRIVELINE
0010 Front Driveline 1657
0020 Rear Driveline 1658
140 FRONT AXLE
0040 Wheel, Rim and Tyre 1625 Rev 2
160 REAR AXLE
0020 Differential 1626 Rev 1
0020 Differential (Optional) 1907
0030 Axle Group 1627 Rev 2
0050 Wheel, Rim and Tyre 1628 Rev 3
165 BRAKE PARTS
0020 Brake Parts - Front Axle 1629 Rev 1
0030 Brake Parts - Rear Axle 1630 Rev 4
180 SUSPENSION SYSTEM
0030 Ride Cylinder - Front 1631 Rev 3
0050 Ride Cylinder - Rear 1632 Rev 4
190 CIRCUIT DIAGRAMS
0000 Circuit Diagrams 2313 Rev 2
0270 Switches and Sensors 2046 Rev 3
200 FUEL SYSTEM
0010 Fuel Tank and Mounting 1634 Rev 1
210 COOLING SYSTEM
0000 Cooling System 1263 Rev 1
0040 Radiator, Header Tank and Mounting 1900 Rev 1
0050 Disc Brake Oil Cooler 1636 Rev 1
0060 Transmission Oil Cooler 1637 Rev 1
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SM1617 Rev 26 07-19
6
* * * *
TABLE OF CONTENTS
Section No. Description SM No.
220 STEERING SYSTEM
0000 Steering System Schematic 1661 Rev 2
0050 Steering Pump 2575 Rev 2
0080 Accumulator 1205 Rev 1
0090 Steering Valve 1640 Rev 2
0110 Double Relief Valve 1208 Rev 1
0120 Steering Cylinder and Linkage 1641 Rev 2
0130 Accumulator Valve 1642 Rev 1
0150 Steering Filter 1593 Rev 1
230 BODY SYSTEM
0000 Body System Schematic 1646 Rev 3
0040 Hydraulic Tank 2756
0050 Main Hydraulic Pump 1644 Rev 1
0060 Body Control Valve 1659 Rev 5
0081 Body Control Joystick 1277 Rev 1
0100 Manifold Relief Valve 1645 Rev 1
0121 Pilot Supply Valve 1599 Rev 1
0123 Proportional Pilot Control Valve 2757
0127 Emergency Body Down Lever 2758
0130 Body Cylinder 1279 Rev 1
250 BRAKING SYSTEM
0000 Braking System Schematic 1660 Rev 2
0050 Brake Manifold Valve 1647 Rev 1
0055 Tandem Pump 1648 Rev 1
0060 Accumulator 1600 Rev 1
0070 Treadle Valve 1649 Rev 1
0090 Directional Control Valve 1226 Rev 1
0100 Monoblock Brake Valve 1227 Rev 3
0110 Pressure Reducing Valve 2045 Rev 1
0130 Retarder Control Valve 1650 Rev 2
0140 Shuttle Valve 1229 Rev 1
0151 Parking Brake Valve 1651 Rev 1
0152 Brake Dump Valve 1652 Rev 1
260 OPERATOR'S COMPARTMENT
0010 Cab and Mounting 1602 Rev 2
0090 Driver Seat and Mounting 1901 Rev 2
0110 Passenger Seat and Mounting 1902 Rev 1
0130 Air Conditioning 1903
270 BODY
0010 Body and Mounting 1653 Rev 2
0015 Body Safety Pins 2578
300 MISCELLANEOUS
0020 Lubrication System 1654 Rev 15
0070 Service Tools 1662 Rev 2
0080 Standard Bolt and Nut Torque Specifications 1238 Rev 1
0090 Unit Storage 1239 Rev 2
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Section 000-0000
1
SM 1618 Rev6 03 -19
GENERAL INFORMATION - TR100 Mining Truck
MOT05117
TRANSMISSION
Make/Model ...................Allison 6620 ORS Automatic CEC 5
Automatic electronic control with soft shift feature. Remote
mounted in the frame with integral TC 682 torque converter
and planetary gearing. Six speeds forward, one reverse.
Automatic converter lockup action in all speed ranges. With
body up, gear range is limited to 1st forward only. Downshift
inhibitor. Integral hydraulic retarder.
Fig. 1 - Machine Dimensions
ENGINE
Make/Model ....................................Cummins KTA-38-C1050
Type .................................4 Cycle, Turbocharged/Aftercooled
Gross Power
at 2 100 rev/min ................... 783 kW (1 050 hp, 1 094 PS)
Net Power at 2 100 rev/min ........... 692 kW (928 hp, 967 PS)
Note: Power ratings to SAE J1995 June 1990. Net Power is
after deductions for fan and alternator. Engine requires no
derating up to 3 050 m (10 000 ft) altitude.
Maximum Torque ..................................4630 Nm (3415 lbf ft)
at 1300 rev/min
Number of Cylinders/Configuration ................................. 12V
Bore x Stroke..........................159 x 159 mm (6.25 x 6.25 in)
Total Displacement .................................37.7 litres (2300 in³)
Starting .......................................................................Electric
Maximum Speed, Full Load...............................2100 rev/min
Maximum Speed, No Load................................2400 rev/min
Idle Speed ...........................................................750 rev/min
Speeds With Standard Planetary
Forward
Gear 1 2 3 4 5 6
Ratio 4.24 2.32 1.69 1.31 1.00 0.73
km/h 8.2 15.0 20.6 26.5 34.8 47.6
mile/h 5.1 9.3 12.8 16.5 21.6 29.6
Reverse
Ratio 5.75
km/h 6.0
mile/h 3.8
TRUCKS
TRUCKS
4 825 (15-10)
5 935 (19-6)
Optional
Spillguard
4 850
(15-11)
5 235
(17-2)
4 700
(15-5)
2 945 (9-8)
3 760 (12-4)
4 570 (15-0)
275
(0-11)
755
(2-7)
1 635
(5-4)
1 220
(4-0)
5 080 (16-8)
1 755 (5-9)
3 420 (11-3)
Max
Body
Depth
4 575
(15-0)
Vehicle Clearance Diameter (SAE) 24.5 m (80 ft)
3 150 (10-4) 4 570 (15-0) 3 100 (10-2)
10 820 (35-6)
Dimensions in mm (ft-in)
4 445
(14-7)
6 880
(22-7)
8 640
(28-4)
6 080
(19-11)
8 960
(29-5)
660 (2-2)
510
(1-8)
58°
4 730
(15-6)
5 150
(16-11)
815 (2-8)
15°
MOT05117
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Section 000-0000
General Information - TR100 Mining Truck
SM 1618 Rev6 03 -19
2
Parking
Application of rear brakes by springs in brake disc pack.
Hydraulically released.
Hold-off Pressure.................................... 83 bar (1200 lbf/in²)
Retardation
Modulated lever control of rear disc pack.
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 (1200 lbf/in²). Steering conforms to ISO 5010,
SAE J53.
System Pressure .................................. 159 bar (2300 lbf/in²)
Relief Pressure..................................... 207 bar (3000 lbf/in²)
Steering Cylinders .....................Double Acting, Single Stage
Accumulator:
Oil Capacity ......................................16.4 litres (4.33 US gal)
Nitrogen Precharge Pressure................... 55 bar (800 lbf/in²)
Steering Angle (Left and Right) ........................................ 39°
Pump:
Type ..............................................................................Piston
Capacity at 2100 rev/min........... 1.57 litres/s (25 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 (2750 lbf/in²)
Pump:
Type ................................................................................Gear
Capacity at 2100 rev/min..................365 l/m (97 US gal/min)
Control Valve ........................ Servo Controlled, Open Centre
Body Raise Time .................................................14 Seconds
Body Lower Time.................................................18 Seconds
ELECTRICAL
Type ....................................................24 V, Negative Ground
Battery ...............Four, 12 V, 210 Ah each, Maintenance Free
Accessories .................................................................... 24 V
Alternator................................................................... 70 Amp
Alternator................................................................. 100 Amp
(Optional)
Starter.................................................................... Two, 9 kW
DRIVE AXLE
Heavy duty axle with full floating axle shafts, single
reduction spiral bevel gear differential and planetary
reduction at each wheel.
Ratios: Standard Optional
Differential ............................................. 2.16:1 2.16:1
Planetary ............................................. 13.75:1 10.50:1
Total Reduction.................................... 29.70:1 22.68:1
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 ............................................................ 229 mm (9.0 in)
Rear.............................................................. 175 mm (6.9 in)
Maximum Rear Axle Oscillation.......................± 7.0 Degrees
WHEELS AND TYRES
Wheel Rim Width......................................................... 19.5 in
Tyres (Front & Rear)
Standard................................................. 27.00 R 49** Radial
Optional ................................................27.00-49 (48 PR) E-4
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 ................ 159 bar (2300 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 1 calliper per wheel
Disc Diameter................................................ 965 mm (38 in)
Pad Area, Total ..........................................2015 cm² (320 in²)
Rear:
Type ................................... Oil cooled, multiple friction discs,
completely sealed from dirt and water.
Braking Surface, Total ..................... 87567 cm² (13573 in²)
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Section 000-0000
3
SM 1618 Rev6 03 -19
General Information - TR100 Mining Truck
BODY
Longitudinal 'V' type floor with integral transverse box-
section stiffeners. The body is exhaust heated and rests on
resilient impact absorption pads.
Body wear surfaces are high hardness (360-440 BHN)
abrasion resistant steel.Yield strength of plates 1000 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).............................................. 41.6 m³ (54.4 yd³)
Heaped 2:1 (SAE) .....................................57.0 m³ (74.5 yd³)
SERVICE CAPACITIES
Engine Dry Fill ...................................136 litres (35.9 US gal)
Transmission Dry Fill ..............................91 litres (24 US gal)
Cooling System ...............................ASR litres (ASR US gal)
Fuel Tank Dry Fill...........................1275 litres (336.8 US gal)
Hydraulic Tank ..........................522 litres (16.1137.9 US gal)
Differential (Standard) ............................95 litres (25 US gal)
Traction Bias Differential (Option)........65 litres (17.2 US gal)
Planetary LH........................................39 litres (10.3 US gal)
Planetary RH .......................................39 litres (10.3 US gal)
Differential ...........................................61 litres (16.1 US gal)
Front Ride Strut (Extended)...................34 litres (7.1 US gal)
Rear Ride Strut (Extended) ................36.6 litres (4.8 US gal)
Power Takeoff .......................................1.5 litres (0.4 US gal)
Air Conditioning Compressor........0.135 litres (0.036 US gal)
Sound Power Level ISO6395 TR100
A - Weighted sound power level Lwa 88.5 dba
in decibels
Uncertainty Kwa, in decibels TBA
Sound Pressure Level at Operators TR100
Station ISO6396
A - Weighted emission sound pressure 79
level Lpa in decibels
Uncertainty Kwa, in decibels 2.09
The sound level values are in compliance with Directive
2000/14/EC and BS EN 474.
Note: 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 Exposure Level to the operator and bystander
personnel may be higher depending upon proximity to
buildings, rock piles, machinery, etc.. The actual job site
Noise Exposure Level must be measured and applicable
regulations complied with in respect to Employee Hearing
Protection.
* * * *
VEHICLE WEIGHTS (MASS)
kg lb
Chassis, with hoists 53240 117380
Body, standard 15020 33115
Net Weight 68260 150490
PAYLOAD, maximum 90702 90000
Maximum Gross Weight* 158980 350495
FOR UNIT EQUIPPED WITH OPTIONAL BODY LINER
PLATES:
Chassis, with hoists 53240 117380
Body, with wear plates 20550 45300
Net Weight 73790 162680
PAYLOAD, maximum 85190 187815
Maximum Gross Weight* 158980 350495
* Maximum permissible gross vehicle weight with options,
attachments, full fuel tank and payload.
WEIGHT DISTRIBUTION Front Axle Rear Axle
Empty % 49 51
Loaded % 34 66
Hands and Arm Vibration
The weighted root mean square acceleration to which
hand and arms of the operator are exposed is less
than 2.5 m/s2 under normal operating conditions.
Whole Body Vibration TR100
Vibration Emission Value a 0.73m/s2
UncertaintyK 0.37m/s2
Operating Mode:
Value Obtained under simulated field duty cycle.
Note: The whole body vibrations on construction
machines are influenced by many factors independent
of machine design, for example ground conditions,
working methods, correct seat adjustment, operator
input to vehicle speed.
The single whole-body emission value listed above is
determined under particular operating and terrain
conditions. In accordance with EN474, it is not
intended to be used to determine the whole-body
vibration exposure to the operator using the Machine
Note: It is recognized that the appropriate design of the
operator's seat is the most effective construction
measure to minimize the whole - body vibration
emission of a particular machine family.
This machine is equipped with an operator's seat which
meets the criteria of EN ISO 7096 representing vertical
vibration under severe operating conditions.
The seat is this machine has been tested with input
spectral class EMI and has a seat transmissibility
factor SEAT > 1.1.
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Section 000-0000
General Information - TR100 Mining Truck
SM 1618 Rev6 03 -19
4
THIS PAGE IS INTENTIONALLY BLANK
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Section 000-0010
SM 2172 10-02 5
Welding
WARNINGS
Before any welding is done on a machine
equipped with any electronic systems,
disconnect the following (if applicable) in
this order: Battery earth cable, battery supply
cable, alternator earth cables, alternator supply
cables and electrical connections at the engine
ECM, transmission ECU, body control lever,
hydraulics ECU and cab bulkhead to avoid
damage to electrical components. Turn off
battery master switch to isolate the batteries
before disconnecting any components.
After welding connect all of the above in the
reverse order.
Before any welding is done ensure all paint
has been removed from the area to be welded.
Failure to do so may result in hazardous fumes
being given off from the paint.
Note: Always fasten the welding machines ground
cable to the piece/frame being welded if possible.
Electric arc welding is recommended for all welded
frame repairs. 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 out of alignment, 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 Customer
Support Department can be consulted regarding the
feasibility of welding repairs.
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.
Note: The current from the welding rod always follows
the path of least resistance. If, for example, the ground
clamp is attached to the rear frame when welding is
performed on the front frame, the current must pass
a frame connection to return to the welding machine.
Since the pivot coupling offers the least resistance but
not a sound electrical connection, small electric arcs
may be set up across the moving parts which may
cause welding blotches on their wearing surfaces and
increase the wear rate of these components.
General Welding Procedure
The following general procedure should be used for
the repair of defects outwith the vicinity of alloy steel
castings.
1. Completely ARC-AIR gouge or grind out the crack
until sound metal is reached. If ARC-AIR method is
employed, pre-heat area to 100° C (212° F), measure
3 - 4" either side of repair prior to gouging. On
completion of gouging grind to remove thin carbon
layer.
2. Apply dye-penetrant check to ensure crack has
been completely removed.
GENERAL INFORMATION - Welding Procedure

General Information - Welding Procedure
Section 000-0010
SM 2172 10-02
6
3. Pre-heat area to 100° C (212° F), measured 3 - 4"
either side of repair. Avoid local overheating.
4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from
moisture pick-ups at all times.
5. Allow repair weld to cool slowly.
6. Grind and blend repair to original contour. Paint
heat damaged areas.
The following general procedure should be used for
the repair of defects in alloy steel castings and in the
welds joining steel castings.
1. Completely ARC-AIR gouge or grind out the crack
until sound metal is reached. If ARC-AIR method is
employed, pre-heat area to 200° C (392° F), measure
3 - 4" either side of repair prior to gouging. On
completion of gouging grind to remove thin carbon
layer.
2. Apply dye-penetrant check to ensure crack has
been completely removed.
3. Pre-heat area to 200° C (392° F), measured 3 - 4"
either side of repair. Avoid local overheating.
4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected
from moisture pick-ups at all times.
5. On completion of welding, post-heat repair area to
400° C (752° F), measure 3 - 4" either side of repair.
6. If welding has to be interrupted for any reason, e.g.
overnight, post-heat immediately as in Step 5.
* * * *

Section 100-0010
7
SM 1898 Rev1 03-19
MOT04727
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 through 6 (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 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.
Fig. 1 - Exploded View of Chassis and Guards
1 - Frame Assembly
2 - Bushing
3 - Engine Guard
4 - Transmission Guard
5 - Nut
6 - Hardened Washer
7 - Bolt
8 - Hardened Washer
9 - Bolt
10 - Nut
11 - Spring Disc
12 - Hardened Washer
13 - Hardened Spacer
1
2
4
9
5
13
12
11
8
7
5
13
12
11
8
7
6
10
3
MOT04727

Chassis - Chassis, Hood and Fenders
Section 100-00100
8SM 1898 Rev1 03-19
MAINTENANCE
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
7
4
1
18 7
75
17 RH
7
6
7
5
16 LH
6
7
7
18
15
12
7
10
47
13
7
7
14
8
10
13 7714
9
7
12
11
74
713
7
4
KEYS
9268892
LOCK
9268885 2
3
MOT00003
MOT00003
1 - Hood Assembly
2 - Door Assembly
3 - Latch Spring
4 - Bolt
5 - Bolt
6 - Locknut
7 - Hardened Washer
8 - Plate Assembly - Base
9 - Baffle Assembly
14 - Nut
15 - Beading
16 - Bracket - Hood LH
17 - Bracket - Hood RH
18 - Bolt
10 - Bracket
11 - Plate Assembly - Top
12 - Bolt
13 - Bolt
Fig. 2 - Exploded View of Hood and Mounting

Section 100-0010
9
SM 1898 Rev1 03-19
Chassis - Chassis, Hood and Fenders
1 - Fender Extension
2 - Fender Assembly - LH
3 - Fender Assembly - RH
4 - Platform Assembly - RH
5 - Front Crossmember
6 - Rear Crossmember
7 - Cover Plate Assembly
8 - Mudguard
9 - Mudguard
10 - Handrail - LH
11 - Handrail - RH
12 - Plate Assembly
13 - Bolt
14 - Mirror
15 - Block
16 - Spacer
17 - Washer
18 - Kickstrip
19 - Locknut
20 - Bolt
21 - Bolt
22 - Bolt
23 - Bolt
24 - Bolt
25 - Kickstrip
26 - Bolt
27 - Bolt
28 - Bolt
29 - Bolt
30 - Bolt
31 - Bolt
32 - Lockwasher
33 - Locknut
34 - Nut
35 - Plate Cover
36 - Bolt
37 - Hardened Washer
38 - Hardened Washer
39 - Hardened Washer
40 - Hardened Washer
41 - Plug
42 - Mirror - Wide Angle
43 - Nut
44 - Bracket
45 - Bracket
46 - Bolt
47 - Hardened Washer
48 - Locknut
49 - Mirror Attachment Ass.
50 - Plate
51 - Mirror Arm Assembly
52 - Mirror Mounting Bar
53 - Rod Assembly
54 - Bracket Assembly
55 - Bolt
56 - Lockwasher
57 - Washer
58 - Nut
59 - Lochwasher
60 - Washer
61 - Bolt
62 - U-Bolt Assembly
63 - Nut
64 - Extension Bar
65 - Plate
66 - Cover Plate
67 - Screw
68 - Fender Extension
69 - Spacer
70 - Handrail Assembly - Rear
71 - Capscrew
72 - Nut
73 - Washer
74 - Mirror
Fig. 3 - Exploded View of Fenders and Mounting
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.
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
polyurethane enamel.
To keep rust and corrosion to a minimum, periodic
painting of abrasions and other exposed metal areas
on the frame is highly recommended.
SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS for part numbers of general service
tools required. These tools are available from your
dealer.
57
56
55
51
54
52, 63
2140
234043
42
68
11
22
40
4
39
33
26
7
39
26
40
27
41
3
'A'
'A'
41
2
'B'
'B'
33
34
38
29
38
15
16
23
39
SECT 'A-A'
31
39
12
33
39
23
33
39
23 21
40 33
21
40 33
33 40 24
1
5
40
23
40 21
43
25
10
21
40
8
33 40 28
40
4
6
27 37
30
SECT 'B-B'
6
46
47
47
48
46
47
47
48
44 19
17
45
17
13
SECS.
260-0030 & 260-0040
66
70
9
35
36
32
69
71
73
72
18
67
62
64
14
74
53
65
50
62
62
62
61
6059
58
49
MOT00002

Chassis - Chassis, Hood and Fenders
Section 100-00100
10 SM 1898 Rev1 03-19
MOT06285
1 - Bolt
2 - Bolt
3 - Bolt
4 - Bolt
5 - Bolt
6 - Nut
7 - Locknut
8 - Hardened Washer
9 - Bracing Bracket - LH
10 - Bracing Bracket - RH
11 - Hardened Washer
12 - Hardened Washer
13 - Bolt
14 - Locknut
15 - Washer
16 - Step Assembly - LH
17 - Step
18 - Capscrew
19 - Step Assembly - RH
20 - Step
21 - Capscrew
22 - Hoodside Assembly - LH
23 - Hoodside Assembly - RH
24 - Panel Assembly - LH
25 - Panel Assembly - RH
26 - Bumper Extension - LH
27 - Bumper Extension - RH
28 - Treadplate
29 - Side Washer Clamp
30 - Step Bracket - RH
31 - Step Bracket - LH
32 - Bolt
33 - Nut
34 - Hardened Washer
35 - Plate
36 - Plate
37 - U-Bolt
38 - Step Support Strip
39 - Bolt
40 - Washer
41 - Nut
42 - Spacer
Fig. 4 - Exploded View of Ladders and Handrails
34
1
A
A
A
20
21
19
111 7
23
27
68
5
1,11
12,7
30
28
38
28 38
31
29
15
13
15
15
13
14
35 37
32
34
33
37
34
32
10
1112 7
1
12
7
24
22 12 1
7
11
11
1
12 2
34
37
34,32
9
37
36
33
34
32
111 7
17
18
16
1
11
7
712 3
1
12
7
26
25
1
12
7
4
39
40
41
42
42
39
40 41

Section 100-0010
11
SM 1898 Rev1 03-19
Chassis - Chassis, Hood and Fenders
MOT05155
Fig. 5 - Exploded View of Radiator Guard and Mounting
1 - Radiator Guard
2 - Grille
3 - Bolt
4 - Washer
5 - Button Plug
6 - Bolt
7 - Hardened Washer
8 - Washer
9 - Plate
10 - Clamp Plate
11 - Lockwasher
12 - Bolt
13 - Angle Bracket
14 - Bolt
4
1
6
7
7
8
6
1
5
2
4
3
11
1
3
9
10
11
12
MIRROR MOUNTING
MOT05155

Chassis - Chassis, Hood and Fenders
Section 100-00100
12 SM 1898 Rev1 03-19
P12241
1 - Mudguard
2 - Clamp Plate
3 - Backing Plate
4 - Bolt
5 - Bolt
6 - Lockwasher
7 - Nut
8 - Hardened Washer
9 - Mudflap - LH
10 - Bracket - LH
11 - Angle Support Assembly
12 - Bracket Assembly - Front RH
13 - Mudflap - RH Front Lower
14 - Mudflap - RH Rear
15 - Clamp Plate
16 - Clamp Plate
17 - Mudflap - LH
18 - Mudflap - RH Front Upper
19 - Mudflap - LH
20 - Angled Mounting
21 - Bolt
22 - Clamp Plate
23 - Clamp Plate
24 - Backing Plate
25 - Bolt
26 - Bracket Assembly
27 - Plate
28 - Clamp Plate
29 - Backing Plate
Fig. 6 - Mudguards
* * * *
5
6
7
517 28
4
56
6
7
10
11
9
3
1
5
6
6
5
6
5
6
26
14
29
29
7
5
7
4
6
8
12
13
22
6
5
76
8
25
18
7
7
7
6
8
11
6
5
16
7
6
5
27
19
24
1
3
P12241
5
23
6
7
20
7
6
5
21
6
2

13
SM 1655 Rev 2 06-14
Section 110-0030
ENGINE - Engine and Mounting
DESCRIPTION
Numbers in parentheses refer to Fig. 1.
For engine make, model and specification, refer to
Section 000-0000, GENERAL INFORMATION. For
detailed engine servicing and repair data refer to the
engine manufacturers service manual.
There are four full flow lube oil filters (30), two lube oil
bypass filters (27) two fuel filters (28) and four coolant
filters (29) installed on engine (1). Mounted at the front
left hand side of the engine is the fuel pump and at
the front right hand side of the engine is the alternator.
There are two starter motors mounted at the rear right
hand side of the engine, one of which is a prelube
starter motor.
43 - Clip
44 - Dipstick
45 - Bolt
46 - Lockwasher
47 - Spacer
48 - Fan
49 - Bolt
50 - Adaptor
51 - Bolt
52 - Hardened Washer
53 - Drive Coupling
54 - Bolt
55 - Flange Coupling
1 - Engine
2 - Reducer Bush
3 - Drain Cock
4 - Bolt
5 - Support
6 - Crossmember
7 - Bolt
8 - Hardened Washer
9 - Shock Mount
10 - Bolt
11 - Hardened Washer
12 - Hardened Washer
13 - Locknut
14 - Bolt
15 - Rear Mount
16 - Clamp
17 - Latch
18 - Latch
19 - Bolt
20 - Locknut
21 - Lock
22 - Key
23 - Bolt
24 - Tube Assembly
25 - Tube Assembly
26 - Reducer Bushing
27 - Lube Oil Bypass Filter
28 - Fuel Filter
29 - Coolant Filter
30 - Lube Oil Filter
31 - Hand Hole Cover
32 - Plate Assembly
33 - Bolt
34 - Hardened Washer
35 - Clamp
36 - Dipstick Hose
37 - Filler Hose
38 - T-bar Clamp
39 - Twisted Bracket
40 - Bolt
41 - Nut
42 - Clip
Fig. 1 - Exploded View of Engine Mounting

SM 1655 Rev 2 06-14
Engine - Engine and Mounting
Section 110-0030
14
6. If the vehicle is equipped with an air conditioning
system, evacuate refrigerant from the system and
disconnect lines at the compressor. Refer to Section
260-0130, AIR CONDITIONING.
7. Place a suitable container under the engine
drain port, remove drain plug and drain the oil. After
draining, reinstall drain plug in the engine sump and
tighten securely.
8. With suitable containers in position, open drain
cocks and drain coolant from the radiator assembly
and engine (1) assembly. Close all drain cocks after
draining.
9. Identify all cooling lines for ease of installation and
with suitable containers in position, disconnect all
cooling lines from engine (1).
10. Using suitable lifting equipment, carefully remove
the radiator, shroud and screen assemblies from
the vehicle. Refer to Section 210-0040, RADIATOR,
HEADER TANK AND MOUNTING.
11. Disconnect and remove air cleaner intake pipes
from the engine turbochargers and air cleaner plenum
chamber. Refer to Section 110-0050, AIR CLEANER.
12. Disconnect and remove exhaust tubes from the
engine turbochargers.
13. Disconnect throttle control linkage from engine (1).
14. Identify heater lines for ease of installation and,
with a suitable container in position, disconnect heater
lines from engine (1).
15. Close fuel shutoff valve at filter head, identify
fuel lines for ease of installation and, with a suitable
container in position, disconnect fuel lines from
engine (1).
16. Slacken T-bar clamp (38) and clamp (35) securing
filler hose (37) and dipstick hose (36) respectively to
hand hole cover (31) on left hand side of engine (1).
Remove hose assemblies (36 & 37) from hand hole
cover (31) and cover hose ends and fittings to prevent
entry of dirt.
17. Remove bolt (40), nut (41) and clips (42 & 43)
from twisted bracket (39).Tie hose assemblies (36 & 37)
away from engine (1) to prevent fouling during engine
removal.
REMOVAL
Numbers in parentheses refer to Fig. 1.
WARNINGS
To prevent personal injury and property
damage, ensure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
High electrical current. Disconnect
battery equalizer and battery cables at the
batteries before removing engine attachments.
High electrical current can cause sparks and
personal injury from burns.
Note: Tag and identify all lines, hoses, cables and
linkages disconnected to remove the engine.
1. Position the vehicle in a level work area, ensure
the body is fully lowered, apply the parking brake and
switch off the engine.
2. Turn steering wheel several times to relieve
pressure in the steering circuit. Block all road wheels.
3. Disconnect electrical connections as follows:
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.
4. Remove mounting hardware securing the hood and
hoodsides on the vehicle. Remove hood and hood
side assemblies from the vehicle. Refer to Section
100-0010, CHASSIS, HOOD AND FENDERS.
5. Disconnect electrical connections from the radiator
guard and remove mounting hardware securing
the radiator guard on the vehicle. Remove radiator
guard from the vehicle. Refer to Section 100-0010,
CHASSIS, HOOD AND FENDERS.
WARNING
Harmful gas. Before disconnecting any air
conditioner lines refer to Section 260-0130, AIR
CONDITIONING. Refrigerant will rapidly freeze
all objects with which it comes into contact,
and it can cause serious damage to the skin
and eyes.