140
P R O D U C T T R A I N I N G TA40 (A820) SYSTEMS FAMILIARISATION

Dumper Terex Super

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Page 1: Dumper Terex Super

PRODUCT

TRAINING

TA40 (A820)

SYSTEMS FAMILIARISATION

Page 2: Dumper Terex Super

Book Issue; 090903

Product Training

Issued by;Customer Support Department

Terex Equipment LimitedNewhouse Industrial Estate

Motherwell, ML1 5RYScotland

Tel; +44 (0) 1698 732121Fax; +44 (0) 1698 503210

www.terex.co.uk

Re-Order Part Number15275747

Page 3: Dumper Terex Super

For further information on the subject mater detailed within this training book, pleaserefer to Terex Equipment Limited Service Manuals, Operators Handbooks and ProductParts Books.

Alternatively, please contact;

Customer Support DepartmentTerex Equipment Limited

Newhouse Industrial EstateMotherwell, ML1 5RY

Tel; +44 (0) 1698 732121Fax; +44 (0) 1698 503210

The illustrations, technical information, data and descriptive text in this manual, to thebest of our knowledge, were correct at the time of print. The right to changespecifications, equipment and maintenance instructions at any time without notice, isreserved as part of the Terex Equipment Limited policy of continuous development andimprovement 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 priorpermission of Customer Support Department - Terex Equipment Limited.

Please refer to TEREX Specification Sheets or consult Factory Representatives to ensurethat information is current.

Page 4: Dumper Terex Super

22

Pro

duc

t Tra

inin

g

TA4

0(A

820

) ST

EER

ING

SY

STEM

TA4

0(A

820

) ST

EER

ING

SY

STEM

Page 5: Dumper Terex Super

33

Pro

duc

t Tra

inin

g

STEE

RIN

G S

CH

EMA

TIC

STEE

RIN

G S

CH

EMA

TIC

Page 6: Dumper Terex Super

44

Pro

duc

t Tra

inin

g

HY

DR

AU

LIC

TA

NK

HY

DR

AU

LIC

TA

NK

Page 7: Dumper Terex Super

77

Pro

duc

t Tra

inin

g

HY

DR

AU

LIC

TA

NK

FIL

TER

HY

DR

AU

LIC

TA

NK

FIL

TER

FILTER

STRAINER

SER

VIC

E;1

00

0 H

RS

FILT

ER C

HA

NG

E

20

00

HR

SD

RA

IN/R

EFI

LL

(CLE

AN

STR

AIN

ER)

FILT

ER B

Y-P

AS

S 3

.5 B

ar (

50

PS

I) M

AX

Page 8: Dumper Terex Super

66

Pro

duc

t Tra

inin

g

MA

IN P

UM

P (

STE

ERIN

G/B

OD

Y)

MA

IN P

UM

P (

STE

ERIN

G/B

OD

Y)

Page 9: Dumper Terex Super

77

Pro

duc

t Tra

inin

g

FLO

W A

MP

LIFI

ER V

ALV

EFL

OW

AM

PLI

FIER

VA

LVE

Page 10: Dumper Terex Super

88

Pro

duc

t Tra

inin

g

FLO

W A

MP

LIFI

ER V

ALV

E -

PO

RTI

NG

FLO

W A

MP

LIFI

ER V

ALV

E -

PO

RTI

NG

ACo

unte

r Pr

essu

re &

Ant

i-cav

itatio

n Va

lve

- 5

Bar

(73

PSI)

BSy

stem

Rel

ief Va

lve

- 20

6 Ba

r (3

000

PSI)

CPr

iorit

y Sp

ool

DSh

ock

Valv

e -

241

Bar

(350

0 PS

I)E

Ampl

ifier

Spo

olF

Dire

ctio

nal S

pool

LSLo

ad S

ensi

ng P

ress

ure

EFEx

cess

Flo

wH

PPu

mp

Supp

lyPP

Pilo

t Pr

essu

reP

Pum

p Su

pply

to

Stee

ring

Valv

eH

TTa

nk R

etur

nT

Stee

ring

Valv

e Ta

nk R

etur

nR

Stee

ring

Valv

e Ri

ght

Turn

(Fr

om S

teer

ing

Valv

e)L

Stee

ring

Valv

e Le

ft T

urn

(Fro

m S

teer

ing

Valv

e)CR

Rig

ht T

urn

Cylin

der

Oil

Supp

lyCL

Left

Tur

n Cy

linde

r O

il Su

pply

Page 11: Dumper Terex Super

99

Pro

duc

t Tra

inin

g

FLO

W A

MP

LIFI

ER V

ALV

EFL

OW

AM

PLI

FIER

VA

LVE

HTP T R CL

CRL

APP

B

HP EF LS

CD

EF

Page 12: Dumper Terex Super

1010

Pro

duc

t Tra

inin

g

STEE

RIN

G S

YST

EM R

ELIE

F V

ALV

EST

EER

ING

SY

STEM

REL

IEF

VA

LVE

Rel

ief Pr

essu

re S

ettin

g20

6 Ba

r (3

000

PSI)

REL

IEF

VALV

E

ANTI

-CA

VIATI

ON

Page 13: Dumper Terex Super

1111

Pro

duc

t Tra

inin

g

STEE

RIN

G S

YST

EM C

HEC

K P

OIN

TSST

EER

ING

SY

STEM

CH

ECK

PO

INTS

STEE

RIN

G R

ELIE

FPR

ESSU

RE

CHEC

K PO

INT

LUBR

ICAT

E IN

BOARD

STEE

RIN

G C

YLIN

DER

PIN

SEV

ERY

50 H

OU

RS

Page 14: Dumper Terex Super

1212

Pro

duc

t Tra

inin

g

FLO

W A

MP

LIFI

ER S

PO

OLS

FLO

W A

MP

LIFI

ER S

PO

OLS

SHO

CK L

OAD

VALV

E x

2*P

RIO

RITY

SPO

OL

*DIR

ECTI

ON

ALCO

NTR

OL

SPO

OL

*AM

PLIF

IER

SPO

OL

(*N

OT

SO

LD S

EPA

RA

TELY

)

Page 15: Dumper Terex Super

1313

Pro

duc

t Tra

inin

g

OR

BIT

RO

L ST

EER

ING

VA

LVE

OR

BIT

RO

L ST

EER

ING

VA

LVE

LS

L

R

P

T

PIN

LET

FRO

M F

LOW

AM

P. V

ALV

E

TTA

NK

RET

UR

N

LS

UP

PLY

TO

LH

STE

ER C

IRC

UIT

(VIA

FLO

W A

MP

VALV

E)

RS

UP

PLY

TO

RH

STE

ER

CIR

CU

IT(V

IA F

LOW

AM

P VA

LVE)

LSLO

AD

SE

NS

E TO

FLO

W A

MP

.

Page 16: Dumper Terex Super

1414

Pro

duc

t Tra

inin

g

FLO

W A

MP

. - N

EUTR

AL

STE

ERFL

OW

AM

P. -

NEU

TRA

L S

TEER

Page 17: Dumper Terex Super

1515

Pro

duc

t Tra

inin

g

FLO

W A

MP

. - R

IGH

T H

AN

D T

UR

NFL

OW

AM

P. -

RIG

HT

HA

ND

TU

RN

Page 18: Dumper Terex Super

1616

Pro

duc

t Tra

inin

g

FLO

W A

MP

. - L

EFT

HA

ND

TU

RN

FLO

W A

MP

. - L

EFT

HA

ND

TU

RN

Page 19: Dumper Terex Super

1717

Pro

duc

t Tra

inin

g

EMER

GEN

CY

STE

ERIN

G V

ALV

EEM

ERG

ENC

Y S

TEER

ING

VA

LVE

Page 20: Dumper Terex Super

1818

Pro

duc

t Tra

inin

g

CH

ECK

VA

LVE

(MA

NIF

OLD

)C

HEC

K V

ALV

E (M

AN

IFO

LD)

EMER

GEN

CYST

EER

VAL

VE

CHEC

KVA

LVE

MAN

IFO

LD

Page 21: Dumper Terex Super

1919

Pro

duc

t Tra

inin

g

EMER

GEN

CY

STE

ERIN

G P

UM

PEM

ERG

ENC

Y S

TEER

ING

PU

MP

Page 22: Dumper Terex Super

2020

Pro

duc

t Tra

inin

g

EMER

GEN

CY

STE

ERIN

G S

CH

EMA

TIC

EMER

GEN

CY

STE

ERIN

G S

CH

EMA

TIC

NO

RM

AL S

TEER

ING

MO

DE

EMER

GEN

CY S

TEER

ING

MO

DE

Page 23: Dumper Terex Super

2121

Pro

duc

t Tra

inin

g

STEE

RIN

G P

RES

SU

RE

SWIT

CH

STEE

RIN

G P

RES

SU

RE

SWIT

CH

Page 24: Dumper Terex Super

2222

Pro

duc

t Tra

inin

g

STEE

RIN

G P

RES

SU

RE

CH

AR

TST

EER

ING

PR

ESS

UR

E C

HA

RT

SYST

EM P

RES

SU

RE

206

Bar

(30

00 P

SI)

SHO

CK

LO

AD

(FLO

W A

MP

. VA

LVE)

241

Bar

(35

00 P

SI)

EMER

GEN

CY

STE

ER C

UT

IN82

Bar

(1

200

PSI

)

PU

MP

WA

RN

ING

SW

ITC

H4.

8 B

ar (

70

PSI

)

PU

MP

CA

PA

CIT

Y @

220

0 R

PM

422

L/M

IN

HY

D. T

AN

K F

ILTE

R B

Y-P

ASS

3.5

Bar

(5

0 P

SI)

Page 25: Dumper Terex Super

22

Pro

duc

t Tra

inin

g

TA4

0(A

820

) B

OD

Y C

ON

TRO

L SY

STEM

TA4

0(A

820

) B

OD

Y C

ON

TRO

L SY

STEM

Page 26: Dumper Terex Super

33

Pro

duc

t Tra

inin

g

WEL

DIN

G P

RO

CED

UR

EW

ELD

ING

PR

OC

EDU

RE

BEF

OR

E W

ELD

ING

ON

TR

UC

K;

•TU

RN

KEY

-SW

ITCH

OFF

•TU

RN

MAS

TER

SWIT

CH O

FF

DIS

CO

NN

ECT;

•BA

TTER

Y SU

PPLY

& E

ARTH

CAB

LES

•AL

TERN

ATO

R EA

RTH

& S

UPP

LY C

ABLE

S

•TR

ANSM

ISSI

ON

ECU

•EN

GIN

E EC

M

•BO

DY

CON

TRO

L JO

YSTI

CK

•AN

Y O

THER

ELE

CTRO

NIC

OPT

ION

Sie

. REA

R VI

EW T

V, L

UBE

SYS

TEM

S et

c.

Page 27: Dumper Terex Super

44

Pro

duc

t Tra

inin

g

BO

DY

LIF

T/LO

WER

SY

STEM

LA

YO

UT

BO

DY

LIF

T/LO

WER

SY

STEM

LA

YO

UT

TO T

IP C

YLIN

DER

S

CHEC

KVA

LVE

MAN

IFO

LDH

YDRAULI

CTA

NK

FLO

WAM

PLIF

IER

VALV

E

BOD

YCO

NTR

OL

VALV

E

DIA

GN

OST

ICCH

ECK

POIN

T

MAIN

GEA

RPU

MPD

IVER

TER

TUBE

Page 28: Dumper Terex Super

55

Pro

duc

t Tra

inin

g

PIL

OT

CO

NTR

OL

LIN

ES L

AY

OU

TP

ILO

T C

ON

TRO

L LI

NES

LA

YO

UT

FRO

M B

RAK

EAC

CUM

ULA

TOR

CHAR

GE

VALV

E

REL

IEF

TO T

AN

K

TO H

YDRAU

LIC

TAN

K

Page 29: Dumper Terex Super

66

Pro

duc

t Tra

inin

g

HY

DR

AU

LIC

TA

NK

HY

DR

AU

LIC

TA

NK

Page 30: Dumper Terex Super

77

Pro

duc

t Tra

inin

g

HY

DR

AU

LIC

TA

NK

FIL

TER

HY

DR

AU

LIC

TA

NK

FIL

TER

FILT

ERST

RAIN

ERSE

RV

ICE;

10

00

HR

SFI

LTER

CH

AN

GE

20

00

HR

SD

RA

IN/R

EFI

LL

(CLE

AN

STR

AIN

ER)

FILT

ER B

Y-P

AS

S 3

.5 B

ar (

50

PS

I) M

AX

Page 31: Dumper Terex Super

88

Pro

duc

t Tra

inin

g

MA

IN T

RIP

LE P

UM

P -

PIL

OT

SUP

PLY

MA

IN T

RIP

LE P

UM

P -

PIL

OT

SUP

PLY

B

C

F

B -

Bra

ke A

ctu

atio

n

F-

Fan

(Eng

ine)

C-

Cool

ing

(Bra

kes)

Page 32: Dumper Terex Super

99

Pro

duc

t Tra

inin

g

BO

DY

PIL

OT

VA

LVE

BO

DY

PIL

OT

VA

LVE

REG

ULA

TIN

GSP

RIN

G

RELI

EFSP

RIN

G

NO

N-A

DJU

STAB

LE V

ALVE

T1P1

U1

U2

P1

FR

OM

AC

C. V

ALV

E

U1

TO

BO

DY

SO

LEN

OID

S

T1 R

ETU

RN

TO

TA

NK

U2

PR

ESS

UR

E C

HEC

K P

OIN

T

Page 33: Dumper Terex Super

1010

Pro

duc

t Tra

inin

g

BO

DY

CO

NTR

OL

VA

LVE

BO

DY

CO

NTR

OL

VA

LVE

SYST

EM R

ELIE

F 1

72

BA

R (

25

00

PS

I)

REL

IEF

VA

LVE

AD

JUS

TME

NT

Page 34: Dumper Terex Super

1111

Pro

duc

t Tra

inin

g

PR

ESS

UR

E R

EDU

CIN

G S

OLE

NO

IDS

PR

ESS

UR

E R

EDU

CIN

G S

OLE

NO

IDS

SO

LEN

OID

S A

RE

INTE

RC

HA

NG

EA

BLE

SU

SC

EPTI

BLE

TO

DIR

T/G

RIT

IN

GR

ESS

Page 35: Dumper Terex Super

1212

Pro

duc

t Tra

inin

g

SOLE

NO

ID P

RES

SUR

E R

EDU

CTI

ON

SSO

LEN

OID

PR

ESSU

RE

RED

UC

TIO

NS

P1

Por

t ‘P

1’

Por

t ‘P

2’

Rai

se3

0 b

ar(4

35

PSI

)0

bar

Ho

ld0

bar

0 b

arFl

oat

0 b

ar3

0 b

ar(4

35

PSI

)Lo

wer

0 b

ar1

3.5

bar

(19

5 P

SI)

P2

CHEC

KPO

INT

‘P1/

P2’ (

X2)

Page 36: Dumper Terex Super

1313

Pro

duc

t Tra

inin

g

BO

DY

CO

NTR

OL

JOY

STI

CK

BO

DY

CO

NTR

OL

JOY

STI

CK

Joys

tick

Ou

tpu

t to

Sol

enoi

ds

Rai

se25

0ma

@ 5

bar

- 1

am

p Fu

ll

Hol

d0

amp

Low

er (

Pow

er D

own)

400m

a

Floa

t1

amp

Wir

ing

Sche

mat

ic;

Bod

y C

ontr

ol S

olen

oid

Res

ista

nce;

Y26

Body

Rai

se S

olen

oid

21.2

Ω @

20°

CY2

7Bo

dy L

ower

Sol

enoi

d

Dis

con

nec

t B

efor

e W

eldi

ng

NO

N-

AD

JUS

TAB

LE

Page 37: Dumper Terex Super

1414

Pro

duc

t Tra

inin

g

BO

DY

CO

NTR

OL

REL

AY

SB

OD

Y C

ON

TRO

L R

ELA

YS

K3

7 -

12

VO

LTS

K3

6 -

24

VO

LTS

K3

5 -

24

VO

LTS

Page 38: Dumper Terex Super

1515

Pro

duc

t Tra

inin

g

FUSE

/REL

AY

BO

XFU

SE/R

ELA

Y B

OX

Page 39: Dumper Terex Super

1616

Pro

duc

t Tra

inin

g

BO

DY

PR

OX

IMIT

Y S

WIT

CH

BO

DY

PR

OX

IMIT

Y S

WIT

CH

SC

HEM

ATI

C S

22

MAX

IMU

M O

PERAT

ING

DIS

TAN

CE 1

5mm

Page 40: Dumper Terex Super

1717

Pro

duc

t Tra

inin

g

F33

Body

Hyd

raul

ic S

yste

m (

5A)

F34

Alte

rnat

or D

rive

Fuse

(3A

)

K37

Body

Sys

tem

Rel

ay

S22

Body

Up

(Pro

xim

ity)

Switc

h

K35

Body

Rai

se R

elay

H2

Body

Rai

se W

arni

ng L

amp

K36

Body

Flo

at R

elay

Y26

Body

Rai

se S

olen

oid

Y27

Body

Low

er S

olen

oid

BO

DY

CO

NTR

OL

- EL

ECTR

ICA

LB

OD

Y C

ON

TRO

L -

ELEC

TRIC

AL

K37

F33 K36

Y26

Y27

S22

H2

K35

TRANSMISSIONECU X7 PIN 11

Page 41: Dumper Terex Super

1818

Pro

duc

t Tra

inin

g

MA

IN P

UM

P (

STE

ERIN

G/B

OD

Y)

MA

IN P

UM

P (

STE

ERIN

G/B

OD

Y)

Page 42: Dumper Terex Super

1919

Pro

duc

t Tra

inin

g

FLO

W A

MP

LIFI

ER V

ALV

EFL

OW

AM

PLI

FIER

VA

LVE

Page 43: Dumper Terex Super

2020

Pro

duc

t Tra

inin

g

FLO

W A

MP

LIFI

ER V

ALV

E -

PO

RTI

NG

FLO

W A

MP

LIFI

ER V

ALV

E -

PO

RTI

NG

ACo

unte

r Pr

essu

re &

Ant

i-cav

itatio

n Va

lve

- 5

Bar

(73

PSI)

BSy

stem

Rel

ief Va

lve

- 20

6 Ba

r (3

000

PSI)

CPr

iorit

y Sp

ool

DSh

ock

Valv

e -

241

Bar

(350

0 PS

I)E

Ampl

ifier

Spo

olF

Dire

ctio

nal S

pool

LSLo

ad S

ensi

ng P

ress

ure

EFEx

cess

Flo

wH

PPu

mp

Supp

lyPP

Pilo

t Pr

essu

reP

Pum

p Su

pply

to

Stee

ring

Valv

eH

TTa

nk R

etur

nT

Stee

ring

Valv

e Ta

nk R

etur

nR

Stee

ring

Valv

e Ri

ght

Turn

(Fr

om S

teer

ing

Valv

e)L

Stee

ring

Valv

e Le

ft T

urn

(Fro

m S

teer

ing

Valv

e)CR

Rig

ht T

urn

Cylin

der

Oil

Supp

lyCL

Left

Tur

n Cy

linde

r O

il Su

pply

Page 44: Dumper Terex Super

2121

Pro

duc

t Tra

inin

g

FLO

W A

MP

LIFI

ER V

ALV

EFL

OW

AM

PLI

FIER

VA

LVE

HTP T R CL

CRL

APP

B

HP EF LS

CD

EF

Page 45: Dumper Terex Super

2222

Pro

duc

t Tra

inin

g

FLO

W A

MP

LIFI

ER -

PR

IOR

ITY

SP

OO

LFL

OW

AM

PLI

FIER

- P

RIO

RIT

Y S

PO

OL

SHO

CK L

OAD

VALV

E x

2*P

RIO

RIT

YSP

OO

L

*DIR

ECTI

ON

ALCO

NTR

OL

SPO

OL

*AM

PLIF

IER

SPO

OL

(*N

OT

SO

LD S

EPA

RA

TELY

)

Page 46: Dumper Terex Super

2323

Pro

duc

t Tra

inin

g

FLO

W A

MP

. VA

LVE

- SC

HEM

ATI

CFL

OW

AM

P. V

ALV

E -

SCH

EMA

TIC

MAI

N P

UM

P PR

ESSU

REEN

TER

S TH

E PR

IORI

TYVA

LVE

AND

EXI

TS ‘E

F’PO

RT T

O T

HE

BOD

YCO

NTR

OL

VALV

E

Page 47: Dumper Terex Super

2424

Pro

duc

t Tra

inin

g

DIV

ERTE

R T

UB

ED

IVER

TER

TU

BE

Page 48: Dumper Terex Super

2525

Pro

duc

t Tra

inin

g

HY

DR

AU

LIC

OIL

CO

OLE

RH

YD

RA

ULI

C O

IL C

OO

LER

Page 49: Dumper Terex Super

2626

Pro

duc

t Tra

inin

g

Syst

em P

ress

ure

172

bar

(25

00 p

si)

Pilo

t S

uppl

y V

alve

30 b

ar (

435

psi

)

Pilo

t S

uppl

y V

alve

Rel

ief

45 b

ar (

652

psi

)

Hyd

. Tan

k Fi

lter

By-

Pas

s3.

5 b

ar (

50

psi

)

Mai

n P

um

p C

apac

ity

@ 2

200

RP

M42

2 l/

min

TA4

0 B

OD

Y P

RES

SUR

E C

HA

RT

TA4

0 B

OD

Y P

RES

SUR

E C

HA

RT

PIL

OT

PR

ESS

UR

E A

T B

OD

Y C

ON

TRO

L V

ALV

E SP

OO

L

Por

t P

1P

ort

‘P2’

Rai

se30

bar

(435

PSI

)0

bar

Hol

d0

bar

0 ba

rFl

oat

0 ba

r30

bar

(435

PSI

)Lo

wer

0 ba

r13

.5 b

ar(1

95 P

SI)

Page 50: Dumper Terex Super

2727

Pro

duc

t Tra

inin

g

1 -

Hyd

raul

ic T

ank

2 -

Body

Con

trol

Val

ve

3 -

Body

Tip

Cyl

inde

rs

4 -

Hyd

raul

ic C

oole

r

5 -

Body

Pilo

t Va

lve

SCH

EMA

TIC

- R

AIS

E P

OSI

TIO

NSC

HEM

ATI

C -

RA

ISE

PO

SITI

ON

Page 51: Dumper Terex Super

2828

Pro

duc

t Tra

inin

g

1 -

Hyd

raul

ic T

ank

2 -

Body

Con

trol

Val

ve

3 -

Body

Tip

Cyl

inde

rs

4 -

Hyd

raul

ic C

oole

r

5 -

Body

Pilo

t Va

lve

SCH

EMA

TIC

- L

OW

ER P

OSI

TIO

NSC

HEM

ATI

C -

LO

WER

PO

SITI

ON

Page 52: Dumper Terex Super

2929

Pro

duc

t Tra

inin

g

SCH

EMA

TIC

- H

OLD

PO

SITI

ON

SCH

EMA

TIC

- H

OLD

PO

SITI

ON

1 -

Hyd

raul

ic T

ank

2 -

Body

Con

trol

Val

ve

3 -

Body

Tip

Cyl

inde

rs

4 -

Hyd

raul

ic C

oole

r

5 -

Body

Pilo

t Va

lve

Page 53: Dumper Terex Super

3030

Pro

duc

t Tra

inin

g

1 -

Hyd

raul

ic T

ank

2 -

Body

Con

trol

Val

ve

3 -

Body

Tip

Cyl

inde

rs

4 -

Hyd

raul

ic C

oole

r

5 -

Pilo

t Su

pply

Val

ve

SCH

EMA

TIC

- F

LOA

T P

OS

ITIO

NSC

HEM

ATI

C -

FLO

AT

PO

SIT

ION

Page 54: Dumper Terex Super

ADT BODY SYSTEM TROUBLESHOOT

BODY SYSTEM TROUBLESHOOTING Product Training

1BODY WILL NOT RAISE OR RAISE AT CORRECT

SPEED

2BODY WILL NOT

LOWER OR LOWER AT CORRECT SPEED

3BODY WILL NOT HOLD

4BODY WILL NOT POWER-DOWN

CHECK BODY PROXIMITY SWITCH

CHECK K36 RELAY

CHECK FOR CONTAMINATION

WITHIN SOLENOID

CHECK FOR ELECTRICAL FAULT TO BODY CONTROL JOY-

STICK

CHECK MAIN BODY VALVE RELIEF

PRESSURE

CHECK FOR SOLENOID FAULT

• CHECK FOR 24V FEED• CHECK K37 RELAY• CHECK ALTERNATOR

CHECK FOR FAULTY ELECTRICAL SIGNALS

TO SOLENOIDS

CHECK PILOT PRESSURE @ PILOT

SUPPLY VALVE

• CHECK ELECTRICAL SUPPLIES BETWEEN JOY-STICK AND SOLENOIDS

• REMOVE• CLEAN• CHECK FOR DAMAGE• REPLACE IF NECESSARY

• CHECK RESISTANCES

CHECK FOR CONTAMINATION

WITHIN MAIN CONTROL VALVE

CHECK TIP CYLINDERS FOR FAULTS

CHECK PUMP PRESSURE AND FLOW

RATING

CHECK PRIORITY VALVE IS OPERATING

PROPERLY

• DISASSEMBLE• CLEAN• CHECK FOR DAMAGE• CHECK SPRINGS/SPOOL

• DISASSEMBLE• CLEAN• CHECK FOR DAMAGE• CHECK SEALS ETC.

SYSTEMOK

NOTOK

• REPAIR

• REPAIR

• REPLACE EFFECTED SOLENOID

• REPAIR/REPLACE EFFECTED SOLENOID

• REPAIR CIRCUIT OR RELPACE JOYSTICK

SYSTEMOK

NOTOK

• REPAIR CIRCUIT

SYSTEMOK

NOTOK

SYSTEMOK

NOTOK

SYSTEMOK

NOTOK

SYSTEMOK

NOTOK

Page 55: Dumper Terex Super

22

Pro

du

ct

Tra

inin

g

TA4

0 B

RA

KIN

G &

CO

OLI

NG

SY

STEM

TA4

0 B

RA

KIN

G &

CO

OLI

NG

SY

STEM

EFFE

CTIV

E FR

OM

A82

0101

1

Page 56: Dumper Terex Super
Page 57: Dumper Terex Super

33

Pro

du

ct

Tra

inin

g

HY

DR

AU

LIC

FLU

ID R

ESER

VO

IRS

HY

DR

AU

LIC

FLU

ID R

ESER

VO

IRS

Cool

ing

Tank

Mai

n H

yd. T

ank

Chec

k Pr

oper

Lev

els

Brak

e &

Coo

ling

Sche

mat

icCl

ick

Her

e

Page 58: Dumper Terex Super

44

Pro

du

ct

Tra

inin

g

HY

DR

AU

LIC

FLU

ID T

YP

ESH

YD

RA

ULI

C F

LUID

TY

PES

Coo

ling

Oil

MIL

-L-2

104E

, MIL

-L-4

6152

B/C

API

CF, C

D, S

F

Act

uat

ion

Oil

MIL

-PRF

-210

4G

Allis

on C

4 Ty

pe (

10W

)

Page 59: Dumper Terex Super

55

Pro

du

ct

Tra

inin

g

HY

D. F

LUID

SER

VIC

E IN

TER

VA

LSH

YD

. FLU

ID S

ERV

ICE

INTE

RV

ALS

Coo

ling

Oil

1st

100

Hrs

Clea

n Fi

lters

1000

Hrs

Dra

in/R

e-Fi

ll, C

hang

eFi

lter

and

Brea

ther

Act

uat

ion

Oil

1000

Hrs

Clea

n Fi

lter

Hou

sing

and

Repl

ace

Elem

ent

2000

Hrs

Dra

in O

il/Re-

Fill

Page 60: Dumper Terex Super

66

Pro

du

ct

Tra

inin

g

MA

IN T

RIP

LE P

UM

PM

AIN

TR

IPLE

PU

MP

B

C

F

B -

Brak

e Ac

tuat

ion

F-

Fan

(Eng

ine)

C-

Cool

ing

(Bra

kes)

Page 61: Dumper Terex Super

77

Pro

du

ct

Tra

inin

g

PR

IOR

ITY

UN

LOA

DER

VA

LVE

CIR

CU

ITP

RIO

RIT

Y U

NLO

AD

ER V

ALV

E C

IRC

UIT

1

76

5

4

3

2

1 Pr

iorit

y U

nloa

der

Valv

e5

Pilo

t Co

ntro

l Val

ve2

Mai

n H

ydra

ulic

Tan

k6

Accu

mul

ator

3 H

ydra

ulic

Pum

p7

Brak

e Ac

cum

ulat

ors

(x2)

4 Br

ake

Man

ifold

Val

ve

Page 62: Dumper Terex Super

88

Pro

du

ct

Tra

inin

g

PR

IOR

ITY

UN

LOA

DER

VA

LVE

PR

IOR

ITY

UN

LOA

DER

VA

LVE

Pre

ssu

re S

etti

ng 1

70

bar

(24

65

PSI

)

Mou

nted

on

RH

S of

Hyd

raul

ic C

radl

e

Page 63: Dumper Terex Super

99

Pro

du

ct

Tra

inin

g

AC

CU

MU

LATO

R -

PR

IOR

ITY

UN

LOA

DER

AC

CU

MU

LATO

R -

PR

IOR

ITY

UN

LOA

DER

Pilo

t Co

ntro

l Val

ve

Accu

mul

ator

Pre

-Cha

rge

30 b

ar (

435

psi)

(Pre

-set

on

Del

iver

y)

Page 64: Dumper Terex Super

1010

Pro

du

ct

Tra

inin

g

BR

AK

E M

AN

IFO

LD V

ALV

EB

RA

KE

MA

NIF

OLD

VA

LVE

PRES

SURE

CH

ECK

POIN

TCO

NN

ECT

GAU

GE

HER

E

Page 65: Dumper Terex Super

1111

Pro

du

ct

Tra

inin

g

PR

OC

EDU

RE

1.En

sure

Bra

ke A

ccum

ulat

or p

ress

ure

is d

issi

pate

d.2.

Atta

ch p

ress

ure

gaug

e to

dia

gnos

tic c

heck

-poi

nt o

n Br

ake

Man

ifold

Val

ve, p

ort

‘P1’

.3.

Star

t tr

uck

and

allo

w p

ress

ures

to

incr

ease

with

eng

ine

atlo

w id

le*.

4.Ta

ke n

ote

of h

ighe

st g

auge

rea

ding

– T

his

is t

he p

ress

ure

sett

ing

of t

he P

riorit

y U

n-Lo

ader

Val

ve.

PR

IOR

ITY

UN

LOA

DER

VA

LVE

- C

HEC

KP

RIO

RIT

Y U

NLO

AD

ER V

ALV

E -

CH

ECK

ENS

UR

E A

/C &

RET

AR

DER

AR

E D

IS-E

NG

AG

ED

* W

arni

ng li

ghts

sho

uld

extin

guis

h ab

out

138

bar

(200

0 ps

i)

Page 66: Dumper Terex Super

1212

Pro

du

ct

Tra

inin

g

PR

IOR

ITY

UN

LOA

DER

VA

LVE

AD

JUS

TMEN

TP

RIO

RIT

Y U

NLO

AD

ER V

ALV

E A

DJU

STM

ENT

Sett

ing

Scre

w

Page 67: Dumper Terex Super

1313

Pro

du

ct

Tra

inin

g

PR

IOR

ITY

UN

LOA

DER

VA

LVE

AD

JUS

TMEN

TP

RIO

RIT

Y U

NLO

AD

ER V

ALV

E A

DJU

STM

ENT

Pri

orit

y U

n-L

oade

r V

alve

TO

O L

OW

If p

ress

ure

read

ing

is t

oo lo

w a

fter

fol

low

ing

step

s 1

thru

4, lo

osen

the

lock

nut

on

relie

fva

lve

and

turn

set

ting

scre

w C

W u

ntil

corr

ect

pres

sure

set

ting

is e

vide

nt. R

e-tig

hten

lock

nut.

NB

. Thi

s pr

oced

ure

mus

t be

car

ried

out

with

eng

ine

R.P.

M. a

t lo

w id

le.

NB

. Alw

ays

adju

st v

alve

pre

ssur

es o

n th

e in

crea

se.

Pri

orit

y U

n-L

oade

r V

alve

TO

O H

IGH

If p

ress

ure

read

ing

is t

oo h

igh

afte

r fo

llow

ing

step

s 1

thru

4;

(a)S

top

engi

ne a

nd d

eple

te b

rake

acc

umul

ator

s.(b

)Loo

sen

lock

nut

on

relie

f va

lve

and

turn

set

ting

scre

w C

CW 2

to

3 fu

ll tu

rns.

(c)R

e-St

art

engi

ne a

nd a

llow

pre

ssur

es t

o ris

e w

ith e

ngin

e in

the

low

idle

con

ditio

n.(d

)Not

e pr

essu

re o

n ga

uge,

adj

ust

sett

ing

scre

w C

W u

ntil

corr

ect

pres

sure

is e

vide

nt.

(e)R

e-tig

hten

lock

nut

.

Page 68: Dumper Terex Super

1414

Pro

du

ct

Tra

inin

g

TA4

0 EN

GIN

E C

OO

LIN

G C

IRC

UIT

TA4

0 EN

GIN

E C

OO

LIN

G C

IRC

UIT

Mai

nH

ydra

ulic

Tank

Low

Tem

p.U

nloa

der

Valv

e Pum

p

Prio

rity

Unl

oade

r Va

lve

Engi

neCo

olin

gFa

nCh

eck

Valv

e

Page 69: Dumper Terex Super

1515

Pro

du

ct

Tra

inin

g

LOW

TEM

P. U

NLO

AD

ER V

ALV

ELO

W T

EMP

. UN

LOA

DER

VA

LVE

Pre

ssu

re S

etti

ng 2

05

bar

(29

70

PSI

)

Mou

nted

to

LHS

of P

riorit

y U

nloa

der

Valv

e

Rem

ove

Har

ness

Page 70: Dumper Terex Super

1616

Pro

du

ct

Tra

inin

g

LOW

TEM

P. U

NLO

AD

ER V

ALV

E C

HEC

KLO

W T

EMP

. UN

LOA

DER

VA

LVE

CH

ECK

PR

OC

EDU

RE

Follo

w d

irect

ly fro

m c

heck

ing

Prio

rity

Unl

oade

r Va

lve

chec

k pr

oced

ure.

5.Re

mov

e el

ectr

ical

con

nect

ion

from

Low

Tem

pera

ture

Unl

oade

r Va

lve.

This

will

ren

der

this

val

ve d

e-en

ergi

sed.

6.In

crea

se e

ngin

e R.

P.M

. to

full

thro

ttle

.7.

Take

not

e of

hig

hest

gau

ge r

eadi

ng -

Thi

s is

the

pre

ssur

e se

ttin

g of

the

Low

Tem

pera

ture

Unl

oade

r Va

lve.

Page 71: Dumper Terex Super

1717

Pro

du

ct

Tra

inin

g

LOW

TEM

P. U

NLO

AD

ER V

ALV

ELO

W T

EMP

. UN

LOA

DER

VA

LVE

Sett

ing

Scre

w

Page 72: Dumper Terex Super

1818

Pro

du

ct

Tra

inin

g

LOW

TEM

P. U

NLO

AD

ER V

ALV

ELO

W T

EMP

. UN

LOA

DER

VA

LVE

AD

JUST

MEN

TS

Low

Tem

pera

ture

Un

-Loa

der

Val

ve T

OO

LO

W

If p

ress

ure

sett

ing

is t

oo l

ow a

fter

fol

low

ing

step

s 5

thru

7,

Loos

en l

ock

nut

on R

elie

fVa

lve

and

turn

set

ting

scre

w C

W u

ntil

corr

ect

pres

sure

is e

vide

nt. R

e-tig

hten

lock

nut

.

NB.

Thi

s pr

oced

ure

to b

e ca

rrie

d ou

t w

ith e

ngin

e at

ful

l thr

ottle

.N

B. A

lway

s ad

just

pre

ssur

e on

the

incr

ease

.

Low

Tem

pera

ture

Un

-Loa

der

Val

ve T

OO

HIG

H

If p

ress

ure

sett

ing

is t

oo h

igh

afte

r fo

llow

ing

step

s 5

thru

7;

(a)B

ring

engi

ne t

o id

le.

(b)D

epre

ss f

oot

brak

e pe

dal s

ever

al t

imes

(c)L

oose

n lo

ck n

ut o

n re

lief

valv

e an

d tu

rn s

ettin

g sc

rew

CCW

2 t

o 3

full

turn

s.(d

)Ret

urn

engi

ne t

o fu

ll th

rott

le.

(e)A

djus

t se

ttin

g sc

rew

CW

unt

il co

rrec

t pr

essu

re is

evi

dent

.(f

)Re-

tight

en lo

ck n

ut.

Page 73: Dumper Terex Super

1919

Pro

du

ct

Tra

inin

g

LOW

TEM

P. U

NLO

AD

ER V

ALV

ELO

W T

EMP

. UN

LOA

DER

VA

LVE

Sol

enoi

d C

oil D

ata

Low

Tem

p U

nloa

der

Valv

e22

wat

t26

Ω0.

9 am

ps

Page 74: Dumper Terex Super

2020

Pro

du

ct

Tra

inin

g

HY

DR

AU

LIC

FA

N M

OTO

R (

ENG

INE)

HY

DR

AU

LIC

FA

N M

OTO

R (

ENG

INE)

A

C

B

A -

Inle

t

B -

Tank

Ret

urn

C -

Case

Dra

in

In-L

ine

Chec

k Va

lve

Page 75: Dumper Terex Super

2121

Pro

du

ct

Tra

inin

g

ENG

INE

FAN

CO

NTR

OL

SIG

NA

LEN

GIN

E FA

N C

ON

TRO

L SI

GN

AL

Ope

ratio

n;W

ire# 5

63 (D

igita

l Out

put

W3)

Gro

unds

Out

Sol

enoi

d @

>96

°C

Cool

ant

Tem

p.>

110°

C O

il Te

mp.

>66

°C

Air

Inta

ke T

emp.

Chec

k;Fa

n ac

tivat

ion

can

be c

heck

ed b

yac

tivat

ing

the

A/C

or t

he T

rans

mis

sion

Reta

rder

.(Re

fer

Follo

win

g Sl

ide)

Fail

Safe

Sys

tem

24V

Coas

t Sp

eed

0VFu

ll Sp

eed

Page 76: Dumper Terex Super
Page 77: Dumper Terex Super

2323

Pro

du

ct

Tra

inin

g

BR

AK

E A

CTU

ATI

ON

PR

ESSU

RE

BR

AK

E A

CTU

ATI

ON

PR

ESSU

RE

Brak

e Ac

tuat

ion

Pres

sure

138

bar

(20

00 P

SI)

F

R

Page 78: Dumper Terex Super

2424

Pro

du

ct

Tra

inin

g

Mai

n Pr

essu

re17

0 ba

r (2

465

psi)

BR

AK

E M

AN

IFO

LD V

ALV

EB

RA

KE

MA

NIF

OLD

VA

LVE

Page 79: Dumper Terex Super

2525

Pro

du

ct

Tra

inin

g

PFr

om B

rake

Pu

mp

PY

To P

ort

‘P1’

On

Tre

adle

Val

veA

CC

1To

Rea

r B

rake

Acc

umu

lato

rP

2To

Por

t ‘P

2’ O

n T

read

le V

alve

AC

C2

To F

ron

t B

rake

Acc

umul

ator

PS1

Bla

nke

dA

To D

irec

tion

al C

ontr

ol V

alve

PS2

Bla

nke

dB

From

Par

k B

rake

PS3

Par

k B

rake

War

nin

g Sw

itch

TTa

nk R

etur

nP

1D

iagn

osti

c P

ress

ure

Ch

eck

Poi

nt

BR

AK

E M

AN

IFO

LD V

ALV

EB

RA

KE

MA

NIF

OLD

VA

LVE

Page 80: Dumper Terex Super

2626

Pro

du

ct

Tra

inin

g

T

ACC2

PS1

PS2

P

PYBA

PS3

P1

ACC1 S

olen

oid

De-

Ener

gis

ed(P

ark

Bra

ke B

utt

on I

n o

r P

ower

Los

s)S

olen

oid

En

erg

ised

(Par

k B

rake

Bu

tton

Ou

t)

BR

AK

E M

AN

IFO

LD V

ALV

EB

RA

KE

MA

NIF

OLD

VA

LVE

T

ACC2

PS1

PS2

P

PYBA

PS3

P1

ACC1

Page 81: Dumper Terex Super

2727

Pro

du

ct

Tra

inin

g

Fron

t B

rake

Pre

ssu

re S

wit

ch(1

)1

15

bar

(1

668

PSI

) Fa

llin

g1

45

bar

(2

100

PSI

) R

isin

gR

ear

Bra

ke P

ress

ure

Sw

itch

(2)

11

5 b

ar (

16

68 P

SI)

Falli

ng

14

5 b

ar (

21

00 P

SI)

Ris

ing

Par

k B

rake

Pre

ssu

re S

wit

ch(3

)4

.9 b

ar (

71

PS

I) F

allin

g

WA

RN

ING

PR

ESSU

RE

SWIT

CH

ESW

AR

NIN

G P

RES

SUR

E SW

ITC

HES

1

2

3

Page 82: Dumper Terex Super

2828

Pro

du

ct

Tra

inin

g

LOW

PR

ESSU

RE

IND

ICA

TOR

LIG

HTS

LOW

PR

ESSU

RE

IND

ICA

TOR

LIG

HTS

FRO

NT

BRAK

ERE

AR B

RAK

E

PARK

BR

AKE

Page 83: Dumper Terex Super

2929

Pro

du

ct

Tra

inin

g

Tere

x Sc

hem

atic

ID

S7

PA

RK

/EM

ERG

ENC

Y C

ON

TRO

LP

AR

K/E

MER

GEN

CY

CO

NTR

OL

Page 84: Dumper Terex Super

3030

Pro

du

ct

Tra

inin

g

Pre-

Char

ge P

ress

ure

55 b

ar (

800

psi)

BR

AK

E A

CC

UM

ULA

TOR

SB

RA

KE

AC

CU

MU

LATO

RS

FR

Page 85: Dumper Terex Super

3131

Pro

du

ct

Tra

inin

g

aA

P

Bb

T

aTr

ansm

issi

on P

ilot

Pres

sure

bCa

se D

rain

APl

ugge

dB

To ‘P

x’ P

ort

On

Trea

dle

PSu

pply

Lin

e Fr

om B

rake

Man

ifold

TTa

nk R

etur

n

DIR

ECTI

ON

AL

CO

NTR

OL

VA

LVE

DIR

ECTI

ON

AL

CO

NTR

OL

VA

LVE

Page 86: Dumper Terex Super

3232

Pro

du

ct

Tra

inin

g

a -

Tran

smis

sion

Pilo

t Pr

essu

rea

- Tr

ansm

issi

onPi

lot

Pres

sure

P -

Supp

ly P

ress

.Fr

om B

rake

Man

ifold

P -

Supp

ly P

ress

.Fr

om B

rake

Man

ifold

TT

AA

To ‘P

x’ O

nTr

eadl

e

To ‘P

x’ O

nTr

eadl

e

Engi

ne O

ff (

No

Pilo

t Pr

ess.

)En

gine

On

DIR

ECTI

ON

AL

CO

NTR

OL

VA

LVE

DIR

ECTI

ON

AL

CO

NTR

OL

VA

LVE

Page 87: Dumper Terex Super

3333

Pro

du

ct

Tra

inin

g

BR

AK

E P

EDA

L P

OR

TIN

GB

RA

KE

PED

AL

PO

RTI

NG

Px

- P

ress

ure

Fro

m D

irec

tion

al C

ontr

ol V

alve

T1 -

Tan

k R

etu

rn (

Fron

t B

rake

s)

P1

- P

ress

ure

In

put

to T

read

le (

Fron

t B

rake

s)B

2 -

Pre

ssur

e O

utpu

t to

Rea

r B

rake

s

T2 -

Tan

k R

etu

rn (

Rea

r B

rake

s)B

1 -

Pre

ssur

e O

utpu

t to

Fro

nt

Bra

kes

P2

- P

ress

ure

In

put

to T

read

le (

Rea

r B

rake

s)

Px

B1

B2

P2

T2P1T1

Page 88: Dumper Terex Super

3434

Pro

du

ct

Tra

inin

g

Serv

ice

or E

mer

genc

y Br

ake

Appl

ySe

rvic

e/Em

erge

ncy

Brak

e Re

leas

e

BR

AK

E TR

EAD

LE V

ALV

E SC

HEM

ATI

CB

RA

KE

TREA

DLE

VA

LVE

SCH

EMA

TIC

Page 89: Dumper Terex Super

3535

Pro

du

ct

Tra

inin

g

BR

AK

E P

AC

K P

OR

TSB

RA

KE

PA

CK

PO

RTS

A B C

AFr

om M

otor

/Trip

le P

ump

BBr

ake

Actu

atio

n Li

ne

CRe

turn

to

Brak

e Co

oler

Alte

rnat

ive

Hos

ing

A B C

Page 90: Dumper Terex Super

3636

Pro

du

ct

Tra

inin

g

BR

AK

E P

EDA

L R

ETA

RD

ER S

WIT

CH

BR

AK

E P

EDA

L R

ETA

RD

ER S

WIT

CH

Ret

arde

r of

f -

Peda

l 0°

Mov

emen

t

Reta

rder

App

licat

ion

- Fi

rst

Peda

l Mov

emen

t

Reta

rder

Prox

imity

Switc

h

Page 91: Dumper Terex Super

3737

Pro

du

ct

Tra

inin

g

RET

AR

DER

LIG

HT

AC

TIV

ATI

ON

RET

AR

DER

LIG

HT

AC

TIV

ATI

ON

Page 92: Dumper Terex Super

22

Pro

du

ct

Tra

inin

g

PA

RK

BR

AK

E A

SSEM

BLY

PA

RK

BR

AK

E A

SSEM

BLY

Page 93: Dumper Terex Super

33

Pro

du

ct

Tra

inin

g

AD

JUST

MEN

T N

UT

AD

JUST

MEN

T N

UT

Page 94: Dumper Terex Super

44

Pro

du

ct

Tra

inin

g

CO

NTR

OL

STR

AP

CO

NTR

OL

STR

AP

Page 95: Dumper Terex Super

55

Pro

du

ct

Tra

inin

g

PA

RK

BR

AK

E A

DJU

STM

ENTS

PA

RK

BR

AK

E A

DJU

STM

ENTS

INS

TALL

ATI

ON

;D

O N

OT

PR

ESS

UR

ISE

BR

AK

E A

CTU

ATO

R U

NTI

L FO

LLO

WIN

G I

NST

RU

CTI

ON

HA

S B

EEN

EXEC

UTE

D.

PR

ESSU

RIS

ING

TH

E A

CTU

ATO

R

PR

IOR

TO

TH

IS

INST

RU

CTI

ON

W

ILL

RES

ULT

IN

SER

IOU

S B

RA

KE

DA

MA

GE.

1.T

urn

th

e ad

just

men

t n

ut

on t

he

slac

k ad

just

er i

n a

clo

ckw

ise

dire

ctio

n u

nti

l lin

ings

are

hard

aga

inst

th

e d

isc.

AD

JUST

MEN

T O

F A

UTO

MA

TIC

SLA

CK

-AD

JUST

ER2

. App

ly f

ull r

elea

se p

ress

ure

to

the

bra

ke a

ctu

ator

.3

. Loo

sen

hex

bol

t at

th

e co

ntr

ol a

rm o

f th

e sl

ack

adju

ster

& s

trap

.4

. P

osit

ion

the

con

trol

arm

to

its

full

rele

ased

pos

itio

n -

for

cin

g it

in

a cl

ockw

ise

dire

ctio

n (a

way

fro

m t

he

actu

ator

) -

un

til i

t ha

s a

pos

itiv

e st

op in

side

th

e co

ntr

ol s

trap

.5

. Re-

secu

re t

he

con

trol

arm

of

the

slac

k ad

just

er t

o th

e co

ntro

l str

ap.

CA

UTI

ON

; FA

ILU

RE

TO A

DJU

ST T

HE

SLA

CK

AD

JUST

ER A

GA

INST

TH

E IN

TER

NA

L ST

OP

MA

Y R

ESU

LT I

N B

RA

KE

DR

AG

.

6.

Use

1.5

mm

fee

ler

betw

een

lin

ing

& d

isc

- tu

rn t

he

adju

stm

ent

nut

on t

he

slac

kad

just

er, u

nti

l th

e 1

.5m

m c

lear

ance

is o

btai

ned

.7

. R

emov

e fe

eler

& a

pply

bra

ke s

ever

al t

imes

. Th

e au

tom

atic

sla

ck a

dju

ster

will

adj

ust

the

linin

g cl

eara

nce

wit

h e

ach

appl

icat

ion.

Cle

aran

ce w

ill s

elf

adju

st t

o th

e sp

ecif

ied

0.7

-1.0

0m

m.

Page 96: Dumper Terex Super

66

Pro

du

ct

Tra

inin

g

Retu

rn t

o M

ain

Hyd

. Tan

k

Supp

ly f

rom

Mai

nH

yd. P

ump

Cool

ing

Pum

p/M

otor

Cool

ing

Tank

2 Sp

eed

Cont

rol V

alve

Brak

e Co

olerBR

AK

E C

OO

LIN

G C

IRC

UIT

BR

AK

E C

OO

LIN

G C

IRC

UIT

AB

CA

- Fr

ont

Axle

Fee

d

B -

Mid

Axl

e Fe

ed

C -

Rear

Axl

e Fe

ed

Page 97: Dumper Terex Super

77

Pro

du

ct

Tra

inin

g

BR

AK

E C

OO

LER

FA

NB

RA

KE

CO

OLE

R F

AN

Page 98: Dumper Terex Super

88

Pro

du

ct

Tra

inin

g

BR

AK

E C

OO

LER

BR

AK

E C

OO

LER

1

2

3

5

41.

Fan

Driv

e In

let

2.Fa

n D

rive

Out

let

3.Fa

n Ca

se D

rain

4.Co

oler

Inl

ets

(x3)

5.Co

oler

Out

lets

(x3

)

Page 99: Dumper Terex Super

99

Pro

du

ct

Tra

inin

g

BR

AK

E C

OO

LER

TA

NK

RET

UR

NS

BR

AK

E C

OO

LER

TA

NK

RET

UR

NS

Brak

e Co

oler

Tan

kR

etur

n M

anifo

ld

Page 100: Dumper Terex Super

1010

Pro

du

ct

Tra

inin

g

FRO

NT

AX

LE M

AN

IFO

LD B

LOC

KFR

ON

T A

XLE

MA

NIF

OLD

BLO

CK

120°

C Te

mp

Switc

hW

arni

ng L

amp

50°C

Tem

p Sw

itch

Cool

ing

Fan

Both

Sw

itche

s N

.O.

To B

rake

Coo

ler

From

Trip

leM

otor

/Pum

p

120°

C Te

mp.

War

ning

Lam

p

Page 101: Dumper Terex Super

1111

Pro

du

ct

Tra

inin

g

TEM

PER

ATU

RE

SWIT

CH

HA

RN

ESS

TEM

PER

ATU

RE

SWIT

CH

HA

RN

ESS

Rem

ove

Har

ness

Brid

ge H

arne

ss

For

Chec

king

Bra

keCo

oler

Fan

Spe

ed

Page 102: Dumper Terex Super

1212

Pro

du

ct

Tra

inin

g

2 SP

EED

CO

NTR

OL

VA

LVE

2 SP

EED

CO

NTR

OL

VA

LVE

Loca

ted

Behi

nd B

rake

Oil

Cool

er

2 Sp

eed

Cont

rol V

alve

Page 103: Dumper Terex Super

1313

Pro

du

ct

Tra

inin

g

2 -

SP

EED

CO

NTR

OL

VA

LVE

2 -

SP

EED

CO

NTR

OL

VA

LVE

Sol

enoi

d C

oil D

ata

2 -

Spee

d Co

ntro

l Val

ve14

wat

t40

Ω0.

6 am

ps

Page 104: Dumper Terex Super

1414

Pro

du

ct

Tra

inin

g

BR

AK

E C

OO

LER

FA

N C

HEC

KB

RA

KE

CO

OLE

R F

AN

CH

ECK

Pro

ced

ure

Chec

k 2

spee

d fu

nctio

n of

the

Bra

ke C

oole

r Fa

n

1.D

isco

nnec

t Fa

n Te

mpe

ratu

re S

witc

h (5

0°C)

har

ness

at

fron

t ax

lem

anifo

ld b

lock

.

2.St

art

Engi

ne a

nd a

llow

to

idle

.

3.Br

idge

con

nect

ion

on t

he t

empe

ratu

re s

witc

h ha

rnes

s. T

his

ener

gise

s th

eso

leno

id in

the

2 S

peed

Con

trol

Val

ve.

4.O

bser

ve in

crea

se in

fan

spe

ed.

5. I

f fa

n sp

eed

does

not

incr

ease

, inv

estig

ate

faul

t on

on

2 Sp

eed

Cont

rol

Valv

e So

leno

id a

nd a

ssoc

iate

d w

iring

.

Page 105: Dumper Terex Super

1515

Pro

du

ct

Tra

inin

g

TRIP

LE C

OO

LIN

G P

UM

P A

CTI

VA

TIO

NTR

IPLE

CO

OLI

NG

PU

MP

AC

TIV

ATI

ON

Page 106: Dumper Terex Super

1616

Pro

du

ct

Tra

inin

g

TRIP

LE C

OO

LIN

G P

UM

P C

HEC

KTR

IPLE

CO

OLI

NG

PU

MP

CH

ECK

Chec

k Ac

tuat

ion

Pres

sure

Her

e

Typi

cal R

eadi

ngs

110

bar

(160

0 PS

I) @

Ful

l Thr

ottle

(Ope

ratin

g Te

mp.

)

Cool

ing

Sect

ion

ofM

ain

Trip

le P

ump

Page 107: Dumper Terex Super

1717

Pro

du

ct

Tra

inin

g

Typi

cal T

riple

Coo

ling

Pum

p O

utle

t Pr

essu

re 1

.17

- 1.

2 ba

r(1

7 -

17.5

PSI

) @

Ful

l Thr

ottle

TRIP

LE C

OO

LIN

G P

UM

P O

UTL

ETS

TRIP

LE C

OO

LIN

G P

UM

P O

UTL

ETS

A -

Fron

t Ax

le F

eed

B -

Mid

Axl

e Fe

ed

C -

Rear

Axl

e Fe

ed

AB

C

Page 108: Dumper Terex Super

1818

Pro

du

ct

Tra

inin

g

TRIP

LE C

OO

LIN

G P

UM

P R

ELIE

FTR

IPLE

CO

OLI

NG

PU

MP

REL

IEF

Rel

ief

Sett

ing

100

bar

(145

0 ps

i)

Page 109: Dumper Terex Super

1919

Pro

du

ct

Tra

inin

g

LOW

PR

ESSU

RE

REL

IEF

VA

LVE

LOW

PR

ESSU

RE

REL

IEF

VA

LVE

Rel

ief

Sett

ing

1.5

bar

(22

psi)

(x3

Valv

es)

Page 110: Dumper Terex Super

2020

Pro

du

ct

Tra

inin

g

BR

AK

E C

OO

LIN

G P

OR

TSB

RA

KE

CO

OLI

NG

PO

RTS

Alte

rnat

ive

Hos

ing

Feed

fro

m T

riple

Mot

or/P

ump

Exit

Brak

e to

Bra

ke C

oole

r

Typi

cal f

or a

ll 3

Axle

s

Page 111: Dumper Terex Super

2121

Pro

du

ct

Tra

inin

g

CEN

TRE

AX

LE M

AN

IFO

LD B

LOC

KC

ENTR

E A

XLE

MA

NIF

OLD

BLO

CK

Brak

e Pa

ck I

nlet

To B

rake

Coo

ler

From

Trip

le M

otor

/Pum

p

Brak

e Pa

ck O

utle

t

Actu

atio

n Pr

essu

re

Actu

atio

n Pr

essu

re

Page 112: Dumper Terex Super

2222

Pro

du

ct

Tra

inin

g

REA

R A

XLE

MA

NIF

OLD

BLO

CK

REA

R A

XLE

MA

NIF

OLD

BLO

CK

Brak

e Pa

ck I

nlet

To B

rake

Coo

ler

From

Trip

le M

otor

/Pum

p

Brak

e Pa

ck O

utle

t

Actu

atio

n Pr

essu

re

Actu

atio

n Pr

essu

re

Page 113: Dumper Terex Super

2323

Pro

du

ct

Tra

inin

g

AD

DIT

ION

AL

MA

INTE

NA

NC

E C

HEC

KS

AD

DIT

ION

AL

MA

INTE

NA

NC

E C

HEC

KS

Page 114: Dumper Terex Super

2424

Pro

du

ct

Tra

inin

g

SER

VIC

E C

AP

AC

ITIE

SSE

RV

ICE

CA

PA

CIT

IES

Fuel

Tan

k4

63

litr

es

Hyd

raul

ic S

yste

m (

Stee

ring,

Bra

king

& B

ody)

20

9 li

tres

Brak

e Co

olin

g Sy

stem

19

9 li

tres

Engi

ne C

oolin

g Sy

stem

80

litr

es

Engi

ne C

rank

case

(w

ith F

ilter

s)3

7 li

tres

Tran

smis

sion

& F

ilter

s (d

ry)

56

litr

es

Tran

smis

sion

& F

ilter

s (w

et)

28

litr

es

Diff

eren

tial (

Fron

t)3

7.5

litr

es

Diff

eren

tial (

Cent

re)

38

litr

es

Diff

eren

tial (

Rea

r)3

1.5

litr

es

Plan

etar

ies

8.5

litr

es

Driv

esha

ft B

earin

gs (

Pivo

t)1

.5 li

tres

Air

Cond

ition

ing

Com

pres

sor

0.1

25

litr

es

Page 115: Dumper Terex Super

2525

Pro

du

ct

Tra

inin

g

AX

LE D

IFF.

SER

VIC

E IN

TER

VA

LSA

XLE

DIF

F. S

ERV

ICE

INTE

RV

ALS

Oil

Typ

eM

IL-L

2105

DAP

I G

L-5

SAE

80W

90 L

S

Cap

acit

ies

Fron

t37

.50

litre

sCe

ntre

38.0

0 lit

res

Rea

r31

.50

litre

s

Ser

vice

In

terv

als

1st 1

00 H

rsD

rain

and

Ref

ill25

0 H

rsCh

eck

Oil

Leve

l20

00 H

rsD

rain

and

Ref

ill

Dan

a-Sp

icer

Diff

eren

tial

Leve

l

Dra

in

Page 116: Dumper Terex Super

2626

Pro

du

ct

Tra

inin

g

PLA

NET

AR

Y S

ERV

ICE

INTE

RV

ALS

PLA

NET

AR

Y S

ERV

ICE

INTE

RV

ALS

Oil

Leve

l Ch

eck

Pro

ced

ure

•Rai

se a

xles

off

gro

und

and

supp

ort

with

sui

tabl

e st

ands

.•R

otat

e ea

ch h

ub s

o th

at b

otto

m o

ffil

ler/

leve

l por

t is

13m

m a

bove

axle

cen

tre

line.

•Che

ck o

il le

vel -

add

oil

if re

quire

d.

Oil

Cap

acit

y8.

5 lit

res

each

hub

Oil

Type

Refe

r to

Diff

eren

tial T

ypes

Serv

ice

Inte

rval

s1s

t 100

Hrs

Dra

in a

nd R

efill

250

Hrs

Chec

k O

il Le

vel

2000

Hrs

Dra

in a

nd R

efill

13m

m

Dra

inPo

rt

Page 117: Dumper Terex Super

2727

Pro

duc

t Tra

inin

g

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ill

Page 118: Dumper Terex Super

2828

Pro

duc

t Tra

inin

g

BR

AK

E P

AC

K W

EAR

PIN

BR

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Page 119: Dumper Terex Super

2929

Pro

du

ct

Tra

inin

g

BR

AK

E P

AC

K S

ERIA

L P

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BR

AK

E P

AC

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L P

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Ensu

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ake

Pack

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Mid

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Rear

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AIL

Page 120: Dumper Terex Super

TA40 (A820) SYSTEMS FAMILIARISATION

PRODUCT TRAININGTA40 (A820) BRAKE & COOLING

SYSTEM CHECKS

Page 121: Dumper Terex Super

TA40 (A820) Brake & Cooling System

TA40 (A820) BRAKE & COOLING SYSTEM CHECKS

Check pressures when oil temperature is at least 15 to 20°C or ambient temperature if higheron initial start up.

SYSTEM SETTINGS

Priority Un-Loader Valve 170 bar (2465 psi)

Low Temperature Un-Loader Valve 205 bar (2970 psi)

Brake Actuation Pressure 138 bar (2000 psi)

CHECKING SETTINGS

U ENSURE A/C & RETARDER ARE BOTH DIS-ENGAGED1. Ensure Brake Accumulator pressure is dissipated.2. Attach pressure gauge to diagnostic check-point on Brake Manifold Valve, port ‘P1’.3. Start truck and allow pressures to increase with engine at low idle.4. Take note of highest gauge reading. This is the pressure setting of the Priority Un-Loader

Valve.5. Remove electrical connection from Low Temperature Un-Loader Valve. This will render

this valve de-energised.6. Increase engine R.P.M. to full throttle.7. Take note of highest gauge reading – This is the pressure setting of the Low Temperature

Un-Loader Valve.

RESETTING VALVE PRESSURES

Priority Un-Loader Valve TOO LOW

If pressure reading is too low after following steps 1 thru 4, loosen the lock nut on reliefvalve and turn setting screw CW until correct pressure setting is evident. Re-tighten lock nut.

NB. This procedure must be carried out with engine R.P.M. at low idle.NB. All adjust valve pressures on the increase.

Priority Un-Loader Valve TOO HIGH

If pressure reading is too high after following steps 1 thru 4;

(a) Stop engine and deplete brake accumulators.(b) Loosen lock nut on relief valve and turn setting screw CCW 2 to 3 full turns.(c) Re-Start engine and allow pressures to rise with engine in the low idle condition.(d) Note highest pressure on gauge, adjust setting screw CW until correct pressure is

evident.(e) Re-tighten lock nut.

Product Training

Page 122: Dumper Terex Super

TA40 (A820) Brake & Cooling System

Low Temperature Un-Loader Valve TOO LOW

If pressure setting is too low after following steps 5 thru 7, Loosen lock nut on Relief Valveand turn setting screw CW until correct pressure is evident. Re-tighten lock nut.

NB. This procedure to be carried out with engine at full throttle.NB. Always adjust pressure on the increase.

Low Temperature Un-Loader Valve TOO HIGH

If pressure setting is too high after following steps 5 thru 7;

(a) Bring engine to idle.(b) Depress foot brake pedal several times(c) Loosen lock nut on relief valve and turn setting screw CCW 2 to 3 full turns.(d) Return engine to full throttle.(e) Adjust setting screw CW until correct pressure is evident.(f) Re-tighten lock nut.

BRAKE COOLER FAN CHECK

Check 2 speed function of the Brake Cooler Fan is operating properly.

(a) Disconnect Fan Activation (N.O.) Temperature Switch (50°C) at front axle manifold block.(b) Start engine and allow to idle.(c) Bridge connection on temperature switch harness. This energises the solenoid within the

2 Speed Control Valve.(d) Observe increase in fan speed.(e) If fan speed does not increase, investigate fault on 2 Speed Control Valve solenoid and

associated wiring.

TRIPLE COOLING PUMP/MOTOR ACTIVATION

Check that motor is achieving sufficient pressure to activate triple pump for the brake coolingoil. Check pressure at cooling section of main triple pump.

(a) Connect pressure gauge at diagnostic pressure check point.(b) Start engine and run at full throttle.(c) Observe pressure, typical readings 110 bar (1600 psi)

Additional check; Triple Pump Outlet Pressure @ full throttle = 1.17 – 1.2 bar (17 – 17.5 psi)at each output port.

Maximum allowable pressure across brake packs 1.0 bar (14.5 psi)

Product Training

Page 123: Dumper Terex Super

TA40 (A820) SYSTEMS FAMILIARISATION

PRODUCT TRAININGTA40 (A820) ELECTRICAL SCHEMATICS

Page 124: Dumper Terex Super

Section 190-0000

1SM 2126 Rev 1 9-02

ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310)

COMPONENT DESIGNATIONSA4 - Radio/cassette

A5 - Radio/cassette speaker

B2 - Coolant temperature sender

B7 - Coolant Level sender

B13 - Rot'nl speed sensor

B15 - Air temperature sender

B19 - Throttle position sender

B20 - Engine oil temp sender

B21 - Trans oil temp sender

B22 - Engine oil press sender

B24 - Turbo boost sender

B25 - Fuel pressure sender

B26 - Fuel temperature sender

B27 - Synchro reference sender

B28 - Timing reference sender

B32 - Trans oil retard temp sender

B33 - Air cond temp sender

E3 - Interior light

E5 - Reverse light

E7 - Inst panel lights

E11 - Side marker light, L

E12 - Taillight, L

E13 - Side marker light, R

E14 - Taillight, R

E15 - High/low beam headlamp, L

E16 - High/low beam headlamp, R

E19 - Rear fog lamp (Option)

E21 - Rotating Beacon (Option)

E23 - Work light (Option)

E26 - High beam headlamp, L

E27 - High beam headlamp, R

E35 - Heated mirror

G1 - Generator

G2 - Battery

H2 - Warning light

H5 - Dir indicator w/l

H6 - Dir indicator, F, L

H7 - Dir indicator, B, L

H8 - Dir indicator, F, R

H9 - Dir indicator, B, R

H10 - Brake light, L

H11 - Brake light, R

H12 - High beam w/l

H23 - Engine check w/l

S10 - Wiper switch, F

S11 - Rear wash/wipe switch

S13 - Horn button

S14 - Hazard w/l switch

S15 - Direction ind switch

S16 - Stoplight switch

S18 - Lights switch

S19 - Dipswitch

S20 - Headlamp flash switch

S22 - Body-up switch

S29 - Retarder switch

S31 - Park brake w/l switch

S37 - Axle difflock switch

S40 - Gear shift selector

S41 - Auxillary lights switch

S43 - Air cond pressure sw

S48 - Accumulator press sw, F

S49 - Accumulator press sw, B

S50 - Brake cooling oil temp switch

S55 - Brake diff press switch

S57 - Steering press switch

S60 - Difflock request switch

S67 - Lock-up press switch

S68 - Diagnostic request & engine

override switch

S71 - Air cond rheostat switch

S74 - Kickdown switch

S77 - Trans difflock switch

S79 - Heated mirror switch

S80 - Engine compression brake

deacceleration mode switch

S81 - Retarder/engine compression

brake selection switch

S82 - Eng comp brake on/off switch

X1 - Handlamp socket

Y3 - Retarder valve

Y4 - Brake diverter valve

Y7 - Difflock valve transmission

Y7 - Difflock valve middle axle

Y20 - Fuel injector

Y26 - Body raise solenoid

Y27 - Body lower solenoid

Y29 - Engine comp brake solenoid

Wire colours

B - Black

N - Brown

U - Blue

R - Red

G - Green

H24 - Engine stop w/l

H27 - Trans stop w/l

K1 - Starter relay

K4 - Dir ind flasher unit

K5 - Air cond compressor clutch

K14 - Start interlock relay

K15 - Headlamp relay

K17 - Reverse relay

K21 - Trans shift clutch

K22 - Lock-up clutch

K23 - Ignition relay

K32 - Eng comp brake relay on

K33 - Radiator fan relay

K34 - Horn relay

K35 - Body up relay

K36 - Body float relay

K37 - Body hyd system relay 12V

K40 - Low temp unloader solenoid

K43 - Radio/cassette relay

K45 - Brake pump compensator

L3 - Reverse alarm

L4 - Buzzer

L5 - Electric horn

M1 - Starter motor

M3 - Heater blower motor

M4 - Washer motor, F

M5 - Wiper motor, F

M6 - Wiper motor, B

M7 - Washer motor, B

M10 - Cab fan motor

M13 - Air seat compressor

N3 - Voltage convertor 12V

N4 - Frequency divider

P1 - Speedometer/odometer

P2 - Tachometer/hourmeter

P15 - Retarder temp gauge

R7 - Cigar Lighter

S1 - Battery master switch

S2 - Starter keyswitch

S4 - W/L test switch

S7 - Emergency/park brake sw

S8 - Blower switch

S9 - Washer switch, F

TERMINAL DESIGNATIONS IN ACCORDANCE

WITH DIN 72 552

L - LEFT R - RIGHT F - FRONT B - BACK

FUSERESISTOR PLUGDIODE

L - Light green

O - Orange

Y - Yellow

P - Purple

W - White

S - Slate

K - Pink

TRAILER

CONNECTION

Page 125: Dumper Terex Super

Section 190-0000

Electrical System - Circuit Diagrams (DDEC III & IV, 6WG 310)

SM 2126 Rev 1 9-022

DDEC III & IV COMPONENT

AND CABLE DESIGNATIONS

STANDARD (DDEC) CABLES

109 - Timing reference sender ground

110 - Timing reference sender supply

111 - Sync reference sender supply

112 - Sync reference sender ground

115 - ECM supply to coolant level sender

120 - Oil temperature sender supply

132 - Air temperature sender supply

133 - Coolant temperature sender supply

150 - ECM to master switch ground

151 - ECM to master switch ground

240 - 24 Volt battery post to ECM via 15A fuse

241 - 24 Volt battery post to ECM via 15A fuse

416 - Engine sender supplys (5VDC)

417 - Throttle position sender signal

419 - Check engine light ground to ECM

432 - Turbo boost sender signal

439 - Ignition sensed supplys

440 - 24 Volt battery post to ignition relay

452 - Engine sender returns

472 - Fuel temperature sender supply

509 - Stop engine light ground to ECM

528 - Diagnostic/stop engine override switch

530 - Oil pressure sender signal

NOTES:

1. DDEC III & IV WIRE NUMBERS ARE IN ( ).

2. WIRES MARKED * ARE SUPPLIED WITH

ENGINE.

3. SOME DDEC III & IV HARNESSES ARE

SHEILDED FROM ELECTRO MAGNETIC

INDUCTION WHERE THEY RUN CLOSE TO

OTHER VEHICLE SYSTEMS.

531 - Digital input transmission lockup

561 - Engine compression brake low solenoid

562 - Engine compression brake medium solenoids

583 - Digital input engine compression brake low

611 - Injector 1 power drive

612 - Injector 5 power drive

613 - Injector 3 power drive

614 - Injector 6 power drive

615 - Injector 2 power drive

616 - Injector 4 power drive

619 - Injectors 1, 2, 3 returns

620 - Injectors 4, 5, 6 returns

900 - Data link diagnostics supply

901 - Data links diagnostics return

905 - Fuel pressure sender signal

911 - PWM radiator fan ground

916 - Throttle sender supply (5VDC)

925 - CAN H / J1939 (+) control link data

926 - CAN L / J1939 (-) control link data

927 - CAN SHLD / J1939 shield

952 - Throttle return

953 - Master switch grounds

979 - Digital input engine compression brake

medium

DIODE

INDICATOR LIGHT RESISTOR

FUSECABLES TWISTED30 TURNS / metre

SCREENEDCABLES

TERMINAL DESIGNATIONS IN ACCORDANCE

WITH DIN 72 552

L - LEFT R - RIGHT F - FRONT B - BACK

TRAILER

CONNECTION

Page 126: Dumper Terex Super

Section 190-0000

3SM 2126 Rev 1 9-02

FUSES

Location Fuse No. Circuit Current Rating

1 Ignition Sensed Relay Contacts (Heater) 30A

2 Keyswitch 15A

3 Cab Fan Ventilator Blower 15A

4 Rear Wash/Wipe 10A

5 Horn Relay Coil, Front Wash/Wipe 10A

Fuse Box - 6 Air Seat Compressor 10A

Column A 7 Lights Switch 10A

8 Main Beam 10A

9 Wiper Park Front and Rear 7.5A

10 Hazards 7.5A

11 Transmission System Ignition Supply 7.5A

12 Reverse System 7.5A

13 Brake Lights 5A

14 Interior Light, Handlamp 5A

15 Direction Indicators, Rocker Switch Lights 5A

16 Alarm Brake/Steering System 3A

17 Warning Lights 3A

Fuse Box - 18 Spare -

Column B 19 Gauges/Ignition Sensed Relay Coils 3A

20 Radiator Fan 3A

21 Neutral Start 3A

22 Washers, Front 3A

23 Washers, Rear 3A

24 Horn 10A

25 Ignition Sensed Relay Contacts (Air Conditioning) 30A

26 Air Conditioning Compressor 15A

27 Spare -

28 Ignition Auxilary Supply Option 10A

29 Work Lights 15A

Fuse Box - 30 Rotating Beacon 5A

Column C 31 Cab Fan 3A

32 Transmission System Battery Supply 7.5A

33 Body Hydraulic System 5A

34 Alternator Drive Signal 3A

35 Heated Mirrors 15A

36 Cigar Lighter 10A

Radio Harness 38 Radio/Cassette Supply (Glass Fuse) 7A

39 Radio/Cassette Supply (Glass Fuse) 1A

40 DDEC III & IV ECM Ignition Sensed Supply 5A

Battery Box 41 DDEC III & IV ECM Battery Supply 15A

42 DDEC III & IV ECM Battery Supply 15A

Electrical System - Circuit Diagrams (DDEC III & IV, 6WG 310)

RELAYS

K23 - Ign/Sense Opt. K35 - Body Up

K23 - Ign/Sense K4 - Flashers

K34 - Horn K33 - Radiator Fan

K15 - Headlights K23 - Engine Ignition

K17 - Rev. Alarm/Lts. K36 - Body Float

K14 - Neutral/Start K37 - Body Hyd (12V)

K5 - Air Conditioner K43 - Radio/Cassette

K23

K23

K34

K15

K17

K14

K5

K35

K4

K33

K23

K37

K43

K36

F1

F2

F3

F4

F5

F6

F7

F8

F9

F10

F11

F12

F13

F14

F15

F16

F17

F18

F19

F20

F21

F22

F23

F24

F25

F26

F27

F28

F29

F30

F31

F32

F33

F34

F35

F36

SM - 2571

Page 127: Dumper Terex Super

SM 2126 Rev 1 9-024

SM

- 2

683A

1531

3937

, Rev

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Page 128: Dumper Terex Super

5SM 2126 Rev 1 9-02

SM

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683B

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Page 129: Dumper Terex Super

SM 2126 Rev 1 9-026

SM

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Page 130: Dumper Terex Super

7SM 2126 Rev 1 9-02

SM

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Page 131: Dumper Terex Super

SM 2126 Rev 1 9-028

SM

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683E

1531

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Page 132: Dumper Terex Super

9SM 2126 Rev 1 9-02

SM

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683F

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Page 133: Dumper Terex Super

SM 2126 Rev 1 9-0210

SM

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Page 134: Dumper Terex Super

11SM 2126 Rev 1 9-02

SM

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683H

1531

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Page 135: Dumper Terex Super

SM 2126 Rev 1 9-0212

SM

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683I

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Page 136: Dumper Terex Super

13SM 2126 Rev 1 9-02

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Page 137: Dumper Terex Super

SM 2126 Rev 1 9-0214

SM

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Page 138: Dumper Terex Super

15SM 2126 Rev 1 9-02

SM

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Page 139: Dumper Terex Super

SM 2126 Rev 1 9-0216

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Page 140: Dumper Terex Super

17SM 2126 Rev 1 9-02

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