Dumper Terex Super

PRODUCT TRAINING
TA40 (A820) SYSTEMS FAMILIARISATION
Product Training
Issued by; Customer Support Department Terex Equipment Limited Newhouse Industrial Estate Motherwell, ML1 5RY Scotland Tel; +44 (0) 1698 732121 Fax; +44 (0) 1698 503210 www.terex.co.uk
Re-Order Part Number
15275747
Book Issue; 090903
For further information on the subject mater detailed within this training book, please refer to Terex Equipment Limited Service Manuals, Operators Handbooks and Product Parts Books. Alternatively, please contact; Customer Support Department Terex Equipment Limited Newhouse Industrial Estate Motherwell, ML1 5RY Tel; +44 (0) 1698 732121 Fax; +44 (0) 1698 503210
The illustrations, technical information, data and descriptive text in this manual, to the best of our knowledge, were correct at the time of print. The right to change specifications, equipment and maintenance instructions at any time without notice, is reserved as part of the Terex Equipment Limited 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 Customer Support Department - Terex Equipment Limited. Please refer to TEREX Specification Sheets or consult Factory Representatives to ensure that information is current.
TA40(A820) STEERING SYSTEM
2 2
Product Training
STEERING SCHEMATIC
3 3
Product Training
HYDRAULIC TANK
4 4
Product Training
HYDRAULIC TANK FILTER

STRAINER
1000 HRS FILTER CHANGE 2000 HRS DRAIN/REFILL
(CLEAN STRAINER)
7 7
FILTER
SERVICE;
FILTER BY-PASS 3.5 Bar (50 PSI) MAX

Product Training
MAIN PUMP (STEERING/BODY)
6 6
Product Training
FLOW AMPLIFIER VALVE
7 7
Product Training
FLOW AMPLIFIER VALVE - PORTING
8 8
A B C D E F LS EF HP PP P HT T R L CR CL
Counter Pressure & Anti-cavitation Valve - 5 Bar (73 PSI) System Relief Valve - 206 Bar (3000 PSI) Priority Spool Shock Valve - 241 Bar (3500 PSI) Amplifier Spool Directional Spool Load Sensing Pressure Excess Flow Pump Supply Pilot Pressure Pump Supply to Steering Valve Tank Return Steering Valve Tank Return Steering Valve Right Turn (From Steering Valve) Steering Valve Left Turn (From Steering Valve) Right Turn Cylinder Oil Supply Left Turn Cylinder Oil Supply
Product Training

B PP A
9 9
HP
EF P HT C D R E F L CR CL T
LS
Product Training
STEERING SYSTEM RELIEF VALVE

Relief Pressure Setting 206 Bar (3000 PSI)
10 10
RELIEF VALVE
ANTICAVIATION
Product Training
STEERING SYSTEM CHECK POINTS

STEERING RELIEF PRESSURE CHECK POINT
11 11
LUBRICATE INBOARD STEERING CYLINDER PINS EVERY 50 HOURS Product Training
FLOW AMPLIFIER SPOOLS

*PRIORITY SPOOL
12 12
SHOCK LOAD VALVE x 2
*DIRECTIONAL CONTROL SPOOL
*AMPLIFIER SPOOL
(*NOT SOLD SEPARATELY)

Product Training
ORBITROL STEERING VALVE
13 13
T L T L TANK RETURN
(VIA FLOW AMP VALVE)
P INLET FROM FLOW AMP. VALVE SUPPLY TO LH STEER CIRCUIT
P LS R
R SUPPLY TO RH STEER CIRCUIT

(VIA FLOW AMP VALVE)
LS LOAD SENSE TO FLOW AMP.
Product Training
FLOW AMP. - NEUTRAL STEER
14 14
Product Training
FLOW AMP. - RIGHT HAND TURN
15 15
Product Training
FLOW AMP. - LEFT HAND TURN
16 16
Product Training
EMERGENCY STEERING VALVE
17 17
Product Training
CHECK VALVE (MANIFOLD)
18 18
CHECK VALVE MANIFOLD
EMERGENCY STEER VALVE
Product Training
EMERGENCY STEERING PUMP
19 19
Product Training
EMERGENCY STEERING SCHEMATIC
20 20
NORMAL STEERING MODE
EMERGENCY STEERING MODE
Product Training
STEERING PRESSURE SWITCH
21 21
Product Training
STEERING PRESSURE CHART
22 22
SYSTEM PRESSURE
206 Bar (3000 PSI) 241 Bar (3500 PSI) 82 Bar (1200 PSI) 4.8 Bar (70 PSI) 422 L/MIN 3.5 Bar (50 PSI)
SHOCK LOAD (FLOW AMP. VALVE)
EMERGENCY STEER CUT IN
PUMP WARNING SWITCH
PUMP CAPACITY @ 2200 RPM
HYD. TANK FILTER BY-PASS
Product Training
TA40(A820) BODY CONTROL SYSTEM
2 2
Product Training
WELDING PROCEDURE
BEFORE WELDING ON TRUCK; TURN KEY-SWITCH OFF TURN MASTER SWITCH OFF DISCONNECT; BATTERY SUPPLY & EARTH CABLES ALTERNATOR EARTH & SUPPLY CABLES TRANSMISSION ECU ENGINE ECM BODY CONTROL JOYSTICK ANY OTHER ELECTRONIC OPTIONS ie. REAR VIEW TV, LUBE SYSTEMS etc.
Product Training
3 3
BODY LIFT/LOWER SYSTEM LAYOUT

DIVERTER TUBE
4 4
DIAGNOSTIC CHECK POINT BODY CONTROL VALVE
FLOW AMPLIFIER VALVE MAIN GEAR PUMP
TO TIP CYLINDERS
CHECK VALVE MANIFOLD
HYDRAULIC TANK
Product Training
PILOT CONTROL LINES LAYOUT
5 5
RELIEF TO TANK
FROM BRAKE ACCUMULATOR CHARGE VALVE TO HYDRAULIC TANK
Product Training
HYDRAULIC TANK
6 6
Product Training
HYDRAULIC TANK FILTER

STRAINER
1000 HRS FILTER CHANGE 2000 HRS DRAIN/REFILL
(CLEAN STRAINER)
7 7
FILTER
SERVICE;
FILTER BY-PASS 3.5 Bar (50 PSI) MAX

Product Training
MAIN TRIPLE PUMP - PILOT SUPPLY

B
8 8
B - Brake Actuation F - Fan (Engine) C - Cooling (Brakes)
Product Training
BODY PILOT VALVE
9 9
U2
REGULATING SPRING
P1 U1
T1
P1 FROM ACC. VALVE
U1 TO BODY SOLENOIDS
T1 RETURN TO TANK
RELIEF SPRING
U2 PRESSURE CHECK POINT
NON-ADJUSTABLE VALVE
Product Training
BODY CONTROL VALVE

RELIEF VALVE ADJUSTMENT
10 10
SYSTEM RELIEF 172 BAR (2500 PSI)

Product Training
PRESSURE REDUCING SOLENOIDS
11 11
SUSCEPTIBLE TO DIRT/GRIT INGRESS
SOLENOIDS ARE INTERCHANGEABLE
Product Training
SOLENOID PRESSURE REDUCTIONS

CHECK POINT P1/P2 (X2)
12 12
P2
P1
Port P1 30 bar(435 PSI) 0 bar 0 bar 0 bar
Port P2 0 bar 0 bar 30 bar(435 PSI) 13.5 bar(195 PSI)

Product Training
Raise Hold Float Lower
BODY CONTROL JOYSTICK

Joystick Output to Solenoids Raise 250ma @ 5 bar - 1 amp Full Hold 0 amp Lower (Power Down) 400ma Float 1 amp
13 13
NONADJUSTABLE
Disconnect Before Welding
Wiring Schematic; Y26 Body Raise Solenoid Y27 Body Lower Solenoid
Body Control Solenoid Resistance; 21.2 @ 20C
Product Training
BODY CONTROL RELAYS
14 14
K37 - 12 VOLTS
K35 - 24 VOLTS
K36 - 24 VOLTS
Product Training
FUSE/RELAY BOX
15 15
Product Training
BODY PROXIMITY SWITCH
16 16
SCHEMATIC S22
MAXIMUM OPERATING DISTANCE 15mm

Product Training
BODY CONTROL - ELECTRICAL

F33 F34 K37 S22 K35
H2 K36
TRANSMISSION ECU X7 PIN 11
17 17
F33
Body Hydraulic System (5A) Alternator Drive Fuse (3A) Body System Relay Body Up (Proximity) Switch Body Raise Relay Body Raise Warning Lamp Body Float Relay Body Raise Solenoid Body Lower Solenoid
K37
K35
H2 K36 Y26 Y27

Y27
Y26
S22
Product Training
MAIN PUMP (STEERING/BODY)
18 18
Product Training
19 19
Product Training
FLOW AMPLIFIER VALVE - PORTING
20 20
A B C D E F LS EF HP PP P HT T R L CR CL
Counter Pressure & Anti-cavitation Valve - 5 Bar (73 PSI) System Relief Valve - 206 Bar (3000 PSI) Priority Spool Shock Valve - 241 Bar (3500 PSI) Amplifier Spool Directional Spool Load Sensing Pressure Excess Flow Pump Supply Pilot Pressure Pump Supply to Steering Valve Tank Return Steering Valve Tank Return Steering Valve Right Turn (From Steering Valve) Steering Valve Left Turn (From Steering Valve) Right Turn Cylinder Oil Supply Left Turn Cylinder Oil Supply
Product Training

B PP A
21 21
HP
EF P HT C D R E F L CR CL T
LS
Product Training
FLOW AMPLIFIER - PRIORITY SPOOL

*PRIORITY SPOOL
22 22
SHOCK LOAD VALVE x 2
*DIRECTIONAL CONTROL SPOOL
*AMPLIFIER SPOOL
(*NOT SOLD SEPARATELY)

Product Training
FLOW AMP. VALVE - SCHEMATIC
23 23
MAIN PUMP PRESSURE ENTERS THE PRIORITY VALVE AND EXITS EF PORT TO THE BODY CONTROL VALVE
Product Training
DIVERTER TUBE
24 24
Product Training
HYDRAULIC OIL COOLER
25 25
Product Training
TA40 BODY PRESSURE CHART

172 bar (2500 psi) 30 bar (435 psi) 45 bar (652 psi) 3.5 bar (50 psi)
26 26
System Pressure
Pilot Supply Valve
Pilot Supply Valve Relief
Hyd. Tank Filter By-Pass
Main Pump Capacity @ 2200 RPM 422 l/min
PILOT PRESSURE AT BODY CONTROL VALVE SPOOL Port P2 0 bar 0 bar 30 bar(435 PSI) 13.5 bar(195 PSI)
Product Training
Raise Hold Float Lower
Port P1 30 bar(435 PSI) 0 bar 0 bar 0 bar
SCHEMATIC - RAISE POSITION
27 27
1 - Hydraulic Tank
2 - Body Control Valve
3 - Body Tip Cylinders
4 - Hydraulic Cooler
5 - Body Pilot Valve
Product Training
SCHEMATIC - LOWER POSITION
28 28
1 - Hydraulic Tank
Product Training
SCHEMATIC - HOLD POSITION
29 29
1 - Hydraulic Tank
Product Training
SCHEMATIC - FLOAT POSITION
30 30
1 - Hydraulic Tank
5 - Pilot Supply Valve
Product Training
BODY SYSTEM TROUBLESHOOTING Product Training

1 BO DY WILL NO TR AISE O R RA ISE A TC ORR EC T SPEED 2 BO DY WILL NO T LO WER O R LOW ERAT CO RRECT SPEED 3 BO DY WILL NO TH OLD 4 BO DY WILL NO T POW ER-D OW N
CH ECKBO DY PRO XIMITY SW ITCH
CH ECKPILOT PRESSUR E @PILOT SUPPLY VA LVE
CH ECKK36 RELA Y
CH ECKMA IN B ODY VALVE R ELIEF PRESSUR E
CH ECKFO R ELECTRICA L FAU LT TO BO DY CO NTROL JOYSTICK
CH EC K FO R 24V FEED CH EC K K37 RELAY CH EC KA LTER NA TO R
REPA IR CIRCU IT
SYSTEM O K NO T O K
CH ECKPU MP PRESSUR EA NDFLO W RA TIN G
CH ECKFO R FA ULTY ELECTRICA L SIGN ALS TO SOLENOID S
CH EC K ELECTRICA L SUPPLIES BETWEEN JO YSTICKAN D SOLEN OIDS
REPA IR CIRCU IT O R RELPA CE JOYSTICK
SYSTEM O K NO T O K
CH ECKPR IORITY VALVE IS OPERA TIN G PRO PERLY CH ECKFO R CO NTAMINA TION W ITHIN SO LENO ID REMO VE CLEAN CH EC K FO R DA MA GE REPLA CE IF NECESSAR Y
REPA IR/REPLA CE EFFECTED SOLEN OID
SYSTEM O K NO T O K
CH ECKFO R SOLEN OID FA ULT
CH EC K RESISTA NCES REPLA CE EFFECTED SOLEN OID
SYSTEM O K NO T O K
CH ECKFO R CO NTAMINA TION W ITHIN MA IN CO NTRO L VALVE
DISA SSEMBLE CLEAN CH EC K FO R DA MA GE CH EC K SPR INGS/SPOO L
REPA IR
SYSTEM O K NO T O K
CH ECKTIP CYLIN DERS FO R FAU LTS
DISA SSEMBLE CLEAN CH EC K FO R DA MA GE CH EC K SEA LS ETC .
REPA IR
SYSTEM O K NO T O K
ADT BODY SYSTEM TROUBLESHOOT
TA40 BRAKING & COOLING SYSTEM

EFFECTIVE FROM A8201011
2 2
Product Training
HYDRAULIC FLUID RESERVOIRS

Check Proper Levels
3 3
Cooling Tank
Main Hyd. Tank
Brake & Cooling Schematic Click Here
Product Training
HYDRAULIC FLUID TYPES

Cooling Oil MIL-L-2104E, MIL-L-46152 B/C API CF, CD, SF
4 4
Actuation Oil MIL-PRF-2104G Allison C4 Type (10W)
Product Training
HYD. FLUID SERVICE INTERVALS

Cooling Oil 1st 100 Hrs Clean Filters 1000 Hrs Drain/Re-Fill, Change Filter and Breather
5 5
Actuation Oil 1000 Hrs 2000 Hrs Clean Filter Housing and Replace Element Drain Oil/Re-Fill
Product Training
MAIN TRIPLE PUMP

B
6 6
B - Brake Actuation F - Fan (Engine) C - Cooling (Brakes)
Product Training
PRIORITY UNLOADER VALVE CIRCUIT

1 2
7 7
6 5 3
1 2 3 4
Priority Unloader Valve Main Hydraulic Tank Hydraulic Pump Brake Manifold Valve
5 Pilot Control Valve 6 Accumulator 7 Brake Accumulators (x2)

Product Training
PRIORITY UNLOADER VALVE

Mounted on RHS of Hydraulic Cradle
8 8
Pressure Setting 170 bar (2465 PSI)

Product Training
ACCUMULATOR - PRIORITY UNLOADER

Accumulator Pre-Charge 30 bar (435 psi) (Pre-set on Delivery)
9 9
Pilot Control Valve
Product Training
BRAKE MANIFOLD VALVE

PRESSURE CHECK POINT CONNECT GAUGE HERE
10 10
Product Training
PRIORITY UNLOADER VALVE - CHECK
11 11
PROCEDURE 1.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.
* Warning lights should extinguish about 138 bar (2000 psi)

ENSURE A/C & RETARDER ARE DIS-ENGAGED
Product Training
PRIORITY UNLOADER VALVE ADJUSTMENT
12 12
Setting Screw
Product Training
PRIORITY UNLOADER VALVE ADJUSTMENT
13 13
Priority Un-Loader Valve TOO LOW
If pressure reading is too low after following steps 1 thru 4, loosen the lock nut on relief valve 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. Always 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 pressure on gauge, adjust setting screw CW until correct pressure is evident. (e)Re-tighten lock nut.
Product Training
TA40 ENGINE COOLING CIRCUIT
14 14
Low Temp. Unloader Valve
Priority Unloader Valve
Pump
Main Hydraulic Tank
Check Valve
Engine Cooling Fan
Product Training
LOW TEMP. UNLOADER VALVE

Mounted to LHS of Priority Unloader Valve
15 15
Remove Harness
Pressure Setting 205 bar (2970 PSI)

Product Training
LOW TEMP. UNLOADER VALVE CHECK
16 16
PROCEDURE
Follow directly from checking Priority Unloader Valve check procedure.
5.Remove electrical connection from Low Temperature Unloader 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 Unloader Valve.
Product Training
17 17
Setting Screw
Product Training

ADJUSTMENTS
18 18
Low Temperature Un-Loader Valve TOO LOW
If pressure setting is too low after following steps 5 thru 7, Loosen lock nut on Relief Valve and 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.
Product Training
(f)Re-tighten lock nut.
19 19
Solenoid Coil Data 22 watt 26 0.9 amps
Low Temp Unloader Valve
Product Training
HYDRAULIC FAN MOTOR (ENGINE)

A - Inlet
20 20
C A
B - Tank Return C - Case Drain
In-Line Check Valve
Product Training
ENGINE FAN CONTROL SIGNAL

Operation; Wire# 563 (Digital Output W3) Grounds Out Solenoid @ >96C Coolant Temp. >110C Oil Temp. >66C Air Intake Temp.
Check; Fan activation can be checked by activating the A/C or the Transmission Retarder.(Refer Following Slide)
21 21
Fail Safe System 0V Full Speed

Product Training
24V Coast Speed
BRAKE ACTUATION PRESSURE

R
23 23
Brake Actuation Pressure 138 bar (2000 PSI)

Product Training

Main Pressure 170 bar (2465 psi)
24 24
Product Training
25 25
P From Brake Pump ACC1 To Rear Brake Accumulator ACC2 To Front Brake Accumulator A To Directional Control Valve B From Park Brake T Tank Return
PY P2 PS1 PS2 PS3 P1
To Port P1 On Treadle Valve To Port P2 On Treadle Valve Blanked Blanked Park Brake Warning Switch Diagnostic Pressure Check Point Product Training

PS3
26 26
PS3
A B P1 B T P PY ACC1 ACC2 PS1 PS2
P1
PY ACC1 ACC2
PS1
PS2
Solenoid De-Energised
Solenoid Energised
(Park Brake Button Out)
Product Training
(Park Brake Button In or Power Loss)
WARNING PRESSURE SWITCHES
27 27
Front Brake Pressure Switch
(1) (2) (3)
115 bar (1668 PSI) Falling 145 bar (2100 PSI) Rising
Rear Brake Pressure Switch
Park Brake Pressure Switch
115 bar (1668 PSI) Falling 145 bar (2100 PSI) Rising 4.9 bar (71 PSI) Falling
Product Training
LOW PRESSURE INDICATOR LIGHTS
28 28
FRONT BRAKE
REAR BRAKE
PARK BRAKE
Product Training
PARK/EMERGENCY CONTROL
Terex Schematic ID S7
29 29
Product Training
BRAKE ACCUMULATORS
30 30
Pre-Charge Pressure 55 bar (800 psi)

Product Training
DIRECTIONAL CONTROL VALVE

A a
31 31
Transmission Pilot Pressure
Case Drain
b B
Product Training
Plugged
To Px Port On Treadle
Supply Line From Brake Manifold
Tank Return
DIRECTIONAL CONTROL VALVE
32 32
T P - Supply Press. From Brake Manifold
P - Supply Press. From Brake Manifold
A a - Transmission Pilot Pressure
A To Px On Treadle a - Transmission Pilot Pressure
To Px On Treadle
Engine Off (No Pilot Press.)
Engine On
Product Training
BRAKE PEDAL PORTING
33 33
T1 P1 T2 P2 B1 B2
Px
Px - Pressure From Directional Control Valve
T1 - Tank Return (Front Brakes) B1 - Pressure Output to Front Brakes
P1 - Pressure Input to Treadle (Front Brakes) B2 - Pressure Output to Rear Brakes
T2 - Tank Return (Rear Brakes)
P2 - Pressure Input to Treadle (Rear Brakes) Product Training
BRAKE TREADLE VALVE SCHEMATIC
34 34
Service or Emergency Brake Apply
Service/Emergency Brake Release

Product Training
BRAKE PACK PORTS

A From Motor/Triple Pump
35 35
A
B Brake Actuation Line C Return to Brake Cooler
C
Alternative Hosing
Product Training
BRAKE PEDAL RETARDER SWITCH

Retarder off - Pedal 0 Movement
36 36
Retarder Proximity Switch
Retarder Application - First 7 Pedal Movement
Product Training
RETARDER LIGHT ACTIVATION
37 37
Product Training
PARK BRAKE ASSEMBLY
2 2
Product Training
ADJUSTMENT NUT
3 3
Product Training
CONTROL STRAP
4 4
Product Training
PARK BRAKE ADJUSTMENTS
5 5
INSTALLATION;
DO NOT PRESSURISE BRAKE ACTUATOR UNTIL FOLLOWING INSTRUCTION HAS BEEN EXECUTED. PRESSURISING THE ACTUATOR PRIOR TO THIS INSTRUCTION WILL RESULT IN SERIOUS BRAKE DAMAGE. 1.Turn the adjustment nut on the slack adjuster in a clockwise direction until linings are hard against the disc.
ADJUSTMENT OF AUTOMATIC SLACK-ADJUSTER
2. Apply full release pressure to the brake actuator. 3. Loosen hex bolt at the control arm of the slack adjuster & strap. 4. Position the control arm to its full released position - forcing it in a clockwise direction (away from the actuator) - until it has a positive stop inside the control strap. 5. Re-secure the control arm of the slack adjuster to the control strap.
MAY RESULT IN BRAKE DRAG.
CAUTION; FAILURE TO ADJUST THE SLACK ADJUSTER AGAINST THE INTERNAL STOP
6. Use 1.5mm feeler between lining & disc - turn the adjustment nut on the slack adjuster, until the 1.5mm clearance is obtained. 7. Remove feeler & apply brake several times. The automatic slack adjuster will adjust the lining clearance with each application. Clearance will self adjust to the specified 0.7-1.00mm. Product Training
BRAKE COOLING CIRCUIT

Cooling Pump/Motor A B C
Return to Main Hyd. Tank
6 6
Cooling Tank
A - Front Axle Feed
B - Mid Axle Feed
C - Rear Axle Feed
Supply from Main Hyd. Pump
Brake Cooler
2 Speed Control Valve
Product Training
BRAKE COOLER FAN
7 7
Product Training
BRAKE COOLER
8 8
4 1 2 3
1. Fan Drive Inlet 2. Fan Drive Outlet 3. Fan Case Drain 4. Cooler Inlets (x3) 5. Cooler Outlets (x3)
Product Training
BRAKE COOLER TANK RETURNS
9 9
Brake Cooler Tank Return Manifold
Product Training
FRONT AXLE MANIFOLD BLOCK

120C Temp. Warning Lamp
10 10
50C Temp Switch Cooling Fan
To Brake Cooler
120C Temp Switch Warning Lamp
From Triple Motor/Pump
Both Switches N.O.
Product Training
TEMPERATURE SWITCH HARNESS

Remove Harness
11 11
Bridge Harness
For Checking Brake Cooler Fan Speed
Product Training
2 SPEED CONTROL VALVE

Located Behind Brake Oil Cooler
12 12
2 Speed Control Valve
Product Training
2 - SPEED CONTROL VALVE
13 13
Solenoid Coil Data 14 watt 40 0.6 amps
2 - Speed Control Valve
Product Training
BRAKE COOLER FAN CHECK

Procedure
14 14
Check 2 speed function of the Brake Cooler Fan
1.Disconnect Fan Temperature Switch (50C) harness at front axle manifold block.
2.Start Engine and allow to idle.
3.Bridge connection on the temperature switch harness. This energises the solenoid in the 2 Speed Control Valve.
4.Observe increase in fan speed.
5. If fan speed does not increase, investigate fault on on 2 Speed Control Valve Solenoid and associated wiring.
Product Training
TRIPLE COOLING PUMP ACTIVATION
15 15
Product Training
TRIPLE COOLING PUMP CHECK
16 16
Check Actuation Pressure Here
Cooling Section of Main Triple Pump
Typical Readings 110 bar (1600 PSI) @ Full Throttle(Operating Temp.)

Product Training
TRIPLE COOLING PUMP OUTLETS

A - Front Axle Feed
17 17
B - Mid Axle Feed C - Rear Axle Feed
Typical Triple Cooling Pump Outlet Pressure 1.17 - 1.2 bar (17 - 17.5 PSI) @ Full Throttle
Product Training
TRIPLE COOLING PUMP RELIEF
18 18
Relief Setting 100 bar (1450 psi)

Product Training
LOW PRESSURE RELIEF VALVE
19 19
Relief Setting 1.5 bar (22 psi)
(x3 Valves)
Product Training
BRAKE COOLING PORTS

Feed from Triple Motor/Pump Exit Brake to Brake Cooler
20 20
Typical for all 3 Axles

Alternative Hosing
Product Training
CENTRE AXLE MANIFOLD BLOCK

From Triple Motor/Pump
21 21
Actuation Pressure
To Brake Cooler Brake Pack Inlet
Brake Pack Outlet
Actuation Pressure
Product Training
REAR AXLE MANIFOLD BLOCK
22 22
Actuation Pressure
From Triple Motor/Pump To Brake Cooler
Brake Pack Inlet
Actuation Pressure Brake Pack Outlet

Product Training
ADDITIONAL MAINTENANCE CHECKS
23 23
Product Training
SERVICE CAPACITIES
463 litres 209 litres 199 litres 80 litres 37 litres 56 litres 28 litres 37.5 litres 38 litres 31.5 litres 8.5 litres 1.5 litres 0.125 litres
Product Training
24 24
Fuel Tank
Hydraulic System (Steering, Braking & Body)
Brake Cooling System
Engine Cooling System
Engine Crankcase (with Filters)
Transmission & Filters (dry)
Transmission & Filters (wet)
Differential (Front)
Differential (Centre)
Differential (Rear)
Planetaries
Driveshaft Bearings (Pivot)
Air Conditioning Compressor
AXLE DIFF. SERVICE INTERVALS

Oil Type MIL-L2105D API GL-5 SAE 80W90 LS Capacities Front Centre Rear 37.50 litres 38.00 litres 31.50 litres
25 25
Level
Drain
Dana-Spicer Differential
Service Intervals 1st 100 Hrs 250 Hrs 2000 Hrs Drain and Refill Check Oil Level Drain and Refill
Product Training
PLANETARY SERVICE INTERVALS
26 26
13mm
Oil Level Check Procedure Raise axles off ground and support with suitable stands. Rotate each hub so that bottom of filler/level port is 13mm above axle centre line. Check oil level - add oil if required. Oil Capacity 8.5 litres each hub Oil Type Refer to Differential Types Service Intervals 1st 100 Hrs Drain and Refill 250 Hrs Check Oil Level 2000 Hrs Drain and Refill
Product Training
Drain Port
COOLING OIL DRAIN/REFILL

Cooling Oil 1st 100 Hrs Change Filters 1000 Hrs Drain/Re-Fill, Change Filter and Breather
27 27
Brake Packs 1000 Hrs Remember to Drain all 6 Brake Packs Prior to Refill
Drain Port
Product Training
BRAKE PACK WEAR PIN

When Wear Pin is flush with counter bore, plates should be replaced.
28 28
Wear Pin Plug
Check every 1000 hours with engine @ idle and emergency/park brake applied.
Product Training
BRAKE PACK SERIAL PLATE

INSTALLATION DETAIL Ensure Proper Brake Pack is Installed onto Proper Axle. Front Axle Mid Axle Rear Axle 6 Plates 4 Plates 4 Plates Serial Plate Detail; Model 26200 or 24200 6 or 4 Refers to No. of plates in each pack. 200 Refers to actuation pressure (2000 psi). Do not use any other setting.
Product Training
29 29
Serial Plate
TA40 (A820) BRAKE & COOLING SYSTEM CHECKS
PRODUCT TRAINING
TA40 (A820) BRAKE & COOLING SYSTEM CHECKS
Product Training
Check pressures when oil temperature is at least 15 to 20C or ambient temperature if higher on initial start up. SYSTEM SETTINGS Priority Un-Loader Valve Low Temperature Un-Loader Valve Brake Actuation Pressure CHECKING SETTINGS 170 bar (2465 psi) 205 bar (2970 psi) 138 bar (2000 psi)
U
1. 2. 3. 4.
ENSURE A/C & RETARDER ARE BOTH DIS-ENGAGED
Ensure Brake Accumulator pressure is dissipated. Attach pressure gauge to diagnostic check-point on Brake Manifold Valve, port P1. Start truck and allow pressures to increase with engine at low idle. 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 relief valve 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.
TA40 (A820) Brake & Cooling System
Product Training
Low Temperature Un-Loader Valve TOO LOW If pressure setting is too low after following steps 5 thru 7, Loosen lock nut on Relief Valve and 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 (50C) 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 cooling oil. 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)
TA40 (A820) Brake & Cooling System
TA40 (A820) ELECTRICAL SCHEMATICS
PRODUCT TRAINING
ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310)
Section 190-0000
COMPONENT DESIGNATIONS
A4 - 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 E5 E7 E11 E12 E13 E14 E15 E16 E19 E21 E23 E26 E27 E35 - Interior light - Reverse light - Inst panel lights - Side marker light, L - Taillight, L - Side marker light, R - Taillight, R - High/low beam headlamp, L - High/low beam headlamp, R - Rear fog lamp (Option) - Rotating Beacon (Option) - Work light (Option) - High beam headlamp, L - High beam headlamp, R - Heated mirror S10 - Wiper switch, F S11 - Rear wash/wipe switch S13 - Horn button K1 - Starter relay S14 - Hazard w/l switch K4 - Dir ind flasher unit S15 - Direction ind switch K5 - Air cond compressor clutch S16 - Stoplight switch K14 - Start interlock relay S18 - Lights switch K15 - Headlamp relay S19 - Dipswitch K17 - Reverse relay S20 - Headlamp flash switch K21 - Trans shift clutch S22 - Body-up switch K22 - Lock-up clutch S29 - Retarder switch K23 - Ignition relay S31 - Park brake w/l switch K32 - Eng comp brake relay on S37 - Axle difflock switch K33 - Radiator fan relay S40 - Gear shift selector K34 - Horn relay S41 - Auxillary lights switch K35 - Body up relay S43 - Air cond pressure sw K36 - Body float relay S48 - Accumulator press sw, F K37 - Body hyd system relay 12V S49 - Accumulator press sw, B K40 - Low temp unloader solenoid S50 - Brake cooling oil temp switch K43 - Radio/cassette relay S55 - Brake diff press switch K45 - Brake pump compensator S57 - Steering press switch S60 - Difflock request switch L3 - Reverse alarm S67 - Lock-up press switch L4 - Buzzer S68 - Diagnostic request & engine L5 - Electric horn override switch S71 - Air cond rheostat switch M1 - Starter motor S74 - Kickdown switch M3 - Heater blower motor S77 - Trans difflock switch M4 - Washer motor, F S79 - Heated mirror switch M5 - Wiper motor, F S80 - Engine compression brake M6 - Wiper motor, B deacceleration mode switch M7 - Washer motor, B S81 - Retarder/engine compression M10 - Cab fan motor brake selection switch M13 - Air seat compressor S82 - Eng comp brake on/off switch N3 - Voltage convertor 12V X1 - Handlamp socket N4 - Frequency divider H24 - Engine stop w/l H27 - Trans stop w/l P1 - Speedometer/odometer P2 - Tachometer/hourmeter P15 - Retarder temp gauge R7 - Cigar Lighter Y3 Y4 Y7 Y7 Y20 Y26 Y27 Y29 - Retarder valve - Brake diverter valve - Difflock valve transmission - Difflock valve middle axle - Fuel injector - Body raise solenoid - Body lower solenoid - Engine comp brake solenoid L O Y P W S K - Light green - Orange - Yellow - Purple - White - Slate - Pink
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
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 DIODE RESISTOR FUSE PLUG
Wire colours
B N U R G - Black - Brown - Blue - Red - Green
TRAILER CONNECTION
SM 2126 Rev 1 9-02
Electrical System - Circuit Diagrams (DDEC III & IV, 6WG 310)
Section 190-0000
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 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
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.
TERMINAL DESIGNATIONS IN ACCORDANCE WITH DIN 72 552 L - LEFT R - RIGHT F - FRONT B - BACK
DIODE
FUSE
CABLES TWISTED 30 TURNS / metre
TRAILER CONNECTION
INDICATOR LIGHT
RESISTOR
SCREENED CABLES
SM 2126 Rev 1 9-02
Section 190-0000
FUSES
Location Fuse No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 38 39 40 41 42 Circuit Ignition Sensed Relay Contacts (Heater) Keyswitch Cab Fan Ventilator Blower Rear Wash/Wipe Horn Relay Coil, Front Wash/Wipe Air Seat Compressor Lights Switch Main Beam Wiper Park Front and Rear Hazards Transmission System Ignition Supply Reverse System Brake Lights Interior Light, Handlamp Direction Indicators, Rocker Switch Lights Alarm Brake/Steering System Warning Lights Spare Gauges/Ignition Sensed Relay Coils Radiator Fan Neutral Start Washers, Front Washers, Rear Horn Ignition Sensed Relay Contacts (Air Conditioning) Air Conditioning Compressor Spare Ignition Auxilary Supply Option Work Lights Rotating Beacon Cab Fan Transmission System Battery Supply Body Hydraulic System Alternator Drive Signal Heated Mirrors Cigar Lighter Radio/Cassette Supply (Glass Fuse) Radio/Cassette Supply (Glass Fuse) DDEC III & IV ECM Ignition Sensed Supply DDEC III & IV ECM Battery Supply DDEC III & IV ECM Battery Supply
SM - 2571
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
Fuse Box Column A
Fuse Box Column B
Fuse Box Column C
Radio Harness
Battery Box
Current Rating 30A 15A 15A 10A 10A 10A 10A 10A 7.5A 7.5A 7.5A 7.5A 5A 5A 5A 3A 3A 3A 3A 3A 3A 3A 10A 30A 15A 10A 15A 5A 3A 7.5A 5A 3A 15A 10A 7A 1A 5A 15A 15A
RELAYS
K23 K23 K34 K15 K17 K14 K5 - Ign/Sense Opt. - Ign/Sense - Horn - Headlights - Rev. Alarm/Lts. - Neutral/Start - Air Conditioner K35 K4 K33 K23 K36 K37 K43 - Body Up - Flashers - Radiator Fan - Engine Ignition - Body Float - Body Hyd (12V) - Radio/Cassette 3
K23 K23 K34 K15
K17 K14 K5 K35
K4 K33 K23 K36 K37 K43
SM 2126 Rev 1 9-02
SM - 2683A
SM 2126 Rev 1 9-02
15313937, Rev A
SM - 2683B
SM 2126 Rev 1 9-02
15313937, Rev A
TRACTOR STANDARD EQUIPMENT
SM - 2683C
6
SM 2126 Rev 1 9-02
15313937, Rev A
SM - 2683D
SM 2126 Rev 1 9-02
15313937, Rev A
SM - 2683E
SM 2126 Rev 1 9-02
15313937, Rev A
SM 2126 Rev 1 9-02

SM - 2683F
15313937, Rev A
ZF 6WG310 TRANSMISSION TEREX HARNESS INTERFACE EST-37
SM - 2683G
10
ZF 6WG310 TRANSMISSION TEREX HARNESS INTERFACE EST-37
SM 2126 Rev 1 9-02
CLICK HERE FOR HORIZONTAL DRAWING
15313937, Rev A
SM - 2683H
SM 2126 Rev 1 9-02
15313937, Rev A
11
TA35
SM - 2683I
12
SM 2126 Rev 1 9-02
15313937, Rev A
SM 2126 Rev 1 9-02
TA40
SM - 2683J
15313937, Rev A
13
SM - 2683K
14
SM 2126 Rev 1 9-02
15313937, Rev A
TRACTOR STANDARD EQUIPMENT DDEC III & IV ENGINE (HARNESSES FITTED BY TEREX)
SM - 2683L
SM 2126 Rev 1 9-02
15313937, Rev A
TRACTOR STANDARD EQUIPMENT DDEC III & IV ENGINE (HARNESSES SUPPLIED AS PART OF ENGINE)
15
SM - 2683M
16
SM 2126 Rev 1 9-02
15313937, Rev A
SM - 2683N
SM 2126 Rev 1 9-02
15313937, Rev A
17

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PRODUCT TRAINING

TA40 (A820) SYSTEMS FAMILIARISATION

Re-Order Part Number

Book Issue; 090903

TA40(A820) STEERING SYSTEM

HYDRAULIC TANK FILTER

FILTER BY-PASS 3.5 Bar (50 PSI) MAX

MAIN PUMP (STEERING/BODY)

FLOW AMPLIFIER VALVE

FLOW AMPLIFIER VALVE - PORTING

FLOW AMPLIFIER VALVE

STEERING SYSTEM RELIEF VALVE

STEERING SYSTEM CHECK POINTS

LUBRICATE INBOARD STEERING CYLINDER PINS EVERY 50 HOURS Product Training

FLOW AMPLIFIER SPOOLS

SHOCK LOAD VALVE x 2

*DIRECTIONAL CONTROL SPOOL

(*NOT SOLD SEPARATELY)

ORBITROL STEERING VALVE

P INLET FROM FLOW AMP. VALVE SUPPLY TO LH STEER CIRCUIT

R SUPPLY TO RH STEER CIRCUIT

LS LOAD SENSE TO FLOW AMP.

FLOW AMP. - NEUTRAL STEER

FLOW AMP. - RIGHT HAND TURN

FLOW AMP. - LEFT HAND TURN

EMERGENCY STEERING VALVE

CHECK VALVE (MANIFOLD)

CHECK VALVE MANIFOLD

EMERGENCY STEER VALVE

EMERGENCY STEERING PUMP

EMERGENCY STEERING SCHEMATIC

NORMAL STEERING MODE

EMERGENCY STEERING MODE

STEERING PRESSURE SWITCH

STEERING PRESSURE CHART

SHOCK LOAD (FLOW AMP. VALVE)

EMERGENCY STEER CUT IN

PUMP WARNING SWITCH

PUMP CAPACITY @ 2200 RPM

HYD. TANK FILTER BY-PASS

TA40(A820) BODY CONTROL SYSTEM

BODY LIFT/LOWER SYSTEM LAYOUT

DIAGNOSTIC CHECK POINT BODY CONTROL VALVE

FLOW AMPLIFIER VALVE MAIN GEAR PUMP

CHECK VALVE MANIFOLD

PILOT CONTROL LINES LAYOUT

FROM BRAKE ACCUMULATOR CHARGE VALVE TO HYDRAULIC TANK

HYDRAULIC TANK FILTER

FILTER BY-PASS 3.5 Bar (50 PSI) MAX

MAIN TRIPLE PUMP - PILOT SUPPLY

B - Brake Actuation F - Fan (Engine) C - Cooling (Brakes)

BODY PILOT VALVE

P1 FROM ACC. VALVE

U2 PRESSURE CHECK POINT

BODY CONTROL VALVE

SYSTEM RELIEF 172 BAR (2500 PSI)

PRESSURE REDUCING SOLENOIDS

SUSCEPTIBLE TO DIRT/GRIT INGRESS

SOLENOIDS ARE INTERCHANGEABLE

SOLENOID PRESSURE REDUCTIONS

Port P1 30 bar(435 PSI) 0 bar 0 bar 0 bar

Port P2 0 bar 0 bar 30 bar(435 PSI) 13.5 bar(195 PSI)

Raise Hold Float Lower