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Terex Fermec 760 Service Training Download Page 79

75

PURGE AIR FROM THE BRAKE SYSTEM (2-wheel steer machines AGCO Axles)

NOTE :

This machine is equipped with hydraulic brakes which must be purged if any part of the brake system has

been disconnected. It is important that this procedure is used to make sure of satisfactory brake operation. The
brakes may be purged either manually or by using a pressurized venting kit. the procedure can only be completed
by two people.

Manual venting

1.

Park the machine on flat level ground.

2.

Fully dump the loader bucket and lower it to the
ground.

3.

Lower the backhoe stabilizers and raise the rear
wheels clear of the ground.

4.

Stop the engine.

5.

Ensure the brakes are adjusted correctly (see
page 4).

6.

Check the brake system fluid level (see page 4).

7.

Fit clear plastic tubes (2) to the vent screws (1).
Position the other ends of the tubes (2) to drain
into suitable containers.

8.

Open the left and the right vent screws (1).

9.

Allow the brake fluid to drain into the containers
until an air-free flow of brake fluid is obtained.

NOTE :

This operation may be aided by pumping the

brake fluid by pressing and releasing the brake
pedals. Make sure the brake pedals remain latched
together and that the brake fluid in the reservoir
remains above the danger mark at all times.

10. Unlatch the brake pedals and close the left vent

screw (1).

11. Press and release the right brake pedal five

times.

12. Close the right vent screw (1) and open the left

vent screw (1).

13. Depress the left brake pedal 12 to 15 mm and

hold it in this position.

14. Press and release the right brake pedal five

times or until an air-free flow of brake fluid is
obtained from the left vent screw (1). Close the
left vent screw (1).

15. Operate the left and the right brake pedals. Make

sure the operation is firm and not ís “spongy”.

16. Only do steps 17 through 21 if the operation of

the pedals is not yet firm.

17. Press the left brake pedal.

18. Open the left vent screw (1) until the flow of

brake fluid stops.

19. Close the left vent screw (1) and release the left

brake pedal.

20. Do steps 17 through 19 until the left brake pedal

is firm.

21. Repeat steps 17 through 20 on the right vent

screw (1) and the right brake pedal.

22. Latch the left and the right brake pedals together.

23. Remove the plastic tubes (2) and the containers.

24. Check the brake system fluid level (see page 4).

789M297A

1

2

Contents

Summary of Contents for Fermec 760

Page 1: ...raining Manual is for Training Purposes Only For Operation Maintenance Service proper manuals must be used for your Machine Proper Manuals can be obtained thru your Dealer TEREX AMERICAS SERVICE TRAINING Contents ...

Page 2: ...oration Major Components Perkins Engine Turner Transmission Danfoss Hydraulics Carraro front axle AGCO rear axle 1999 Models 750B 760B 860B 965B the P100 Series introduced with Danfoss Hydraulics new Electrical relay fuse board Major Components Perkins Engine Turner Transmission Danfoss Hydraulics Carraro front axle AGCO rear axle 2001 Models TX750 TX760 TX860 TX860SB TX960 TX965 Fermec acquired b...

Page 3: ...997 V 0001 THRU 2121 1998 W 2122 THRU 4453 1999 X 4454 THRU 4946 Perkins Green Engine start s n 3538 Backhoe V I N Identification TLK Fermec SMF B44ECO X 8EM 4500 MANUFACTURES ID PRODUCT VARIANTS YEAR BUILT Letter or now MODEL CHASSIS SERIAL B Series Machine Serial Log 1999 X 0001 THRU 2000 Y THRU 2001 1 THRU 3884 TEREX TX750 760 860 960 2002 2 3905 THRU 5416 2003 3 8069 THRU 2004 4 THRU ENGINE OP...

Page 4: ...AGRAM SHEET 1 ELECTRICAL DIAGRAM SHEET 2 SECTION DESCPIPTION 1 MACHINE SPECIFICATIONS 2 CAB CONTROLS BASIC ELECTRICAL 3 ENGINE 4 TRANSMISSION 5 BASIC HYDRAULIC SYSTEM 6 AXLES STEERING 7 BRAKES 8 BACKHOE FUNCTIONS 9 LOADER FUNCTIONS 10 SCHEDULED MAINTENANCE Contents ...

Page 5: ...5 Service Training SECTION 1 MACHINE SPECIFICATIONS Contents ...

Page 6: ...over and falling objects Tinted safety glass wide glazed surface giving total visibility Operator s seat with adjustable suspension Class III as per 1980 ISO DIS 7096 Fresh air heater blower unit full heating control including demist on front and rear windows Optional air conditioning MACHINE WEIGHT Maximum authorized weight 3944lb 8700 kg TRANSMISSION Torque converter Two phase integrated with en...

Page 7: ...c brakes in the rear drive shafts Hydraulic operation by brake pedal master cylinders Parking Or Emergency Brake Hand lever and cables operated through a totally separate mechanical system to directly operate a large caliper type disc brake STEERING Type Hydrostatic Pressure 2500 psi 175 bar Turning circle 760 only Turning circles are the same for both 4WD and 2WD machines Outside front wheels no ...

Page 8: ...operate a spool Optional sideshift backhoe has added Solenoid valves to operate the sideshift clamp Optional craning valve only on center mount backhoe and optional digger bucket quick attach Maximum working pressure 3250 0 100 psi 225 0 7 bar Filtration A return circuit 13 micron interchangeable cartridge filter VIBRATION The machinery safety directive 93 392 EEC requires that machinery be vibrat...

Page 9: ...emp at 140F Stabilizers 7 8 inch 20mm Extendable Dipper 1 inches 40mm Backhoe Bucket 5 8 inch 15mm Dipper 5 8 inch 15mm Boom 5 8 inch 15mm Loader Beam 5 16 inch 8mm Cylinders will leak down because there are no Counterbalance Valves Leakage is at the Control Valves 9 Service Training Contents ...

Page 10: ...10 Service Training SECTION 2 CAB CONTROLS BASIC ELECTRICAL Contents ...

Page 11: ...11 SERVICE TRAINING Front Dash Controls Contents ...

Page 12: ... Side control panel Fuses and relays Test socket 960 965 only 7 in 1 bucket control lever Loader control locking system Park brake lever Backhoe locking lever Loader control lever 4 wheel steer 960 965 only Emergency stop switch 960 965 only Starter key switch Hand throttle Contents ...

Page 13: ...13 SERVICE TRAINING Wiring Harness Contents ...

Page 14: ...ION COLOR CODE B BLACK P PURPLE G GREEN R RED K PINK S SLATE LG LIGHT GREEN U BLUE N BROWN W WHITE O ORANGE Y YELLOW CIRCUIT LOCATION CODE C CHASSIS F FRONT CONSOLE R ROOF S SIDE CONSOLE EXAMPLE WLG 3 WHITE 3MM DIAMETER WIRE WITH A LIGHT GREEN STRIPE Contents ...

Page 15: ...15 Service Training Older Models Contents ...

Page 16: ...id 40 Fuses Rating 1 Headlight Main Left 7 5 2 Headlight Main Right 7 5 3 Headlight Dip Left 7 5 4 Headlight Dip Right 7 5 5 Sidelights Left Number Plate 3 6 Sidelights Right 3 7 Indicators 5 8 Hazard 10 9 Worklights Front 15 10 Worklights Front 15 11 Worklights Rear 15 12 Worklights Rear 15 13 Rotating Beacon 15 14 Brake Light Left 3 15 Brake Light Right 3 16 Instrument Pack Illumination 3 17 Dif...

Page 17: ...17 Service Training 13 Contents ...

Page 18: ...18 Service Training Contents ...

Page 19: ...19 Service Training SECTION 3 ENGINE Contents ...

Page 20: ...965 only Injection Fastram Direct Bore 100mm 3 937in Stroke 127mm 5 00in Capacity 4 liters 243 ins Compression Ratio 17 25 1 Firing Order 1 3 4 2 Rated Power ISO 64 Kw 86hp 760 71 5 Kw 96hp 860 960 965 Maximum Torque ISO 341Nm 1350 rpm 760 371Nm 1400rpm 860 960 965 Lubricating Oil Pressure 280 K Pa 40 lb f in Technical Details Valve Tip Clearances Hot or Cold Inlet 0 20 mm 0 008 ins Outlet 0 45mm ...

Page 21: ...on the threads and underside of the bolt head 3 All M10 bolts should be tightened to 45Nm and the 4 5 inch UNF bolts to 110Nm following the sequence in section 12 of the Perkins Workshop Manual Following the same sequence all fixings should be tightened a further angle depending on their size see below The short and medium M10 bolts should be tightened by 120 degrees The long M10 bolts should tigh...

Page 22: ...e the four torx screws using special tool part number 27610122 on the fuel injection pump gear now the pump can be carefully removed To Re fit the Fuel Injection Pump 1 Check that the engine is still at top dead center 2 With the timing pin fitted to the fuel injection pump it can now be carefully installed on the engine ensuring that all backlash is removed from the gears before tightening Adjust...

Page 23: ...attery inspection before test or charge Reject the battery if 1 The electrolyte is excessively low 2 Electrolyte levels vary by more than 20 mm 0 8 in between cells 3 Battery case lid or mountings are cracked or damaged 4 Terminals are damaged or loose in the case Test the open circuit voltage Test equipment Digital voltmeter Do the open circuit voltage test as follows 1 The engine must be stopped...

Page 24: ...1 CAUTION Parallel charging is not recommended therefore on machines fitted with twin batteries charge each one individually 3 Connect the battery charger to the battery Make sure the polarity of the connections is correct and connect the positive connection first 4 After 30 minutes check the charging voltage the charging current may still be lower than specified Below 12V reject the battery Above...

Page 25: ...me indicated in the table below 6 Set the battery charger to OFF Disconnect the cables from the battery Make sure you disconnect the positive cable first 7 Load test the battery 8 If required install the battery CAUTION Parallel charging is not recommended therefore on machines fitted with twin batteries charge each one individually CAUTION Do not use the standard charge process on a battery produ...

Page 26: ...st charge procedure for batteries producing an open circuit voltage of 11V or less 5 Charge the battery for the time indicated by the table below 6 Set the battery charger to OFF Disconnect the cable from the battery Make sure you disconnect the positive cable first 7 Load test the battery Voltage above 10V refit battery to the machine Refer to testing battery Voltage below 10V charge battery usin...

Page 27: ...ust be limited to 60A CAUTION Parallel charging is not recommended therefore on machines fitted with twin batteries charge each one individually WARNING Check the battery temperature frequently as the high charging current can cause a rapid rise in temperature Stop the charging process if the temperature reaches 60 C 140 F Load testing of the battery Test equipment Current controlled high rate dis...

Page 28: ...d read the battery voltage while the starter motor is operating Voltage should be 10 volts minimum at ambient temperatures above 5 C 9 volts minimum at ambient YES 1 2 Recharge battery see page 6 or 7 NO 1 3 Test open cir cuit voltage Above 12 5 volts YES 1 4 Load test 10 volts or above YES NO NO 2 2 Test alternator output NO 2 3 Check if there are dealer customer fitted accessories such as clock ...

Page 29: ...upport the starter motor 8 and solenoid 4 Remove the three nuts 7 and the P clip mounting bracket 6 from the studs 5 9 Slide the starter motor 8 together with the sole noid 4 from the studs 5 and remove from the engine 10 Put a warning sign in the cab to tell persons not to start the engine Installing the starter motor NOTE The installation of the starter motor is the reverse of the removal Instal...

Page 30: ...30 789M048A Contents ...

Page 31: ...he motor body 9 Use a suitable tube to punch the thrust collar 6 towards the pinion and expose the snap ring 5 10 Remove the snap ring 5 11 Remove the thrust collar 6 12 Pull the pinion and the roller clutch 7 off the armature shaft 13 Pull the intermediate plate 8 off the armature shaft 14 Remove the four screws 11 and carefully pull the field windings 12 from the motor body 15 Inspect and test t...

Page 32: ...bf ft 7 Install the starter motor refer to page 4 Key A STARTER SWITCH B PIVOT PIN 789M051A Testing the battery voltage under load Test equipment 0 to 20 V dc voltmeter NOTE This test can be made with the starter motor still installed on the machine Do the battery voltage under load test as follows 1 Check condition of battery or batteries refer to battery testing 2 Open the hood 3 Disconnect the ...

Page 33: ...es high resistance in cables or contacts 6 High readings indicate high resistance in the starter motor itself 7 Reconnect the wire to fuel injection pump if no further tests are required 8 Install the cover 14 the nut 12 and the pro tective cover 13 9 Close the hood 789M053A Testing the voltage drop on the insulated line Test equipment 0 to 20 V dc voltmeter NOTE This test can be made with the sta...

Page 34: ... the voltmeter should register battery voltage When the starter switch is closed the reading should be zero or fractional value 4 A zero or fractional reading indicates that the high resistance deduced in the voltage drop on the insulated line test must be due either to high resistance in the starter cables or soldered con nections A high reading similar to the voltage drop on the insulated line t...

Page 35: ... test as follows 1 If necessary remove the starter motor from the machine 2 Connect an ammeter in circuit between the starter solenoid and battery 3 Hold the tachometer against the end of the pin ion shaft and operate the starter switch 4 Max current 115 A at 11 V Max speed 5500 to 8000 rpm Excess current indicates that starter is faulty 5 If low current is registered do the continuity of contacts...

Page 36: ...A 5 12 V registered but motor fails to operate indi cates faulty motor Replace the starter motor 6 12 V registered and motor operates test the voltage drop across the contacts Testing the voltage drop across the con tacts Test equipment 0 to 20 V dc voltmeter Test the voltage drop across the contacts as follows 1 Connect the voltmeter across the solenoid termi nals and operate starter switch 2 Vol...

Page 37: ... 600 to 1200 grade abrasive cloth paper 10 Thoroughly clean all components with white spirit and dry with compressed air 11 Measure the length of the brushes 8 Replace the brushes which are 8 mm 5 16 in or less in length 12 Install the brush carrier assembly 9 789M060A 789M061A 13 Lift the springs and engage the brushes 8 14 Test the strength of each brush spring and replace any which exert less t...

Page 38: ...he bush 5 using a 9 16 in Whitworth tap 3 If the bush 1 in the intermediate plate 4 is to be replaced remove the bush 1 using a drift with a pilot diameter of 28 51 mm 1 226 in 4 If the bush 3 in the housing 2 is to be replaced remove the bush 3 using a drift hav ing a pilot diameter of 17 03 mm 0 6705 in 5 Immerse the replacement bush 1 3 or 5 in clean engine oil for 24 hours NOTE The oil absorpt...

Page 39: ...ticeable replace the bush 3 refer to page 13 4 Continue to disassemble the starter motor refer to page 6 steps 7 through 12 5 Inspect the bush 1 in the intermediate plate 5 If the clearance between the bush 1 and the shaft 4 is noticeable replace the bush 1 refer to page 13 6 Complete the disassembly of the starter motor refer to page 6 steps 13 and 14 7 Use a 110 V insulation tester or ohmmeter t...

Page 40: ...40 789M065A 789M066A 789M067A 789M068A Contents ...

Page 41: ...41 Service Training SECTION 4 TRANSMISSION Contents ...

Page 42: ...42 Service Training Contents ...

Page 43: ...ynchroshuttle only Every 1000 hours Oil change Every 1000 hours Total system capacity synchroshuttle only 4 1 US gals 15 litres Extreme pressure oil type API CD SE grade 10W30 screen filter drain 17 mm wrench Service Training 43 Replacing the filter Tools required One filter wrench One 13 mm wrench One oil can Clean around the cover plate and remove it Check the condition of the O ring and replace...

Page 44: ...and adaptor and install plug CI98G502 M5 Oil pump pressure test connection M5 REVERSE CLUTCH PRESSURE TEST Special tool Pressure gauge 600 psi 50 bar with adaptor test procedure 1 Park the machine on a level surface 2 Works the machine until the transmission reaches its working temperature of 176 F 80 C 3 Stop the engine and set the parking brake to on 4 Remove the test point M2 plug and connect t...

Page 45: ...he engine remove the pressure gauge and adaptor and install plug CI98G502 M1 Forward clutch test point M1 TORQUE CONVERTER RELIEF VALVE PRESSURE TEST Tools Pressure gauge 600 psi 50 bar with adaptor Test procedure 1 Park the machine on a level surface 2 Work the machine until the transmission reaches its working temperature of 176 F 80 C 3 Stop the engine and set the parking brake to on 4 Remove t...

Page 46: ...move the pressure gauge and adaptor and install plug CI98G502 M4 Lubrification pressure test point M4 FOUR WHEEL DRIVE CLUTCH PRESSURE TEST Tools Pressure gauge 0 to 50 bar with adaptor Test procedure 1 Park the machine on a level surface 2 Work the machine until the transmission reaches its working temperature of 176 F 80 C 3 Stop the engine and set the parking brake to on 4 Remove the test point...

Page 47: ...iceable Do the torque converter relief valve test as detailed in this section Is the torque converter relief valve serviceable Do the circuit pressure test as detailed in this sec tion Is the circuit pressure correct Is the transmission serviceable Fill the sump with the oil specified Troubleshooting procedure complete Replace or repair the oil pump Replace or repair the cold start relief valve Re...

Page 48: ...ump at the correct level Gap wheels rotate freely Is the engine performance satisfactory Do the torque converter relief valve pressure test as detailed in this section Is the torque converter relief valve serviceable Fill the sump with the oil specified Raise the rear wheels and check for binding Replace or repair the engine as detailed in the engine service manual Replace or repair the torque con...

Page 49: ... verter relief valve serviceable Is the machine being operated correctly Fill the sump with the oil specified or remove excess oil from the sump Troubleshooting procedure complete Remove and flush the oil cooler Replace or repair the oil pump Replace or repair the torque converter relief valve Replace or repair the torque converter Train the operator YES YES YES YES YES NO NO NO NO NO NO YES Do th...

Page 50: ... oil specified Troubleshooting procedure complete Replace the line seals Replace or repair the clutch Replace or repair the torque converter YES YES YES NO NO NO NO YES Is the engine performance satisfactory Is the torque converter clutch serviceable Troubleshooting procedure complete Replace or repair the engine as detailed in the engine Service Manual Replace or repair the torque converter clutc...

Page 51: ...Replace or repair the clutches YES YES NO NO NO YES Are the universal joints and the drive shaft serv iceable Is there a power supply at the four wheel drive selector valve solenoid Is the four wheel drive selector valve solenoid operating correctly Do the four wheel drive clutch pressure test as detailed in this section Is the four wheel drive clutch serviceable Replace or repair the universal jo...

Page 52: ...52 Service Training SECTION 5 BASIC HYDRAULIC SYSTEM Contents ...

Page 53: ...2200 rpm MRV 3250 psi 225 bar Priority Flow Valve Priority to steering system Orbitol Steering Valve Closed center load sensing Relief valve 2540 psi 175 bar 2200 rpm Shock valves 3250 psi 225 bar Unloader Valve Relief valve 207 bar 3000 psi 1800 rpm Loader Control Valve 2 spools Controls Loader Beam and Loader Shovel Backhoe Control Valve 7 spools Controls Slew Boom Dipper Bucket LH RH Stabilizer...

Page 54: ...s operating the oil flows thru front attachment loader control valve back attachment backhoe control valve and thru the to the return line to the backpressure valve 7 The backpressure valve keeps pressure in circuit for operation of backhoe loader functions 8 Without operating any functions the loader and backhoe valve spools are in neutral the oil returns to tank past the backpressure valve then ...

Page 55: ...55 33 Contents ...

Page 56: ...55 1 33 Contents ...

Page 57: ...ure will be 300 PSI 20 Bar No Load 5 Operate Loader function to bottom out a cylinder open Loader MRV Pressure should be 3250 0 100 psi 225 bar Operate Backhoe function to bottom out a cylinder open Backhoe MRV Pressure should be 3250 0 100 psi 225 bar 6 Remove the test fitting gauge from test point MRV and install in Unload test port 7 Operate the backhoe Boom Up function slowly with cylinder bot...

Page 58: ...nd 19 and bolt 18 14 Carefully remove the hydraulic reservoir 1 from the machine 15 Only carry out 16 through 21 if you replace the hydraulic reservoir 1 WARNING The hydraulic reservoir is very heavy Get help to remove the hydraulic reservoir from the machine 16 Loosen the hose clip 20 and remove the manifold 11 and hose 21 from the hydraulic reservoir 17 Remove the bolts 22 O rings 23 and remove ...

Page 59: ...58 17 3 2 1 2 3 4 16 19 18 14 15 7 6 4 9 10 12 11 13 5 24 22 23 27 25 29 26 11 21 20 28 15 Contents ...

Page 60: ... Temp at 140F Stabilizers 7 8 inch 20mm Extendable Dipper 1 inches 40mm Backhoe Bucket 5 8 inch 15mm Dipper 5 8 inch 15mm Boom 5 8 inch 15mm Loader Beam 5 16 inch 8mm Cylinders will leak down because there are no Counterbalance Valves Leakage is at the Control Valves Proper Viscosity of Hydraulic oi must be used ...

Page 61: ...59 Service Training SECTION 6 AXLES STEERING Contents ...

Page 62: ...fferential mechanical lock hydraulically controlled is supported by two bearings mounted on a suitable structure allowing the bevel gear set to be adjusted The ring bevel gear is adjusted by means of two ring nuts located opposite each other The position of the bevel pinion supported by two bearings is adjusted by inserting adjusting shims The wheel hubs containing the epicyclic reduction gears ar...

Page 63: ...el is found then it is advisable to check immediately in order to avoid damages to the mechanical parts Loosen and remove the drain plug for oil draining 4 and 3 1 DIFFERENTIAL OIL FILLING AND LEVEL PLUG 2 OIL BREATHER 3 FILL DRAIN AND LEVEL PLUG OF EPICYCLIC REDUCTION GEAR OIL 4 DIFFERENTIAL OIL DRAIN PLUG GREASING POINTS 5 BRAKE BLEED PLUG 6 SERVICE BRAKE OIL PORT 3 6 5 1 5 5 4 Rear Axle Content...

Page 64: ...62 Service Training A B C E F D G H K I J Differential Differential Brakes Differential Lock Contents ...

Page 65: ... proper lubrication fill up to right level and replace at recommended program Pinion teeth pitting 1 Excessive use 2 Insufficient lubrication Replace bevel gear set Use correct lubrication fill up to the right level and substitute at recommended intervals Axle beam body bent 1 Vehicle over loaded 2 Vehicle s accident 3 Load bump Replace axle beam body Worn out or pitted bearings 1 Insufficient lub...

Page 66: ...ched washers and those with 0 1mm thickness lower than the new ones Inner diameter of tapered roller bearing worn out 1 Excessive use 2 Excessive pinion axial backlash 3 Insufficient lubrication 4 Contaminated oil Replace bearing Check pinion axial backlash Use proper lubrication fill up to right level and replace at recommended intervals Bent or broken halfshaft Vehicle intensively operated or ov...

Page 67: ...65 Service Training DANFOSS Contents ...

Page 68: ...gine delivers so a Unloading Valve is used to divert all the flow from Pump P2 to Tank when the Load Pressure reaches 3000 PSI 207 Bar The Hydraulic Services can then continue working at a reduced speed using the flow from the remaining Pump P1 The output from P1 is delivered first to a Load sensing steering Priority Spool This Spool delivers oil to a Steering Orbitrol Unit according to the demand...

Page 69: ...h the relief valve to tank The pressure drop created across the orifice acting on the end of the Spool exceeds the force of the Spring allowing the Spool to shift opening P2 to Tank When pressure in EF falls below the setting of the Relief Valve it closes the flow through the Orifice stops pressure equalizes at each end of the Spool the spool is then shifted to its original position by the spring ...

Page 70: ...isfy the Steering requirement pressure in CF rises when it exceeds the setting of the spring the spool begins to shift the excess flow is diverted to EF to combine with the flow from P2 to the Hydraulic Control Valves A Load Sense hose directs pressure from the Steering Orbitrol back in to LS Thus regardless of the speed of the turning of the Steering Wheel and regardless of the flow demanded by t...

Page 71: ...cket raise the loader beam and install the safety strut 4 Stop the engine and release the pressure from the hydraulic system 5 Open the hood 6 Connect the pressure gauge to test point P1 Connect the pressure gauge to the test ports 7 Start and run the engine at 1800 rpm 8 Turn the steering to full lock and check the relief valve pressure setting This should be 2500 to 2575 psi 170 to 175 bar 9 Adj...

Page 72: ...lug 3 in To reduce system pressure screw the setting plug 3 out 7 Install the plug 1 in the steering unit and carry out the relief valve test 8 Note the change in pressure and carry out further adjustments to set the correct pressure 9 After the final adjustment fit a new O ring seal 2 on the plug 1 and install the plug 1 10 Remove the test equipment 3 2 1 4 Contents ...

Page 73: ...71 Service Training SECTION 7 BRAKES Contents ...

Page 74: ...8G018 Select second gear then place the direction of travel control lever in the forward position Disengage parking brake Model 860 960 965 Powershift only PSFNR Select second gear then place the transmission control lever in forward drive Disengage parking brake STEP 4 CK98F029 Using the accelerator pedal run the machine at maximum speed STEP 5 CK98F029 Press down on the brake pedals The machine ...

Page 75: ...shuttle only Place the gear change lever in third gear then place the direction of travel control lever in forward drive The audible warning device will sound STEP 2 Model 860 960 965 Powershift only Select third gear then place the transmission control lever in forward drive STEP 3 Using the accelerator pedal increase the engine speed to about 1800 rpm The machine must not move If the machine mov...

Page 76: ...on operates the brake pedal while the other is under the machine to open close bleed screws 4 Using a tube with a check valve or a tube one end on the bleed screw and the other submersed in brake fluid 5 Pump the RH brake pedal until air stops coming out of the tube Hold the pedal down while closing the bleed screw 6 Repeat step 3 to 5 for the LH Brake 7 Join Brake Pedals and apply the brakes The ...

Page 77: ...voir and the inlet pipe assembly 3 6 Release the hose clip 4 and pull the flexible hose 2 from the inlet pipe assembly 3 7 Disconnect the inlet unions 5 from BOTH master cylinders 1 8 Remove the inlet pipe assembly 3 9 Disconnect the pipe 6 from the pressure port of the master cylinder 1 to be removed 10 Disconnect the balance pipe 7 from BOTH master cylinders 1 11 Remove the 2 nyloc nuts 8 and th...

Page 78: ... lift both rear wheels of the ground Lower machine on to stands or blocks with rear wheels off clear of the ground 5 Stop the engine 6 Unlatch both brake pedals 1 and press firmly on each pedal in turm NOTE Do steps 7 through 9 if The stroke of either pedal exeeds 90 mm mesured from the centre of one pedal to the centre of the other Either pedal touches the trim parel 7 Starting on one side tighte...

Page 79: ... fluid by pressing and releasing the brake pedals Make sure the brake pedals remain latched together and that the brake fluid in the reservoir remains above the danger mark at all times 10 Unlatch the brake pedals and close the left vent screw 1 11 Press and release the right brake pedal five times 12 Close the right vent screw 1 and open the left vent screw 1 13 Depress the left brake pedal 12 to...

Page 80: ...ing vent screw is clear and free of entrapped air Make sure the brake fluid in the reservoir remains above the danger mark at all times 10 Depress the left brake pedal 1 2 in 12 to 15 mm 11 Open the left vent screw 1 12 Close the left vent screw 1 when the fluid exhausting vent screw is clear and free of entrapped air 13 Operate the left and the right brake pedals Make sure the operation is firm a...

Page 81: ... flats and check that disc is free to move 4 Tighten outer Locking Nut 17 against inner Adjustment Nut 16 to lock Adjustment Bolt 4 in place Torque to 45 55 ft lbs 62 76 Nm ITEM NO DESCRIPTION 1 TORQUE PLATE FRONT 2 TORQUE PLATE REAR 3 SLEEVE MOUNTING 4 BOLT ADJUSTING 5 LINING CARRIER ASSEMBLY 6 SPRING 7 BI DIRECTIONAL CAM 8 PLASTIC RETAINER 9 BALL BEARING 10 ID SEAL 11 BOOT 12 LEVER 13 THRUST WAS...

Page 82: ... the end of the cable eyes 2 and the brake lever pins 3 4 measures 1 to 2 mm NOTE The cables must not be taut WARNING Before making adjustments to the parking brake is correctly adjusted see Section 7000 PARKING BRAKE SWITCH ADJUSTMENT 750 760 and 860 Versions STEP 1 Place the parking brake in released position STEP 2 Tighten the contactor 5 in the plate 6 until the con tactor plunger is completel...

Page 83: ...79 Service Training SECTION 8 BACKHOE FUNCTIONS Contents ...

Page 84: ...in the pressure gallery and a load sense valve Dipperstick Contained within the dipper circuit are two relief valves set at 4000 PSI 265 Bar piston side 4200 PSI 280 Bar rod side two anti cavitation valves a check valve in the pressure gallery and a load sense valve Bucket Contained within the bucket circuit are two shock valves set at 4200 PSI 280 Bar two anti cavitation valves a check valve in t...

Page 85: ...81 Service Training Contents ...

Page 86: ... the oil to enter the Block The open centre Loader Control Valve is a three spool monobloc which supplies oil to the Loader Beam Bucket 7 in 1 Bucket If fitted On machines fitted with standard Loader Buckets the ports of the Center Spool are blanked off If all the Spools are in the neutral position the oil flows through the open centre of the Loader Valve to the Backhoe Control Valve Oil from the ...

Page 87: ...83 Service Training Contents ...

Page 88: ... been selected to raise the Backhoe Boom on selection of the Spool Load Sense Pressure is relayed via a small bore hose to the spring side of the Bypass Compensator in the Loader Control Valve The Load Sense Pressure plus Spring Pressure closes off the Bypass Compensator diverting the flow from both pumps directly to the Backhoe Control Valve The flow then opens the Pressure Compensator allowing t...

Page 89: ...85 Machine Circuit Diagram Backhoe Boom Selected to Raise Service Training Contents ...

Page 90: ...Contents ...

Page 91: ...Contents ...

Page 92: ...ance between the top of each backhoe control lever and the centre line of the machine corresponds to B 5 Adjust the control rods at the backhoe valve assembly until the distances are correct Standard SAE version Version A B C Standard mm in 10 in 254mm 5 65 in 143 5mm 11 3 in 287mm I S O mm in 10 in 254mm 5 65 in 143 5mm 11 3 in 287mm X Pattern mm in 9 88 in 251mm 6 04 in 153 5mm 12 08 in 307mm A ...

Page 93: ...89 I S O Version CI98G530 X Pattern Version CI98F511 A B B C CENTER LINE OF MACHINE CAB FRAME REF A B B C CAB FRAME REF CENTER LINE OF MACHINE Contents ...

Page 94: ...e left side trim panel to make the control levers vertical or to align the knobs 5 Operate each stabilizer control lever over its full range of movement Make sure that the relevant spool on the backhoe valve operates over its full stroke 6 If the stroke of the spool is not correct adjust the length of the appropriate rod assembly at the backhoe valve CI98F512 1 2 3 4 5 1 Knob 2 Stabilizer control ...

Page 95: ... 2 Adjust the cable sheath stop 2 on the latch side of the boom so the cable is slighty slack 3 Try the boom latch a few times If the catch 3 does not engage in its housing slacken the cable by moving the cable sheath stop 2 towards the boom CI98F514 3 1 2 1 Boom latch control lever 2 Sheath stop 3 Catch Contents ...

Page 96: ...ess 9 Install the retainer plate 8 and torque tighten the bolts 9 to 100 ft lbs 140 Nm Check and adjust the side wear pads 1 Remove the bolts 5 the housings 6 the shims 3 and 4 and the bearing pads 7 2 Assemble a 1 mm shim 4 a 2 mm shim 3 and a new bearing pad 7 in the two housings 6 3 Assemble the housings 6 on one side of the dipperstick housing with the bolts 5 4 Push the inner section hard aga...

Page 97: ...ted at A 2 If adjustment is necessary release both bolts 6 and remove the spacers 5 and the spare shims 4 3 Remove the cover plate 1 and the second set of shims 2 which must be equally reduced in thickness to compensate for the measured wear Use the spare shims removed at step 2 to obtain the correct shim thickness 4 Install the cover plate 1 the spare shims 4 the spacers 5 and the bolts 6 Torque ...

Page 98: ... dipperstick 789M396A 7 Remove the wear pads 8 and 10 and the shims 9 from the sides and the top at the rear of the dipperstick inner section 8 With no shims fit two new wear pads 10 into each side of the inner section and measure the width over the wear pad faces This is dimension A 1 7 6 5 4 3 3 2 3 3 5 6 7 1 2 4 789M397A 9 Measure the internal width of dipperstick outer section This Dimension B...

Page 99: ...linder 1 at its upper eye with suitable lifting equipment 7 Use a soft metal drift to remove the upper pin 9 8 If fitted remove the bolts 11 and the rock guard 10 9 Remove the circlips 13 from the lower pin 12 10 Use a soft metal drift to remove the lower pin 12 11 Remove the stabilizer hydraulic cylinder 1 from the stabilizer leg 2 12 Only carry out Step 13 if you install a replacement stabilizer...

Page 100: ...96 14 2 6 7 8 9 6 5 1 4 11 10 16 1 15 13 13 12 13 3 Contents ...

Page 101: ...97 Service Training SECTION 9 LOADER FUNCTIONS Contents ...

Page 102: ... Beam Shovel 4 in 1 Bucket If fitted On machines fitted with standard Loader Buckets the ports of the Center Spool are blanked off If all the Spools are in the neutral position the oil flows through the open center of the Loader Valve to the Backhoe Control Valve LIFT 4 in 1 BUCKET SHOVEL MAIN RELIEF RELIEFS Contents ...

Page 103: ...99 Service Training Contents ...

Page 104: ...100 Service Training Contents ...

Page 105: ...ic hoses 12 17 Fit blanks to the pipe conections and to hose connections 18 Attach a suitab le lifting equipment to the loader beam 14 Make sure the two front slings are appro ximately 800 mm 31 in longer than the rear pair 19 Remove the locknuts 11 and the bolts 9 which secure the pins 10 to the chassis Discard the locknuts 11 NOTE When installing install new locknuts 11 and tighten the bolts 9 t...

Page 106: ...nnections 7 Disconnect the hydraulic hoses from the bucket cylinder 16 8 Fit blanks to the hose connections and to the bucket cylinder connections 9 Remove the nuts 9 and 11 and the potentiometer operating stud 10 from the link 7 10 Attach suitable lifting equipment to the bucket cylinder 16 11 Remove the circlip 8 from the pin 5 12 Support the link 7 13 Remove the locknut 23 and the bolt 24 attac...

Page 107: ...linder 16 and lower it to the ground 19 Service the bucket cylinder 16 Installation NOTE Install the bucket cylinder and links in the reverse order from that of removal but note the following 1 After installation apply the specified grease to the grease nipples 19 2 After installation of the loader bucket make sure that the bucket cylinder 16 operates correctly 3 Check the level of the hydraulic o...

Page 108: ...itch key STEP 4 Unscrew the return to dig switch lock nut and slide the switch in the groove until the switch contact roller is resting on the loader beam cam then tighten the nut STEP 5 Start the engine raise the loader attachment completely and dump the bucket STEP 6 Place the control lever in return to dig position the loader attachment will lower STEP 7 Check the position of the bucket If the ...

Page 109: ...vent the new cutting edge from fitting correctly A 6 Put the cutting edge in place an use C clamps to hold the cutting edge in place See the illustration for the correct position of the cutting edge CS98M586 B LONG LIP BUCKET 7 Use E 7018 welding rod and weld the cutting edge to the bucket 8 When welding the floor of the bucket to the top of the cutting edge A Start at one end of the bucket and we...

Page 110: ...105 Service Training SECTION 10 SCHEDULED MAINTENANCE Contents ...

Page 111: ...106 Service Training Lubricants and Service Intervals TX760 TX860 TX860SB Contents ...

Page 112: ...S FRONT LOADER 14 10 HOURS FRONT BUCKET 7 IN 1 4 10 HOURS FRONT AXLES AND PIVOT 8 10 HOURS FRONT STEERING RAM 2 10 HOURS REAR CARDAN SHAFT 3 50 HOURS REAR BACKHOE 14 10 HOURS MAST PIVOT 6 10 HOURS BRAKE PEDAL PIVOTS 4 250 HOURS Contents ...

Page 113: ...Contents ...

Page 114: ...Contents ...

Page 115: ...Contents ...

Page 116: ...Guage Kit 6108395M91 Grease Gun Fitting for Axle 6109585M91 New Rear Window With Rigid Frame 6109039M91 Louvered Grill Kit 2068 Ride Control System 662393 Additional Counter Weight 1937 Iso Controls For B Series Danfoss Hydraulics ACC1405 Iso Controls For TX Machines Husco Hydraulics ACC1944 Air Conditioning Filter 6101510M2 Husco Backhoe Valve Special Valve Tool To Install O rings on spools 61937...

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