Terex Fermec 760 Service Training

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TEREX AMERICAS

SERVICE TRAINING

Rear

This Training 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.

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Summary of Contents for Terex Fermec 760

Page 1 TEREX AMERICAS SERVICE TRAINING Rear This Training 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. Contents...
Page 2 Major Components- Perkins Engine, Turner Transmission, Danfoss Hydraulics, Carraro front axle, AGCO rear axle. • 2001- Models TX750 / TX760 / TX860 / TX860SB / TX960 / TX965, Fermec acquired by Terex corporation In June, Husco Hydraulics and Carraro axles were installed starting at s/n3905 on TX700/800 series only.
Page 3 SERVICE TRAINING Backhoe V.I.N. Identification TLK / Fermec “B” Series / Terex MANUFACTURES ID PRODUCT VARIANTS MANUFACTURES ID YEAR BUILT= Letter or now # PRODUCT VARIANTS MODEL / CHASSIS YEAR BUILT ENGINE OPTION MODEL MECH CONTROLS SERIAL # SERIAL #...
Page 4 Service Training SECTION DESCPIPTION MACHINE SPECIFICATIONS CAB CONTROLS & BASIC ELECTRICAL ENGINE TRANSMISSION BASIC HYDRAULIC SYSTEM AXLES & STEERING BRAKES BACKHOE FUNCTIONS LOADER FUNCTIONS SCHEDULED MAINTENANCE HYDRAULIC SCHEMATIC ELECTRICAL DIAGRAM SHEET 1 ELECTRICAL DIAGRAM SHEET 2 Rev 2/27/03 Contents...
Page 5: Section 1 Machine Specifications
Service Training SECTION 1 MACHINE SPECIFICATIONS Contents...
Page 6: Electrical System
Service Training SPECIFICATIONS ENGINE (MODEL 760) • Make and type................... PERKINS 1004-40T • Displacement......................4 liters • Number of cylinders ......................4 • Bore and stroke ..................100 x 127 mm • Injection system..................FASTRAN direct • Compression ratio ....................17.25:1 • SAE J 1349 horsepower............86 hp (64 kW) @ 2200 rpm •...
Page 7 Service Training AXLES • Fixed rear axle Manufacturer – CARRARO, differential with lock, planetary gears, epicyclical hubs and wet disc brakes. • Oscillating front axle All models - Make..CARRARO TIRES WHEEL TIGHTENING TORQUE • Front wheel nuts (750/760/860 only)........220 ft lbs (300 Nm) •...
Page 8: Hydraulic System
Service Training HYDRAULIC SYSTEM Pump (750/760/860) • Tandem gear pumps, TX750/760 Inner pump @ 21 gpm, Outer Pump @ 16.7 gpm, TX860 both pumps @ 21 gpm. • Combined flow..TX750/760 - 38 gpm(142 L/min), TX860 42 gpm(159 L/min) @ 2200 rpm / Main Relief Valve (MRV) 3250 psi(225 bar) Loader control valve •...
Page 9 Service Training Cylinder Leak Down Rates The Normal amount of Leak down in a 10 minute period with Hyd. Oil Temp at 140F. • Stabilizers – 7/8 inch (20mm) • Extendable Dipper – 1 ½ inches (40mm) • Backhoe Bucket – 5/8 inch (15mm) •...
Page 10 Service Training SECTION 2 CAB CONTROLS & BASIC ELECTRICAL Contents...
Page 11 SERVICE TRAINING Front Dash Controls Contents...
Page 12 Service Training 4 wheel steer (960/965 only) Emergency Loader stop switch control (960/965 lever only) Hand Fan, heater and air conditioning throttle Side control panel Starter key switch 7 in 1 bucket control lever Test socket (960/965 only) Fuses and relays Loader control Park brake Backhoe locking lever...
Page 13: Wiring Harness
SERVICE TRAINING Wiring Harness Contents...
Page 14: Color Code
Service Training ELECTRICAL SCHEMATIC WIRE IDENTIFICATION COLOR CODE CIRCUIT LOCATION CODE B= BLACK P= PURPLE C= CHASSIS G= GREEN R= RED F= FRONT CONSOLE K= PINK S= SLATE R= ROOF LG= LIGHT GREEN U= BLUE S= SIDE CONSOLE N= BROWN W= WHITE O= ORANGE Y= YELLOW...
Page 15: Older Models
Service Older Models Training Contents...
Page 16 Service Training Main Fuses Rating Fuses Rating Alternator Headlight - Main – Left Cab (Ignition) Headlight - Main – Right Cab (Battery) Headlight - Dip – Left Ignition Feed (Thermostart) Headlight - Dip – Right Starter Relay and Solenoid Sidelights - Left/Number Plate Sidelights –...
Page 17 Service Training Contents...
Page 18 Service Training Contents...
Page 19 Service Training SECTION 3 ENGINE Contents...
Page 20 Service Training Technical Specification for Perkins 1004.40T General Description 1004 40T (Engine Prefix AQ) Fitted to 760, 860, 960, 965 Governed Engine Speed Idling 700/800 rpm Rated Speed 2,200 rpm Flight Speed 2,310 rpm Number of Cylinders Induction System Turbo Charged with Wastegate (760, 860, 960 &...
Page 21 Service Training Cylinder Head Gasket Asbestos Free, Fit Dry The cylinder head tightening procedure for the AQ model engine remains the same as previous 1000 NOTE Series engines. However, the tightening procedure for Model AS (103mm Naturally Aspirated Engine) varies, the following procedure must be followed. 1.
Page 22 Service Training Fuel injection pump timing The new 1000 Series engines are fitted with a hub driven fuel injection pump which is pin timed, the manufacturer fits the hub to the pump, there is no key way locating the shaft to the hub so if the central nut in the hub is disturbed, the fuel pump timing will be lost and the hub will need to be re-fitted using specialist equipment.
Page 23: Installing The Battery
4003-6 Installing the battery Test the open circuit voltage The installation of the battery is the reverse of the Test equipment removal. Digital voltmeter Install the battery in the reverse order of the removal Do the open circuit voltage test as follows : but note the following : 1.
Page 24: Special Tools
Slow charge the battery 3. Connect the battery charger to the battery. Make sure the polarity of the connections is correct and Special tools connect the (+) positive connection first. 4. After 30 minutes, check the charging voltage (the Battery charger - constant current type with an output charging current may still be lower than of at least 14A and an upper voltage limit of 50V per specified).
Page 25 4003-8 Standard charge of the battery MINIMUM charging period Special tools Open circuit volts Charge period (hours) Above 12.5 Battery charger - constant current type with an output of at least 14A. 12.4 Charge procedure 12.3 12.2 CAUTION Parallel charging 12.1 recommended, therefore on machines fitted with...
Page 26 Fast charge of the battery 5. Charge the battery for the time indicated by the table below : Special tools MAXIMUM charging period Battery charger - constant current type with an output Open circuit volts Charge period (hours) of at least 35A. Above 12.5 Charge procedure 12.4...
Page 27 4003-10 Boost charging of the battery Load testing of the battery Special tools Test equipment Battery charger - with an output of 60A. Current controlled, high rate discharge tester - with at least 500A capacity. Charge procedure Digital voltmeter CAUTION Boost charging Load test the battery as fommows :...
Page 28 Diagnostic test with the battery still on the machine Fault : Battery performance seems poor Proceed with battery test Test complete. Battery OK START 1.1 - Check open 2.1 - Test charging 3.1 - Check quies- 4.1 - Connect circuit voltage refer system voltage cent current drain.
Page 29: Removing The Starter Motor
4004-4 Removing and installing the starter motor Removing the starter motor Remove the nut (11), the washer (10) and dis- connect the four electrical cables (9) from the Remove the starter motor as follows: starter motor (8). Disconnect the battery. Remove the two nuts (15), the two washers (16) and disconnect the three electrical cables (17) NOTE : Make sure the key is removed from the start...
Page 30 789M048A Contents...
Page 31: Disassembling The Starter Motor
4004-6 Disassembling the starter motor 12. Pull the pinion and the roller clutch (7), off the armature shaft. Disassemble the starter motor as follows: 13. Pull the intermediate plate (8) off the armature Remove the starter motor, refer to page 4. shaft.
Page 32 Adjusting the pinion stroke Testing the battery voltage under load Adjust the pinion stroke as follows: Test equipment Remove the starter motor, refer to page 4. 0 to 20 V dc voltmeter NOTE : This test can be made with the starter motor Screw the pivot pin (B) fully into the casting and then slacken off one full turn and position the still installed on the machine.
Page 33 4004-8 Testing the starter motor terminal voltage Testing the voltage drop on the insulated under load line Test equipment Test equipment 0 to 20 V dc voltmeter 0 to 20 V dc voltmeter NOTE : This test can be made with the starter motor NOTE : This test can be made with the starter motor still installed on the machine.
Page 34 Testing the voltage drop across the sole- noid contacts STARTER SWITCH TACHOMETER POSITION 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 voltage drop across the solenoid contacts test as follows: Remove the protective cover (13), the nut (12) and the cover (14).
Page 35 4004-10 Testing the voltage drop in earth line Do the no-load current and speed test as follows: If necessary, remove the starter motor from the Test equipment machine. 0 to 20 V dc voltmeter Connect an ammeter in circuit between the NOTE : This test can be made with the starter motor starter solenoid and battery.
Page 36 Testing the continuity of contacts Testing the voltage drop across the con- tacts Test equipment Test equipment 0 to 20 V dc voltmeter 0 to 20 V dc voltmeter Test the continuity of contacts as follows: Test the voltage drop across the contacts as follows: Open the hood.
Page 37 4004-12 Servicing the end cover and brush car- rier Service the end cover and brush carrier as follows: Open the hood. NOTE : If space within the engine compartment per- mits the removal of the motor body bolts (3), the end cover can be serviced without removing the starter motor from the engine, provided that the electrical cables to the starter are disconnected.
Page 38 Replacing the starter motor brushes Replacing the bushes in the starter motor Replace the brushes as follows: Replace the bushes in the starter motor as follows: Gain access to brushes, refer to page for Servicing end cover (steps 1 through 10). Gain access, as necessary to the bush (1), (3) or (5) to be replaced.
Page 39 4004-14 Removing the starter motor solenoid Inspecting and testing the starter motor Remove the starter motor solenoid as follows: Test equipment (Diagrams on Next Page) Remove the starter motor. 110 volt insulation tester or ohmmeter Remove the two nuts (3) and the copper link (4). Inspect and test the starter motor as follows: Remove the two nuts (1) which secure the sole- Inspect the bush (7) in the alternator cap (8).
Page 40 789M065A 789M066A 789M068A 789M067A Contents...
Page 41: Section 4 Transmission
Service Training SECTION 4 TRANSMISSION Contents...
Page 42 Service Training Contents...
Page 43: Service Specification
Service Training TRANSMISSION Service specification Check transmission mounting bolt torques ... Every 250 hours (After the first 50 hours during the running in period) Tool required -A torque wrench Check the tightness of the eight transmission mounting bolts. (4 each side of machine) 90 - 120 ft lbs.
Page 44: Oil Pump Pressure Test
Service 6002-10 Training OIL PUMP PRESSURE TEST Special tools Pressure gauge 600 psi (50 bar) with adaptor. Test procedure Park the machine on a level surface. Work the machine until the transmission reaches its working temperature of 176°F (80°C). Stop the engine and set the parking brake to on. Remove the test point M5 plug and connect the pressure gauge to the test point.
Page 45 FORWARD CLUTCH PRESSURE TEST Tools Pressure gauge 600 psi (50 bar) with adaptor. Test procedure Park the machine on a level surface. Work the machine until the transmission reaches its working temperature at 176°F (80°C). Stop the engine and set the parking brake to on. Remove the test point M1 plug and connect the pressure gauge to the test point.
Page 46 6002-12 LUBRICATION CIRCUIT PRESSURE TEST Tools Pressure gauge 0 to 50 bar with adaptor. Test procedure Park the machine on a level surface. Work the machine until the transmission reaches its working temperature of 176°F (80°C). Stop the engine and set the parking brake to on. Remove the test point M4 plug and connect the pressure gauge to the test point.
Page 47: Troubleshooting Procedures
TROUBLESHOOTING PROCEDURES Transmission fails to drive in forward or reverse Check the machine for oil leaks and damaged or missing parts. Repair as required. IIs the oil in the sump at the correct level ? Fill the sump with the oil speciﬁed Replace or repair the oil pump Do the oil pump pressure test as detailed in this section.
Page 48 6002-6 Transmission drives in one direction only Do the relevant clutch pressure test as detailed Replace or repair the clutch in this section. Is the clutch serviceable ? Replace or repair the clutch Is the relevant clutch pack serviceable ? Replace or repair the piston/shaft seals Are the piston/shaft seals serviceable ? Replace or repair the transmission...
Page 49: Transmission Overheating
Transmission overheating Is the oil in the sump at the correct level ? Fill the sump with the oil speciﬁed or remove excess oil from the sump. Remove and ﬂush the oil cooler. Is the oil cooler operating correctly ? Replace or repair the oil pump Do the oil pump pressure test as detailed in this section.
Page 50 6002-8 High stall speed Is the oil in the sump at the correct level ? Fill the sump with the oil speciﬁed Replace the line seals. Is the system free from air ? Replace or repair the clutch Are the forward and reverse clutches servicea- ble ? Is the torque converter serviceable ? Replace or repair the torque converter...
Page 51 Machine hesitates when changing between forward and reverse Is the oil in the sump at the correct level ? Fill the sump with the oil speciﬁed Replace or repair the oil pump Do the oil pump pressure test as detailed in this section.
Page 52 Service Training SECTION 5 BASIC HYDRAULIC SYSTEM Contents...
Page 53 Service Training Basic Hydraulic Components • Hydraulic oil specification DIN 51524 Hydraulic oil viscosity - Below 30°C (86°C) ISO VG46 - Above 30°C (86°C) ISO 68 • Hydraulic tank....Capacity 12 US gallons (45 liters) Oil Change period 1000 hours • Suction Strainer.....125 micron, Clean every 1000 hours •...
Page 54: General Description
Service Training Hydraulic Circuit TX760 General Description 1. Oil drawn from the reservoir thru a strainer into the tandem gear pumps. 2. Oil from inner gear pump flows to steering priority flow valve. 3. If the steering orbitrol unit is in neutral the oil is directed to the loader control valve. 4.
Page 55 Contents...
Page 56 55.1 Contents...
Page 57 Service Training HYDRUALIC PRESSURE TESTS (Husco System) Backhoe & Loader Main Relief Valves (MRV) & Unload Relief Valve (URV) Pressure Test Pressure check for TX750, 760 & 860 - MRV = 3250 PSI, URV = 3000 PSI. 1. Work the machine until hyd. oil temp. is at minimum 125° F (5°C). Park the machine on a level surface. 2.
Page 58 9011-6 REMOVAL AND INSTALLATION OF THE HYDRAULIC RESERVOIR 1. Park the machine on a level surface. 16. Loosen the hose clip (20) and remove the manifold (11) and hose (21) from the hydraulic 2. Raise the loader and lock the support strut to reservoir.
Page 59 Contents...
Page 60 SERVICE TRAINING Cylinder Leak Down Rates The Normal amount of Leak down in a 10 minute period with Hyd. Oil Temp at 140F. • Stabilizers – 7/8 inch (20mm) • Extendable Dipper – 1 ½ inches (40mm) • Backhoe Bucket – 5/8 inch (15mm) •...
Page 61 Service Training SECTION 6 AXLES & STEERING Contents...
Page 62 Service Training Carraro Rear Axle General description The axle described in this manual, designed and manufactured following the customer’s requests, consists of a beam casing, housing the differential in the middle and a wheel hub unit at each end. The differential - mechanical lock, hydraulically controlled - is supported by two bearings mounted on a suitable structure allowing the bevel gear set to be adjusted.
Page 63 Service Training Rear Axle DIFFERENTIAL OIL FILLING AND LEVEL PLUG OIL BREATHER FILL / DRAIN AND LEVEL PLUG OF EPICYCLIC REDUCTION GEAR OIL DIFFERENTIAL OIL DRAIN PLUG GREASING POINTS BRAKE BLEED PLUG SERVICE BRAKE OIL PORT Routine checks: In the axle, lubricant should be flush with control plug (1) and (3).
Page 64: Differential Lock
Service Training Differential Differential Brakes Differential Lock Contents...
Page 65 Service CARRARO Axle Troubleshooting Training Problem Cause Action Ring gear tooth broken at the outer side 1. Excessive gear load compared to the Replace bevel gear set one foreseen Follow carefully the recommended 2. Incorrect gear adjustment (excessive operations for the adjustment of bevel backlash) gear set backlash 3.
Page 66 Service Training Problem Cause Action Side gear spline worn out. Excessive use Replace differential gear group. Replace all scratched washers Replace halfshaft if required (Excessive backlash) Thrust washer surface worn out or 1. Insufficient lubrication Use correct lubrication and fill up to right scratched.
Page 67 Service Training DANFOSS Contents...
Page 68 HUSCO UNLOADER & STEERING PRIORITY VALVE The P100 Backhoe Loader fitted with the combined Oil Control Steering Priority / Unloader Manifold uses two Hydraulic Pumps both delivering 21 GPM at 2200 Engine RPM (860 Machine) or 21 / 16.5 GPM at 2200 RPM (750 / 760 Machine). The power needed to drive both Pumps up to maximum relief valve pressure of 225 Bar is more than the Engine 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).
Page 69 Service Training HUSCO UNLOADER VALVE OPERATION Oil from P2 enters the Valve, flows through the Check Valve & combines with the flow from the Steer Priority Spool & exits through Port EF to the Loader & Backhoe ControlValveS. A drilling in the Block feeds oil from EF back to the end of the Unloader Spool, through the orifice in the center of the spool, through the Spring Chamber to the Relief Valve &...
Page 70 Service Training STEERING PRIORITY VALVE OPERATION Oil from P1 enters the center port of the Steer Priority Spool and is diverted to the controlled flow port CF. Pressure in CF is sensed through 2 small drillings in the Spool and is directed to the end of the Spool through a .030 in. (0.8 mm) diameter orifice. When sufficient oil is delivered to the Steering Orbitrol unit to satisfy the Steering requirement, pressure in CF rises &...
Page 71 CHECKING PISTON PACKING FOR THE STEERING CYLINDER 1. Apply the parking brake and lower the loader 7. Turn the steering wheel all the way to the right and continue to turn the steering wheel to the bucket to the floor. right while another person checks for leakage at 2.
Page 72 5001-8 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).
Page 73 Service Training SECTION 7 BRAKES Contents...
Page 74: Service Specification
Service Training SERVICE BRAKE OPERATION CHECK Service specification Check ....................... Every 50 hours Check and adjustment ................. Every 2000 hours Service Brake Check (all STEP 3 Model 750/760/860 Synchroshuttle only models) STEP 1 Park the machine on flat, level ground and engage parking brake.
Page 75 Service Training PARK BRAKE OPERATION CHECK Service specification Check ....................... Every 50 hours Check and adjustment ................. Every 2000 hours STEP 2 Model 860/960/965 Powershift only Parking Brake Check (all models) STEP 1 Select third gear, then place transmission control lever in forward drive. Engage the parking brake and start the STEP 3 engine.
Page 76: Brake Discs
Service Training CARRARO (2 WHEEL) STEER SERVICE BRAKES Brake Discs Bleeding Brakes One at a Time (2 Man Job) Park on ﬂat level ground & apply park brake. Fully dump loader bucket & lower it to ground. Stop the engine. The bleeder screws are on top of the rear axle near the differential housing.
Page 77: Installation
MASTER CYLINDER (2-wheel steer machines AGCO Axles) Removal Installation NOTE : There are two master cylinders, connected by NOTE : The installation of the master cylinder is the a balance tube and compensator valves. Removal of reverse of the removal. one master cylinder is described here.
Page 78 7000-4 CHECKING THE BRAKE FLUID LEVEL (2-wheel steer machines ) Park the machine on ﬁrm level ground. Raise the loader beam to maximum height and fit the safety support. Stop the engine. Open the hood. Check that the fluid level is midway between the marks (2) and (3) moulded on the reservoir.
Page 79 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.
Page 80 7000-6 Venting with pressure kit AGCO Axles 10. Depress the left brake pedal 1/2 in (12 to 15 mm). 11. Open the left vent screw (1). Park the machine on ﬂat level ground. 12. Close the left vent screw (1) when the fluid Fully dump the loader bucket and lower it to the exhausting vent screw is clear and free of ground.
Page 81 Service Training PARK BRAKE ADJUSTMENT PROCEDURE (Carraro Axle) 1. Loosen two Adjustment Locking Nuts (16, 17) (one full and one jam). 2. Tighten inner Adjustment Nut (16) until firm contact is made with the disc by the linings. Torque to 80-120 ft lbs (110-165 Nm). Make certain lever is in proper operating position for application. 3.
Page 82: Parking Brake Switch Adjustment
9001-6 PARKING BRAKE ADJUSTMENT PARKING BRAKE SWITCH (750, 760 and 860 Versions AGCO Axle) ADJUSTMENT (750, 760 and 860 Versions) WARNING : Before making adjustments to STEP 1 the parking brake is correctly adjusted (see Section 7000). Place the parking brake in released position. STEP 2 STEP 1 Tighten the contactor (5) in the plate (6) until the con-...
Page 83 Service Training SECTION 8 BACKHOE FUNCTIONS Contents...
Page 84 Service Training Danfoss Backhoe Control Valve End Module The control valve module of the backhoe control valve houses the following valves: 1. Inlet compensator spool - 175-230 PSI (12-16 bar). 2. Full flow main relief valve - 3250 PSI (225 bar) @ 1800 rpm. 3.
Page 85 Service Training Contents...
Page 86 Service Training HUSCO HYDRAULIC CIRCUIT 750,760,860 BACKHOE VALVE GENERAL DESCRIPTION. (NEUTRAL FLOW) Oil is drawn from the Hydraulic Reservoir through a 125 Micron Suction Strainer into the Tandem Gear Type Pumps. Oil from the inner Pump flows to the Steering Flow Priority Valve Mounted on the Chassis.
Page 87 Service Training Contents...
Page 88 Service Training HYDRAULIC CIRCUIT (BACKHOE BOOM SPOOL SELECTED). The Husco Isocomp Backhoe Control is a Closed Center, Load Sensing, Flow Sharing 7 Spool Valve. The Monobloc Valve features Pressure Compensation on each Spool, compared to the Danfoss Valve with Pressure Compensation on the Slew Section only.
Page 89 Service Training Contents...
Page 90 Contents...
Page 91 Contents...
Page 92 9001-8 BACKHOE CONTROL LEVER ADJUSTMENT Adjustment procedure Check that the distance between the top of each backhoe control lever and the centre line of the Park the machine on a level surface. machine corresponds to B. Switch off the engine. 5.
Page 93 I.S.O. Version CENTER-LINE OF MACHINE CAB FRAME CI98G530 X Pattern Version CENTER-LINE OF MACHINE CAB FRAME CI98F511 Contents...
Page 94 STABILIZER CONTROL LEVER ADJUSTMENT Adjustment procedure Operate each stabilizer control lever over its full range of movement. Make sure that the relevant Park the machine on a level surface. spool on the backhoe valve operates over its full Switch off the engine. stroke.
Page 95 9001-14 BOOM LATCH CABLE ADJUSTMENT Make sure the cable is correctly ﬁxed to the Try the boom latch a few times. If the catch (3) boom latch control lever (1). does not engage in its housing, slacken the cable by moving the cable sheath stop (2) Adjust the cable sheath stop (2) on the latch side towards the boom.
Page 96 9008-18 CHECKING AND ADJUSTING THE EXTERNAL WEAR PADS Check and adjust the top and Check and adjust the side wear bottom bearing pads pads Position the dipperstick so that the inner section Remove the bolts (5), the housings (6), the shims is extended approximately 12 inches (300 mm) and (3) and (4) and the bearing pads (7).
Page 97 CHECKING AND ADJUSTING THE UPPER WEAR PAD Position the digger to full reach and 3/4 extension of the extending dipperstick, but with the bucket 2 inches (50mm) off ground. Any wear will show as a gap between the outer wear pad (3) and the dipperstick.
Page 98 9008-20 CHECKING AND ADJUSTING THE INTERNAL WEAR PADS Remove the bucket, the bucket linkage and the bucket cylinder from the external dipperstick. Lower the boom and the dipperstick until they are horizontal and extend the dipperstick 3/4 out. Remove the external wear pads from the front end of the dipperstick (top pad, bottom pad and four side panels).
Page 99 9011-22 REMOVAL AND INSTALLATION OF THE STABILIZER HYDRAULIC CYLINDER (Centermount machines) This information is applicable to a left-hand stabilizer 11. Remove the stabilizer hydraulic cylinder (1) from hydraulic cylinder. The procedure for a right-hand the stabilizer leg (2). stabilizer hydraulic cylinder is identical. 12.
Page 100 Contents...
Page 101 Service Training SECTION 9 LOADER FUNCTIONS Contents...
Page 102 Service Training LIFT 4 in 1 BUCKET SHOVEL The open center Loader Control Valve is a three spool Monoblock which supplies oil to the Loader Beam / Shovel & 4 in 1 Bucket (If fitted). On machines fitted with standard Loader Buckets the ports of the Center Spool are blanked off.
Page 103 Service Training Contents...
Page 104 Service Training Contents...
Page 105 9006-28 LOADER BEAM Removal Park the machine on a le vel surf ace. Remove the loader b ucket (see page 11). Remove the bucket cylinder and links (see page 21). If ﬁtted, remo ve the quic k attach unit (see page 24).
Page 106 BUCKET CYLINDER AND LINKS Removal CS98M596 Park the machine on a level surface. Remove the nuts (9) and (11) and the potentiometer operating stud (10) from the link Lower the loader beam and position the bucket (7). ﬂat on the ground. Attach suitable lifting equipment to the bucket Depressurize the hydraulic system cylinder (16).
Page 107 9006-22 When the pin (5) is sufﬁciently removed, remove the soft metal drift and lower the link (7) onto the loader crossbeam. Support the link (6) and fully remove the pin (5). Lower the link (6) onto the loader beam. Remove the bucket cylinder (16) and lower it to the ground.
Page 108: Tools Required
Service Training LOADER BUCKET RETURN-TO-DIG ADJUSTMENT 960/965 only Loader bucket return to dig is calibrated by the manufacturer prior to the machine being sold. Consult your local dealer if this needs re-setting. 750/760/860 only STEP 5 Start engine, raise loader Tools required attachment completely and dump the bucket.
Page 109 REPLACEMENT OF WELD-ON CUTTING EDGE FOR STANDARD BUCKETS If the bucket is not removed from the machine, Put the cutting edge in place an use C-clamps to raise the bucket to a suitable height and use hold the cutting edge in place. See the illustration suitable supports to hold the loader frame and for the correct position of the cutting edge.
Page 110: Section 10 Scheduled Maintenance
Service Training SECTION 10 SCHEDULED MAINTENANCE Contents...
Page 111 Service Training Lubricants and Service Intervals Contents...
Page 112 Service Training GREASING POINTS FRONT LOADER 10 HOURS FRONT BUCKET (7 IN 1) 10 HOURS FRONT AXLES AND PIVOT 10 HOURS FRONT STEERING RAM 10 HOURS REAR CARDAN SHAFT 50 HOURS REAR BACKHOE 10 HOURS MAST + PIVOT 10 HOURS BRAKE PEDAL PIVOTS 250 HOURS.
Page 113 Contents...
Page 114 Contents...
Page 115 Contents...
Page 116 Service Training TX750/60 & 860 Backhoe Key Part & Kit Numbers • Service Manual # 6198135M2 & Supplement # 6198267M1 • Brake Booster Kit # 1958 • Air Conditioning Kit # TX760 SNA11 • LHM Brake Fluid # 3621216M1 • Agco Axles Anti-Squawk # 1889891M2 •...