Terex Fermec 760 Manual

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.
TEREX AMERICAS
SERVICE TRAINING
Contents

SERVICE
TRAINING
Terex Backhoe History Summary
Backhoes are manufactured by Terex –Fermec in Manchester, England.
•1995-Models 750 / 760 / 860 / 965-4WD & 4W steer, FERMEC with Kobe Steel started marketing
Backhoe loaders in USA As Kobelco thru Kobelco distributors.
Major Components-Perkins Engine, Turner Transmission, Danfoss Hydraulics, Carraro front axle, AGCO rear axle.
•1996-Models 750 / 760 / 860 / 965-4WD & 4W steer, In October FERMEC acquired by Case corporation.
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 by Terex corporation
In June, Husco Hydraulics and Carraro axles were installed starting at s/n3905 on TX700/800 series only.
Major Components-Perkins Engine, Turner Transmission, Danfoss Hydraulics, Carraro front axle, Carraro rear axle.
Contents

Rev 3/18/2003 3
SERVICE
TRAINING
SMF B44SRO X 860 4500
MANUFACTURES ID
PRODUCT VARIANTS
YEAR BUILT
MODEL
SERIAL #
TLK/Fermec Machine Serial Log
1993 =P -0000 THRU 0973
1994 =R -0974 THRU 3117
1995 =S -3118 THRU 6305
1996 =T -6306 THRU 9231
1997 =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 OPTION
MECH CONTROLS
“B” Series / Terex

Rev 2/27/03 4
Service
Training
HYDRAULIC SCHEMATIC
ELECTRICAL DIAGRAM SHEET 1
ELECTRICAL DIAGRAM SHEET 2
SECTION DESCPIPTION
1MACHINE SPECIFICATIONS
2CAB CONTROLS & BASIC ELECTRICAL
3ENGINE
4TRANSMISSION
5BASIC HYDRAULIC SYSTEM
6AXLES & STEERING
7BRAKES
8 BACKHOE FUNCTIONS
9LOADER FUNCTIONS
10 SCHEDULED MAINTENANCE
Contents

5
Service
Training
SECTION 1
MACHINE SPECIFICATIONS
Contents

6
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
•ISO 9249 horsepower ............................................................79 hp (59 kW) @ 2200 rpm
•ISO 9249 maximum torque ........................................251 ft lbs (341 Nm) @ 1350 rpm
ELECTRICAL SYSTEM
•Voltage ..................................................................................................................12 volts
•Battery (single) ..................................................................................12 volts (115 amp/h)
•Battery (double).................................................................................. 12 volts (72 amp/h)
•Alternator............................................................................................. Standard -70 amp
•Air conditioning -100 amp
CAB
•ROPS and FOPS type (with protection against rolling 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 engine flywheel. Stall ratio .................... 2.87 to 1
•Gearbox -TURNER Synchroshuttle with 4 synchronized gears, 4 forward and 4 reverse gears (Specific to certain countries,
the fourth gear is not fitted). Electrical transmission cut-out using push button on gear change lever or loader control lever.
•Travel speed
Speeds in forward and reverse with engine speed at 2200 rpm.
Contents

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)
•Rear wheel nuts (all models).................................................... 220 ft lbs (300 Nm)
BRAKES
Service Brakes
•Oil-immersed disc 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 brakes................................................................. 27’ 7” (8.4 m)
•Outside front wheels, with brakes .............................................................. 23’ 8” (7.2 m)
•Outside bucket, no brakes ......................................................................... 36’ 5” (11.1 m)
•Outside bucket, with brakes ..................................................................... 32’ 10” (10.0 m)
psi
Contents

8
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
•Two spool open center mono block valve.
•Single lever operation of bucket and lift spools.
•An optional three spool closed center valve is available for clamshell bucket.
•Maximum working pressure ....................................................................... 3250 –0/+100 psi (225 –0/+7 bar)
Backhoe control valve
•The backhoe control valve is a closed center seven spool mono block.
•The seven spool Valve controls the boom, dipper, bucket, swing, stabilizer, extendable dipper and auxiliary circuits.
•Circuit relief valves protect the boom, dipper, bucket, swing, extendable dipper and auxiliary circuits.
•Optional extendable dipper / hammer (auxiliary circuit)uses a solenoid operated changeover valve is used to divert hydraulic flow to
either the extendable dipper or hammer. A separate foot pedal is used to 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 vibration tested. These machines were all measured in
hand vibration tests to be less than 2.5 m/s 2. For body vibrations, these machines were all measured to be less than 0.5 m/s 2.
CAPACITIES
•Fuel tank ........................................................................ 33.0 US Gal (120 ltr)
•Hydraulic reservoir .........................................................12.4 US Gal (45 ltr)
•Engine (with filter) .......................................................... 3.0 US Gal (10.7 ltr)
•Front drive axle (750/760/765 only) ................................2.2 US Gal (8 ltr)
•Front axle reduction gear (each) (750/760/765 only) .....0.27 US Gal (1.0 ltr)
•Rear axle (750/760/860 only)...........................................6.2 US Gal (22.5 ltr)
•Transmission (Synchroshuttle only)................................4.1 US Gal (15 ltr)
•Cooling system................................................................4.5 US Gal (16.5 ltr)
CYCLE TIMES 760 (with Multipurpose Bucket) Engine set to 2200 rpm, Hydraulic oil at 55 -60°C.
•Raising (with self level)....................................................4.4 seconds
•Lowering (power down) ................................................. 2.9 seconds
•Lowering (float)................................................................4.0 seconds
Dumping (at maximum height) ........1.1 seconds Dumping (at maximum height)
Contents

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 ½inches (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

10
Service
Training
SECTION 2
CAB CONTROLS & BASIC ELECTRICAL
Contents

11
SERVICE
TRAINING
Front Dash Controls
Contents

12
Service
Training
1
2
5
13
3
6 7 8
4 9 12 10 11
Fan, heater and air conditioning
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

13
SERVICE
TRAINING
Wiring Harness
Contents

14
Service
Training
ELECTRICAL SCHEMATIC WIRE IDENTIFICATION
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

15
Service
Training
Older Models
Contents

16
Service
Training
Relays
1Headlight -Main
2Headlight -Dip
3Sidelights / Number Plate / Illum Inst Pack
4Brake Lights
5Hazard enable
6Indicator/hazard enable
7Front Wiper
8Rear Wiper
9Front Washer
10 Rear Washer
11 Front Horn / Rear Horn
12 Indicators flasher unit
13 Front Worklights
14 Rear Worklights
15 Rotating Beacon
16 Float enable relay
17 Clamp
18 Digger Quick Attach
19 RTD
20 Unloader
21 Loader Quick Attach
22 Ride Control Solenoids
23 Gearbox -Forward
24 Gearbox -Reverse
25 4WD Switch
26 Hose Burst
27
Gearbox
-Declutch
Main Fuses Rating
1Alternator 125
2Cab (Ignition) 80
3Cab (Battery) 80
4Ignition Feed (Thermostart) 20
5 Starter Relay and Solenoid 40
Fuses Rating
1Headlight -Main –Left 7.5
2Headlight -Main –Right 7.5
3Headlight -Dip –Left 7.5
4Headlight -Dip –Right 7.5
5Sidelights -Left/Number Plate 3
6Sidelights –Right 3
7Indicators 5
8Hazard 10
9Worklights –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 Difflock / 4WD 7.5
18 Clamp / Q/A Digger / Q/A Loader 7.5
19 RTD / Unloader Valve 5
20 Fr Wiper / Rear Wiper /
Fr Wash / Rear Wash 15
21 Interior Light / Radio 7.5
22 Front Horn / Rear Horn 10
23 Ride Control Solenoids 10
24 Gearbox -Forward/Reverse 5
25 Fuel Solenoid / Fuel Enrich 7.5
26 HMU 15
27 Air Conditioning Switch 7.5
28 Cigar Lighter 15
29 Heater 25
30 Switch Pack & I Pack –Ignition 10
31 Switch Pack & I Pack –Battery 3
32 Battery Relay Coils 5
33 Ignition Relay Coils 5
Contents

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Training
13
Contents

18
Service
Training
Contents

19
Service
Training
SECTION 3
ENGINE
Contents

19.1
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 4
Induction System Turbo Charged with Wastegate
(760, 860, 960 & 965 only)
Injection Fastram Direct
Bore 100mm (3.937in)
Stroke 127mm (5.00in)
Capacity 4 liters (243 ins³)
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/in²)
Technical Details
Valve Tip Clearances (Hot or Cold)
Inlet 0.20 mm (0.008 ins)
Outlet 0.45mm (0.018ins)
1234
Cylinder and
Valve Number 12345678
Valve
I = Inlet
E = Exhaust
I E I E I E I E
Contents