Terex 3340 User manual

3340 and 3345
Off-Highway Trucks
Service Manual
TECHNICALPUBLICATIONSDEPARTMENT
TEREX EQUIPMENT LIMITED,
MOTHERWELL,SCOTLAND,ML15RY
REF. NO. SM507
SM 799 Rev 5 6-97

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TEREX SERVICE DEPARTMENT
PURPOSE:
To advise potentially hazardous condition.
DETAIL:
It has been brought to our attention that 'Viton' material used in manufacture of oil seals and 'O' rings, produces a
highly corrosive acid (Hydrofluoric) when subjected to temperatures above 315° C.
The resulting contamination can have extreme consequences on human tissue since it is almost impossible to
remove after contact.
We therefore recommend the following procedure when it is necessary to inspect any equipment that has been
subjected to a high temperature i.e. fire.
a. Visually inspect for any gaskets or seals which have suffered from heat; they will appear black and sticky.
b. If this is affirmed - Do Not Touch
c. Make enquiries to ascertain the material composition. Any Fluoro-elastomer (Viton, Fluorel or Tecmoflon)
should be considered dangerous but natural rubber and nitrile are non-hazardous.
d. If Fluoro-elastomer seals have been used, then the affected area MUST be decontaminated before
undertaking further work.
e. Disposable Heavy Duty Gloves (Neoprene) MUST be worn and the affected area decontaminated by washing
thoroughly with Limewater (Calcium Hydroxide solution).
f. Any cloths, residue and gloves used MUST be safely discarded after use.
Note: Burning of the discarded items is NOT RECOMMENDED, except in an approved incineration process
where the gaseous products are treated by alkaline scrubbing.
Service
Information
Alert
DATE: April 1994 B168
MODEL: General
SUBJECT: VITON 'O' RINGS AND SEALS (FLUORO-ELASTOMERS) - SAFETY HAZARDS
TEREX Equipment Limited, Motherwell, Scotland ML1 5RY Tel. [phone] Tlx. 77141 Fax. [phone]
TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. [phone] Fax. [phone]
The information contained within this
Alert must not be made available to
third parties not authorised to receive it.
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SM 222 Rev 1 9-93
Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service
procedures recommended and described in this publication, are effective methods for performing service
operations. Some of these service operations require the use of tools specially designed for the purpose.
The special tools should be used when, and as recommended.
It is important to note that this publication contains various WARNINGS and NOTES which should be
carefully read in order to minimize the risk of personal injury to personnel, or the possibility that improper
service methods will be followed which may damage the vehicle or render it unsafe. It is also important to
understand these WARNINGS and NOTES are not exhaustive. It is not possible to know, evaluate and
advise the service trade of ALL conceivable ways in which service might be carried out, or, of the
possible hazardous consequences of each way. Consequently, no such broad evaluation has been
undertaken. Accordingly, anyone who uses a service procedure, or tool, which is not recommended, must
first satisfy themselves thoroughly that neither their safety, nor vehicle safety, will be jeopardized by the
service method he/she selects.
Two types of heading are used in this manual to attract your attention.
1. WARNING - This symbol is used when an operating procedure, practice, etc., which, if not correctly
followed could result in personal injury or loss of life. Look for this symbol to point out important safety
precautions. It means - ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
2. Note - This is used when an operating procedure, practice, etc., which, if not strictly observed, could result in
damage to or destruction of equipment.
IMPORTANT SAFETY NOTICE
WARNING
Never use parts which are altered, modified, or weakened in operation. This can seriously
jeopardize the integrity of the machine and could result in property damage or serious personal
injury.
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SM 832 Rev 6 6-97 1
TABLE OF CONTENTS
Section No. Description SM No.
0 GENERAL INFORMATION
0 3340 Off-Highway Truck 797 Rev 4
0 3345 Off-Highway Truck 798 Rev 2
1 CHASSIS
1 Chassis, Hood and Fenders 841
2 ENGINE
2-2 Engine and Mounting (Cummins) 819 Rev 1
2-2 Engine and Mounting (Detroit Diesel) 1011
2-3 Air Cleaner 846 Rev 2
2-12 Power Takeoff 820
4 TRANSMISSION
4-1 Transmission and Mounting 821 Rev 1
4-12 ATEC Plus II Shift System 822 Rev 2
4-14 Power Takeoff 838 Rev 1
4-16 Transmission Oil Filter 837
7 DRIVELINE
7-1 Front Driveline 653 Rev 1
7-2 Rear Driveline 655
8 REAR AXLE
8-1 Differential 835
8-2 Axle Group 834
8-3 Wheel, Rim and Tyre 831 Rev 1
8-4 Brake Parts 830 Rev 2
8-13 Ride Cylinder 827 Rev 1
9 FRONT AXLE
9-3 Wheel, Rim and Tyre 829 Rev 2
9-4 Brake Parts 678 Rev 2
9-13 Ride Cylinder 828 Rev 1
12 STEERING SYSTEM
12-0 Steering System Schematic 914 Rev 2
12-1A Steering Valve - Pre July 1995 Production 684 Rev 2
12-1A Steering Valve - From July 1995 Production 903
12-5 Steering Cylinder and Linkage 911
12-7 Steering Pump 688 Rev 2
12-9 Steering and Brake Control Tank 803 Rev 2
12-15 Accumulator 692 Rev 1
12-16 Accumulator Valve 804
12-16A Double Relief Valve 805
13 CIRCUIT DIAGRAMS
13-1 Circuit Diagrams 959
13-1 Circuit Diagrams (DDEC III) See Note
13-29 Switches and Sensors 1003
13-29 Switches and Sensors (Series 60 Engine) 997
15 FUEL SYSTEM
15-1 Fuel Tank and Mounting 850
15-2 Fuel Lines (Series 60 Engine) 1017
15-4 Electronic Foot Pedal (Series 60 Engine) 996
Note: Sections in process for issue later.
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SM 832 Rev 6 6-97
2
* * * *
TABLE OF CONTENTS
Section No. Description SM No.
16 COOLING SYSTEM
16-1 Cooling System 842 Rev 1
16-1 Cooling System (Series 60 Engine) See Note
16-2 Radiator, Header Tank and Mounting 843 Rev 1
16-9 Disc Brake Oil Cooler 840 Rev 1
16-9 Transmission Oil Cooler 839 Rev 1
17 OPERATORS COMPARTMENT
17-1 Cab and Mounting 847
17-9 Passenger Seat and Mounting 849
17-10A Air Conditioning (Optional) 848 Rev 1
18 BODY
18-1 Body and Mounting 845
26 BODY SYSTEM
26-0 Body System Schematic 915 Rev 2
26-2 Body and Disc Brake Cooling Tank 807 Rev 3
26-3 Body Cylinder 731 Rev 2
26-5 Tandem Pump 733 Rev 1
26-6 Body Control Valve 808 Rev 1
26-7 Body Control Linkage 809
26-9 Kick-over Valve 738 Rev 1
27 BRAKING SYSTEM
27-0 Braking System Schematic 1004 Rev 1
27-2 Treadle Valve 1007
27-4 Accumulator 811 Rev 1
27-9 Brake Manifold Valve 1008
27-10 Directional Control Valve 909
27-13 Retarder Control Valve 1009
27-22 Shuttle Valve 816 Rev 1
27-25 Monoblock Brake Valve 817 Rev 1
59 MISCELLANEOUS
59-2 Lubrication System 800 Rev 4
59-10 Service Tools 852 Rev 2
59-91 Standard Bolt and Nut Torque Specifications 43 Rev 4
59-99 Unit Storage 168
Note: Sections in process for issue later.
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Section 0
1
SM 797 Rev 4 6-97
GENERAL INFORMATION - 3340 Off-HighwayTruck
SM - 1316
ENGINE - Cummins
Make/Model ......................................CumminsKTA-19-C487
Type .................................4CycleTurbocharged/Aftercooled
Gross Power at 2 100 rev/min ........ 363 kW (487 hp, 494 PS)
Net Power at 2 100 rev/min............. 340 kW (456 hp, 462 PS)
Note: Power ratings to SAE J1995. Net Power is after
deductionsforfanandalternator.Enginerequires
noderating upto 2600m(8 500 ft) altitude.
MaximumTorque .................................2 069 Nm (1 526 lbf ft)
at1 400 rev/min
NumberofCylinders/Configuration ........................... 6,inline
Bore x Stroke .......................... 159 x 159 mm (6.25 x 6.25 in)
TotalDisplacement ................................ 18.9 litres (1 150 in³)
Starting ...................................................................... Electric
MaximumSpeed,FullLoad............................... 2100rev/min
MaximumSpeed,NoLoad................................ 2450rev/min
IdleSpeed ........................................................... 700rev/min
Safe Operating Angle .................................. 30°/60% Grade
ENGINE - Cummins
Make/Model ......................................... Cummins N14-C475
Type ............................... 4 Cycle Turbocharged/Aftercooled
Gross Power at 2 100 rev/min ......354 kW (475 hp, 481 PS)
Net Power at 2 100 rev/min ..........331 kW (444 hp, 450 PS)
Note: Power ratings to SAE J1995 Jun 90. Engine
emission meets USA EPA/CARB MOH 40 CFR 89 and
proposed EU non-road mobile machinery directive.
Maximum Torque .............................. 2 034 Nm (1 500 lbf ft)
at 1 400 rev/min
Number of Cylinders/Configuration .........................6, in line
Bore x Stroke ........................ 140 x 152 mm (6.25 x 6.25 in)
Total Displacement ................................. 14.0 litres (885 in³)
Starting...................................................................... Electric
Maximum Speed, Full Load ............................ 2 100 rev/min
Maximum Speed, No Load ............................. 2 400 rev/min
Idle Speed............................................... 800 (Free) rev/min
Safe Operating Angle ................................ 45°/100% Grade
Fig. 1 - Machine Dimensions
4 370
(14-4)
4 060
(13-4)
4 170
(13-8)
4 450
(14-7)
510 (1-8)
2 765 (9-1)
3 325 (10-11)
3 885 (12-9)
4 240 (13-11)
3 900 (12-10)
1 520 (5-0)
2 710 (8-11)
810
(2-8) 450
(1-6)
4 630
(15-2)
Opt.
2 350 (7-9) 3 940 (12-11) 2 410 (7-11)
8 700 (28-7)
510 (1-8)
15˚ 3 200
(10-6)
7 380
(24-2)
4 700
(15-5)
5 485
(18-0)
7 120
(23-4)
58˚
3 780
(12-5)
330
(1-1)
3340
3 530
(11-7)
3 800
(12-6)
4 060
(13-4)
Max
Body
Depth1 120
(3-8)
Dimensions in mm
(
ft-in
)
Vehicle Clearance Diameter (SAE) 20m (66ft)
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Section 0
General Information - 3340 Off-HighwayTruck
SM 797 Rev 4 6-97
2
ENGINE - Detroit Diesel
Make/Model .................................... Detroit Diesel Series 60
Type .... 4 Cycle Diesel, Turbocharged with air-to-air charge
cooling, water-cooled. Electronic management.
Gross Power at 2 100 rev/min ......354 kW (475 hp, 481 PS)
Net Power at 2 100 rev/min ..........331 kW (444 hp, 450 PS)
Note: Power ratings to SAE J1995. Net Power is after
deductionsforfanandalternator.Enginerequires
no deaeration up to 3 050 m (10 000 ft) altitude.
MaximumTorque .................................2 101 Nm (1 550 lbf ft)
at1 200 rev/min
NumberofCylinders/Configuration ........................... 6,inline
Bore x Stroke .......................... 130 x 160 mm (5.12 x 6.30 in)
TotalDisplacement ................................... 12.7 litres(774 in³)
Starting ...................................................................... Electric
MaximumSpeed,FullLoad............................... 2100rev/min
MaximumSpeed,NoLoad................................ 2225rev/min
Idle Speed.......................................................... 700 rev/min
Safe Operating Angle .................................. 30°/57% Grade
TRANSMISSION
Make/Model ....................................Allison CLT-5963 ATEC
Automatic electronic control with soft shift feature.
Remote mounted in the frame. Integral torque converter
and planetary gearing. Six speeds forward, two reverse.
Automatic converter lockup action in all speed ranges.
Downshift inhibitor.
Rear: Variable rate nitrogen/oil cylinders with A-frame
linkage and lateral stabilizer bar.
Maximum Strut Stroke
Front ......................................................... 251 mm (9.9 in)
Rear .......................................................... 182 mm (7.2 in)
Maximum Rear Axle Oscillation..................... ± 6.5 Degrees
WHEELS AND TYRES
Wheel Rim Width .......................................................... 13 in
Standard Tyres (Front & Rear) ..............18.00 R 33** Radial
Inflation Pressures (Front & Rear) ..........7.5 bar (109 lbf/in²)
Note: Tyre pressures should be regarded as nominal only. It
isrecommended thatfortyresboth listed andunlisted,the
usershould consultthetyre manufacturer andevaluateall job
conditionsinorderto maketheproper selection.
BRAKES
Service
All hydraulic brake system. Transmission mounted pressure
compensatingpump provideshydraulicpressurefor brakes
andsteering. Independentcircuitsfront andrear.Each circuit
incorporatesa nitrogen accumulator whichstoresenergyto
provideconsistentbrakingresponse.
Front Brake Circuit Pressure ................ 159 bar(2300lbf/in²)
Rear Brake Circuit Pressure......................52bar(750lbf/in²)
Accumulators:
NitrogenPrechargePressure ................. 55bar(800lbf/in²)
Front:
Type............................... Dry Disc with 1 calliper per wheel
DiscDiameter .......................................... 660mm(25.5in)
PadArea,Total ..................................... 1 395 cm²(216 in²)
Rear:
Type..................Oilcooled,multiplefrictiondiscs (14total),
completelysealedfromdirtandwater.
BrakingSurface,Total ...................... 38 310 cm² (5 938 in²)
CoolingFlow,Max. .............. 9.2 litres/sec(146 USgal/min)
Parking
Application of rear brakes by springs in brake disc pack.
Hydraulicallyreleased.
Hold-offPressure ................................... 83 bar(1200lbf/in²)
Retardation
Modulated lever control of rear disc pack.
RetarderActuationPressure ............ upto33bar (480 lbf/in²)
Emergency
Push button solenoid control applies service and parking
brakes. Automatically applies when engine is switched off.
Parking brake applies should system pressure fall below a
predetermined level.
Brakes conform to ISO 3450, SAE J1473 OCT 90.
Speeds With Standard Differential TABLE838
Forward
Gear 1 2 3 4 5 6
Ratio 4.00 2.68 2.01 1.35 1.00 0.67
km/h 9.7 14.5 19.3 28.7 38.7 57.8
mile/h 6.0 9.0 12.0 18.0 24.0 36.0
Reverse
Gear R1 R2
Ratio 5.12 3.46
km/h 7.6 11.2
mile/h 4.7 7.0
DRIVE AXLE
Heavy duty axle with single reduction spiral bevel gear
differential, full floating axle shafts, and planetary reduction
at each wheel.
Ratios: Standard Optional
Differential.............................................. 3.15:1 3.73:1
Planetary ............................................... 5.66:1 5.66:1
TotalReduction.................................... 17.83:1 21.11:1
SUSPENSION
Front: King pin strut type independent front wheel
suspension by self-contained, variable rate, nitrogen/oil
cylinders.
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