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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Section 0
3
SM 797 Rev 4 6-97
General Information - 3340 Off-HighwayTruck
STEERING SYSTEM
Independent hydrostatic steering with closed-centre
steering valve, accumulator and pressure compensating
piston pump.
Accumulator provides uniform steering regardless of engine
speed. In the event of loss of engine power it provides
steering of approximately two lock-to-lock turns. A low
pressure indicator light warns of system pressure below 83
bar (1 200 lbf/in²). Steering meets SAE J53.
System Pressure................................ 159 bar (2 300 lbf/in²)
Relief Pressure ...................................207 bar (3 000 lbf/in²)
Steering Cylinders ................... Double Acting, Single Stage
Accumulator:
Oil Capacity ................................. 14.0 litres (3.70 US gal)
Nitrogen Precharge Pressure...............55 bar (800 lbf/in²)
Steering Angle (Left and Right) .......................................39°
Pump:
Type......................................................................... Piston
Capacity at 2 100 rev/min .......... 1.4 litres/s(22 US gal/min)
BODY HYDRAULICS
Two body hoist cylinders are mounted between the frame
rails. Cylinders are two-stage with power down in the second
stage.Thebody hydraulic system is independent of the
steeringhydraulic system.
System Relief Pressure ........................ 190 bar(2750 lbf/in²)
Pump:
Type........................................................................... Gear
Capacity at 2 100 rev/min ....... 3.5 litres/s (55.5US gal/min)
Control Valve ............ Mechanically Controlled Open Centre
Body Raise Time................................................ 13 Seconds
Body Lower Time ................................................. 9 Seconds
ELECTRICAL
Type ............................................. 24 Volt, Negative Ground
Battery......... Two, 12 Volt, 165 Ah each, Maintenance Free
Accessories................................................................ 24 Volt
Alternator ..................................................................70 Amp
Starter ........................................................................ 8.9 kW
BODY
Longitudinal 'V' type floor with integral transverse box-
section stiffeners. The body rests on resilient impact
absorption pads.
Body wear surfaces are high hardness (360-440 BHN)
abrasion resistant steel. Yield strength of plates 1 000 MPa
(145 000 lbf/in²).
VEHICLE WEIGHTS (MASS) TABLE839
kg lb
Chassis, with hoists
Body, standard
Net Weight
25 400
9 200
34 600
56 000
20 300
76 300
PAYLOAD, maximum 36 300 80 000
Maximum Gross Weight* 70 900 156 300
FOR UNIT EQUIPPED WITH OPTIONAL BODY LINER
PLATES:
Chassis, with hoists
Body, with wear plates
Net Weight
25 400
13 650
39 050
56 000
30 100
86 100
PAYLOAD, maximum 31 850 70 200
Maximum Gross Weight* 70 900 156 300
* Maximum permissible gross vehicle weight with options,
attachments, full fuel tank and payload.
WEIGHT DISTRIBUTION Front Axle Rear Axle
Empty %
Loaded % 48 34 52 66
* * * *
Plate Thicknesses:
Floor............................................................. 19 mm (0.75 in)
Side.............................................................. 10 mm (0.39 in)
Front, lower .................................................. 10 mm (0.39 in)
ROPS Cabguard SAE J1040 Feb 86. ISO 3471
Volumes:
Struck (SAE) ............................................ 17.2 m³ (22.5 yd³)
Heaped 3:1 .............................................. 21.7 m³ (28.4 yd³)
Heaped 2:1 (SAE).................................... 23.9 m³ (31.2 yd³)
SERVICE CAPACITIES
Cummins Engine Crankcase & Filters 55 litres (14.5 US gal)
Detroit Engine Crankcase & Filters...... 36 litres (9.5 US gal)
Transmission and Filters....................... 68 litres (18 US gal)
Cooling System................................... 164 litres (43 US gal)
Fuel Tank .......................................... 606 litres (160 US gal)
Steering Hydraulic Tank .................... 61 litres (16.1 US gal)
Steering System.................................... 72 litres (19 US gal)
Body and Brake Cooling Tank ............ 216 litres (57 US gal)
Body and Brake Cooling System ........ 258 litres (68 US gal)
Planetaries (Total) ............................. 66 litres (17.4 US gal)
Differential.......................................... 60 litres (15.8 US gal)
Front Ride Strut (Each) ........................ 14 litres (3.7 US gal)
Rear Ride Strut (Each)......................... 17 litres (4.5 US gal)
Power Takeoff........................................ 4 litres (1.1 US gal)
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Section 0
1
SM 798 Rev 2 3-96
GENERAL INFORMATION - 3345 Off-HighwayTruck
SM - 1317
ENGINE
Make/Model ....................................Cummins KTA-19-C487
Type ...............................4 Cycle Turbocharged/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
deductions for fan and alternator. Engine requires
no deaeration up to 2 600 m (8 500 ft) altitude.
Maximum Torque..............................2 069 Nm (1 526 lbf ft)
at 1 400 rev/min
Number of Cylinders/Configuration .........................6, in line
Bore x Stroke ....................... 159 x 159 mm (6.25 x 6.25 in)
Total Displacement ..............................18.9 litres (1 150 in³)
Starting ..................................................................... Electric
Maximum Speed, Full Load............................ 2 100 rev/min
Maximum Speed, No Load............................. 2 450 rev/min
Idle Speed.......................................................... 700 rev/min
Safe Operating Angle .................................. 30°/60% 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.
Fig. 1 - Machine Dimensions
Speeds With Standard Differential TABLE847
Forward
Gear 1 2 3 4 5 6
Ratio 4.00 2.68 2.01 1.35 1.00 0.67
km/h 11.0 16.5 22.0 32.7 44.2 65.9
mile/h 6.9 10.2 13.7 20.3 27.4 41.0
Reverse
Gear R1 R2
Ratio 5.12 3.46
km/h 8.6 12.8
mile/h 5.4 7.9
Opt.
Vehicle Clearance Diameter (SAE) 21 m (69 ft)
Max
Body
Depth1 195
(3-11)
3345
1 440
(4-9)
885
(2-11) 525
(1-9)
2 710 (8-11)
3 980 (13-1)
4 240 (13-11)
4 630 (15-2)
4 370 (14-4)
4 525
(14-10)
4 245
(13-11)
4 135
(13-7)
585
(1-11)
2 685 (8-10)
3 325 (10-11)
3 965 (13-0)
3 855
(12-8)
2 350 (7-9) 3 940 (12-11)
8 700 (28-7)
2 410 (7-11)
585
(1-11)
3 430
(11-3)
4 700
(15-5)
5 485
(18-0)
7 120
(23-4)
58˚ 430
(1-5)
7 455
(24-6)
3 530
(11-7)
3 800
(12-6)
4 060
(13-4)
Dimensions in mm
(
ft-in
)
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Section 0
General Information - 3345 Off-HighwayTruck
SM 798 Rev 2 3-96
2
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
Total Reduction...................................17.83:1 21.11:1
SUSPENSION
Front: King pin strut type independent front wheel
suspension by self-contained, variable rate, nitrogen/oil
cylinders.
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 .......................................................... 15 in
Standard Tyres (Front & Rear)............. 21.00 R35 ** Radial
Inflation Pressures (Front & Rear) .......... 5.5 bar (80 lbf/in²)
Note: Tyre pressures should be regarded as nominal only.
It is recommended that for tyres both listed and unlisted,
the user should consult the tyre manufacturer and evaluate
all job conditions in order to make the proper selection.
BRAKES
Service
All hydraulic brake system. Transmission mounted
pressure compensating pump provides hydraulic pressure
for brakes and steering. Independent circuits front and
rear. Each circuit incorporates a nitrogen accumulator
which stores energy to provide consistent braking
response.
Front Brake Circuit Pressure ............. 159 bar (2 300 lbf/in²)
Rear Brake Circuit Pressure................... 52 bar (750 lbf/in²)
Accumulators:
Nitrogen Precharge Pressure ............. 55 bar (800 lbf/in²)
Front:
Type..............................Dry Disc with 1 calliper per wheel
Disc Diameter ........................................ 660 mm (25.5 in)
Pad Area, Total ...................................1 395 cm²(216 in²)
Rear:
Type...............Oil cooled, multiple friction discs (14 total),
completely sealed from dirt and water.
Braking Surface, Total................... 38 310 cm² (5 938 in²)
Cooling Flow, Max............ 9.2 litres/sec (146 US gal/min)
Parking
Application of rear brakes by springs in brake disc pack.
Hydraulically released.
Hold-off Pressure................................. 83 bar (1 200 lbf/in²)
Retardation
Modulated lever control of rear disc pack.
Retarder Actuation Pressure ......... up to 33 bar (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.
STEERING SYSTEM
Independent hydrostatic steering with closed-centre
steering valve, accumulator and pressure compensating
piston pump.
Accumulator provides uniform steering regardless of
engine speed. In the event of loss of engine power it
provides steering of approximately two lock-to-lock turns. A
low pressure indicator light warns of system pressure
below 83 bar (1 200 lbf/in²). Steering meets SAE J53.
System Pressure ............................... 159 bar (2 300 lbf/in²)
Relief Pressure .................................. 207 bar (3 000 lbf/in²)
Steering Cylinders ................... Double Acting, Single Stage
Accumulator:
Oil Capacity .................................14.0 litres (3.70 US gal)
Nitrogen Precharge Pressure ............. 55 bar (800 lbf/in²)
Steering Angle (Left and Right) .......................................39°
Pump:
Type......................................................................... Piston
Capacity at 2 100 rev/min ...... 1.4 litres/s (22 US gal/min)
BODY HYDRAULICS
Two body hoist cylinders are mounted between the frame
rails. Cylinders are two-stage with power down in the
second stage. The body hydraulic system is independent of
the steering hydraulic system.
System Relief Pressure ..................... 190 bar (2 750 lbf/in²)
Pump:
Type........................................................................... Gear
Capacity at 2 100 rev/min ... 3.5 litres/s (55.5 US gal/min)
Control Valve ............Mechanically Controlled Open Centre
Body Raise Time ............................................... 13 Seconds
Body Lower Time................................................. 9 Seconds
ELECTRICAL
Type ............................................. 24 Volt, Negative Ground
Battery ........Two, 12 Volt, 165 Ah each, Maintenance Free
Accessories................................................................24 Volt
Alternator ..................................................................70 Amp
Starter ........................................................................8.9 kW
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Section 0
3
SM 798 Rev 2 3-96
General Information - 3345 Off-HighwayTruck
BODY
Longitudinal 'V' type floor with integral transverse box-
section stiffeners. The body rests on resilient impact
absorption pads.
Body wear surfaces are high hardness (360-440 BHN)
abrasion resistant steel. Yield strength of plates 1 000 MPa
(145 000 lbf/in²).
Plate Thicknesses:
Floor ............................................................ 19 mm (0.75 in)
Side ............................................................. 10 mm (0.39 in)
Front, lower................................................. 10 mm (0.39 in)
ROPS Cabguard SAE J1040 Feb 86. ISO 3471
Volumes:
Struck (SAE) ............................................19.6 m³ (25.6 yd³)
Heaped 3:1 ..............................................23.8 m³ (31.1 yd³)
Heaped 2:1 (SAE) ................................... 26.0 m³ (34.0 yd³)
SERVICE CAPACITIES
Engine Crankcase and Filters ...........55 litres (14.5 US gal)
Transmission and Filters ...................... 68 litres (18 US gal)
Cooling System...................................164 litres (43 US gal)
Fuel Tank .......................................... 606 litres (160 US gal)
Steering Hydraulic Tank ....................61 litres (16.1 US gal)
Steering System ...................................72 litres (19 US gal)
Body and Brake Cooling Tank............ 216 litres (57 US gal)
Body and Brake Cooling System........258 litres (68 US gal)
Planetaries (Total) .............................66 litres (17.4 US gal)
Differential..........................................60 litres (15.8 US gal)
Front Ride Strut (Each) .......................14 litres (3.7 US gal)
Rear Ride Strut (Each) ........................17 litres (4.5 US gal)
Power Takeoff........................................ 4 litres (1.1 US gal)
VEHICLE WEIGHTS (MASS) TABLE848
kg lb
Chassis, with hoists
Body, standard
Net Weight
26 685
9 600
36 285
58 830
21 165
79 995
PAYLOAD, maximum 40 825 90 000
Maximum Gross Weight* 77 110 169 995
FOR UNIT EQUIPPED WITH OPTIONAL BODY LINER
PLATES:
Chassis, with hoists
Body, with wear plates
Net Weight
26 685
14 100
40 785
58 830
31 085
89 915
PAYLOAD, maximum 36 325 80 085
Maximum Gross Weight* 77 110 170 000
* Maximum permissible gross vehicle weight with options,
attachments, full fuel tank and payload.
WEIGHT DISTRIBUTION Front Axle Rear Axle
Empty %
Loaded % 48 34 52 66
* * * *
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Section 1-1
1
SM8415-95
SM - 1389
CHASSIS - Chassis, Hood and Fenders
REMOVAL
WARNING
To prevent personal injury and property
damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the
job safely.
To remove any of the components shown in
Figs. 1, 2, 3 or 4 (or similar components) the following
procedures should be carried out.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. Turn steering
wheel several times to relieve pressure in the steering
circuit.
2. Block all road wheels and place the battery master
switch in the 'Off' position.
3. Attach a suitable lifting device to the component
and remove mounting hardware. Remove the
component from the vehicle.
INSTALLATION
Note: Tighten all fasteners to standard torques listed
in Section 59-91, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
WARNING
To prevent personal injury and property
damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the
job safely.
Using a suitable lifting device, align the component to
be installed in position on the chassis. Secure the
component securely to the chassis with mounting
hardware removed during removal.
Fig. 1 - Exploded View of Chassis and Guards
1 - Frame Assembly
2 -Bushing
3 -EngineGuard
4 -Channel
5 - Bolt
6 - Nut
11 - Bolt
12 -HardenedWasher
13 - Locknut
14 - Spring Disc
15 - Washer
7 -Lockwasher
8 - Washer
9 - Bolt
10 -TransmissionGuard
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Chassis - Chassis, Hood and Fenders
Section 1-1
2SM8415-95
SM - 1390MAINTENANCE
Inspection
Inspect the frame and attached parts at intervals not
exceeding 250 hours for cracked or broken welds and
bending/twisting of the frame. Any defects found
should be repaired before they progress into major
failures. Contact your dealer for recommended weld
and repair instructions.
Welding
Note: It is important that the electrical connections
are disconnected in the following order to prevent
damage to the electrical components:
a. Disconnect battery equalizer ground cables.
b. Disconnect battery cables from terminal posts
(ground cable first).
c. Disconnect battery equalizer positive cables.
d. Disconnect electrical connections at the ECU.
After welding, reconnect all of the above in the
reverse order.
WARNING
Welding and flame cutting cadmium plated
metals produce odourless fumes which are
toxic. Recommended industrial hygiene
practice for protection of the welding operator
from the cadmium fumes and metallic oxides
requires enclosure ventilation specifically
designed for the welding process. A
respiratory protective device such as the
M.S.A. 'Gasfoe' respirator with G.M.A.
cartridge will provide protection against
cadmium, fumes and metallic oxides. The
'Gasfoe' respirator has been approved by the
U.S. Bureau of Mines: Approval number
23B-10, and is designed to protect against
gases, vapours, and/or metal fumes.
Electric arc welding is recommended for all chassis
welding. Since the nature and extent of damage to the
frame cannot be predetermined, no definite repair
procedure can be established. As a general rule
however, if parts are twisted, bent or pulled apart, or a
frame is bent or twisted, no welding should be done
until the parts are straightened or realigned.
Successfully welded repairs will depend to a great
extent upon the use of the proper equipment,
materials and the ability of the welder. The Service
Department can be consulted regarding the feasibility
of welding repairs.
Painting
A check of the condition of the paint should be made
approximately twice a year and chassis repainted if
necessary.
If painting of the actual frame of the unit is required,
thoroughly clean the areas to be painted. Apply a
primer coat of synthetic red oxide and then a finish
coat of synthetic enamel.
To keep rust and corrosion to a minimum, periodic
painting of abrasions and other exposed metal areas
on the frame is highly recommended.
1 - Hood Assembly
2 -Plate
3 - Bolt
4 -HardenedWasher
5 - Nut
6 -Baffle
7 -Beading
Fig. 2 - Exploded View of Hood and Mounting
54
3
54
3
2
1
7
6
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Section 1-1
3
SM8415-95
SM - 1391
Chassis - Chassis, Hood and Fenders
Fig. 3 - Exploded View of Fenders and Mounting
25 - Washer
26 - Bolt
27 - Bolt
28 - Bolt
29 -Mudguard
30 -Mudguard
31 - Cover
1 - LH Fender Assembly
2 - LH Platform Assembly
3 - RH Fender Assembly
4 - RH Platform Assembly
5 -Crossmember
6 -Support
7 -Stiffener
8 - Bolt
9 - Lockwire
10 -HardenedWasher
11 - Bolt
12 - Washer
13 - Locknut
14 - Bolt
15 - Locknut
16 -HardenedWasher
17 - Bolt
18 - Locknut
19 -HardenedWasher
20 -Tapered Washer
21 - LH Handrail
22 - Bolt
23 - RH Handrail
24 - Nut
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Chassis - Chassis, Hood and Fenders
Section 1-1
4SM8415-95
SM - 1392
1 - LH Step Assembly
2 - RH Step Assembly
3 - LH Support Step
4 - RH Support Step
5 - Step
6 - Spacer
7 - Washer
8 - Bolt
9 - Locknut
10 - Nut
11 - Bolt
12 -HardenedWasher
13 - Bolt
14 - Nut
15 -HardenedWasher
Fig. 4 - Exploded View of Ladders and Handrails
CHASSIS
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