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Section 120-0000 TRANSMISSION - Transmission and Mounting SERVICE MANUAL
2nd POWER TAKE-OFF
SCHEDULE OF MEASURING POINTS SM - 1824
CONVERTER
Measurements to be carried out with oil at normal operating 14
RETARDER WK
temperature of 80° C and operating at full speed.
KV K1

MEASURING POINTS FOR PRESSURE OIL AND 1st POWER TAKE-OFF

TEMPERATURE:
51 = Before the Convertor - Opening Pressure 8.5 bar INPUT
52 = Behind the Convertor - Opening Pressure 5 bar
53 = Clutch forward 16+2 bar KV KR K2
55 = Clutch reverse 16+2 bar KR PUMP
56 = Clutch 16+2 bar K1
57 = Clutch 16+2 bar K2
6 31
58 = Clutch 16+2 bar K3 K4 K3
60 = Clutch 16+2 bar K4
63 = Temperature 100° C behind the retarder (short time 150° C)
65 = System pressure 16+2
66 = Temperature 100° C behind the converter (short time 120° C) 39
OUTPUT OUTPUT
67 = WK-Control pressure 13±1 bar
58
56 ENGAGEMENT AND DISENGAGEMENT DIFFERENTIAL
53
DIFFERENTIAL LOCK
60 D C

INDUCTIVE TRANSMITTERS AND SPEED SENSORS

E B
55 6 = Inductive Transmitter n Turbine
F A
14 = Inductive Transmitter n Engine
G
31 = Speed Sensor n Output and Speedometer
J H K
57 39 = Inductive Transmitter n Central Gear Train

66 • PRESS REG. UNDER VOLTAGE

51
52 SPEED Y1 Y2 Y3 Y4 Y5 Y6
F1 • •
F2 • •
F3 • •
F4 • •
F5 • •
F6 • •
63 R1 • •
67 65 R2 • •
R3 • •
N
CLUTCH KR K4 K1 K3 KV K2
POS. VALVE F E D C B A
POINTS 55 60 56 58 53 57

Fig. 4 - Typical Schedule of Measuring Points and Gear Pattern

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Section 120-0000 TRANSMISSION - Transmission and Mounting SERVICE MANUAL

KR K4 K1 K3 KV K2 SM - 2570

F 55 E 60 D 56 C 58 B 53 A 57
P1 P2 P3 P4 P5 P6
B D B D B D B D B D B D

Y1 NFS Y2 NFS Y3 NFS Y4 NFS Y5 NFS Y6 NFS

RV-9
TEMP

No. Denomination of the Position Port

K 65
NOT SCOPE OF SUPPLY ZF
15 To the heat exchanger
WK-M HDV
HYDRAULIC PRESSURE 16 From the heat exchanger
WK-V 28 To the ZF-filter
29 From the ZF-filter
32 Behind the Convertor to heat exchanger
PRESSURE REDUCTION VALVE
33 Before the Convertor to heat exchanger
5.5 bar 34 From heat exchanger to lubrication into Transmission
CONVERTER
67 WK 51 Before the Convertor - Opening Pressure 8.5 bar H
52 Behind the Convertor - Opening Pressure 5 bar
51
53 Clutch forward 16+2 bar KV B
55 Clutch reverse 16+2 bar KR F
H 56 Clutch 16+2 bar K1 D
TO THE RETARDER VALVE WSV 57 Clutch 16+2 bar K2 A
5.5 bar 66 52 58 Clutch 16+2 bar K3 C
60 Clutch 16+2 bar K4 E
29 63 Temp. 100° C behind the retarder (short time 150° C)
WGV 65 System pressure 16+2 K
66 Temp. 100° C behind the converter (short time 120° C)
BYPASS VALVE 67 WK-Control pressure 13±1 bar
ZF-FINE FILTER
32
WT (SCOPE OF SUPPLY CUSTOMER) 28

16 15

WITH RETARDER
RT-V
LEGEND:
FILLING POSITON IN THE CABIN TRANSMISSION PUMP = MAIN PRESSURE
63 = CONTROLLED MAIN PRESSURE
= PILOT PRESSURE
= CONVERTER INLET PRESSURE
WITHOUT RETARDER = CONVERTER EXIT PRESSURE
= LUBRICATION
= RETURN TO SUMP
COARSE FILTER
LUBRICATION

33 34

RT OIL SUMP

Fig. 5 - Oil Circulation Diagram for Typical Transmission with Lockup Clutch and Retarder
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams - Pre June 1999 Production SERVICE MANUAL
SM - 1891A
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams - Pre June 1999 Production SERVICE MANUAL
SM - 1891B
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams - Pre June 1999 Production SERVICE MANUAL
SM - 1891C
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams - Pre June 1999 Production SERVICE MANUAL
SM - 1891D
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams - Pre June 1999 Production SERVICE MANUAL
SM - 1891E
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams - Pre June 1999 Production SERVICE MANUAL
SM - 1891F

ZF 6WG310 TRANSMISSION TEREX HARNESS INTERFACE EST-37

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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams - Pre June 1999 Production SERVICE MANUAL
SM - 1891G

ZF 6WG310 TRANSMISSION TEREX HARNESS INTERFACE EST-37

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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams - Pre June 1999 Production SERVICE MANUAL
SM - 1891H
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams - Pre June 1999 Production SERVICE MANUAL
SM - 1891I

TRACTOR STANDARD EQUIPMENT DDEC III ENGINE (HARNESSES FITTED BY TEREX)

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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams - Pre June 1999 Production SERVICE MANUAL
SM - 1891J

TRACTOR STANDARD EQUIPMENT DDEC III ENGINE (HARNESSES SUPPLIED AS PART OF ENGINE)
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams - Pre June 1999 Production SERVICE MANUAL
SM - 1891K
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams - Pre June 1999 Production SERVICE MANUAL
SM - 1891L
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310) SERVICE MANUAL
SM - 2426A

15306270, Rev B
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310) SERVICE MANUAL
SM - 2426B

15306270, Rev B
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310) SERVICE MANUAL
SM - 2426C

15306270, Rev B
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310) SERVICE MANUAL
SM - 2426D

15306270, Rev B
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310) SERVICE MANUAL
SM - 2426E

15306270, Rev B
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310) SERVICE MANUAL
SM - 2426F

15306270, Rev B ZF 6WG310 TRANSMISSION TEREX HARNESS INTERFACE EST-37

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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310) SERVICE MANUAL
SM - 2426G

15306270, Rev B ZF 6WG310 TRANSMISSION TEREX HARNESS INTERFACE EST-37

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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310) SERVICE MANUAL
SM - 2426H

15306270, Rev B
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310) SERVICE MANUAL
SM - 2426I

15306270, Rev B TRACTOR STANDARD EQUIPMENT DDEC III & IV ENGINE (HARNESSES FITTED BY TEREX)
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310) SERVICE MANUAL
SM - 2426J

15306270, Rev B TRACTOR STANDARD EQUIPMENT DDEC III & IV ENGINE (HARNESSES SUPPLIED AS PART OF ENGINE)
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310) SERVICE MANUAL
SM - 2426K

15306270, Rev B
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Section 190-0000 ELECTRICAL SYSTEM - Circuit Diagrams (DDEC III & IV, 6WG 310) SERVICE MANUAL
SM - 2426L

15306270, Rev B
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Section 220-0000 STEERING SYSTEM - Steering System Schematic SERVICE MANUAL
SM - 2419

CR CL

8 8

L R 5
7 L

P T LS

EF P PP HP LS HT T R BODY
CONDITION BASED ON HOIST
A SYSTEM
ENGINE SHUTDOWN

1 - Hydraulic Tank
2 - Main Hydraulic Pump 6
4
3 - Emergency Steering Pump
4 - Emergency Valve
5 - Flow Amplifier Valve 2 3
6 - Check Valve
7 - Steering Valve 1
8 - Steering Cylinders

PRESSURE TEST POINT

A - Steering System Pressure

Fig. 1 - Steering System Schematic

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Section 230-0000 BODY SYSTEM - Body System Schematic SERVICE MANUAL
SM - 1848A

B
P2 T2 U2
5

30
bar

45
3 3 bar

FROM
P1 T1 U1
BRAKING
SYSTEM
L T R
2

P2 P1

T2 T1

COMPONENTS
1 - Hydraulic Tank
2 - Body Control Valve P
3 - Body Cylinders A
4 - Hydraulic Oil Cooler 4
5 - Pilot Supply Valve FROM EF PORT
IN FLOW AMPLIFIER
COLOUR CODES 1 VALVE
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil
Orange - Pilot Pressure
Yellow - Static Oil

Fig. 2 - Body Hoist System Schematic - Body Control Valve in the 'Float' Position
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Section 230-0000 BODY SYSTEM - Body System Schematic SERVICE MANUAL
SM - 1848B

B
P2 T2 U2
5

30
bar

45
3 3 bar

FROM
P1 T1 U1
BRAKING
SYSTEM
L T R
2

P2 P1

T2 T1

COMPONENTS
1 - Hydraulic Tank
2 - Body Control Valve P
3 - Body Cylinders A
4 - Hydraulic Oil Cooler 4
5 - Pilot Supply Valve FROM EF PORT
IN FLOW AMPLIFIER
COLOUR CODES 1 VALVE
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil
Orange - Pilot Pressure
Yellow - Static Oil

Fig. 3 - Body Hoist System Schematic - Body Control Valve in the 'Lower' Position
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Section 230-0000 BODY SYSTEM - Body System Schematic SERVICE MANUAL
SM - 1848C

B
P2 T2 U2
5

30
bar

45
3 3 bar

FROM
P1 T1 U1
BRAKING
SYSTEM
L T R
2

P2 P1

T2 T1

COMPONENTS
1 - Hydraulic Tank
P
2 - Body Control Valve
3 - Body Cylinders A
4 - Hydraulic Oil Cooler 4
5 - Pilot Supply Valve FROM EF PORT
IN FLOW AMPLIFIER
COLOUR CODES 1 VALVE
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil
Orange - Pilot Pressure
Yellow - Static Oil

Fig. 4 - Body Hoist System Schematic - Body Control Valve in the 'Hold' Position
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Section 230-0000 BODY SYSTEM - Body System Schematic SERVICE MANUAL
SM - 1848D

B
P2 T2 U2
5

30
bar

45
3 3 bar

FROM
P1 T1 U1
BRAKING
SYSTEM
L T R
2

P2 P1

T2 T1

COMPONENTS
1 - Hydraulic Tank
2 - Body Control Valve P
3 - Body Cylinders A
4 - Hydraulic Oil Cooler 4
5 - Pilot Supply Valve FROM EF PORT
IN FLOW AMPLIFIER
COLOUR CODES 1 VALVE
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil
Orange - Pilot Pressure
Yellow - Static Oil

Fig. 5 - Body Hoist System Schematic - Body Control Valve in the 'Raise' Position
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Section 250-0000 BRAKING SYSTEM - Braking System Schematic SERVICE MANUAL
SM - 1875

A B

D
6
1 8
Px
C
A
T

B T P
P1 P2

B1 B2
3

5 5 PS3 2
7

A P1

B T

TO PILOT
SUPPLY VALVE
(BODY SYSTEM)
P
PY
ACC1

ACC2
PS1 PS2

4 4

CONDITION BASED ON
ENGINE SHUTDOWN 3 - Parking Brake Pressure Switch 6 - Treadle Valve PRESSURE TEST POINTS
1 - Brake Pump 4 - Brake Circuit Pressure Switches 7 - Stop Light Pressure Switch A - Front Brake System Pressure
2 - Brake Manifold Valve 5 - Brake Accumulators 8 - Directional Control Valve B - Rear Brake System Pressure

Fig. 1 - Braking System Schematic

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Section 250-0000 BRAKING SYSTEM - Braking System Schematic SERVICE MANUAL

FRONT AXLE TWIN CALIPERS FROM SM - 2308A

SERVICE BRAKES DECEMBER '99 PRODUCTION PARKING BRAKE

REAR AXLE
SERVICE BRAKES

TO PILOT SUPPLY
A VALVE PORT 'P1'
(BODY SYSTEM) 5 5
B

CENTRE AXLE
SERVICE BRAKES 1
T P 8
b
a

6
B A
PX

P1
B1

ACC2
ACC1
T1

PY
A B 2

P
P
T 9 4
PS3 PS1

P PS2
3
4
P2
B2

7 T2
P2

P1 T

COMPONENTS PRESSURE TEST POINTS COLOUR CODES

1 - Brake Pump 6 - Treadle Valve A - Front Brake System Pressure Red - Pressurized Oil
2 - Brake Manifold Valve 7 - Stop Light Pressure Switch B - Rear Brake System Pressure Blue - Exhaust or Return Oil
3 - Parking Brake Pressure Switch 8 - Directional Control Valve C - Rear Brake System Pressure Green - Intake Oil
4 - Brake Circuit Pressure Switches 9 - Differential Pressure Switch Orange - Pilot Pressure
5 - Brake Accumulators Yellow - Static Oil
Fig. 2 - Braking System Schematic - Engine Shutdown
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Section 250-0000 BRAKING SYSTEM - Braking System Schematic SERVICE MANUAL

FRONT AXLE TWIN CALIPERS FROM SM - 2308B

SERVICE BRAKES DECEMBER '99 PRODUCTION PARKING BRAKE

REAR AXLE
SERVICE BRAKES

TO PILOT SUPPLY
A VALVE PORT 'P1'
(BODY SYSTEM) 5 5
B

CENTRE AXLE
SERVICE BRAKES 1
T P 8
b
a

6
B A
PX

P1
B1

ACC2
ACC1
T1

PY
A B 2

P
P
T 9 4
PS3 PS1

P PS2
3
4
P2
B2

7 T2
P2

P1 T

COMPONENTS PRESSURE TEST POINTS COLOUR CODES

1 - Brake Pump 6 - Treadle Valve A - Front Brake System Pressure Red - Pressurized Oil
2 - Brake Manifold Valve 7 - Stop Light Pressure Switch B - Rear Brake System Pressure Blue - Exhaust or Return Oil
3 - Parking Brake Pressure Switch 8 - Directional Control Valve C - Rear Brake System Pressure Green - Intake Oil
4 - Brake Circuit Pressure Switches 9 - Differential Pressure Switch Orange - Pilot Pressure
5 - Brake Accumulators Yellow - Static Oil

Fig. 3 - Braking System Schematic - Brakes Off

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Section 250-0000 BRAKING SYSTEM - Braking System Schematic SERVICE MANUAL

FRONT AXLE TWIN CALIPERS FROM SM - 2308C

SERVICE BRAKES DECEMBER '99 PRODUCTION PARKING BRAKE

REAR AXLE
SERVICE BRAKES

TO PILOT SUPPLY
A VALVE PORT 'P1'
(BODY SYSTEM) 5 5
B

CENTRE AXLE
SERVICE BRAKES 1
T P 8
b
a

6
B A
PX

P1
B1

ACC2
ACC1
T1

PY
A B 2

P
P
T 9 4
PS3 PS1

P PS2
3
4
P2
B2

7 T2
P2

P1 T

COMPONENTS PRESSURE TEST POINTS COLOUR CODES

1 - Brake Pump 6 - Treadle Valve A - Front Brake System Pressure Red - Pressurized Oil
2 - Brake Manifold Valve 7 - Stop Light Pressure Switch B - Rear Brake System Pressure Blue - Exhaust or Return Oil
3 - Parking Brake Pressure Switch 8 - Directional Control Valve C - Rear Brake System Pressure Green - Intake Oil
4 - Brake Circuit Pressure Switches 9 - Differential Pressure Switch Orange - Pilot Pressure
5 - Brake Accumulators Yellow - Static Oil
Fig. 4 - Braking System Schematic - Service Brakes Apply
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Section 250-0000 BRAKING SYSTEM - Braking System Schematic SERVICE MANUAL
SM - 2308D
FRONT AXLE TWIN CALIPERS FROM
SERVICE BRAKES DECEMBER '99 PRODUCTION PARKING BRAKE

REAR AXLE
SERVICE BRAKES

TO PILOT SUPPLY
A VALVE PORT 'P1'
(BODY SYSTEM) 5 5
B

CENTRE AXLE
SERVICE BRAKES 1
T P 8
b
a

6
B A
PX

P1
B1

ACC2
ACC1
T1

PY
A B 2

P
P
T 9 4
PS3 PS1

P PS2
3
4
P2
B2

7 T2
P2

P1 T

COMPONENTS PRESSURE TEST POINTS COLOUR CODES

1 - Brake Pump 6 - Treadle Valve A - Front Brake System Pressure Red - Pressurized Oil
2 - Brake Manifold Valve 7 - Stop Light Pressure Switch B - Rear Brake System Pressure Blue - Exhaust or Return Oil
3 - Parking Brake Pressure Switch 8 - Directional Control Valve C - Rear Brake System Pressure Green - Intake Oil
4 - Brake Circuit Pressure Switches 9 - Differential Pressure Switch Orange - Pilot Pressure
5 - Brake Accumulators Yellow - Static Oil

Fig. 5 - Braking System Schematic - Park/Emergency Brake Apply