Terex 2566c, 2766c, 3066c Articulated Dumptruck Full Service & Repair Manual

2566C, 2766C and 3066C Articulated Dumptruck Service Manual SM 991 Rev 2 5-98 TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED MOTHERWELL, SCOTLAND ML1 5RY REF. NO. SM 700/710/734 CLICK HERE TO RETURN TO MAIN LIBRARY INDEX CLICK HERE FOR TABLE OF CONTENTS

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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. (0698) 732121 Tlx. 77141 Fax. (0698) 734046 TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. (918) 446-5581 Fax. (918) 446-9752 The information contained within this Alert must not be made available to third parties not authorised to receive it.

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.

SM 968 Rev 3 8-98 1 TABLE OF CONTENTS 2566C, 2766C and 3066C Section No. Description SM No. 0 GENERAL INFORMATION (Specification) 0 General Information (2566C) 962 0 General Information (2766C) 963 0 General Information (3066C) 964 Rev 1 1 CHASSIS 1-1 Frames 2 Rev 2 1-1A Articulation and Oscillation Pivot 635 Rev 1 1-2 Hood and Cowl 978 1-3 Fenders and Mounting 1150 2 ENGINE AND MOUNTING 2-2 Engine and Mounting (2566C and 2766C) 966 Rev 1 2-2 Engine and Mounting (3066C) 967 Rev 1 2-2A Viscous Fan 396 Rev 1 2-3 Air Cleaner 979 2-5A Exhaust Brake (2566C Only) 1139 6 TRANSMISSION 6-1 Transmission and Mounting (2566C and 2766C) 99 Rev 6 6-1 Transmission and Mounting (3066C) 981 6-1 Transmission and Mounting (3066C with 6WG 260 Transmission) 1367 7 DRIVELINES 7-1 Front and Rear Drivelines 863 8 REAR AXLE GROUP 8-1 Differential 8 Rev 4 8-2 Axle Group 112 Rev 5 8-3 Wheel Rim and Tyre 864 8-4 Brake Parts 49 Rev 6 8-7 Rear Suspension 860 8-31 Differential (Centre Axle) 188 Rev 3 9 FRONT AXLE GROUP 9-1 Axle Group (Refer to Section 8-2) - 9-3 Wheel Rim and Tyre (Refer to Section 8-3) - 9-4 Brake Parts (Refer to Section 8-4) - 9-6 Front Suspension 406 Rev 3 9-6 Air Spring 55 Rev 4 9-7 Levelling Valve 408 9-9 Differential (Refer to Section 8-1) - 10 PARKING BRAKE 10-2 Parking Brake and Mounting 407 11 AIR SYSTEM 11-0 Air System Schematic 985 11-32 Pressure Protection Valve 21 Rev 3 11-33 Safety Valve 22 Rev 3 11-33 Check Valve (One Way) 56 Rev 2

SM 968 Rev 3 8-98 2 TABLE OF CONTENTS 2566C, 2766C and 3066C Section No. Description SM No. 12 STEERING SYSTEM 12-0 Steering Schematic 39 Rev 3 12-1A Steering Valve 983 12-5 Steering Cylinder 24 Rev 4 12-7 Steering Pump 25 Rev 3 12-10 Steering Filter 265 Rev 2 12-15 Accumulator 110 Rev 4 12-16 Accumulator Valve 264 Rev 2 12-16 Crossover Relief Valve 28 Rev 3 13 ELECTRICAL SYSTEM 13-1 Circuit Diagrams (2566C and 2766C) 960 13-1 Circuit Diagrams (3066C) 961 13-1 Circuit Diagrams (3066C with 6WG 260 Transmission) 1159 13-29 Switches and Sensors (2566C and 2766C) 982 13-29 Switches and Sensors (3066C) 989 13-29 Switches and Sensors (3066C with 6WG 260 Transmission) 1148 15 FUEL SYSTEM 15-1 Fuel Tank, Lines and Mounting (2566C and 2766C) 986 Rev 1 15-1 Fuel Tank, Lines and Mounting (3066C) 987 Rev 1 16 COOLING SYSTEM 16-1 Cooling System 988 16-1 Radiator and Mounting 365 Rev 1 16-9 Transmission Oil Cooler 367 Rev 2 16-11 Hydraulic Oil Cooler 368 Rev 1 17 CAB 17-1 Cab and Mounting 980 Rev 1 17-10A Air Conditioning 1459 18 BODY 18-1 Body and Mounting 984 26 BODY SYSTEM 26-0 Body Hoist Schematic 372 Rev 2 26-0 Body Hoist Schematic (3066C with 6WG 260 Transmission) 1422 26-2 Hydraulic Tank 34 Rev 1 26-3 Body Cylinder 266 Rev 1 26-5 Hydraulic Pump 38 Rev 1 26-6 Body Control Valve 369 Rev 1 26-6 Body Control Valve (3066C with 6WG 260 Transmission) 1153 26-7 Body Control Valve Linkage 370 Rev 2 26-7A Body Control Joystick (3066C with 6WG 260 Transmission) 1151 26-10A Pilot Supply Valve (3066C with 6WG 260 Transmission) 1152 27 BRAKING SYSTEM 27-0 Air Braking System Schematic 442 Rev 1 27-1 Hydraulic Braking System Schematic 443 27-2 Treadle Valve 15 Rev 1 27-3A Pressure Convertor 16 Rev 1 27-3B Air Breather 389 27-5 Relay Emergency Valve 19 27-15 Air Tanks and Mounting 104 27-17 Park/Emergency Control Valve 17 27-18 Air Drier 65 Rev 1

SM 968 Rev 3 8-98 3 TABLE OF CONTENTS 2566C, 2766C and 3066C Section No. Description SM No. 59 MISCELLANEOUS 59-2 Lubrication System 965 Rev 1 59-10 Service Tools 870 Rev 2 59-91 Axle Bolt and Nut Torque Specifications 40 Rev 1 59-91 Standard Bolt and Nut Torque Specifications 43 Rev 4 59-99 Unit Storage 168 * * * *

Terex 2566c, 2766c, 3066c Articulated Dumptruck Full Service & Repair Manual

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