Terex TC16 Excavator Workshop Repair Service Manual

SERVICE - MANUAL R TW 70 TW 85 TW 110 TC 60 TC 75 TC 125 TC 29 TC 35 TC 48 TC 15 TC 20 TC 37 TC 50 TC 25 TL 60 TL 65 TL 80 TL 80AS TL 100 TL 210 TL 120 TL 260 TL 160 TL 310 SKL 200 TL70s TC 16 List of Contents 1 General 2 Technical Data 3 Diesel Engine 4 Hydraulic System 5 Setting Instructions 6 Functional Description 7 Electrical System 8 Maintenance 9 Operation 10 Options 11 Repair Instructions 12 BDE/Special tooling 01.2012

01 General _____________________________________________________________________________________________________________________________________________________________________________________ Date: 01-September-2011 Germany Service manual Page 01/01 All types of machines R Subgroups list General Machine type Theme File Number General Foreword / Information fort the User 1.100.01 General Safety and Accident Prevention 1.200.01-05 General Tighten torques, piston nuts 1.500.01 General Pictograms 1.500.50-52 General Test ports 1.600.01 General Drift values 1.650.01 General Units 1.800.01-02 TL 65, 70s, 80, 100 Tighten torques 1.900.24 TL 210, 260 Tighten torques 1.900.30 TW 70 Tighten torques 1.900.49 TW 85, 110 Tighten torques 1.900.51-52

In this Service Manual the individual components of the Terex construction machinery range as well as the functions and adjustments of the aggregates in- stalled are described. The hydraulic and electrical diagrams as well as cut-off views in connection with the operating manual and parts catalogue are to facilitate the repair and maintenance work. We have purposely left out assembly and working steps as major repairs are normally carried out by experienced and qualified workshop personnel familiar with these type of repairs. When carrying out a repair, safety and cleanliness at the workplace are essential. The use of excellent tools and the replacement of sealing parts at every repair should be self-evident. Unless any special values are indicated, screw fittings are to be tightened using correct torque specifications. This Service Manual is issued by the Customer Service Department of Messrs. Terex. It is to develop the after-sales service of Terex construction machinery together. The Service Bulletins we issue for your information can serve as a supplement. This Manual is kept up-to-date through periodic supplements. This document is not to be copied and / or distributed completely nor in part without our full written consent, nor is it to be passed on to a third party. Typ/Model/Type General Datum/Edition/Date 01.2007 Benennung/Description/Dénomination Foreword / Information for the User Blatt/Page/Feuille 1.100.01

The Service Manual is subdivided into main groups, subgroups and page numbers so that you can easily find special groups and pages. This structuring will also facilitate the filing of revised versions and supplements within the framework of the technical alteration service. E.g. main group subgroup page no. 1. 01. 01 For the division of the main groups, please refer to the list of contents. The subgroup division is done starting from the main group. The page number follows the subgroup and main group number. Please strictly follow the regulations for Accident Prevention valid in your country (see also 1.20). The best safety measure to avoid accidents is to be careful when carrying out repairs. We therefore recommend to carefully study the corresponding information referring to the repair you intend to do. Any maintenance and repair work on machines located in the field may only be performed when the work equipment is lowered to the ground, the engine is switched off, the machine is secured so that it cannot roll, and the hydraulic system is relieved. If qualified personnel perform repair work in the workshop, the relevant Accident Prevention Regulations also apply. 1.100.01/01.2007

Safety and Accident Prevention 1 Introductory remarks Please read the operating instructions carefully before putting an earth-moving machine into operation and strictly follow the following remarks for a safe operation. National safety regulations - e.g. the Accident Prevention Regulations, “Earth- Moving Machinery” (VBG 40) and “Vehicles” (VBG 12) in the Federal Republic of Germany - must also be complied with. In addition to the operating instructions, legal regulations governing road traffic and road safety measures must also be observed. Such requirements could also apply in respect of handling hazardous goods or the wearing of personal safety equipment, for example. Furthermore, safety laws governing work in particular locations (tunnels, adits, quarries, pontoons, contaminated areas, etc.) must likewise be observed. 2 Correct use The earth-moving machine with normal shovel equipment is only to be used for work which is suitable for the machine’s functions and its attachment. Such work includes the digging, loading, displacing and dumping out of earth, stones or other materials and the loading of these materials onto lorries, conveyor belts or other means of transportation. The transport of the loading material, however, is mainly carried out by moving the earth- moving machine. If special attachments, such as Uni-shovel, side dump shovel, sweeper, fork lift attachment etc. are mounted, special jobs can be done with the attachment. Another or additional application, e.g. for transportation of passengers or using the lifting device as working platform etc. is not considered as correct use. The supplier is not liable for subsequent damage. The enduser himself bears the full risk. It is part of the correct use to follow the operating and maintenance instructions and to carry out the maintenance as well as to follow the maintenance intervals. 3 General safety notes It is important to refrain from any working methods which impair safety. The earth-moving machine may only be used when it is in a safe, operational condition. The manufacturer’s operating instructions must be complied with for operation, maintenance, repair, assembly and transportation. The plant operator must provide additional special safety instructions, wherever necessary, for specific local conditions. The operating instructions and any information pertaining to safety must be carefully kept in the driver’s cab. The operating instructions and safety notes must be complete and fully readable. Safety devices on earth-moving machines must not be deactivated or removed. Typ/Model/Type Datum/Edition/Date General 01.2007 Benennung/Description/Dénomination Safety and Accident Prevention Blatt/Page/Feuille 1.200.01

during operation. Rings, scarves and unbuttoned jackets are to be avoided. Protective goggles, protective boots, helmets, gloves, reflecting jackets, ear- muffs, etc. may be required. Before commencing work, information must be obtained on first aid and possible means of rescue (ambulance, fire brigade, helicopters). A check must be carried out to ensure that the first aid box is at hand and that its contents comply with regulations. Personnel must be aware of the location and method of operation of the fire extinguishers on the earth-moving machine as well as on-site fire-warning and fire-fighting equipment. Loose parts such as tools or other accessories must be secured to the earth- moving machine. Open doors, windows, covers, flaps, etc. must be secured so that they cannot slam shut. 4 Operation Earth-moving machines may only be independently operated and serviced by people who - are physically and mentally fit - have been instructed in the operation or maintenance of the earth-moving machine and have demonstrated this ability to the plant operator - can be expected to perform their allocated duties reliably All these people must be of the legal minimum age. They must be designated by the plant operator to operate or service the earth- moving machine. Operating equipment (controls) may only be activated from the driver’s seat. The earth-moving machine may only be ascended and entered using the entrances and surfaces intended for this purpose. The operator has to ensure that the cab, steps and other walked-on surfaces of the earth-moving machine are free of dirt, grease, oil, ice and snow. 5 Danger zone •No one may enter the danger zone of earth-moving machines. •The danger zone encompasses the area around the earth-moving machine in which people may be injured by movements of the earth-moving machine during operation, its working equipments and attachments, or by swinging out or falling loads, or by falling working equipment. •The machine operator may only work with the earth-moving machine when the danger zone is free of personnel. •The machine operator must give a warning signal to persons who may be in danger. •The machine operator has to stop work with the earth-moving machine if anyone remains in the danger zone despite the warning. •To ensure no danger of crushing, a sufficient safety distance (min. 500 mm) must be kept from solid objects, e.g. buildings, excavation slopes, scaffolding, other machines, etc. If the above safety distance cannot be maintained, the area between solid objects and the working zone of the earth-moving machine must be blocked off. 1.200.01/01.2007

•If conditions are such that the machine operator’s view of the driving and working zone is restricted, he must be guided or the driving and working zone must be marked by a solid barricade. The windows must be clean and free of ice. Driving tracks must be designed so as to ensure smooth, safe operation, i.e. they must be sufficiently wide, on ground which has sufficient carrying capacity and as few slopes as possible. Downhill tracks must be set out in such a way that loading machines can be braked safely. 6 Transport of passengers Passengers must not be transported on the machine. 7 Stability Earth-moving machines must be used, driven and operated in such a manner that their stability against overturning is ensured at all times. The machine operator must drive at speeds which are suitable for local conditions. The permitted payload of the earth-moving machine must not be exceeded. Earth-moving machines must remain at a sufficient distance from the edges of quarries, pits, mounds and slopes to ensure there is no risk of falling. Earth-moving machines must be secured so that they cannot roll or slip when in the vicinity of excavations, shafts, ditches, pits and slopes. 8 Travel operation Before putting the earth-moving machine into operation, the driver’s seat, mirrors and controls must be so adjusted as to ensure safe working. The carrying capacity of bridges, cellar roofs, vaults, etc. must be verified before the earth-moving machine can drive over them. The internal dimensions of constructions must be noted before entering underground passages, tunnels, etc. On steep drops and uphill gradients, the load must be carried on the uphill side, if possible, in order to increase stability. Before driving downhill, the appropriate gear for the terrain must be selected and the gear lever must not be moved during downhill travel (normal or crawler gear). Earth-moving machines may only be driven on the open road when both the machine and the driver have the appropriate licence as required by the country in question. Outside areas covered by general traffic regulations, e.g. on construction sites, traffic regulations should be applied in the proper manner. This should also apply with regard to drivers’ licences. Typ/Model/Type General Datum/Edition/Date 01.2007 Benennung/Description/Dénomination Safety and Accident Prevention Blatt/Page/Feuille 1.200.02

Terex TC16 Excavator Workshop Repair Service Manual

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