The confidence placed in this model will be rewarded
by the efficient and economical performance of the machine.
These Operating Instructions contain all information
necessary for the correct use of the machine.
This Instruction Book is intended for use by personnel
responsible for operation, maintenance, repair and supervision of the machine.
Please read it carefully before putting the machine
into operation and make sure that it is kept at hand at all times.
Should you need further explanations or should
anything be unclear, please contact your dealer 1 immediately.
Special equipment and attachments are not included
in these Operating Instructions.
We reserve the right to make improvements on the
machine within the scope of impending technical developments, without incurring any obligation to change these Operating Instructions.
Attention HR1.6-05-01
Any modifications of Terex products and their
Fig. 1 Type label equipment using extras and work attachments which are not included in our product range require our written approval. If our approval is not sought, our warranty expires, as does our product liability for any resulting consequential damage.
Please state the vehicle type and vehicle
identification number when making inquiries or orders, and in all written correspondence.
Attention The vehicle identification number of the machine is stamped onto the type label (1/1).
Operating Manual Crawler Excavator TC20 7
1 Introduction 1.1 Warranty and maintenance 1.2 Copyright
The warranty period covers twelve months, beginning This Operating Manual is copyrighted. It must not be with the day the machine is handed over or put into copied, disseminated or used for competitive operation. purposes, either fully or in part, without prior written permission. Safe working conditions and good working order of the machine are prerequisites for efficient work. Your Terex crawler excavator fulfils these requirements when correctly handled and when serviced and 1.3 Notes on using the Operating maintained as specified. Instructions Careful observation of the machine whilst in function Presentation of Figures and Positions and the use of the specified lubricants will prevent malfunction. (1/1) = Figure 1, Item number 1 Trained specialist personnel are responsible for any Presentation of cross references to Chapters and servicing of the machine which requires expert activities knowledge. Inspections and repairs must therefore be carried out by your dealer’s customer service. Î 1.3, 8 = Chapter/Section 1.3, Page 8 In respect of possible claims for damages during the Pictogram "Danger to life" warranty period, all work specified in the maintenance and inspection plan must be carried out at the Danger to life specified intervals. This indicates a potential danger represented After the warranty period, too, regular maintenance by the machine which, if appropriate must be performed in order to ensure that the precautions are not taken, may result in machine is constantly in good working order and death. enjoys a reasonable service life.
Insist that only original Terex spare parts are used in Pictogram "Danger of injury/machine damage" the event of any repair work. In this way, you will have a product of lasting high quality, thereby ensuring that Danger of injury/machine damage your machine maintains its original condition. This indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or property/equipment damage.
Pictogram "Attention"
Attention This symbol is employed for information containing important notes about the correct use and/or how to proceed. Non-compliance may lead to malfunction.
observed for all tasks performed on and with the machine.
During installation, repair and maintenance tasks,
particular care must be taken that substances that would damage the environment such as – lubricating greases and oils – hydraulic oils – fuels – coolant – cleaning fluids containing solvents
do not seep into the ground or the sewerage system.
These substances must be kept, transported,
collected and disposed of in suitable containers.
If the substances listed above do reach the soil, the
leak or outlet must be stopped immediately and the fluid must be cleaned up with a suitable absorbent material. If necessary, the soil involved must be removed. Absorbent materials and removed soil must be disposed of properly. Applicable environmental requirements must be observed.
Operating Manual Crawler Excavator TC20 9
1 Introduction 1.5 Pictograms
The following Table explains the meaning of the
pictograms which may be attached to your machine.
Symbol Description Symbol Description
Danger to life Windshield washer and wiper system
On machine: Travel speed, FAST
Caution, safety distance In Operating Instructions: Danger of injury/machine damage Attention Travel speed, SLOW
Battery charge indicator Horn
Preheating Working floodlight(s)
Engine oil pressure Rotating beacon
Engine oil level Dozer blade
Coolant temperature Hydraulic rock breaker
Air filter Working hydraulics shut-off
Fuel, fuel level Fire extinguisher
Hydraulic oil Danger of injury
Hydraulic oil level
Hydraulic oil filter clogging indicator Observe notes in Operating Instructions
Fan for heating/ventilation Grease gun
Air conditioning system
Tab. 1 Pictograms on the machine
10 Operating Manual Crawler Excavator TC20
Safety and Accident Prevention 2
2 Safety and Accident Prevention
2.1 Declaration of Conformity
Declaration of Conformity The machine complies with the fundamental requirements stipulated in the applicable European guidelines. Conformity has been proven. The respective documents and the original of the Certificate of Conformity are kept by the manufacturer. A copy of the Certificate of Conformity is attached to the sales documents.
EC declaration of conformity according to the machinery directive 2006/42/EC 1. We hereby declare that the earth-moving machine of type TC 20: Crawler excavator: TC 20 Vehicle ID No.: TC0020 Actual productivity: 13.1 kW
2. complies with all the relevant requirements of Machinery Directive 2006/42/EC.
3. The machine also complies with the relevant requirements of the following directives: 2004/108/EC (EMC), 2000/14/EC Annex VIII (noise emission), 97/68/EC (exhaust emissions)
4. Representative sound power level:
92.9 dB (A)
5. Guaranteed sound power level:
93 dB (A)
6. Applied harmonized standards:
EN ISO 12100 EN 474-1 EN 474-5
7. Document editor, who is authorized to compile technical documentation:
8. Conformity assessments according to RL 2000/14/EC appendix VIII and voluntary type
examination by: DGUV Test testing and certification office Technical Committee Landsberger Straße 309 D-80687 Munich, Germany Notified Body number: 0515
The EC declaration of conformity only applies if the earth-moving machine is used in accordance with the operating instructions. It includes the use of original Terex work attachments and other work attachments, which are mentioned in the operating instructions or in other Terex documentation for application at this earth-moving machine. Replaceable equipment manufactured by Terex or third party manufacturers may only be installed and used if the installation at the affected earth-moving machine is performed by Terex. In all other cases, special written approval is required from Terex.
Date of the declaration of conformity 01.12.2011
Crailsheim
Operating Manual Crawler Excavator TC20 11
2 Safety and Accident Prevention 2.2 Preliminary remarks 2.3 Proper use
Before putting the earth-moving machine into The earth-moving machine with standard bucket operation, read these Operating Instructions carefully equipment is intended solely for work which is and strictly observe the indicated references for safe suitable for the function of the machine and its work operation. implements.
National safety regulations - e.g. the Accident Such work involves loosening, taking up, transporting Prevention Regulations, “Earth-Moving Machinery” and dumping soil, rock or other materials as well as (VBG 40) and “Vehicles” (VBG 12) in the Federal loading these materials on trucks, conveyor belts or Republic of Germany - must also be complied with other means of transport. when operating the earth-moving machine. The assembly of special work implements such as In addition to the Operating Instructions, legal clamshell grab, hydraulic rock breaker, etc. allows the regulations governing road traffic and road safety machine to perform above mentioned work. measures must also be observed. Such requirements could also apply in respect of handling hazardous Any usage above and beyond that specified here, e.g. goods or the wearing of personal safety gear, for the transport of persons or the transport of loading example. material and any non-compliance with the manufacturer’s instructions is regarded as improper Furthermore, safety laws governing work in particular use. The supplier cannot be held responsible for any locations (tunnels, adits, quarries, pontoons, damage resulting from improper use. This risk is contaminated areas, etc.) must likewise be observed. borne solely by the user.
Compliance with the Operating and Maintenance
Instructions, the performance of maintenance work as specified and adherence to replacement intervals all form part of the concept of proper use.
12 Operating Manual Crawler Excavator TC20
Safety and Accident Prevention 2 2.4 General safety notes 2.5 Operation
– It is important to refrain from any working methods Earth-moving machines are only to be independently which impair safety. operated and serviced by persons who: – The earth-moving machine may only be operated – are physically and mentally suitable with cabin or canopy. – have been instructed in the operation or – The earth-moving machine is only to be used if it maintenance of earth-moving machines and have is in a safe, operational condition. demonstrated this ability to the plant operator – The manufacturer’s instructions must be complied – can be expected to perform their allocated duties with for operation, maintenance, repair, assembly, reliably. and transportation. All such persons must be of the legal minimum age. – The plant operator must provide additional special safety instructions, wherever necessary, for They must be designated by the plant operator to specific local conditions. operate or service the earth-moving machine.
– The Operating Instructions and any information Operating equipment and controls are only to be pertaining to safety must be carefully kept in the operated from the driver’s seat. driver's cabin. The earth-moving machine is only to be ascended – The Operating Instructions and safety notes must and entered using the entrances and surfaces be complete and fully readable. intended for this purpose. – Safety equipment on earth-moving machines must It is the driver’s responsibility to ensure that the not be deactivated or removed. operator’s stand, entrances and other surfaces of the – Protective clothing must be worn during operation. earth-moving machine which have to be stepped on Rings, scarves and unbuttoned jackets are to be are kept free of dirt, grease, oil, ice, and snow. 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 (emergency 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 closed or secured against slamming shut if in an open condition.
Operating Manual Crawler Excavator TC20 13
2 Safety and Accident Prevention 2.6 Danger zone 2.8 Stability
– Nobody must be allowed to remain in the danger – The earth-moving machine must be used, driven zone of an earth-moving machine. and operated in such a manner that its stability against overturning is ensured at all times. – The danger zone encompasses the area around the earth-moving machine in which persons may – The machine operator must drive at speeds which be injured by movements of the earth-moving are suitable for local conditions. machine during operation, its work implements – The permitted payload of the earth-moving and attachments, or by swinging out or falling machine must not be exceeded. loads. – The earth-moving machine must remain at a – The machine operator is only to work the earth- sufficient distance from the edges of quarries, pits, moving machine if nobody is in the danger zone. mounds and slopes to ensure there is no risk of – The machine operator must give a warning signal falling. If this is not possible, it must be secured to to persons who may be in danger. prevent rolling or slipping. – The machine operator must stop work with the earth-moving machine if someone remains in the danger zone despite the warning. – To ensure no danger of crushing, a sufficient safety distance (min. 0.5 m) 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. – 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.
2.7 Transport of persons
The transport of persons on the machine is forbidden.
14 Operating Manual Crawler Excavator TC20
Safety and Accident Prevention 2 2.9 Driving 2.10 Operation
Before putting the earth-moving machine into Daily before commencing work and after every operation, the driver's seat, mirrors and operator change of work attachments, the machine operator controls must be adjusted so as to ensure safe must check the correct fastening of the work working. attachment as well as the correct lock of the quick- attach system (QAS). Work attachments are to be A safety belt (seat belt), if installed, must always be carefully moved at low height. During this check fastened. nobody must be allowed to remain in the danger zone The windows must be clean and free of ice. of the earth-moving machine.
Driving tracks must be designed so as to ensure The machine operator may only swing the work smooth, safe operation, i.e. they must be sufficiently equipment over occupied drivers' seats, operator wide, on ground which has as few slopes as possible consoles and workplaces of other machines if these and sufficient carrying capacity. Downhill tracks must are protected by canopies (FOPS). be set out in such a way that earth-moving machines If a cabin does not have the required protection, the can be safely braked. driver of this vehicle must leave the operator’s stand Downhill tracks must be set out in such a way that while the work equipment is being swung overhead. earth-moving machines can be safely braked. The vehicles must be loaded in such a manner as to Before driving downhill, the appropriate gear for the ensure that there is no overloading and no material terrain must be selected and the gear lever not be can be lost as long as the machine is moving. The moved during downhill travel (road or off-road gear). vehicle must be loaded from the lowest possible height. On steep drops and uphill gradients, the load must be carried on the uphill side, if possible, in order to At dumping points, earth-moving machines may only increase stability. be operated if suitable measures have been taken to prevent rolling or falling. The carrying capacity of bridges, cellar roofs, vaults, etc. must be verified before the earth-moving machine can drive over them. 2.11 Guides The internal dimensions of constructions must be noted before entering underground passages, Guides must be easily recognizable, e.g. by means of tunnels, etc. reflective clothing. They must remain within the machine operator’s field of vision. It is the plant operator's responsibility to ensure that equipment such as first-aid box, warning triangle, While guiding the machine, guides shall not be given hazard lights are kept with the earth-moving machine other jobs which may distract them from their task. according to the traffic regulations valid in the user’s country and that the driver has the appropriate license as required by the national traffic laws of 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’ licenses.
Operating Manual Crawler Excavator TC20 15
2 Safety and Accident Prevention 2.12 Danger of falling objects 2.14 Working in the vicinity of overhead power lines Earth-moving machines are only to be used where there is a danger of falling objects if the operator’s If the earth-moving machine is being used in the stand has a canopy (FOPS). A front guard must be vicinity of overhead power lines and trolley wires, a employed if there is a risk of materials breaking safety distance which varies depending on the through into the cabin. nominal voltage of the overhead line must be maintained between the lines and the earth-moving In front of walls e.g. of stacked materials, earth- machine and its work equipment, to prevent current moving machines must be positioned and operated in overspill. This also applies to the distance between such a way that the driver's seat and entry to the these lines and attached implements or loads. driver's seat are not situated on the side facing the wall. The safety distances specified below must be complied with. Demolition work is only to be performed by earth- moving machines where there is no danger to Nominal voltage Safety distance persons and if the machine is equipped with canopy, in kV in meters cabin-mounted front guard and the appropriate work –1 1.0 implement. >1 to 110 3.0 See regulations book "Demolition work" (ZH 1/614) >110 to 220 4.0 published by the German Tiefbau- >220 to 380 5.0 Berufsgenossenschaft (Civil Engineering Employer’s nominal voltage unknown 5.0 Liability Insurance Association). Tab. 2 Prescribed safety distances
In the observation of safety distances, all working
2.13 Working in the vicinity of movements of earth-moving machines, e.g. positions underground power lines of the work equipment and the dimensions of attached loads must be taken into consideration. Uneven ground which would cause the earth-moving Before commencing excavating work using earth- machine to be inclined and thus nearer to overhead moving machines, it must be determined whether any lines must also be taken into account. underground power lines are present in the intended working zone which may present a danger to During work in windy conditions, both overhead lines persons. and work equipment may swing out, thus reducing the safety distance. If underground power lines are present, their exact position and course must be determined in If it is impossible to maintain sufficient distance from consultation with the proprietor or operator of the overhead power lines and trolley wires, the plant lines, and the necessary safety precautions decided operator must consult with the proprietor or operator and implemented. of the overhead lines to find other safety precautions to prevent current overspill. Such measures could be, The course of power lines in the work area must be e.g. clearly marked, under supervision, before commencing any excavation work. If the position of – Switching off the current, lines cannot be determined, search ditches must be – Re-routing the overhead line, dug - manually, if need be. – Cabling, or If underground power lines are encountered unexpectedly or they or their protective covers are – Limiting the work zone of earth-moving machines. damaged, the machine operator must discontinue work immediately and notify the supervisor.
16 Operating Manual Crawler Excavator TC20
Safety and Accident Prevention 2 2.15 Operation in closed spaces 2.17 Load hook applications
If earth-moving machines are to be used in closed Load hook applications are the hoisting, transporting spaces, these areas must be sufficiently ventilated and lowering of loads with the aid of a fixing device and special regulations observed. (rope, chain, etc.), whereby the assistance of personnel is required to attach and release the load. Such work covers e.g. the lifting and lowering of pipes, tubbing rings or containers using earth-moving 2.16 Work stoppages machines.
Before rest periods and at the end of the working day, Earth-moving machines are only to be used for load the driver of the earth-moving machine must park the hook applications if the prescribed safety devices are machine on ground which has sufficient carrying present and in full working order. For earth-moving capacity and is as level as possible, and must secure machines, these are: it against unintended movement. – Secure attachment of loading implements Before rest periods and at the end of the working day, – Table of carrying capacity the driver must lower the work equipment onto the ground or secure it so that it cannot move. – Overload warning device 1
The driver is not to leave the earth-moving machine if – Hose-rupture valve on boom cylinder 1 the work equipment has not been lowered to the 1 Only if the permissible carrying capacity exceeds 1000 kg. ground or secured. Loads must be attached in such a way that they Earth-moving machines are only to be parked in cannot slip or fall out. places where they do not present an obstacle to others, e.g. on the construction site or to plant traffic. Personnel guiding the machine and attaching loads Warning devices, e.g. triangles, warning cordons, must always remain in the machine operator’s field of flashing or hazard lights are to be used if necessary. vision.
Before leaving the operator stand, the driver must The machine operator must carry loads as close to bring all operating equipment and controls into home the ground as possible and prevent them from position, switch off the working hydraulics and apply swinging. the brakes. Earth-moving machines may only move with an If the driver is leaving the earth-moving machine attached load if the path of travel is fairly level. unattended, he must first turn off the engine and If earth-moving machines are used for load hook ensure that it cannot be started up by unauthorized applications, personnel attaching loads is only to persons (e.g. removing ignition keys). approach the boom from the side and with the machine operator’s permission. The machine operator is only to give his permission if the earth- moving machine is standing still and the work equipment is not in motion.
Do not use fixing devices (ropes, chains, shackles)
which are damaged or of inadequate dimensions. Protective gloves must always be worn when working with fixing devices.
Operating Manual Crawler Excavator TC20 17
2 Safety and Accident Prevention 2.18 Change of work attachments, • Before working on the electrics or when maintenance, repair performing arc-welding on the machine, the connection to the battery must be disconnected. Earth-moving machines are only to be converted, • When disconnecting the battery, first the negative maintained or serviced under the guidance of a pole then the positive pole must be disconnected. suitable person designated by the plant operator and The battery must be re-connected in reverse following the manufacturer’s Operating Instructions. order.
After every change of work attachments, the driver • During repair work around the battery, it must be must convince himself that the quick-attach system is covered with insulating material. Tools should correctly fastened and locked never be placed on or near the battery.
Work on e.g. Protective devices of moving machine parts are only
to be opened or removed after the drive has been – braking, switched off and cannot be switched on again by – steering, unauthorized persons. Protective devices are e.g. engine/motor covers, doors, protective grating, trim. – hydraulic and Upon completion of assembly, maintenance or repair – electric systems work, all protective devices must once more be of the machine is only to be carried out by expert attached in the proper manner. personnel specially trained in these areas. Load-bearing parts of earth-moving machines are Stability must be ensured during all type of work on only to be welded following consultation with the the machine at all times. manufacturer and in accordance with recognized welding principles. The machine must be suitably secured by chocks so that it cannot roll away whenever work is performed, Protective structures (ROPS; FOPS) are not to be particularly under the machine. welded or drilled in any way.
The work equipment must be secured against Alterations, such as welding of the hydraulic system, movement by lowering it to the ground or equivalent are only to be undertaken with the manufacturer’s measures, e.g. cylinder supports, trestles. As long as permission. the engine is running, the unprotected working range Before commencing work on the hydraulic system, must not be entered. the operating pressure, pilot pressure, back pressure When jacking up earth-moving machines, jacking and pressure inside the tank must be let off. devices must be positioned so that they cannot slip. Swallowing lubricants as well as long and repeated Jacks must be positioned and applied absolutely skin contact can be hazardous to health and should straight, without tilting. therefore be avoided. When used properly, there is no Raised earth-moving machines must be supported by particular danger to health. The safety specification suitable structures such as crosswise stacks of sheets from the mineral companies must be planks, square timbers or steel trusses. observed.
Earth-moving machines which are raised with work Only the hoses specified by the manufacturer may be equipment must be stabilized by a supporting used. structure immediately after lifting. Work under raised Hydraulic hoses must be routed and assembled by machines which are only supported by their expert personnel. hydraulics is forbidden. In the vicinity of fuel or batteries, smoking and naked The engine/motor(s) must be turned off prior to all flames are prohibited. maintenance and repair work. These requirements may only be ignored in the case of maintenance or repair work which cannot be performed without the engine/motor(s) running.
When performing maintenance and repair work on
the hydraulic system, the hydraulic system must be relieved of pressure. With the engine turned off, lower the work equipment to the ground and actuate all hydraulic control levers until there is no more pressure in the hydraulic system.
18 Operating Manual Crawler Excavator TC20
Safety and Accident Prevention 2 2.19 Recovery, Loading and Hydraulic hoses must be replaced as soon as the Transporting following damage is recognized: – Damage to the outer layer which reaches the Earth-moving machines are only to be loaded onto intermediate layer, recovery vehicles if adequate towing vehicles are – Embrittled patches on the outer layer, used. – Deformations when under pressure or without The tow fixing points specified by the manufacturer pressure which differ from the original shape of the must be employed. installed hose, For loading and transportation, earth-moving – Leaks, machines and all necessary auxiliary equipment must be secured against unwanted movement. – Damage to hose fittings or to the connection between the fitting and the hose. The traveling gear and crawler unit of earth-moving machines must be sufficiently cleaned of mud, snow The coolant level may only be checked after the and ice to ensure that ramps can be driven up without engine has cooled down; the cap must be turned risk of slipping. carefully in order to let off excess pressure.
When transporting the earth-moving machine on Prior to operations, the machine operator must check trucks, flatbed trailers, or by rail, it must be sufficiently the function of the safety devices. secured with chocks and by attachment to the lashing The machine operator must advise the supervisor points. immediately - and his replacement, if there is a Before setting off, the route to be taken must be change of operator - with regard to any shortcomings. examined to determine whether the roads are wide In the event of shortcomings which jeopardize the enough, entrances and passages under bridges are operating safety of the earth-moving machine, it is not large enough and that roads and bridges have to be used until these have been eliminated. sufficient carrying capacity.
2.20 Monitoring and inspections
The machine must be submitted to a general
inspection according to the regulations in force in the user's country (e.g. Accident Prevention Regulations in Germany); this inspection must be carried out by an expert (e.g. machine engineer or machine foreman): – before the machine is put into operation for the first time and before the machine is again put into operation after essential modifications have been made – at least once a year – in the meantime, according to operating conditions and local environments
The results of this inspection have to be recorded in
writing and this record kept until the next inspection takes place.
Prior to every work shift, the machine operator must
check the earth-moving machine according to the inspection and maintenance plan.
Operating Manual Crawler Excavator TC20 19
2 Safety and Accident Prevention 2.21 Fire protection
• Switch off the engine when filling the fuel tank and take special care as long as the engine is hot. • Never smoke or handle open flames whilst refueling the tank of the machine.
The fire extinguisher must be kept in the
cabin.
The fire extinguisher symbol must be
attached.
2.22 Notes concerning residual dangers
Failure of hydraulic system
If the hydraulic system fails because the diesel engine
is not running, the hydraulic pump is damaged or hydraulic oil has been lost, only the EMERGENCY function "Lower work equipment" can still be performed.
A) Total width of uppercarriage B) Total width of dozer blade
22 Operating Manual Crawler Excavator TC20
Technical Specifications 3
420 550
60°
60° C
1340 mm D
2560 mm A
2800 mm B
Fig. 4 Slew circle
A = slew circle 180°
B = slew circle 360° – bucket heaped
C = loading position – max. height
D = undercarriage extended
E = dimensions when working with Knickmatik
Operating Manual Crawler Excavator TC20 23
3 Technical Specifications 3.2 Engine
Engine Manufacturer Mitsubishi Type L3E four-stroke diesel engine Design 3 cylinders in line Displacement 952 cm3 Power in accordance with ISO 9249 13.1 kW / 2250 min-1 Permissible inclined positions continuously 25° on all sides; briefly 30° (max. 30 minutes) Specific fuel consumption 272 g/kWh Practical fuel consumption approx. 3.3 l/hr at medium load Cooling Water-antifreeze mixture for all-year operation Heating Warm water with 2-speed fan Max. torque 54.9 / 2100 min-1 Tab. 3 Technical specifications - Engine
3.3 Electrical system
Electrical system Operating voltage 12 V Battery 12 V – 74 Ah Generator 12 V – 40 A Starter 12 V – 1.7 kW Tab. 4 Technical specifications - Electrical system
3.4 Chassis
Chassis Crawler-type undercarriage Maintenance-free crawler-type undercarriage. Idler suspension with hydraulic crawler-chain tension. Travel speeds Forward - Reverse 0 – 2.4 km/h Max. hill climbing ability 60 % Power transmission Two-stage hydrostatic travel drive with axial piston variable-displacement motor Optional: Two-stage hydrostatic travel drive and reduction gear directly acting on crawler-chain sprockets. Travel brake valves for downhill driving. Chain width Steel or rubber, 230 mm Overall length of chassis 1 490 mm Track width adjustment Horizontally adjustable crawler frames. Hydraulically adjustable from driver's seat. Range of adjustment, outside edge of crawler chains: 990 – 1340mm Driving – steering Independent individual control of crawler chains, also counterwise thanks to dual-circuit hydraulic system. 2 combined hand levers/ foot pedals for operation. Tab. 5 Technical specifications - Chassis
24 Operating Manual Crawler Excavator TC20
Technical Specifications 3 3.5 Hydraulic system
Hydraulic system Excavator hydraulics Dual fixed-displacement pump with power switch. Pump capacity: 1 x 33.6 l/min 1 x 19.2 l/min Max. pressure: 180 bar Excavator installation Hydraulically pilot-operated control valve for the functions "boom, dipperstick, bucket, uppercarriage, slewing"; Proportional control of all functions. Pilot pressure 28 bar with pressure accumulator Additional control Control circuit for grab, rock breaker, etc. circuit Capacities available: 33 l/min at 100 bar 30 l/min at 140 bar max. 180 bar Open return Hydraulic filter Full-flow return filter installed in the oil tank. Hydraulic cylinders Double-acting work cylinders, partially with end-position damping. Swing drive Hydrostatic, swing motor and drive pinion on internally toothed ring gear of swing bearing. Swing range: 360° unlimited Swing speed: 0 – 10 rpm Additional spring-loaded multi-disk brake serving as parking brake: - by operating the push-button on the left-hand joystick - with the diesel engine switched off and ignition OFF. Knickmatik®: On the right: swing angle 60° On the left: swing angle 60° Bend mechanism for the lateral parallel adjustment of the boom axle at total digging depth, left/right by approx. 420/550 mm. Dozer blade Hand lever providing sensitive control, independent from drive. Dozer blade with pluggable extensions with full support function. Width 1 340 mm Height 235 mm Lift below road level 160 mm Lift above road level 200 mm Slope angle 25° Tab. 6 Technical specifications - Hydraulic system
Operating Manual Crawler Excavator TC20 25
3 Technical Specifications 3.6 Fuels, lubricants, and coolants
3.6.1 Fluid capacities
All values stated are approximate. The level marking is always the decisive factor.
Fluid capacities in liters Fuels and lubricants
Fuel 30.0 Diesel Engine oil, engine and filter 3.1 + 0.5 HD-oil (change quantity) Hydraulic oil, tank and system 35.0 Hydraulic oil Hydraulic oil tank 25.0 Hydraulic oil (change quantity) Crawler gear units 0.3 each Transmission oil Swing gear 0.1 Transmission oil Coolant 4.2 Water with anti-corrosion agent and antifreeze1 Tab. 7 Fluid capacities 1 The mixture ratio must be adjusted to the level of antifreeze required.
26 Operating Manual Crawler Excavator TC20
Technical Specifications 3 3.6.2 Fuel, lubricant, and coolant specifications
Prescribed fuels, lubricants, and coolants
for Central Europe Application Code Designation Specification, standards, Remarks designation Quality according to Bi 1 Engine – Diesel fuel EN 590 Attention ASTM D975 1-D / 2-D Before using RME fuels (rape oil methyl ester), it is essential to consult your responsible Terex dealer for further details. Engine EO 1540 A Engine oil SAE 15W-40 See also engine manufacturer's API CF4 Operating Manual. Cooling for SP-C Coolant Antifreeze based on See also engine manufacturer's Engine ethylene glycol Operating Manual. Hydraulic HYD 1040 Hydraulic oil or HVLP 46 The following viscosity limit values system multi-grade or must be observed (according to engine oil SAE 10W-40 ASTM 445): at 100 °C min. 8 mm2/s (cSt) at –10 °C approx. 1500 mm2/s (cSt) BIO-E-HYD- Biodegradable Filling according to customer The same viscosity specifications HEES hydraulic oil on specifications. Brand label on apply as for mineral hydraulic oils. synthetic ester machine. base Machine damage Attention caused by non-mixable bio When changing from oils. mineral to biodegradable hydraulic oils, the tank and • Do not mix bio oils from hydraulic system must be different completely drained, manufacturers. cleaned and flushed. For further details before changing oils, please consult your responsible Terex dealer. Transmission(s) GO 90 LS Transmission oil SAE 85W-90LS Alternative recommendation: API-GL 5 SAE 80-90LS Lubricating MPG-A Multi-purpose, K2K-30 points lithium DIN 51825 -soap based grease Tab. 8 Fuel, lubricant, and coolant specifications 1 In conformity with the regulation lubricants of the Main Association of the German Building Industry e.V.
Operating Manual Crawler Excavator TC20 27
3 Technical Specifications Alternative recommendation for other temperature ranges
Engine oil Hydraulic oil
according to API CG 4 or CF 4 and ACEA E3 or E2 according to DIN 51524.T3 HVLP
Ambient temperature Ambient temperature
Fig. 5 Recommended viscosity classes for engine oil Fig. 6 Recommended viscosity classes for hydraulic oil
3.7 Specific ground pressure
Specific ground pressure 1
with rubber crawler chain with cabin 0.30 da N/cm2 with canopy 0.29 da N/cm2 with steel crawler chain with cabin 0.31 da N/cm2 with canopy 0.30 da N/cm2 Tab. 9 Specific ground pressure 1 Specifications without driver
3.8 Sound level values, vibration
Sound level values Driver's cabin Canopy
Guaranteed sound power level LWA 93 dB (A) LWA 93 dB (A)
Sound pressure level (at driver's ear) LpA 77 dB (A) LpA 78 dB (A) Tab. 10 Sound level values in compliance with directive 2000/14/EC and EN 474
Vibration Effective values of acceleration below 0.5 m/s2 for entire body and 2.5 m/s2 for upper limbs Tab. 11 Vibration values in compliance with directive 2002/44/EC and EN 474
28 Operating Manual Crawler Excavator TC20
Technical Specifications 3 3.9 Dimensions and operating weights 1 Weight Excavator equipment LS LS 1100 mm 1300 mm Machine weight: 1 950 kg Digging depth2 2 300 mm 2 500 mm with 400-mm bucket, control circuit for work Deepest bucket hinge point 2 1 770 mm 1 970 mm attachments, open return, without driver, with rubber crawler and cabin Transport weight with tank half full, w/ quick- 1 900 kg Maximum possible height 3 620 mm 3 740 mm attach system, w/out bucket Cabin 180 kg Dump height2 2 600 mm 2 720 mm Canopy 80 kg Maximum height of bucket hinge 3 130 mm 3 250 mm point2 Dimensions Maximum reach 4 200 mm 4 370 mm Total width (crawler-type undercarriage 1 000 mm Bucket angle of rotation 192° 192° retracted) Total length (travel position) 2 680 mm Ripping force1 11 000 N 9 700 N Total length (transport position) 4235 mm Breakout force1 15 700 N 15 700 N Total height (travel position) 2 390 mm Height (cabin roof) 2 290 mm Uppercarriage tail swing 1 160 mm Ground clearance 170 mm Drawbar pull 1st speed range 1 500 daN Drawbar pull 2nd speed range 730 daN Tab. 12 Dimensions and operating weights 1 Values are theoretical according to DIN 24086. 2 Dimensions apply to machine standing on level ground, but can be increased by tilting the machine using the blade.
Operating Manual Crawler Excavator TC20 29
3 Technical Specifications 3.10 Carrying capacity
The stated carrying capacities in tons (t) were
determined according to ISO 10567 and include a stability factor of 1.33 or 87% of the hydraulic lifting- load capacity.
Attention The dead-weight of the work attachment must be deducted from the stated payload.
Carrying capacity tables with the following
equipment: – boom – with quick-attach system – without bucket – rubber crawler chain, 230 mm wide – full tank, with driver
Permissible values Load radius from center of ring gear in meters
crawler chain retracted 1.5 2.0 2.5 3.0 3.5 and dipperstick 1100 mm longt. trans- longt. trans- longt. trans- longt. trans- longt. trans- verse verse verse verse verse A -- -- -- -- 0,40 0,32 0,38 0,25 -- -- 2.0 V -- -- -- -- 0,39 0,31 0,37 0,24 -- -- A -- -- 0,66 0,44 0,44 0,31 0,38 0,24 0,31 0,19 Height 1.0 V -- -- 0,65 0,43 0,43 0,30 0,37 0,23 0,30 0,18 of bucket pivot A -- -- 0,74 0,40 0,52 0,29 0,39 0,23 0,28 0,18 in meters 0.0 V -- -- 0,63 0,38 0,45 0,27 0,38 0,21 0,27 0,17 A 0,99 0,56 0,64 0,39 0,42 0,29 0,30 0,23 -- -- -0.75 V 0,98 0,53 0,63 0,37 0,40 0,27 0,30 0,21 -- -- Tab. 13 Table of carrying capacity in tons A) supported by dozer blade
V) movable
Permissible values Load radius from center of ring gear in meters
crawler chain extended 1.5 2.0 2.5 3.0 3.5 and dipperstick 1100 mm longt. trans- longt. trans- longt. trans- longt. trans- longt. trans- verse verse verse verse verse A -- -- -- -- 0,40 0,40 0,38 0,35 -- -- 2.0 V -- -- -- -- 0,39 0,38 0,37 0,33 -- -- A -- -- 0,66 0,52 0,44 0,44 0,38 0,36 0,31 0,30 Height 1.0 V -- -- 0,65 0,50 0,43 0,42 0,37 0,34 0,30 0,29 of bucket pivot A -- -- 0,74 0,58 0,52 0,43 0,39 0,33 0,28 0,28 in meters 0.0 V -- -- 0,72 0,56 0,50 0,40 0,38 0,31 0,27 0,27 A 0,99 0,99 0,64 0,64 0,42 0,33 0,30 0,25 -- -- -0.75 V 0,98 0,74 0,63 0,47 0,40 0,31 0,30 0,23 -- -- Tab. 14 Table of carrying capacity in tons
A) supported by dozer blade
V) movable
30 Operating Manual Crawler Excavator TC20
Technical Specifications 3
Permissible values Load radius from center of ring gear in meters
crawler chain retracted 1.5 2.0 2.5 3.0 3.5 and dipperstick 1300 mm longt. trans- longt. trans- longt. trans- longt. trans- longt. trans- verse verse verse verse verse A -- -- -- -- 0,46 0,32 0,38 0,25 -- -- 2.0 V -- -- -- -- 0,36 0,31 0,30 0,24 -- -- Height A -- -- 0,66 0,44 0,44 0,31 0,38 0,24 0,31 0,19 1.0 of bucket V -- -- 0,41 0,43 0,36 0,30 0,27 0,23 0,22 0,18 pivot A -- -- 0,74 0,40 0,52 0,29 0,39 0,23 0,28 0,18 in meters 0.0 V -- -- 0,49 0,38 0,38 0,27 0,29 0,21 0,19 0,17 A 0,99 0,56 0,64 0,39 0,42 0,29 0,30 0,23 -- -- -0.75 V 0,74 0,53 0,47 0,37 0,40 0,27 0,30 0,21 -- -- Tab. 15 Table of carrying capacity in tons
A) supported by dozer blade
V) movable
Permissible values Load radius from center of ring gear in meters
crawler chain extended 1.5 2.0 2.5 3.0 3.5 and dipperstick 1300 mm longt. trans- longt. trans- longt. trans- longt. trans- longt. trans- verse verse verse verse verse A -- -- -- -- 0,46 0,45 0,38 0,35 -- -- 2.0 V -- -- -- -- 0,36 0,38 0,30 0,32 -- -- Height A -- -- 0,66 0,52 0,44 0,44 0,38 0,36 0,31 0,30 1.0 of bucket V -- -- 0,41 0,48 0,36 0,38 0,27 0,29 0,22 0,25 pivot A -- -- 0,74 0,58 0,52 0,43 0,39 0,33 0,28 0,28 in meters 0.0 V -- -- 0,49 0,49 0,38 0,40 0,29 0,31 0,19 0,22 A 0,99 0,99 0,64 0,64 0,42 0,42 0,30 0,30 -- -- -0.75 V 0,74 0,74 0,47 0,47 0,40 0,40 0,30 0,30 -- -- Tab. 16 Table of carrying capacity in tons A) supported by dozer blade
V) movable
Operating Manual Crawler Excavator TC20 31
3 Technical Specifications 3.11 Working range for grab operations
Danger of injury due to overturning hazard of machine. • For safety reasons, ensure that the indicated reach distances are not exceeded when the grab is full.
45° 45°
B max. 3,0 m
90°
H R 13 0 8
Fig. 7 Working range of grab
A) Maximum reach B) Restricted reach
32 Operating Manual Crawler Excavator TC20
Technical Specifications 3 3.12 Work attachments
Standard Quick-attach mounting
Width in mm Capacity in Width in mm Capacity in liters liters Bucket 220 21 – – Bucket with ejector 220 21 – – Bucket – – 250 22 Bucket with ejector – – 250 25 Bucket 260 25 – – Bucket with ejector 260 25 – – Bucket 300 29 300 26 Bucket with ejector 300 29 300 32 Bucket 400 40 400 38 Bucket – – 500 49 Bucket 600 61 600 60 Ditch-cleaning bucket 850 72 – – Ditch-cleaning bucket 1 000 85 1 000 – Swing bucket 850 47 850 – Swing bucket 1 000 56 1 000 – Clamshell grab type GL1 – – 250 – Hydraulic rock breaker type SH 50/SMS – – – – Tab. 17 Work attachments
Attention Additional work attachments available from the manufacturer.
attachments – Hydraulically telescopic undercarriage with dozer blade extension – Canopy (weight reduction: 100 kg) – Dipperstick 1300 mm – FOPS-skylight guard – Rear-end protection – Cabin-mounted working floodlights, front/rear – Boom-mounted working floodlight – Yellow rotating beacon – Travel motion alarm (acoustic signal) – Crane lifting beam – Floor plates rubberized for steel crawler chains – Quick-mounting adapter for hydraulic rock breaker – Catalytic converter – Electric drive – Biodegradable oil – Immobilizer – Electrical refueling pump – Radio – Cutting unit
Attention Additional accessories available from the manufacturer.
Machine damage due to unauthorized alterations to the design, additional equipment and work attachments of Terex products. • Please note that any modification requires the written approval from the manufacturer. If our approval is not sought, our warranty expires, as does our product liability for any resulting consequential damage.
34 Operating Manual Crawler Excavator TC20
Operation 4
4 Operation
4.1 Initial familiarization
• If you are not familiar with the operator controls
and display elements of this machine, read this Chapter carefully before operating the machine.
This Chapter deals with all functions.
• Before driving and working with the machine it is necessary to thoroughly familiarize yourself with the display elements and operator controls. • Each time before putting the machine into operation it must be subjected to a thorough visual inspection. Ensure that there is no damage, loose or missing screws, oil accumulations, oil or fuel leakage. Shortcomings must be remedied immediately. In the event of shortcomings which jeopardize the operating safety, the machine must not be put into operation until these have been eliminated. • Before putting the machine into operation, the inspections according to Î 7.7, 61 must be carried out.
Operating Manual Crawler Excavator TC20 35
4 Operation 4.2 Display elements and operator controls
16 5 6 7
2 15 17 2 9 12
1 10 8
4/4 h. 3 13
14 11 HR2.0-04-08
Fig. 8 Operator controls
1 Operation – excavator installation 2 OFF switch – excavator hydraulics / exit barrier 3 Brake – swing motion of uppercarriage 4 Operation – articulation 5 Crawler unit, left 6 Crawler unit, right 7 Additional control circuit – rock breaker, etc. 8 Operation – dozer blade up / down or track width adjustment smaller / larger (in connection with changeover level pos. 17) 9 Manual throttle 10 Operation – excavator installation 11 Fuse and relay box 12 Change-over "ISO" to "SAE" control (option) 13 Vandalism guard (canopy only) (option) 14 Windshield washer fluid tank 15 Horn 16 Storage space for control rod of quick-attach system 17 Change-over – dozer blade / track width adjustment (optional)
36 Operating Manual Crawler Excavator TC20
Operation 4
23 18 21 22 33
2 R 4 4/
90° 0
h.
HR3.7-03-102
20 19 25 24 27 28 29 30 34 32 26
Fig. 9 Operator controls
18 Battery charge indicator (red) 19 Preheating monitor (yellow) 20 Engine oil pressure indicator (red) 21 Air filter clogging indicator (yellow) 22 Hydraulic oil filter clogging indicator (yellow) 23 Fuel gauge 24 Operating-hour meter 25 Coolant temperature (red) 26 Power socket 27 Travel, FAST/SLOW (option) 28 Windshield wiper and washer system (only for the cab) 29 Working floodlight(s) 30 Heating/ventilation (only for the cab) 31 - 32 Rotating beacon (option) 33 Glow plug and starter switch (ignition lock) 34 Travel motion alarm ON/OFF (option)
Operating Manual Crawler Excavator TC20 37
4 Operation 4.3 Engine
4.3.1 Starting
Attention Each time before putting the machine into operation, the inspections according to (Î 7.7, 61) must be carried out.
Danger to life due to presence in the danger zone. • Before switching on the engine always ensure that no-one is in the danger zone of the machine.
• All gearshift levers in neutral position.
• Insert ignition key in glow plug and starter switch 2 2 (10/33). 9 • Turn ignition key clockwise to Position "1"; the indicator lamps (10/18,10/20) light up. • Pre-heating starts; the indicator lamp (10/19)
0 lights up.
4/ 4 h. • Move manual throttle (10/9) to full-throttle position.
R • After the indicator lamp (10/19) has gone out, turn the glow plug and starter switch to Position "2". As soon as the engine is running, turn the ignition key back to Position "1" and decrease the revs to low idle speed. The indicator lamps should go out. 18 33 • If the engine has not started after max. 30 seconds, turn the ignition key to "1" or "0", and 0 1 pause for at least 1 minute before trying again; 2 repeat the start-up procedure. R 4 4/ 0
• If the engine has not started after 4 start-up
h.
procedures, determine the source of fault.
HR1.6-04-11 Engine damage 20 19 Avoid damaging the engine by: • not driving the engine at full throttle straight Fig. 10 Starting the engine away. • driving with restraint until the engine has reached its operating temperature.
38 Operating Manual Crawler Excavator TC20
Operation 4 4.3.2 Monitoring the machine during operation
The machine is fitted with a warning buzzer emitting a
signal if the following malfunctions occur: – Insufficient engine oil pressure (11/20) – Air filter clogging indicator (11/21) – Excessively high coolant temperature (11/25)
Engine damage due to fault which has not been remedied. • The fault must be remedied before restarting the engine and operating the machine again.
• As soon as the warning buzzer sounds, check
which indicator lamp is activated and proceed accordingly. • If the battery charge indicator (11/18) or the engine 9 oil pressure indicator lamp (11/20) lights up, switch off the engine immediately and determine the cause. If necessary, call for service personnel.
0 • If the air filter maintenance indicator (11/21) lights
4/ 4 h. up, perform the necessary maintenance work. • If the permitted coolant temperature (11/25) is
R exceeded, stop work, open the engine hood and keep the engine running at idle speed to allow it to cool down. Once the engine has cooled down, turn it off and determine the cause. If necessary, call for service personnel. 18 21 22 33 • If the hydraulic oil filter clogging indicator (11/22) lights up, replace the filter element and determine the cause of clogging. R 4 4/ 0
Attention h.
If the hydraulic oil is cold, the hydraulic oil filter
clogging indicator may light up briefly. It will go HR1.6-05-11
out once the operating temperature has been
reached. 20 25
Fig. 11 Monitoring and switching off the engine
4.3.3 Switching off
Attention Do not switch off the engine when running at full throttle, but allow it to run for a short time without load at low idle-running speed.
• Move the manual throttle (11/9) to low idle
position. • Turn the ignition key (11/33) to Position "0". • The engine stops automatically.
Operating Manual Crawler Excavator TC20 39
4 Operation 4.4 Driver's seat
The comfort seat meets international quality and
safety standards (Fig. 12).
1. Horizontal adjustment 2. Handle for weight adjustment – the driver's weight can be adjusted for in 9 stages (10 kg each). Move the weight adjustment handle clockwise until the stop; the weight adjustment mechanism automatically switches to the 50-kg position 3. Seat-back inclination adjustment 3 2 1 HR5.0_5.1_6
Fig. 12 Driver's seat
4.5 Heating/ventilation 1 Heating • Before putting the heater into operation, the hot water supply (13/1) in the engine compartment must be opened. • The heater fan, which is connected to the coolant circuit, is switched on and off using the switch (14/30). • Hot air is distributed and aimed as desired via a windshield nozzle in the pedal console and by adjusting the air vent on the seat console.
HR2.0-01-13
Fig. 13 Heating Ventilation • In ventilating mode the hot water supply (13/1) remains turned off. • The fan is switched on and off using the switch (14/30). R 4 4/
• Air is distributed and aimed as desired via a
0
windshield nozzle in the pedal console and by
h.
adjusting the air vent on the seat console.
HR3.7-03-15
30
Fig. 14 Ventilation
40 Operating Manual Crawler Excavator TC20
Operation 4 4.6 Front window
• To open the windshield, release the two levers
(15/1). • Pull the window back and up at the same time. • Lock the window in the upper position using the levers (15/1). 1
HR5.0_7.1_2_1
Fig. 15 Front window
Operating Manual Crawler Excavator TC20 41
4 Operation 4.7 Driving and steering
Danger to life C A due to incorrect operation. • Always observe that the direction of travel always relates to the undercarriage (drive at the rear, dozer blade in front)
Attention D B The engine must be switched off before lifting the exit barrier (16/2) and leaving the 5 6 machine.
Driving 2
– Rocker pedal / hand lever (16/6) for right-hand 2
crawler chain: A) forward
0 B) reverse
4/4 h. – Rocker pedal / hand lever (16/5) for left-hand
R crawler chain: C) forward D) reverse
Driving forward or reverse
• Move the rocker pedal / hand lever on the right (16/6) and the left (16/5) equally forward or backward.
Cornering • Reduce the speed of one crawler chain according to the curve.
Spot-turning • Operate the rocker pedal / hand lever for the right and left-hand crawler chains in an opposed manner.
Turning over one crawler chain
• Operate the rocker pedal / hand lever for the right or left-hand crawler chain.
HR1.6-03-17
Fig. 16 Driving and steering
42 Operating Manual Crawler Excavator TC20
Operation 4 4.8 Track width adjustment
Attention The hydraulic track width adjustment must be carried out on a plane and paved surface.
Danger of injury due to incorrect operation of the control. • Before actuating the lever (17/8) for “Dozer blade/Track width adjustment”, check the position of the changeover lever (17/17). • Familiarize yourself with the control. 17
• Change-over lever (17/17) in position “Track width
adjustment”. 8
4/ 4 Attention
h. If ground conditions are unfavorable, the crawler unit should be slackened.
R • Pull lever (17/8) backward, track width is retracted. HR2.0-04-19 • Push lever (17/8) forward, track width is extended. Fig. 17 Actuation of hydraulic track width adjustment • Move the change-over lever (17/17) back to position "Dozer blade".
Operating Manual Crawler Excavator TC20 43
4 Operation 4.9 Operations with rubber crawler chains
Attention This crawler excavator can be equipped with either steel or rubber crawler chains. If the excavator is equipped with rubber crawler chains, work on paved roads, within buildings, etc. can be performed without damaging the road ways.
When using rubber crawlers, the following points
have to be observed: – The rubber crawler chain must have the correct tension. Incorrect crawler chain tension is detrimental to travel performance and adds to the wear of the crawler chain. – Do not drive or turn over sharp edges or stairs since the crawler chain is stressed only on special points (18/A) and fissuring or cracking of the rubber and the steel insert may occur. – Prevent stones and other substances from getting A into the crawler chain as they may cause the crawler chain to be extended or damaged. – Do not undertake any sharp turns on surfaces with a high friction resistance such as rough concrete. – Avoid that the rubber crawler chain is contaminated by fuel or oil and clean immediately if this has occurred. – When working on salt water beaches, the rubber crawler chains must be thoroughly cleaned every day using clean water. The steel insert in the A rubber crawler chains may be damaged due to corrosion.
HR1220
Fig. 18 Operations with rubber crawler chains
44 Operating Manual Crawler Excavator TC20
Operation 4 4.10 Switching off the machine (parking)
• Park the machine on a preferably level, solid
ground. 2 • Lower the work attachment onto the ground. • Lower the dozer blade. 2 • Turn off the engine and remove the ignition key (19/33). • Apply and lock the vandalism guard (19/13)
4/ 4 (optional in case of canopy).
h. • Raise the working hydraulics shut-off / exit barrier 13 (19/2).
R • Windows and doors must be closed and/or locked. • Secure the machine against rolling away. 33
R 4 4/ 0
h.
HR1.6-03-21
Fig. 19 Switching off the machine (parking)
Operating Manual Crawler Excavator TC20 45
4 Operation
46 Operating Manual Crawler Excavator TC20
Working operation 5
5 Working operation
The excavator is equipped as standard with an "ISO"-
control (function of control levers 20/1 and 20/10) on which the following description is based.
There is the option to fit the excavator with a
switchable control system for the work equipment. Switching is accomplished by operating the lever (20/12).
Danger to life due to incorrect operation of the control 2 system. • Check your excavator to see which control 2 system is installed (only ISO-control or ISO 12 and SAE-control systems). • If you can choose between ISO and SAE, 1 10
0 check which control system (ISO or SAE)
4/ 4 h. is activated before working with the excavator.
R • Familiarize yourself with the control system. HR1.6-03-22
Danger of injury Fig. 20 Operating the exit barrier due to uncontrolled movements of the machine. • When lifting and lowering the exit barrier, ensure that no other control levers and/or pedals are operated.
Attention If the exit barrier (20/2) is lifted, all travel and work functions are deactivated.
Before working with the excavator:
• Memorize the lever controls well. • Start at low engine speed when familiarizing yourself with the controls.
Operating Manual Crawler Excavator TC20 47
5 Working operation 5.1 Work functions
5.1.1 Mode of operation
Danger to life due to incorrect operation of the control system. • Before working with the excavator check if the ISO or SAE control system (option) is activated. • Familiarize yourself with the control system.
1 10 Danger of injury 3 12 due to uncontrolled movements of the machine. • For special jobs it is necessary to additionally lock the uppercarriage by
4/ 4 applying a brake. To do so, press and hold
h. the push-button (21/3).
R • (Option) Select the desired mode of operation of the work equipment using the lever (21/12). A = ISO control system HR1.6-03-23
B = SAE control system Fig. 21 Checking the mode of operation
5.1.2 Work function: Articulation
Danger to life due to lack of care when using extra-wide work attachments (e. g. ditch-cleaning buckets, swing buckets, extra-wide buckets, special attachments). 4 • Exercise special caution when using the Knickmatik system. 0
4/ 4 h.
HR1.6-03-24 Fig. 22 Operation of articulation
48 Operating Manual Crawler Excavator TC20
Working operation 5 5.1.3 Work function: Dozer blade and track width adjustment
Dozer blade
Danger of injury due to incorrect operation of the control system. • Before commencing work, check if the control is in position "Dozer blade" or "Track width adjustment" (23/17).
• Pull lever (23/8) backward, dozer blade moves up.
• Push lever (23/8) forward, dozer blade moves down.
Hydraulic track width adjustment
17 Danger of injury 17 due to incorrect operation of the control system. • Before commencing work, check if the 17 control is in position "Dozer blade" or "Track width adjustment" (23/17). • After adjusting the track width, move the change-over lever (23/17) back to position "Dozer blade". 8
4/ 4 h. • Change-over lever (23/17) in position "Track width adjustment". R
• Slacken the crawler chain if required.
• Pull lever (23/8) backward, track width is retracted. HR1.6-04-25
• Push lever (23/8) forward, track width is extended.
Fig. 23 Operating the dozer blade / hydraulic track width • Move the change-over lever (23/17) back to adjustment position "Dozer blade".
Operating Manual Crawler Excavator TC20 49
5 Working operation 5.1.4 Work function: Additional control circuit
The additional control circuit is operated using the
right-hand rocker pedal (24/7).
4/ 4 h.
R HR1.6-03-26
Fig. 24 Operation of additional control circuit
5.2 Changing work attachments
Various work attachments are available to achieve
maximum utilization of the machine for a variety of applications.
The machine may be equipped with a quick-attach
system to shorten the time it would take to install attachments.
Attention Under special circumstances it is possible to use the work attachments of predecessor models for our machines. When mounting the work attachments of predecessor models they may have to be adjusted and/or may be subject to utilization restrictions. • It is essential to consult your dealer before mounting such a work attachment.
Danger of injury due to attachments tilting and overturning. • If work attachments are not used, they must be secured with wedges or similar.
50 Operating Manual Crawler Excavator TC20
Working operation 5 5.2.1 Installation and removal of work attachments
Attention Ensure that the bearings of the quick-attach system and work attachment and/or the dipperstick, bucket rod and work attachment are clean.
Changing procedure using the quick-attach
system
Attention concerning hydraulically actuated additional work attachments. 1
• Release the pressure in the hydraulic
system. • Disconnect the hydraulic connection.
• Lower the work attachment onto the ground and
position so that it cannot tilt. • Open the quick-attach system using the control rod (25/1) until the locking pins are completely retracted. • Move the quick-attach system out of the work HR1228 attachment. Fig. 25 Quick-attach system • Check the function of the quick-attach system lock and grease the pins if necessary. • Attach another work attachment and close the quick-attach system until the locking pins are completely extended and the lock has engaged. • Keep the control rod in the storage space (26/16) 16 inside the driver's cabin.
Procedure for changing work attachments
without quick-attach system
Attention concerning hydraulically actuated additional work attachments. 0
• Disconnect the hydraulic connection
4/ 4 h.
(hydraulic system must be without
pressure). R
• Lower the work attachment onto the ground and
position so that it cannot tilt. HR1.6-04-28
• Remove the pins connecting the work attachment Fig. 26 Storage space for control rod to the dipperstick and the bucket rod. • Attach another work attachment.
Operating Manual Crawler Excavator TC20 51
5 Working operation 5.2.2 Hydraulically actuated additional work attachments
• Mechanical installation is similar to the attachment
of a bucket with or without quick-attach system. • The hydraulic pressure supply is connected to the lines of the additional control circuit (27/1) by 2 means of a coupling. 1
5.2.3 Clamshell grab
Changing procedure using the quick-attach right
system 3
• Attach the clamshell grab and close the quick-
attach system until the locking pins are completely extended.
Machine damage 4 due to the bucket cylinder piston rod not having fully retracted. • Ensure that the bucket cylinder piston rod 1 is fully retracted. left 2 • Fully retract the bucket cylinder piston rod and HR1.6-04-29
close the ball valve (27/3). Fig. 27 Additional control circuit
• Connect the swivel motor to the couplings (27/1 additional control circuit) and the "Open/Close" function to the couplings (27/2 bucket cylinder).
Attention • After the clamshell grab has been removed, re-open the ball valve (27/3).
Changing procedure without quick-attach system
(clamshell grab attached directly)
Machine damage due to the bucket cylinder piston rod not having fully retracted. • Ensure that the bucket cylinder piston rod is fully retracted and close the ball valve (27/3).
• Connect the grab to the dipperstick using the
suspension pin and secure. • Connect the swivel motor to the couplings (27/1 additional control circuit) and the "Open/Close" function to the couplings (27/2 bucket cylinder).
Attention • After the clamshell grab has been removed, re-open the ball valve (27/3).
52 Operating Manual Crawler Excavator TC20
Working operation 5 5.2.4 Hydraulic rock breaker
Attaching the hydraulic rock breaker
Machine damage due to inappropriate hydraulic rock breaker. – Only use rock breakers approved by Terex. – The Mounting & Operating Instructions of the hydraulic rock breaker manufacturer must be observed. – Neither the permissible capacity in liters in the rock breaker supply line nor the permissible operating pressure of the rock breaker (= pressure at rock breaker entry during operations) must be exceeded. If malfunctions occur, the max. pressure of the additional control circuit is limited to 180 bar (operating pressure of machine). – When working in or under water, special rock breaker types must be used.
• Mechanical installation is similar to the attachment
of a bucket with or without quick-attach system. • The hydraulic pressure supply is connected to a line of the additional control circuit (28/1) by 2 means of a coupling. 1 • Connect the return line to the coupling (28/4) of the "open return".
Hydraulic rock breaker operations right
3 Machine damage due to improper use. Ensure that the rock breaker is always used properly; improper use may lead to severe damage to the rock breaker, holder and the 4 excavator itself. • The notes and instructions provided by the hydraulic rock breaker manufacturer must 1 be observed. left 2 HR1.6-04-29 Maintenance of the hydraulic rock breaker Fig. 28 Additional control circuit • Maintenance of the hydraulic rock breaker must be performed according to the instructions of the hydraulic rock breaker manufacturer.
Operating Manual Crawler Excavator TC20 53
5 Working operation 5.3 Removing the cabin
For particular operations it is better to work without
cabin.
Attention In order to dismount the cabin and to install the canopy, the original Terex crane lifting beam should be used (weight of the cabin approx. 180 kg). A
Danger to life due to falling objects. A B • If you work without cabin, the canopy has to be mounted.
Removing the cabin
• Open the cabin door and engage in support. A B • Remove the floor mat and the floor panel in front of the seat console inside the cabin. • Remove the front panel of the seat console, both 4/4
0 h.
right-hand and left-hand side.
A • Remove the rear cover. • Loosen the cable connections leading towards the cabin. • If a radio is installed, it must be removed along A B with the console. Unplug the antenna and loudspeaker cables from the radio and draw back the cables. A B 1 5 • Screw the crane lifting beam onto the cabin using the 4 bolts. 2 2 4 • Remove the fastening screws (29/1 - 4 pcs.) with 4 washers (29/2) (screwing 29/A). 3 • Remove the nuts (29/5 - 2 pcs.) (screwing 29/B). 3
• Unhinge the cabin using a crane and place it
carefully down onto the ground. • Put on the canopy and fasten (tightening torque HR2.0-02-29
MA = 80 Nm). Fig. 29 Attachment of the cabin
• Plug in the cable for the working floodlight(s). A) Screw
• Re-install the rear cover, front panel and floor mat. B) Nut
Attention For the removal of the canopy and re- installation of the cabin, proceed in the same manner as above but in reverse order.
54 Operating Manual Crawler Excavator TC20
Recovery, Loading and Transporting 6 6 Recovery, Loading and Transporting
6.1 Recovery 2 Attention We recommend recovering the machine using a crane.
2 The following towing lugs are available if the machine has to be pulled for recovery: – Lug (30/1) on chassis 1 – Two drilled holes (30/2) on dozer blade 2
HR2.0-01-30
Fig. 30 Towing lugs
6.2 Loading the machine by use of a 1
crane
Attention Only use the original Terex crane lifting beam for the cabin or the canopy.
Machine damage due to exceeding the maximum weight-lifting capacity. • Ensure that the weight-lifting capacity of 1 the crane is at least 2500 kg.
HR1.6-04-34 • Empty and fold in the bucket. Fig. 31 Crane suspension • Position the work equipment to be pointing straight ahead. • Raise the boom. • Retract the dipperstick. • Stop the engine. • Leave the excavator and close the doors. • Screw the crane lifting beam (31/1) onto the cabin or the canopy using the 4 bolts. • Attach the excavator to the crane lifting beam in the correct manner.
Operating Manual Crawler Excavator TC20 55
6 Recovery, Loading and Transporting 6.3 Transport 1 1 2 • During transport on a flat bed trailer, by truck and rail, etc., the machine must be properly lashed at the marked points (chassis 32/1 and dozer blade 32/2) and be secured with chocks. • Lower the dozer blade and position the work equipment on the ground.
Danger to life due to disregarding the total transport height. HR2.0-01-32-1 • Be aware of the total clearance height 1 1 2 when driving in tunnels, under bridges, etc. Fig. 32 Lashing the machine Danger of injury due to uncontrolled movements of the machine. • For loading and transportation purposes, adjust the machine to a wide track width.
Loading the machine onto a truck (Fig. 33)
• Connect the loading platform (ramp) to the excavator (max. angle 15°). • Secure the machine to be loaded with chocks against rolling away. HR3.7-03-36 • Drive the machine in reverse onto the truck and drive it forward when unloading it from the truck. • Carefully lash the machine for transport. Fig. 33 Loading the machine onto a truck
56 Operating Manual Crawler Excavator TC20
Care and Maintenance 7
7 Care and Maintenance
The good operating condition and life expectancy of
machines are largely influenced by care and maintenance.
For this reason, it is in every machine owner’s interest
to perform the specified maintenance work and comply with the service intervals. This Chapter deals in detail with periodic maintenance, inspection and lubricating tasks.
The type-specific maintenance and inspection plan
lists all work to be performed on the machine at regular intervals. Maintenance and inspection plans for this purpose are contained in every Instruction Book.
It is essential that the recommendations in the
Chapter "Safety and Prevention of Accidents" are observed (Î 2, 11).
7.1 Intervals
Initial inspection once before first putting into operation Î 7.7.1, 61
Daily jobs Every 10 operating hours or every work shift 1 Î 7.7.2, 62 Weekly jobs Weekly or after 50 operating hours 1 Î 7.7.2, 62 100 operating hours once after first putting into operation 2 Î 7.7.4, 66 Every 500 operating hours After every 500 operating hours Î 7.7.4, 66 Every 1000 operating hours After every 1000 operating hours Î 7.7.4, 66
Tab. 18 Intervals 1 whichever comes first 2 also applicable if new or overhauled diesel engines are put into operation.
Operating Manual Crawler Excavator TC20 57
7 Care and Maintenance 7.2 Regular oil analyses
Oil analyses are not intended as a substitute for the
oil change intervals but – apart from a possible reduction of maintenance costs and as a form of preventive maintenance – they take into account the increasing environmental awareness.
Advantages of an oil analysis
– Extension of the oil change intervals under standard or light-duty operating conditions. – Minimum wear of high-quality components with optimum use of the lubricants. – Periodic laboratory analyses enable an early detection of imminent damage. – Repairs performed before they actually become absolutely necessary help prevent serious and unexpected damage. – Sequential damage can be avoided.
How often should the oil be analyzed?
Periodic oil analyses reveal trends in the condition of
the oil and the machine. The oils should be analyzed at the following intervals: – Hydraulic oil: 1 000 operating hours – Transmission oil: 500 operating hours – Engine oil: 100 operating hours
Based on the first results, the laboratory recommends
the interval for the next sampling. Ask your Terex dealer for an information booklet detailing the scope and procedures of the oil analysis.
7.3 Warranty
During the warranty period thorough inspections are
stipulated which are obligatory and must be carried out by trained specialist dealer personnel.
Attention The inspections are obligatory and must be paid for. The performance of inspections as specified must be confirmed on the inspection cards in the warranty/handing- over certificate. If omitted, this may affect the warranty covered by us.
58 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 7.4 Inspection parts and aids
Tab. 19 --
Attention Maintenance and wearing parts for inspections should be ordered well in advance. Contact your dealer!
Lubricants – The machine’s life expectancy and operating condition largely depend on the use of the specified lubricants and compliance with the service intervals. – If lubricants which do not conform to our recommendations are used, consequential damage may occur for which we will not assume liability, even inside the warranty period. – Observe the specifications for fuels, lubricants, and coolants (Î 3.6, 26).
Operating Manual Crawler Excavator TC20 59
7 Care and Maintenance 7.5 Care and cleaning
Attention Engine oil
The machine must be cleaned on a suitable – The oil viscosity (SAE class) should be selected surface with an oil separator. according to the ambient temperature at the machine's place of operation. • Neither a steam-jet appliance nor a high-pressure Coolant cleaning apparatus may be used for cleaning during the first two months after the machine has – Before the beginning of the cold season, check been used for the first time, or when newly the level of antifreeze and adjust in line with the painted, to ensure that the paint can harden ambient temperature if necessary. At the factory, sufficiently. the antifreeze protection is set to approx. –40 °C. • Do not use aggressive detergents for cleaning the Condition of the battery machine. We recommend using commercially available cleaning agents for passenger cars. – A good cold start performance requires a well- charged battery. By warming the battery to • When cleaning with a steam-jet appliance, the hot approx. +20 °C (remove the battery after the water jet should not exceed 80 °C and a spray engine has been turned off and store it in a warm pressure of 70 bar. room), the minimum starting temperatures can be • Linings (insulating materials, etc.) should not be lowered by 4 – 5 °C. exposed directly to water, steam or high-pressure – When installing the battery, ensure good contact jets. of terminal connections. • When cleaning with water or steam jets, take care – Only tighten terminal screws so that they are not to spray exhaust-gas and air filter openings. "hand-tight", to prevent deformation of the • When cleaning the engine with water or steam terminal cones. jets, do not expose sensitive engine parts, such as generator, cabling, oil pressure switches, etc. Fuel directly to the jet. • Only use commercially available brand-named • After each wet clean, the machine must be diesel fuel with a sulfur content of less than 0.5 %. lubricated in accordance with the lubricating plan and a test of all work cycles, support and driving Use only winter diesel fuel in winter to prevent line functions carried out. connections becoming blocked through paraffin deposits. At very low temperatures, troublesome deposits may also occur when winter diesel is used.
7.6 Notes for winter operation
The following points - and the relevant notes in the
Engine Instruction Book - should be observed during winter operation:
Hydraulic oil – If the machine is not used for longer periods at temperatures around and below freezing, warm it up by running the engine at medium speed (approx. 3 – 5 min).
60 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 7.7 Checking, maintenance and inspection plans
7.7.1 Initial inspection (Handing-over
inspection)
13
4/4 h.
R HR2.0-01-34
8 6 9 7 3 2 1 5 4/13
Fig. 34 Initial inspection
Work to be carried out by trained dealer service
personnel.
Activities Chapter 1 Check whether machine-specific Operating Manual is in the machine. 2 Check the engine oil level. Î 7.8.2, 68 3 Check the hydraulic oil level. Î 7.8.9, 80 4 Check the fuel level. Î 7.8.5, 72 5 Check the coolant level. Î 7.8.4, 70 6 Check the oil level in the crawler gear units. Î 7.8.13, 83 7 Check the oil level in the swing gear Î 7.8.17, 86 8 Check the crawler-chain tension. Î 7.8.15, 84 9 Check the battery fluid level and charge. Î 7.8.19, 87 10 Grease machine (all lubricating points). Î 7.7.3, 64 11 Test run, hydraulic function check and test work. 12 Visual inspection for tightness of all hoses, pipes, cylinders, etc. 13 Check function of electrical indicating and warning elements, and the lighting system. 14 Initial delivery/handing-over certificate and return to manufacturer. Tab. 20 Work involved in initial inspection
Operating Manual Crawler Excavator TC20 61
7 Care and Maintenance 7.7.2 Daily and weekly tasks
Inspection and maintenance jobs to be performed by
operating personnel.
18
15
16
HR2.0-04-37
5/17
11
13
14 R 4/4 0
h.
12
19
Fig. 35 Inspection and maintenance plan
62 Operating Manual Crawler Excavator TC20
Care and Maintenance 7
Daily Chapter 1 Check the hydraulic oil level. Î 7.8.9, 80 2 Check the engine oil level. Î 7.8.2, 68 3 Check the fuel level (fuel gauge on instrument panel). Î 7.8.5, 72 4 Check windshield washer-fluid level. Î 7.8.18, 86 5 Check crawler-chain tension of rubber chains. Î 7.8.15, 84 6 General visual inspection for material cracks, external damage, completeness, etc. 7 Check for leaks in pipes, hoses, control unit, hydraulic pumps, cylinders, etc. Attention The screw-in couplings must be locked when tightening hose or line connections to prevent rotation. 8 Check function of electrical indicating and warning elements, and the lighting system. 9 Check smooth running of operator controls. 10 Grease machine according to overview of lubricating points. Î 7.7.3, 64 Tab. 21 Daily tasks
Weekly Chapter 11 Clean the cooling fins of the water cooler and the hydraulic oil cooler Î 7.8.4, 70 Machine damage Î 7.8.10, 81 due to strong accumulation of dust. • Shorten the cleaning intervals. 12 Check whether there is water in the fuel line of the water separator and if necessary, drain. Î 7.8.5, 73 13 Check the coolant level. Î 7.8.4, 70 14 Clean the dust ejection valve on the air filter. Î 7.8.6, 74 Machine damage due to strong accumulation of dust. • Shorten the cleaning intervals. 15 Check the function of the front windshield. 16 Check that door catches function perfectly. 17 Check the crawler-chain tension of the steel chains. Î 7.8.15, 84 18 Check bearing bushings and pins/bolts of the work equipment. 19 Check the function, condition and completeness of safety devices (e.g. exit barrier, etc.). 20 Grease machine according to overview of lubricating points. Î 7.7.3, 64 Tab. 22 Tasks to be performed weekly
Operating Manual Crawler Excavator TC20 63
7 Care and Maintenance 7.7.3 Overview of lubricating points
Machine damage due to damaged lubricating nipples. • Replace damaged grease nipples immediately and check if grease passes through.
7 8 9
3 3 1 21
2 1 10 11
12
14 13 16
R 4/4
25 0
h.
HR2.0-04-38
17 18
Fig. 36 Overview of lubricating points
64 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 • Grease all lubricating points with multi-purpose grease.
Attention The intervals stated are valid for single-shift operation. • Shorten the lubrication intervals for special operations, e.g. on sandy ground in order to achieve self-cleaning of the bearing points.
Item Lubricating point Number daily weekly Chapter
1 Bucket rod – bucket and/or quick-attach system 1 X 2 Dipperstick – bucket and/or quick-attach system 1 X 3 Bucket cylinder – Bucket rod – Tilt lever 3 X 4 Dipperstick – tilt control lever 1 X 5 Bucket cylinder – Dipperstick 1 X 6 Dipperstick cylinder – Dipperstick 1 X 7 Boom – Dipperstick 1 X 8 Dipperstick cylinder – Boom 1 X 9 Boom cylinder – Boom 1 X 10 Boom cylinder – Slewing column 1 X 11 Slewing column – Boom 1 X 12 Articulated cylinder – Slewing column 1 X 13 Uppercarriage – Slewing column 2 X 14 Dozer blade cylinder 2 X 15 - 16 Ring gear – bearing races 2 X Î 7.8.16, 85 17 Ring gear – Toothing 1 X Î 7.8.16, 85 18 Articulated cylinder – uppercarriage (open cabin floor) 1 X 19 - - 20 - - 21 Quick-attach system 2 X Machine damage For lubrication, place the bucket on the ground, open the quick-attach system (the pins must be fully retracted) - and start to lubricate. Close the quick- attach system. 22 - - Item Special equipment 25 Clamshell grab 11 X Tab. 23 Lubricating points
Operating Manual Crawler Excavator TC20 65
7 Care and Maintenance 7.7.4 Inspection Table
Work to be carried out by trained dealer service
personnel.
O = Checking, maintenance operating hours min. min.
X = Replace 2x 1x Perform work with machine at operating temperature after eve- eve- eve- annu- annu- Chapter 100 ry ry ry ally ally 300 600 1200 1 Check whether machine-specific Operating Manual is in the O O machine. 2 Change engine oil. X X X Î 7.8.2, 68 3 Change the engine oil filter. X X X Î 7.8.3, 69 4 Drain water from the fuel tank. O O O Î 7.8.5, 72 5 Change fuel filter. X X X Î 7.8.5, 72 6 Check air intake. O O Î 7.8.6, 74 7 Replace air filter main cartridge. according to the X Î 7.8.6, 74 service indicator 8 Replace the air filter safety cartridge. as required 1 Î 7.8.6, 74 9 Clean cooling fins of the hydraulic oil cooler. O O O Î 7.8.10, 81 Machine damage due to strong accumulation of dust. • Shorten the cleaning intervals. 10 Clean cooling fins of the water cooler. O O O Î 7.8.4, 70 Machine damage due to strong accumulation of dust. • Shorten the cleaning intervals. 11 Check level of antifreeze in the coolant. O Î 7.8.4, 70 12 Change the coolant. as required 1 Î 7.8.4, 70 13 Check V-belt tension. O O Î 7.8.7, 76 14 Check engine mount and pump attachments. O O 15 Check engine speed adjustment, upper and lower idling speeds. O O 16 Check valve lash on the engine and adjust if necessary. O O O Î 7.8.8, 79 17 Check injection nozzles. O 18 Check injection pump. O 19 Check acid level and battery connections. O O Î 7.8.19, 87 20 Check condition of crawler chains. O O Î 7.8.15, 84 21 Check secure fastening of crawler-chain sprocket, crawler gear units O O and hydraulic motor. 22 Check smooth running of bottom and top rollers. O O 23 Check bearing bushings and pins/bolts of work equipment and O O adjust until they are without play. 24 Check electrical indicating and warning elements and lighting O O equipment. 25 Check smooth running of operator controls and adjust if necessary. O O Tab. 24 Inspection plan 1 At least every two years. 2 Extension of oil change intervals according to oil sample analysis and laboratory report Î 7.2, 58. 3 Within warranty.
66 Operating Manual Crawler Excavator TC20
Care and Maintenance 7
O = Checking, maintenance operating hours min. min.
X = Replace 2x 1x Perform work with machine at operating temperature after eve- eve- eve- annu- annu- Chapter 100 ry ry ry ally ally 300 600 1200 26 Check for leaks in all pipes, hoses, control valves, hydraulic pumps, O O cylinders, etc. Attention The screw-in couplings must be locked when tightening hose and line connections to prevent rotation. 27 Check or change the hydraulic oil. O O X2 X Î 7.8.9, 80 28 Replace the hydraulic oil return filter insert. X according to X Î 7.8.11, 82 service indicator 29 Replace breather. X X Î 7.8.12, 82 30 Check or replace oil of crawler gear units. X O X X Î 7.8.13, 83 31 Check secure fastening of swing bearing attachment. O O O Î 7.8.17, 86 32 Check that the ring gear attachment screws are securely fastened. O O O Î 7.8.16, 85 33 Grease machine according to overview of lubricating points. O O Î 7.7.3, 64 34 Check function, condition and completeness of safety devices. O O 35 Check function of brake valves. O O Î 7.8.14, 83 36 Hydraulic function check with pressure function test. O O 37 Test run and test work. O O 38 Initial inspection card and return to manufacturer. O O3 Î 7.3, 58 Tab. 24 Inspection plan 1 At least every two years. 2 Extension of oil change intervals according to oil sample analysis and laboratory report Î 7.2, 58. 3 Within warranty.
Operating Manual Crawler Excavator TC20 67
7 Care and Maintenance 7.8 Inspection and maintenance work
7.8.1 Opening and closing the engine hood
Danger of injury due to unlocked engine hood. 1 Ensure that the engine hood lock snaps into place correctly when opening the engine hood.
Machine damage due to securing device which has not been unlocked. • Before closing the engine hood, push lever (37/1) upward.
Fig. 37 Closing the engine hood
7.8.2 Engine oil
Checking the engine oil level
• The oil level must be checked daily before start-up with the machine standing on level ground. • Insert the oil dipstick (38/3) until the stop. The 3 notches on the dipstick indicate the minimum and maximum oil levels. 4 • Top up engine oil if necessary. Open the filler neck 2 (38/2) and add oil using a clean container. Close the filler neck again.
1 HR1.6-01-41
Fig. 38 Engine oil
68 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 Changing the engine oil
Attention • Collect the waste oil in a suitable container and dispose of in compliance with 3 regulations. 4 • Run the engine until it reaches operating 2 temperature, engine oil temperature approx. 80 °C. • Park the machine on a level surface. • Stop the engine. • Place suitable drip pans under the opening. 1 • Screw the oil drain hose onto the oil-change valve (39/1). HR1.6-01-41
Danger of scalding Fig. 39 Engine oil
due to hot oil getting into contact with skin or
eyes. • Wear appropriate protective clothing and safety goggles.
• Remove the oil drain hose and screw the
protective cap onto the valve (39/1). • Change the engine oil filter (Î 7.8.3, 69). • Replenish engine oil via the oil filler neck (39/2) to the "MAX" mark on the oil dipstick (39/3).
7.8.3 Engine oil filter
The engine oil filter must be replaced every time the
engine oil is changed. • Unscrew the filter cartridge (40/4) using a 3 tightening scrap wrench or similar tool and dispose of in compliance with regulations. 4 • Clean the filter head and check its condition. 2
• Wet the seal ring with oil and tighten firmly by
hand. • Check the tightness of the engine oil filter cartridge.
1 HR1.6-01-43
Fig. 40 Engine oil
Operating Manual Crawler Excavator TC20 69
7 Care and Maintenance 7.8.4 Engine - cooling system
Checking the coolant level
Danger of scalding due to hot oil getting into contact with skin or eyes. • Only check the coolant level after the engine has cooled down. • Wear appropriate protective clothing/safety goggles.
• Release pressure from the cap (41/1).
1 • Remove cap (41/1) and check the water level. • The water level must be up to the overflow pipe 2 (41/2). • If required, top up with a mixture of water and antifreeze (50 %/50 %).
Water cooler – cleaning the cooling fins
Machine damage due to overheated engine. • Clean the cooler thoroughly. HR1.6-04-43 • Clean the water cooler from the outlet side with compressed air. Fig. 41 Water cooler
Clean with cold detergent or a steam-jet appliance if
required, e.g. if there is oil in the cooler. • Park the machine on a cleaning area equipped with an oil separator. • Clean the machine using a steam-jet appliance. • After cleaning, run the engine until it reaches operating temperature to dry the cooler.
70 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 Changing coolant
Danger of scalding 1 due to hot oil getting into contact with skin or eyes. 2 • Only change coolant after the engine has cooled down. • Wear appropriate protective clothing and safety goggles.
• Park the machine on a level surface.
• Place a drip pan under the engine and cooler. • Before removing the cooler cap (42/1), release pressure from the cap. HR1.6-04-43 • Open the drain valve (43/1) on the cooler and drain coolant. Fig. 42 Water cooler • Unscrew the water-drain plug (43/2) on the cylinder block and drain coolant. 2 • If necessary, flush the cooling system with clean water. • Refit the drain plug to the engine and close again the drain valve on the cooler. • Fill the cooling system with coolant and close the cooler with the cap (42/1). • Start the engine and bring to operating temperature; turn off the engine and allow to cool. • Check the coolant level and top up coolant 1 (several times, if necessary). HR1.6-01-46
Fig. 43 Changing coolant
Operating Manual Crawler Excavator TC20 71
7 Care and Maintenance 7.8.5 Fuel system
Checking the fuel level
• Check the fuel level using the fuel gauge (44/23). • In order to prevent condensation from forming 23 before the machine is next put into operation, top up fuel every day after use (45/1).
4 4/ 0
h. HR3.7-03-49
Fig. 44 Checking the fuel level
HR2.0-04-47
Fig. 45 Fuel tank
Replacing the fuel filter
Attention • Collect the fuel in a suitable container.
• Unscrew drainage unit (46/1).
• Loosen and remove filter unit (46/2). 2 • Collect any escaping fuel. 1 • Screw the drainage unit (46/1) to the new filter unit. • Install new fuel filter. • Check for leakages.
Attention Fig. 46 Replacing the fuel filter The fuel system does not have to be vented.
72 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 Venting the fuel system
Note • The fuel system must be vented if the fuel tank has been completely emptied.
• Fill the fuel tank.
• Operate the pump (47/2) at the fuel filter (47/1) 1 until fuel flows through the fuel filter. 2 Draining the fuel system • Place a suitable container under the opening of the water separator. • Unscrew the drain valve (47/3) until fuel flows out of it. • Remove the container and dispose of the fuel.
Fig. 47 Venting and draining the fuel filter
Operating Manual Crawler Excavator TC20 73
7 Care and Maintenance 7.8.6 Air filter, air intake
Machine damage due to dust being drawn into the engine. • All maintenance work on the air intake system must be carried out with the engine off. • Do not start the engine while the filter cartridge is removed.
Cleaning the dust ejection valve
The dust ejection valve (48/1) is largely maintenance- free. • Any baked-on dust can be removed by squeezing the valve together.
Cleaning or replacing the air intake
• Clean impurities (leaves, etc.) from the air intake section in front of the air filter. • Check the air filter attachment for damage and repair or replace if necessary. • Check the tightness of the air duct after the air filter. • Examine rubber parts for damage and replace if 1 HR12-03-53 necessary. Fig. 48 Cleaning the dust ejection valve
74 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 Cartridge maintenance intervals The air filter main cartridge must be replaced if, during operation, the filter maintenance indicator lamp (49/21) in the instrument panel lights up. 21 Attention A brief delay in maintenance does not result in lower filter efficiency. R
4 4/ Replace the air filter safety cartridge:
h. – after the third maintenance of the main cartridge – after 2 years of operation at the latest HR3.7-04-54
– if the service indicator switches on after the main
cartridge has just been serviced – if the main cartridge is damaged – if the safety cartridge is damaged. Fig. 49 Maintenance switch indicator lamps
Changing the main cartridge
• Open the tension brackets (50/5) and remove the cover (50/1) along with the dust ejection valve. • Withdraw the dirty air filter cartridge (50/2) by carefully turning and tilting and dispose of it. • Note down the date of maintenance on the safety cartridge. 5
• Clean the filter housing (50/4) with a damp cloth,
especially the seal area for the air filter cartridge. • Check whether the new air filter cartridge is damaged.
Machine damage 4 3 2 1 due to dust being drawn into the engine. HR1253
• Do not install damaged air filter cartridges.
Fig. 50 Changing air filter cartridges • Mount the air filter cartridge into the filter housing by slightly turning. • Re-mount the cover along with the dust ejection valve to the bottom and re-fasten with tension brackets (50/5).
Operating Manual Crawler Excavator TC20 75
7 Care and Maintenance Changing the safety cartridge • Remove main cartridge (51/2). • Remove the safety cartridge (51/3) by carefully turning and tilting and dispose of it according to regulations. • Clean the filter housing (51/4) with a damp cloth, especially the seal area for the cartridges. 5
• Install the new safety cartridge in the filter housing
by slightly turning it. • Install the main cartridge in the filter housing. • Re-mount the cover (51/1) along with the dust ejection valve to the bottom and re-fasten with 4 3 2 1 tension brackets (51/5). HR1253
7.8.7 V-belt Fig. 51 Changing air filter cartridges Danger of injury due to rotating V-belts. • Only check and tension V-belts with the engine off. • Secure the engine against unauthorized starting.
• Check the entire V-belt for damage (visual
inspection). Replace damaged or worn V-belts immediately.
Checking V-belt tension
Attention We recommend checking the V-belt tension using a V-belt belt tensioner gauge. • Check the tension in accordance with the manufacturer’s Operating Instructions.
76 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 Checking without a belt tensioner gauge • Press the V-belt with your thumb in the middle of the greatest free length, and measure the V-belt sag.
Attention Using medium thumb pressure of approx. 45 N (approx. 4.5 kg), the V-belt sag should equal 10 mm.
Tensioning the V-belt
• Stop the engine and remove the ignition key. • Open the engine hood. 1 • Slacken the fastening screw (52/1) of the 14Nm generator. • Rotate the generator until the tension is correct. • Re-tighten the fastening screws 52/1 and 52/2 of the generator. 2 • Check the tension again. 22Nm 10 mm • Close the engine hood.
HR1.6-04-53
Fig. 52 Tensioning the V-belt
Operating Manual Crawler Excavator TC20 77
7 Care and Maintenance Changing V-belts • Open the engine hood. • Disconnect the battery. 1 • Loosen the fastening screw of the protective grill 14Nm (option) and remove the protective grill (option). • Loosen the clamping bolt (53/1) of the generator and remove the V-belt. • Slightly press the water cooler to the right and take 2 out the V-belt above the fan blade. 22Nm 10 • Mount the new V-belt and tighten according to mm instructions. • Re-mount the screw of the protective grill (option). • Re-connect the battery. HR1.6-04-53
• Check the correct function of the fan blade.
Fig. 53 Changing V-belts • Perform a test run. • After 15 minutes, check the tension of the new V- belts and adjust if necessary.
78 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 7.8.8 Valve lash
• Test the valve lash (54/1) on a cold engine by
placing a feeler gauge between the upper part of the tappet (54/3) and the rocker arm (54/2).
The correct valve lash is as follows:
Inlet valve = 0.25 mm Exhaust valve = 0.25 mm
Attention The 1st cylinder is located at the front on the fan side of the engine. Firing sequence: 1 – 3 – 2 6 • Remove the valve cover 2 • Turn the crankshaft clockwise until the valves 5 intersect at the 1st cylinder. 4 • The markings (54/6) on the housing and V-belt 1 pulley must coincide. Check the overlapping of the valve by moving the crankshaft by approx. 20° in both directions. The rocker arm must not move. 3 • If the rocker arm moves, the crankshaft must be turned further by one full turn (360°). • In this position, check the valve lash of the valves on the 1st cylinder. HR1258 Attention If necessary, adjust the valve lash as follows: Fig. 54 Adjusting the valve lash
• Slacken lock nut (54/4).
• Using a screwdriver, adjust the setting screw (54/5) in such a way that the correct valve lash (54/1) is obtained after the lock nut is tightened.
• To adjust the other cylinders, turn the crankshaft
further by 240° in each case. Order of adjustment = firing sequence • Check and adjust the valves as specified for the 1st cylinder. • Re-install the valve cover.
Operating Manual Crawler Excavator TC20 79
7 Care and Maintenance 7.8.9 Hydraulic oil tank
Checking the hydraulic oil level
• Remove the return filter cover (55/2). • Check the oil level using the sight glass (55/3) and replenish hydraulic oil if necessary. 1 Attention 2 The excavating equipment must be extended and lowered to the ground. • Ensure that the hydraulic oil level lies between the two markings. 3
Changing the hydraulic oil
Attention • Only change the hydraulic oil when it is at operating temperature. HR1.6-04-56
• Retract all hydraulic cylinders.
Fig. 55 Checking the hydraulic oil level, changing the • Stop the engine. hydraulic oil • Unscrew the breather (55/1). • Place suitable drip pans under the opening.
Danger of scalding due to hot oil getting into contact with skin or eyes. • Wear appropriate protective clothing/safety goggles.
• Unscrew the drain plug (56/1) from the hydraulic
oil tank and drain oil into clean containers.
Attention • Dispose of the waste oil according to regulations.
• Screw back on the drain plug carefully.
• Loosen the return filter cover. • Fill up with clean hydraulic oil until the correct level on the sight glass (55/3) is reached. 1 • Re-mount the filter cover. HR1.6-04-57 Fig. 56 Drain plug • Screw back in the breather.
80 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 7.8.10 Hydraulic oil cooler
Machine damage due to overheated engine. • Clean the cooler thoroughly.
• The hydraulic oil cooler (57/1) is cleaned from the
outlet side using compressed air.
Clean with cold detergent or a steam-jet appliance if
required, e.g. if there is oil in the cooler. • Park the machine on a cleaning area equipped with an oil separator. 1 • Clean the machine using a steam-jet appliance. HR1.6-04-58 • After cleaning, run the engine until it reaches operating temperature to dry the cooler. Fig. 57 Hydraulic oil cooler
Operating Manual Crawler Excavator TC20 81
7 Care and Maintenance 7.8.11 Hydraulic oil return filter
Attention • After a larger repair job, renew the filter 1 insert following the test run. 2 • Damaged hydraulic attachments may shorten the operating life of the return filter.
Changing the filter insert 3
• Switch off the engine.
Attention Always place a receptacle for the collection of waste oil under the working area when draining oil or removing the filter insert. HR1.6-04-56
Fig. 58 Hydraulic oil tank
• Remove the cover (59/1) of the return filter (58/2)
using an auxiliary tool and unscrew. 1 • Check the condition and O-rings of the cover. 2
• Pull out the filter element and dispose of according
to regulations. • Clean the filter bowl if necessary. • Check O-rings and replace any damaged part. • Check the condition of the clogging indicating sensor. • Insert a new filter element. • Apply a light coat of grease to the cover and tighten the cover by hand. • Check the tightness of the filter.
7.8.12 Breather
• Remove the breather (58/1), replace it by a new
filter and tighten so that it is hand-tight.
Attention The breather must also be replaced if it is dirty, for example due to hydraulic oil vapor. Fig. 59 Return filter
82 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 7.8.13 Crawler gear units
Checking the oil level
– Move the crawler gear unit to the inspection position. – Remove the inspection screws (60/2) and top up oil up to bottom edge of the drill holes if required.
Carrying out an oil change
Attention A 3 • Dispose of waste oil in compliance with regulations.
• The oil must be changed at operating temperature
with the machine parked on level ground. • Position the transmission in such a way that the drain plug (60/1) is right at the bottom. 2
• Open the filler/inspection plug (60/2) on the
transmission. • Open the drain plug (60/1) and catch any escaping oil. B • Flush out the transmission with flushing oil if necessary. 1 • Carefully re-insert the drain plug with sealing tape and top up transmission oil using the filler/inspection plug (60/2) until oil escapes from the hole. • Carefully re-insert the filler/inspection plug with HR1.6-06-63 sealing tape. Fig. 60 Crawler gear units 7.8.14 Brake valves A) Filling and inspection position B) Drain position Function check • Move both levers equally forward into the "Machine rolling" position. • Move both levers to neutral position at the same time. The machine should brake in a constant manner and must not drift sideways.
Operating Manual Crawler Excavator TC20 83
7 Care and Maintenance 7.8.15 Crawler chains
Checking the crawler chain tension
• This check must be carried out on a level surface. • Slew the uppercarriage by 90° and lift on one side until the crawler is free above ground.
• The sag of the crawler chain between lower roller
and crawler chain (Fig. 61, distance "a") should a be: Steel chain approx. 25 – 35 mm 2 Rubber chain approx. 15 – 20 mm .
Tensioning the crawler chain grease
1 • Remove the covers on the right-hand and left- hand side of the crawler frame and re-tension the crawler chain using the hand grease gun via the grease nipple (61/1). • Move the crawler chain and check the crawler- HR2.0-01-61
Attention in case of new rubber crawler chains. • Check the sag of the rubber chains on the first day of operation 2 - 3 times and retension if necessary.
Releasing the crawler chain tension
Danger of injury due to grease spurting out under pressure. • Wear appropriate protective clothing and safety goggles. • Release the crawler chain tension slowly and carefully.
• Slowly loosen the valve (61/2) with the grease
nipple and let grease drain out until the correct crawler chain tension is obtained. • Re-tighten the valve using the grease nipple. • Remove any grease and dispose of according to regulations. • Move the crawler chain and check the crawler- chain tension again.
84 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 7.8.16 Swing bearing
Lubrication of toothing R 4/4
0 h.
The grease nipple (62/1) mounted on the left side
inside the cabin lubricates the toothing of the ring gear via a nozzle tube (62/2). To do so: • Slowly slew the uppercarriage and lubricate it thoroughly at the same time using a grease gun.
Lubrication of bearing races
1 The bearing races are lubricated via the lubricating 4 nipples (62/3) mounted on the ring gear. To do so: • Slowly slew the uppercarriage and lubricate it thoroughly until the gasket has a collar (62/4) of fresh grease. 3 4 Checking the secure fastening of the swing bearing 2 Attention • When mounting for the first time, the bolts must again be checked after 100 operating hours. HR1.6-05-63
Fig. 62 Ring gear
The following assembly conditions are prerequisites for an optimum bolted connection on the chassis and the uppercarriage: – The contact faces of bolts must be of bright metal, i.e. absolutely free from grease and paint. – The thread and the bolt head must not be MA = 125 Nm damaged. A MA = 125 Nm MA = 64 Nm Machine damage MA = 64 Nm due to damaged screws/bolts. C 8 6
• Replace damaged screws/bolts
immediately. 2
B 4 • All screws/bolts must be examined to ensure that 6 they are tightened to the torques specified in 8 Fig. 63. HR1.6-04-64
Checking the swing bearing attachment
• All screws/bolts must be examined to ensure that Fig. 63 Swing bearing they are tightened to the torques specified in A) Uppercarriage Fig. 63. B) Chassis C) Oval hole (x3) (below the oval cover)
Operating Manual Crawler Excavator TC20 85
7 Care and Maintenance 7.8.17 Swing gear
Attention The swing gear has lifetime lubrication. Oil changes are therefore unnecessary.
HR2.0-03-66
Fig. 64 Swing gear
7.8.18 Windshield washer system
• Top up the windshield washer tank (65/14) as
required. • Add antifreeze when temperatures are around or below freezing.
4/ 4 h.
R 14 HR1.6-04-68
Fig. 65 Washer-fluid container
86 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 7.8.19 Electrical equipment
Battery The battery (66/1) is located under the floor panel on the left-hand side inside the cabin.
Attention R
4/4 0
h. The instructions of the battery manufacturer must be observed when using the battery for the first time.
• Only check the battery with the engine switched
off. • The acid level should be approx. 10 mm above the plates. If necessary, top up with pure distilled 1 water. HR1.6-04-63
Attention In the case of maintenance-free batteries, Fig. 66 Battery this check is not necessary.
Operating Manual Crawler Excavator TC20 87
7 Care and Maintenance Removing the battery • Open the cabin floor. • First disconnect the battery ground cable (-), then the positive cable (+). 1 • Slacken the clamping bracket (67/1). • Lift out the battery.
Installing the battery
• Place the battery into the machine. • Secure with the clamping bracket. • Connect first the positive battery cable, then the ground cable.
HR1.6-05-70 Machine damage due to reverse of terminals. Fig. 67 Removing the battery • Ensure that the negative terminal is connected to the negative pole (-) and the positive terminal to the positive pole (+).
• Close again the cabin floor.
Attention In winter, in particular, the battery charge should be closely monitored.
Checking the lighting and warning equipment
• Check the function of the lighting equipment. • Check the function of the indicator lamps. • Check the function of the warning equipment.
88 Operating Manual Crawler Excavator TC20
Care and Maintenance 7 7.9 Immobilization
7.9.1 Preservation (temporary immobilization ) 7.9.2 During immobilization
Machine damage When the machine is out of use for 6 months, after due to damage from storage (e.g. corrosion this time all assemblies must be brought to operating damage) during shutdown periods over three temperature and maneuvered for months. approx. 15 minutes. • Perform the preservation measures. Beforehand, the anti-corrosion coat must be Preservation measures: removed from the piston rods, and the openings of • We recommend keeping the machine in a dry, the air filter system and the exhaust pipe freed. dust-free room during the storage period. After the maneuvering cycle, preserve the machine • Thoroughly clean the inside and outside of the once more as previously described. machine, including the engine. • Lubricate the machine according to the 7.9.3 After immobilization lubrication plan. Before putting the machine into operation once • Check the oil levels of all assemblies such as more, the following measures must be carried out: transmission(s), etc. and top up if necessary. • Anti-corrosion coat must be cleaned from the • Check the hydraulic oil level and top up if piston rods. necessary. • Seal off the air intake opening of the air filter and • Repair any paint damage. the exhaust pipe opening. • Fill the diesel tank completely, to prevent • Check the condition of the air filter main cartridge corrosion of the tank walls. and the safety cartridge and replace if necessary. • Check the antifreeze level in the coolant and • Clean the machine with a neutral detergent. adjust if necessary. • Check and, where required, re-charge and re- • Perform all preservation measures specified in install the battery. the diesel engine Operating Manual. • Carry out all measures for putting the diesel • Ensure that the crawler chain tension engine back into operation listed in the Engine corresponds to the prescribed value and protect Operating Manual. rubber crawler chains from direct sunlight. • Lubricate the machine according to the • Treat bare piston rods with a commercially lubrication plan. available anti-corrosion agent. • Remove and clean the battery and keep it If the machine has been out of use for more than according to regulations in a dry - in winter, frost- 6 months proof - room. Coat connections with a little pole – The oil in the assemblies such as axles, grease. transmission(s), etc. must be changed. • Seal off the air intake opening of the air filter – Replace hydraulic oil filters (suction and return system and the exhaust pipe opening. filters, breathers, if installed).
Operating Manual Crawler Excavator TC20 89
7 Care and Maintenance
90 Operating Manual Crawler Excavator TC20
Trouble-shooting 8
8 Trouble-shooting
Operating problems are often the result of incorrect
handling of the machine, the use of unsuitable materials or irregular maintenance.
The following Table presents a summary of a range of
problems and their probable causes.
If a problem can only be eliminated through repair,
then your responsible Service Agent must be called in.
8.1 Engine
All faults in the diesel engine must be examined as
described in their specific Engine Operating Instructions.
During the warranty period, malfunctions must be
dealt with by your responsible Service Agent or a specialist workshop.
8.2 Table of faults
Possible cause Remedy
Machine fails to drive Engine damaged. Check engine. Too little hydraulic oil in tank. Top up hydraulic oil to recommended mark. Hydraulic pump has failed. Have pump checked for mechanical damage by specialist. Replace hydraulic pump completely. Clutch or pump drive damaged. Replace pump drive. Determine cause of damage. Main relief valve damaged or wrongly adjusted. Replace main relief valve. Insufficient driving performance Insufficient engine power. Check diesel engine. Main relief valves damaged or wrongly adjusted. Check pressure, re-adjust valves, replace if necessary. Oil loss in rotary joint. Re-seal rotary joint. Crawler chains tensioned too tightly. Check crawler-chain tension and reduce if required. Excavator installation not working Exit barrier lifted and/or shutoff valve damaged. Lower exit barrier and/or check shutoff valve; replace or repair if required. Oil supply to hydraulic pump interrupted. Check lines. Hydraulic pump has failed. Have hydraulic pump checked by specialist and replace if necessary. Main relief valves have failed or are wrongly Check main relief valve and replace if necessary. adjusted. Decrease in machine's performance Insufficient engine power. Check diesel engine. Insufficient hydraulic oil level. Top up hydraulic oil to the recommended mark. Pump is sucking in air. Re-tighten hose connections. Replace O-ring or seals. Insufficient operating pressure. Re-adjust main relief valves or replace if required. Machine working too slowly and hydraulic oil is becoming too hot Tab. 25 Table of faults
Operating Manual Crawler Excavator TC20 91
8 Trouble-shooting
Possible cause Remedy
Incorrect adjustment of main relief valves or valves Re-adjust main relief valves or replace if required. are damaged. Hydraulic pump worn. Replace hydraulic pump. Incorrect hydraulic oil. Quality of hydraulic oil must conform to our recommendation. Insufficient oil level. Top up oil to mark on sight glass. Oil cooler dirty or damaged. Clean, check and replace if necessary. Air in hydraulic system. Tighten connections with engine off and system relieved of pressure. Uppercarriage slewing too far Secondary valves damaged or wrongly adjusted. Re-adjust secondary valves; replace if required. Swing motor is leaking – internal wear. Replace hydraulic motor. Working cylinders not operating satisfactorily Seals in cylinders worn. Re-seal cylinder(s). Secondary valves damaged or wrongly adjusted. Check secondary valves and replace completely if required. Main relief valves wrongly adjusted. Check main relief valves and replace if required. Faults in the electrical system Outside and/or internal lighting without function. Check cables, connections, bulbs, and fuses. Windshield wiper not working. Check cables, connections, and fuses. Examine windshield wiper for mechanical damage, replace if necessary. Windshield washer system not working. Check water level. Check cables, connections and fuse. Check water pump and water pipes and replace if necessary. Horn not responding. Check cables, connections and fuses, replace horn if necessary. Warning/indicating elements are imprecise. Determine the fault or source of the problem and eliminate it, call service personnel if necessary. Tab. 25 Table of faults
92 Operating Manual Crawler Excavator TC20
Appendix 9
9 Appendix
9.1 Electrical system
Fig. 68 Fuse and relay box – assignment diagram
Item Amps Assigned to
FA 30 A Main fuse FB 60 A Pre-heating fuse F1 5A Instrument cluster 15, immobilizer 15 F2 10 A Fuel pump, generator F3 15 A Working floodlights, front F4 15 A Working floodlights rear, boom F5 10 A Travel fast/slow, travel motion alarm F6 10 A Swing brake, dozer blade F7 15 A Heater fan F8 15 A Washer and wiper system F9 10 A Horn, radio 15 F10 20 A Optional: 2nd control circuit, optional: electrical seat, air conditioning system F11 5A Instrument cluster 30, immobilizer 30 F12 10 A Interior light, radio 30, rotating beacon F13 15 A Socket F14 15 A Optional: refueling pump optional: 30 K1 – Main relay K2 – Swing brake K3 – Front dozer blade K10 – Glow plug timing unit K12 -- Time relay engine shut-off Tab. 26 Assignment
Abbrev. Color Abbrev. Color Abbrev. Color Abbrev. Color
bg beige dgr dark gray hbr light brown rt red bl blue ge yellow hgr light gray sw black br brown gn green hr light red vie violet dbl dark blue gr gray nt natural colors ws white dbr dark brown hbl light blue or orange Tab. 27 Cable and plug colors
Operating instructions TC20 crawler excavator 93
9 Appendix 9.2 Immobilizer
Note The immobilizer is self-activating; that is, without additional activation or divergent actions. If the mechanical start switch is in position "0" (terminal 15 off), the immobilizer is generally activated.
• Set the start switch key to position "0".
• The immobilizer is automatically activated after 5 sec. • The immobilizer becomes and remains activated if the key remains inserted in position "0".
Deactivating the immobilizer
Note The immobilizer is deactivated if a valid mechanical key and a valid electronic key (transponder) are present.
• Set the start switch key to position “1”.
• The transponder is not read until the mechanical key in the start switch has activated terminal 15. This makes it necessary to first open the mechanical locking system before the electronic key is inspected. A manipulation of the immobilizer with the ignition deactivated is thereby impossible.
94 Operating instructions TC20 crawler excavator
Handing over the Machine and Instructing the Operator 3. Warranty – Explanation of warranty offered by manufacturer. The following checklist should be followed when handing over the machine to the operator: – Explanation of inspection cards and note on maintenance and inspection plan. – The warranty/handing-over card must be filled out correctly and sent back to the 1. Operating Manual manufacturer. Go through the Operating Instructions (page by page) and explain them in detail through practical training on the machine. Items which are particularly important include: – Accident Prevention Regulations published by the employers liability insurance associations in the users country – Technical Specifications – Operator controls, indicating and warning elements – Checks before putting the machine into operation – Diesel engine running-in instructions Crawler Excavator – Starting and stopping the diesel engine – Explanation of hydrostatic crawler drive – Driving TC20 – Recovery and transport of the machine – Operation of all functions – Tensioning crawler chains – Explanation of maintenance intervals and points according to Maintenance and Maintenance and Inspection Plan Inspection Plan by demonstrating and explaining maintenance points on machine (for trained dealer service personnel) – Lubrication intervals and points of lubrication according to lubrication chart and demonstration of these points on the machine The careful performance of all prescribed inspections is the best prerequisite for the machines continuous readiness for operation. – Handing-over of Diesel Engine Operating Instructions The inspections are obligatory. If omitted, this may affect the warranty covered by us. 2. Spare Parts List The following applies to maintenance and inspection work: – Structure of Spare Parts List, Figures and the associated texts • The machine must be thoroughly cleaned before inspection takes place. – Instructions for ordering spare parts - always state the type of machine, the vehicle • All maintenance work specified should be performed in the prescribed sequence identification number ("Fz-Id.Nr."), parts designation, complete spare part number, with the machine at operating temperature. number of pieces, delivery address, etc. O = Checking, maintenance operating hours min. min. O = Checking, maintenance operating hours min. min. X = Replace 2x 1x X = Replace 2x 1x Perform work with machine at after every every annu- annu- Perform work with machine at after every every annu- annu- operating temperature 100 500 1000 ally ally operating temperature 100 500 1000 ally ally 1 Check whether machine-specific Operating O O 24 Check electrical indicating and warning elements O O Manual is in the machine. and lighting equipment. 2 Change engine oil. X X X 25 Check smooth running of operator controls and O O 3 Change the engine oil filter. X X X adjust if necessary. 4 Drain water from the fuel tank. O O O 26 Check for leaks in all pipes, hoses, control valves, O O 5 Change fuel filter. X X X hydraulic pumps, cylinders, etc. 6 Check air intake. O O Attention 7 Replace air filter main cartridge. according to the X The screw-in couplings must be locked service indicator when tightening hose and line connections to prevent rotation. 8 Replace the air filter safety cartridge. as required 1 9 Clean cooling fins of the hydraulic oil cooler. O O O 27 Check or change the hydraulic oil. O O X2 X 28 Replace the hydraulic oil return filter insert. X X X Machine damage 29 Replace breather. X X due to strong accumulation of dust. 30 Check or replace oil of crawler gear units. X O X X • Shorten the cleaning intervals. 31 Check secure fastening of swing bearing O O O 10 Clean cooling fins of the water cooler. O O O attachment. Machine damage 32 Check that the ring gear attachment screws are O O O due to strong accumulation of dust. securely fastened. 33 Grease machine according to overview of O O • Shorten the cleaning intervals. lubricating points. 11 Check level of antifreeze in the coolant. O 34 Check function, condition and completeness of O O 12 Change the coolant. as required 1 safety devices. 13 Check V-belt tension. O O 35 Check function of brake valves. O O 14 Check engine mount and pump attachments. O O 36 Hydraulic function check with pressure function O O 15 Check engine speed adjustment, upper and lower O O test. idling speeds. 37 Test run and test work. O O 16 Check valve lash on the engine and adjust if O O O 38 Initial inspection card and return to manufacturer. O O3 necessary. 1 At least every two years. 17 Check injection nozzles. O 2 Extension of oil change intervals according to oil sample analysis and laboratory report Î 7.2, 58. 18 Check injection pump. O 3 Within warranty. 19 Check acid level and battery connections. O O 20 Check condition of crawler chains. O O 21 Check secure fastening of crawler-chain sprocket, O O crawler gear units and hydraulic motor. 22 Check smooth running of bottom and top rollers. O O 23 Check bearing bushings and pins/bolts of work O O equipment and adjust until they are without play. Index 10
