Professional Documents
Culture Documents
Crawler Excavator
HR 1.6
Ausgabe • Edition
2006-01
GÜLTIG AB FZ-ID.NR. • VALID FROM SERIAL NO. • A PARTIR DU NO. DE SERIE
01600R/0100 >
TEREX | SCHAEFF GMBH • D-74595 LANGENBURG
Hauptverwaltung/Verkauf Kundendienst Ersatzteile
Direction générale/Vente Service après-vente Pièces de rechange
Central Administration/Sales Service Department Spare parts
TEREX | Schaeff GmbH Terex Deutschland GmbH TEREX | Ersatzteile GmbH
Postfach 61 • D-74595 Langenburg Postfach 12 64 • D-91534 Rothenburg Postfach 12 64 • D-91534 Rothenburg
Schaeffstr.8 • D-74595 Langenburg Erlbacher Str. 113 • D-91541 Rothenburg Erlbacher Str. 115 • D-91541 Rothenburg
Phone + 49 (0) 7905/58-0 Phone + 49 (-451) 9861/972-0 Phone + 49 (0) 9861/972-0
Fax +49 (0) 7905/58-114 Fax + 49 (0) 9861/972-460 Fax + 49 (0) 9861/972-410
1 Introduction
Attention
Fig. 1 Type label
Any modifications of TEREX | Schaeff
products and their 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.
Attention
The vehicle identification number of the ma-
chine is stamped onto the type label (1/1) .
The warranty period covers 12 (twelve) months, This Operating Manual is copyrighted. It must not be
beginning with the day the machine is handed over or copied, disseminated or used for competitive
put into 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 | Schaeff crawler excavator fulfils these
requirements when correctly handled and when 1.3 Notes on using the Operating
serviced and 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. è 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 | Schaeff spare parts Pictogram "Danger of injury/machine damage"
are used in the event of any repair work. In this way,
you will have a product of lasting high quality, thereby Danger of injury/machine damage
ensuring that your machine maintains its original This indicates a potentially hazardous
condition. 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.
– 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.
– 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.
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.
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.
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 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.
• 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.
3 Technical Specifications
3.1 Views
2390
2290
3
3
2
0
1
1
4
25°
0
1
3900
4085
2
3
4
5
2300 1060
Optional
2430 1220
Extra-long dipperstick 2830 1670
2960 1870
3350 2200
3460 2400
3
3
2
0
1
1
4
3860
4050
2
3
4
6217500002
5
1700 2710
1820 2910
1920 2930
2040 3130
2290
HR1.6-04-03
R1130
B A
1000
1340
370 510
60°
60°
C
1340 mm D
2370 mm
A
2500 mm
B 6187500005
D = undercarriage extended
Engine
Manufacturer Mitsubishi
Type L3E four-stroke diesel engine
Design 3 cylinders in line
Displacement 952 cm3
Power output according to DIN 70020 13.3 kW at 2400 rpm
Permissible inclined positions continuously 25° on all sides; briefly 30° (max. 30 minutes)
Specific fuel consumption 247 g/kWh
Practical fuel consumption approx. 3.0 l/hr at medium load
Cooling Water-antifreeze mixture for all-year operation
Heating Warm water with 2-speed fan
Tab. 3 Technical specifications - Engine
Electrical system
Operating voltage 12 V
Battery 12 V – 74 Ah
Generator 12 V – 40 A
Starter 12 V – 1.7 kW
Starting aid Glow plugs, glow-time control
Lighting system Working floodlight(s)
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 – 2.7 km/h
Max. hill climbing ability 60 %
Power transmission Single-stage hydrostatic travel drive with axial piston variable-displacement
motor 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 1490 mm
Track width adjustment Horizontally adjustable crawler frames.
Hydraulically adjustable from driver's seat – mechanical adjustment as an option.
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
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: 165 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: 32 l/min at 100 bar
26 l/min at 140 bar
max. 165 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
The hydrostatic swing drive acts as a wear-free swing brake.
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. 370/510 mm.
Dozer blade Independent from drive, right-hand joystick providing sensitive control with push-button pressed.
2-part dozer blade.
Blade frame width 980 mm with full support function.
Detachable blade body.
Width 1340 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
All values stated are approximate. The level marking is always the decisive factor.
Fig. 5 Recommended viscosity classes for engine oil Fig. 6 Recommended viscosity classes for hydraulic oil
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 98/37/EEC and EN 474
Attention
The dead-weight of the work attachment
must be deducted from the stated payload.
V) movable
V) movable
V) movable
V) movable
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°
max. 2,5 m
90°
B
H
R
16
-0
4-
07
A) Maximum reach
B) Restricted reach
Attention
Additional work attachments available from
the manufacturer.
Attention
Additional accessories available from the
manufacturer.
Machine damage
due to unauthorized alterations to the design,
additional equipment and work attachments
of TEREX | Schaeff 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.
4 Operation
16 5 6 7
2
15
17
2
9
12
1 8
10
4/4
h.
3
13
14
11
HR1.6-04-101
23 18 21 22 33 34 26
R
4
4/
90°
0
h.
HR3.7-03-102
20 19 25 24 27 28 29 30 32
4.3.1 Starting
Attention
Each time before putting the machine into
operation, the inspections according to
(è 7.7, 63) 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.
4/
4
h.
• Move manual throttle (10/9) to 2/3-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 sec-
onds, turn the ignition key to "1" or "0", and pause
for at least 1 minute before trying again; repeat the R
4
start-up procedure.
4/
0
h.
Engine damage 20 19
Avoid damaging the engine by: Fig. 10 Starting the engine
• not driving the engine at full throttle straight
away.
• driving with restraint until the engine has
reached its operating temperature.
Engine damage
due to fault which has not been remedied.
• The fault must be remedied before
restarting the engine and operating the
machine again.
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.
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.
1. Horizontal adjustment
2. Seat-back inclination adjustment
1
3. 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 2
automatically switches to the 50-kg position.
3
HR1213
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.
HR1.6-01-13
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/
30
Fig. 14 Ventilation
View looking up
HR2.0-04-15
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
0
B) reverse
4/4
h.
– Rocker pedal / hand lever (16/5) for left-hand
R
crawler chain:
C) forward
D) reverse
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.
HR1.6-03-17
Danger to life
due to machine tilting.
• Observe that each of the crawler units can
be independently clamped in any position
within the adjustment range. The reduced
rollover resistance must always be taken
into consideration!
HR1.6-17
Machine damage
due to improper guide pipes.
• Ensure that the guide pipes are free from
debris and dirt!
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 joystick (19/10) for
“Dozer blade/Track width adjustment”,
check the position of the change-over
lever (19/17).
• Familiarize yourself with the control. 17
4/
4
h.
Attention
If ground conditions are unfavorable, the
crawler unit should be slackened.
R
Keep the push-button (19/8) pressed while pulling or
pressing the joystick (19/10). HR1.6-04-19
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.
HR1220
0
(optional in case of canopy).
4/
4
h.
• Raise the working hydraulics shut-off / exit barrier 13
(21/2).
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
5 Working operation
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. 22 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 (22/2) is lifted, all travel and
work functions are deactivated.
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.
4/
4
h.
R
HR1.6-03-23
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. 24 Operation of articulation
Dozer blade
Danger of injury
due to incorrect operation of the control
system.
This danger only applies to the hydraulic
track width adjustment (option).
• Before commencing work, check if the
control is in position "Dozer blade" or
"Track width adjustment" (option) (25/17).
Danger of injury
due to incorrect operation of the control
system.
17
• Before commencing work, check if the
control is in position "Dozer blade" or 17
"Track width adjustment" (25/17).
• After adjusting the track width, move the
change-over lever (25/17) back to position 17
"Dozer blade".
4/
• Move the change-over lever (25/17) back to Fig. 25 Operating the dozer blade / hydraulic track width
position "Dozer blade". adjustment
4/
4
h.
R
HR1.6-03-26
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.
Attention
Ensure that the bearings of the quick-attach
system and work attachment and/or the
dipperstick, bucket rod and work attachment
are clean.
Attention
concerning hydraulically actuated additional
work attachments. 1
Attention
concerning hydraulically actuated additional
work attachments.
• Disconnect the hydraulic connection
0
4/
4
h.
• Remove the pins connecting the work attachment Fig. 28 Storage space for control rod
to the dipperstick and the bucket rod.
• Attach another work attachment.
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
Attention
• After the clamshell grab has been
removed, re-open the ball valve (29/3).
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
(29/3).
Attention
• After the clamshell grab has been
removed, re-open the ball valve (29/3).
Machine damage
due to inappropriate hydraulic rock breaker.
– Only use rock breakers approved by
TEREX | Schaeff.
– 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
165 bar (operating pressure of machine).
– When working in or under water, special
rock breaker types must be used.
Attention
In order to dismount the cabin and to install
the canopy, the original TEREX | Schaeff
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.
• 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.
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 (32/1) on chassis 1
– Two drilled holes (32/2) on dozer blade
2
HR2.0-01-30
Attention
Only use the original TEREX | Schaeff crane
lifting beam for the cabin or the canopy.
Machine damage
4/
4
h.
due to exceeding the maximum weight-lifting
capacity. 3
R
• Ensure that the weight-lifting capacity of
the crane is at least 2000 kg. HR1.6-04-33
HR1.6-04-34
Danger to life
due to disregarding the total transport height.
• Be aware of the total clearance height
1 2
when driving in tunnels, under bridges, etc.
HR2.0-01-32
HR3.7-03-36
7.1 Intervals
7.3 Warranty
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.
Attention
Maintenance and wearing parts for
inspections should be ordered well in
advance.
Observe our offer on service packages for
the inspections. 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 (è 3.6, 26).
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.
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).
13
4/4
h.
R
HR1.6-01-37
8 6 9 7 3 2 1 5 4/13
Activities Chapter
1 Check whether machine-specific Operating Manual is in the machine.
2 Check the engine oil level. è 7.8.2, 70
3 Check the hydraulic oil level. è 7.8.9, 82
4 Check the fuel level. è 7.8.5, 74
5 Check the coolant level. è 7.8.4, 72
6 Check the oil level in the crawler gear units. è 7.8.13, 85
7 Check the oil level in the swing gear è 7.8.17, 88
8 Check the crawler-chain tension. è 7.8.15, 86
9 Check the battery fluid level and charge. è 7.8.19, 89
10 Grease machine (all lubricating points). è 7.7.3, 66
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
18
15
16
HR1.6-04-37
5/17
11
13
14
R
4/4
0
h.
12
19
Daily Chapter
1 Check the hydraulic oil level. è 7.8.9, 82
2 Check the engine oil level. è 7.8.2, 70
3 Check the fuel level (fuel gauge on instrument panel). è 7.8.5, 74
4 Check windshield washer-fluid level. è 7.8.18, 88
5 Check crawler-chain tension of rubber chains. è 7.8.15, 86
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. è 7.7.3, 66
Tab. 21 Daily tasks
Weekly Chapter
11 Clean the cooling fins of the water cooler and the hydraulic oil cooler è 7.8.4, 72
Machine damage è 7.8.10, 83
Machine damage
due to damaged lubricating nipples.
• Replace damaged grease nipples
immediately and check if grease passes
through.
7 8 9
2
3
3
1
2
21
1
10 HR1.6-04-38
11
12
14 13 16
25
R
4/4
0
h.
17 18
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.
Attention
Observe our offer on service packages for
the inspections. Contact your dealer for
further information!
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
(40/1) upward.
1
HR1.6-01-41
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
(42/1). HR1.6-01-41
1
HR1.6-01-43
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.
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. 44 Water cooler
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.
4
4/
0
h.
HR3.7-03-49
HR1.6-04-47
Attention
• Collect the fuel in a suitable container. 2
Attention
HR1.6-01-49
The fuel system does not have to be vented.
Fig. 49 Replacing the fuel filter
Attention
The water separator (50/4) is located under 4
the floor panel of the engine compartment, on
the side of the seat console.
• Re-assemble the water separator and re-open the Fig. 50 Cleaning the water separator
shutoff cock.
Fuel tank
• Clean the filling strainer, check for damage and
replace if necessary.
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.
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
Machine damage 4 3 2 1
due to dust being drawn into the engine. HR1253
7.8.7 V-belt
Fig. 54 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.
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.
Attention
Using medium thumb pressure of approx.
45 N (approx. 4.5 kg), the V-belt sag should
equal 10 mm.
HR1.6-04-53
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 (57/6) 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. 57 Adjusting the valve lash
Attention
• Only change the hydraulic oil when it is at
operating temperature.
HR1.6-04-56
Danger of scalding
due to hot oil getting into contact with skin or
eyes.
• Wear appropriate protective
clothing/safety goggles.
Attention
• Dispose of the waste oil according to
regulations.
Machine damage
due to overheated engine.
• Clean the cooler thoroughly.
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.
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
7.8.12 Breather
Attention
The breather must also be replaced if it is
dirty, for example due to hydraulic oil vapor.
Fig. 62 Return filter
Attention A 3
• Dispose of waste oil in compliance with
regulations.
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.
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.
Lubrication of toothing R
4/4
0
h.
B
• All screws/bolts must be examined to ensure that
4
Fig. 66.
8
HR1.6-04-64
Attention
The swing gear has lifetime lubrication. Oil
changes are therefore unnecessary.
2
1
HR1.6-05-67
4/
4
h.
14
HR1.6-04-68
Battery
The battery (69/1) 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.
Attention
In the case of maintenance-free batteries, Fig. 69 Battery
this check is not necessary.
HR1.6-05-70
Machine damage
due to reverse of terminals.
Fig. 70 Removing the battery
• Ensure that the negative terminal is
connected to the negative pole (-) and the
positive terminal to the positive pole (+).
Attention
In winter, in particular, the battery charge
should be closely monitored.
8 Trouble-shooting
8.1 Engine
9 Appendix
K1 K2 K3 K4
0
A B
4/4
h.
R
1 2 3 4 5 6 7 8 9 10 11 12 13
K10 HR1.6-04-E01
K1 – Main relay
K2 – Swing brake
K3 – Dozer blade
K4 – 2nd control circuit
K10 – Glow-time controller
Tab. 26 Assignment
10 Index
A Fire extinguisher . . . . . . . . . . . . . . . . . . 19
Additional control circuit . . . . . . . . . . . . . . 52 Fire protection . . . . . . . . . . . . . . . . . . . 19
Air filter . . . . . . . . . . . . . . . . . . . . . . 76 Front window . . . . . . . . . . . . . . . . . . . . 41
Air intake . . . . . . . . . . . . . . . . . . . . . 76 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 62
Articulation . . . . . . . . . . . . . . . . . . . . 50 Fuel filter . . . . . . . . . . . . . . . . . . . . . . 74
Assignment diagram . . . . . . . . . . . . . . . 95 Fuel system . . . . . . . . . . . . . . . . . . . . . 74
B Fuel tank . . . . . . . . . . . . . . . . . . . . . . 75
Battery . . . . . . . . . . . . . . . . . . . . . . . 89 Fuel, lubricant, and coolant specifications . . . . . 27
Bearing races . . . . . . . . . . . . . . . . . . . 87 Fuels, lubricants, and coolants . . . . . . . . .26, 27
Biodegradable oils . . . . . . . . . . . . . . . . 27 G
Brake valves . . . . . . . . . . . . . . . . . . . 85 Ground pressure . . . . . . . . . . . . . . . . . . 28
Breather . . . . . . . . . . . . . . . . . . . . . . 84 Guides . . . . . . . . . . . . . . . . . . . . . . . 14
Bucket . . . . . . . . . . . . . . . . . . . . . . . 33 H
C Handing-over inspection . . . . . . . . . . . . . . 63
Cabin . . . . . . . . . . . . . . . . . . . . . 22, 56 Heating . . . . . . . . . . . . . . . . . . . . . . . 40
Cable and plug colors . . . . . . . . . . . . . . . 95 Hydraulic additional work attachments . . . . . . . 54
Canopy . . . . . . . . . . . . . . . . . . . . . . 15 Hydraulic oil . . . . . . . . . . . . . . . 28, 62, 82
Care . . . . . . . . . . . . . . . . . . . . . . 59, 62 Hydraulic oil cooler . . . . . . . . . . . . . . . . . 83
Carrying capacity . . . . . . . . . . . . . . . . . 30 Hydraulic oil level . . . . . . . . . . . . . . . . . . 82
Cartridge maintenance intervals . . . . . . . . . 77 Hydraulic oil return filter . . . . . . . . . . . . . . 84
Change of work attachments . . . . . . . . . . . 17 Hydraulic oil tank . . . . . . . . . . . . . . . . . . 82
Changing work attachments . . . . . . . . . . . 52 Hydraulic rock breaker . . . . . . . . . . . . . . . 55
Chassis . . . . . . . . . . . . . . . . . . . . . . 24 Hydraulic track width adjustment . . . . . . . . . . 45
Clamshell grab . . . . . . . . . . . . . . . . 33, 54 Hydraulics . . . . . . . . . . . . . . . . . . .19, 25
Cleaning . . . . . . . . . . . . . . . . . . . . . . 62 I
Closed spaces . . . . . . . . . . . . . . . . . . 16 Immobilization . . . . . . . . . . . . . . . . . . . 91
Condition of the battery . . . . . . . . . . . . . . 62 Initial inspection . . . . . . . . . . . . . . . . . . 63
Coolant . . . . . . . . . . . . . . . . . . . . 62, 73 Inspection plan . . . . . . . . . . . . . . . . . . . 68
Copyright . . . . . . . . . . . . . . . . . . . . . . 8 Intervals . . . . . . . . . . . . . . . . . . . . . . 59
Crawler chain tension . . . . . . . . . . . . . . . 86 ISO control system . . . . . . . . . . . . . . . . . 50
Crawler chains . . . . . . . . . . . . . . . . . . 86 L
Crawler gear units . . . . . . . . . . . . . . . . . 85 Lighting equipment . . . . . . . . . . . . . . . . . 90
D Load hook applications . . . . . . . . . . . . . . . 16
Daily tasks . . . . . . . . . . . . . . . . . . . 64, 65 Loading . . . . . . . . . . . . . . . . . . . . .18, 57
Danger zone . . . . . . . . . . . . . . . . . . . 13 Lubricants . . . . . . . . . . . . . . . . . . . . . 61
Declaration of Conformity . . . . . . . . . . . . . 11 M
Digging envelope . . . . . . . . . . . . . . . . . 21 Main cartridge . . . . . . . . . . . . . . . . . . . 77
Dimensions . . . . . . . . . . . . . . . . . . . . 29 Maintenance . . . . . . . . . . . . . . . . . .17, 59
Ditch-cleaning bucket . . . . . . . . . . . . . . . 33 Maintenance and Inspection Plan . . . . . . . . . 97
Dozer blade . . . . . . . . . . . . . . . . . . . . 51 Maintenance plan . . . . . . . . . . . . . . . . . . 64
Drawbar pull . . . . . . . . . . . . . . . . . . . . 29 Mode of operation . . . . . . . . . . . . . . . . . 50
Driver's seat . . . . . . . . . . . . . . . . . . . . 40 Monitoring . . . . . . . . . . . . . . . . . . . . . 18
Driving . . . . . . . . . . . . . . . . . . . . . 14, 42 O
Dust ejection valve . . . . . . . . . . . . . . . . 76 Oil analyses . . . . . . . . . . . . . . . . . . . . 60
E Oil change . . . . . . . . . . . . . . . . . . . . . 85
Electrical equipment . . . . . . . . . . . . . . . . 89 Oil level . . . . . . . . . . . . . . . . . . . . . . . 85
Electrical system . . . . . . . . . . . . . . . 24, 95 Operating weights . . . . . . . . . . . . . . . . . 29
Engine . . . . . . . . . . . . . . . . . . . . . 24, 93 Operation . . . . . . . . . . . . . . . . . . . .12, 35
Engine - cooling system . . . . . . . . . . . . . . 72 Operator controls . . . . . . . . . . . . . . . . . . 36
Engine oil . . . . . . . . . . . . . . . . . . . 28, 71 Overhead power lines . . . . . . . . . . . . . . . 15
Engine oil filter . . . . . . . . . . . . . . . . . . 71 Overview of lubricating points . . . . . . . . .66, 67
Engine oil level . . . . . . . . . . . . . . . . . . 70 P
Environmental protection . . . . . . . . . . . . . . 9 Preservation . . . . . . . . . . . . . . . . . . . . 91
Extending the track width . . . . . . . . . . . . . 43
Q
F Quick-attach system . . . . . . . . . . . . . .53, 54
Filter insert . . . . . . . . . . . . . . . . . . . . 84