R

SERVICE - MANUAL
List of Contents
TL 60 SKL 200
TL 65 1 General
TL 80 TL70s
TL 80AS 2 Technical Data
3 Diesel Engine
4 Hydraulic System
TL 100 TL 120 TL 160 5 Setting Instructions
TL 210 TL 260 TL 310 6 Functional Description

TW 70 7 Electrical System

TW 85 8 Maintenance

TW 110 9 Operation
10 Options
11 Repair Instructions
TC 60
12 BDE/Special tooling
TC 75
TC 125

TC 29
TC 35
TC 48

TC 15 TC 16
TC 20 TC 25
TC 37 TC 50
01.2012
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01 General R
_____________________________________________________________________________________________________________________________________________________________________________________

Subgroups list General

Machine type Theme File Number

General Foreword / Information fort the User 1.100.01

General Safety and Accident Prevention 1.200.01-05

General Tighten torques, piston nuts 1.500.01

General Pictograms 1.500.50-52

General Test ports 1.600.01

General Drift values 1.650.01

General Units 1.800.01-02

TL 65, 70s, 80, 100 Tighten torques 1.900.24

TL 210, 260 Tighten torques 1.900.30

TW 70 Tighten torques 1.900.49

TW 85, 110 Tighten torques 1.900.51-52

Date: 01-September-2011 Germany Service manual

Page 01/01 All types of machines

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In this Service Manual the individual replacement of sealing parts at every
components of the Terex construction repair should be self-evident.
machinery range as well as the functions
and adjustments of the aggregates in- Unless any special values are indicated,
stalled are described. screw fittings are to be tightened using
correct torque specifications.
The hydraulic and electrical diagrams as
well as cut-off views in connection with the This Service Manual is issued by the
operating manual and parts catalogue are Customer Service Department of Messrs.
to facilitate the repair and maintenance Terex. It is to develop the after-sales
work. service of Terex construction machinery
together. The Service Bulletins we issue
We have purposely left out assembly and for your information can serve as a
working steps as major repairs are supplement.
normally carried out by experienced and
qualified workshop personnel familiar with This Manual is kept up-to-date through
these type of repairs. periodic supplements.

This document is not to be copied and / or

When carrying out a repair, safety and distributed completely nor in part without
cleanliness at the workplace are essential. our full written consent, nor is it to be
The use of excellent tools and the passed on to a third party.

Typ/Model/Type Datum/Edition/Date

General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille

Foreword / Information for the User 1.100.01

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The Service Manual is subdivided into This structuring will also facilitate the filing
main groups, subgroups and page of revised versions and supplements
numbers so that you can easily find within the framework of the technical
special groups and pages. alteration service.

E.g.
main group

subgroup

page no.

1. 01. 01

For the division of the main groups, please information referring to the repair you
refer to the list of contents. intend to do.
The subgroup division is done starting
from the main group. Any maintenance and repair work on
The page number follows the subgroup machines located in the field may only
and main group number. be performed when the work equipment
is lowered to the ground, the engine is
Please strictly follow the regulations for switched off, the machine is secured so
Accident Prevention valid in your country that it cannot roll, and the hydraulic
(see also 1.20). system is relieved.

The best safety measure to avoid If qualified personnel perform repair work
accidents is to be careful when carrying in the workshop, the relevant Accident
out repairs. We therefore recommend to Prevention Regulations also apply.
carefully study the corresponding

1.100.01/01.2007

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Safety and Accident Prevention

If special attachments, such as Uni-shovel,

1 Introductory remarks
side dump shovel, sweeper, fork lift
attachment etc. are mounted, special jobs
Please read the operating instructions
can be done with the attachment.
carefully before putting an earth-moving
machine into operation and strictly follow
Another or additional application, e.g. for
the following remarks for a safe operation.
transportation of passengers or using the
National safety regulations - e.g. the lifting device as working platform etc. is
Accident Prevention Regulations, “Earth- not considered as correct use. The
Moving Machinery” (VBG 40) and supplier is not liable for subsequent
“Vehicles” (VBG 12) in the Federal damage. The enduser himself bears the
Republic of Germany - must also be full risk.
complied with.
It is part of the correct use to follow the
In addition to the operating instructions,
operating and maintenance instructions
legal regulations governing road traffic and
and to carry out the maintenance as well
road safety measures must also be
as to follow the maintenance intervals.
observed. Such requirements could also
apply in respect of handling hazardous
goods or the wearing of personal safety 3 General safety notes
equipment, for example.
It is important to refrain from any working
Furthermore, safety laws governing work methods which impair safety.
in particular locations (tunnels, adits,
quarries, pontoons, contaminated areas, The earth-moving machine may only be
etc.) must likewise be observed. used when it is in a safe, operational
condition.

2 Correct use The manufacturer’s operating instructions

must be complied with for operation,
maintenance, repair, assembly and
The earth-moving machine with normal
transportation.
shovel equipment is only to be used for
work which is suitable for the machine’s The plant operator must provide additional
functions and its attachment. special safety instructions, wherever
necessary, for specific local conditions.
Such work includes the digging, loading,
The operating instructions and any
displacing and dumping out of earth,
information pertaining to safety must be
stones or other materials and the loading
carefully kept in the driver’s cab.
of these materials onto lorries, conveyor
belts or other means of transportation. The The operating instructions and safety
transport of the loading material, however, notes must be complete and fully
is mainly carried out by moving the earth- readable.
moving machine.
Safety devices on earth-moving machines
must not be deactivated or removed.

Typ/Model/Type Datum/Edition/Date

General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille

Safety and Accident Prevention 1.200.01

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

1.200.01/01.2007

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

Typ/Model/Type Datum/Edition/Date

General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille

Safety and Accident Prevention 1.200.02

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9 Operation
Earth-moving machines may only be used
where there is a danger of falling objects if
The operator has to check the correct
the driver’s seat and operator consoles
fastening of the attachments and / or lock
have an overhead guard (FOPS). A front
of the quick exchange device daily before
guard must be employed if there is a risk
start of operation and after every
of materials breaking into the cab.
attachment change. Move the attachment
carefully at low height. Please ensure that In front of walls e.g. of stacked materials,
nobody is in the danger zone during these earth-moving machines must be
checks. positioned and operated in such a way
that the driver’s seat and entry to the
The machine operator may only swing the driver’s seat are not situated on the side
working equipment over occupied drivers’ facing the wall.
seats, operator consoles and workplaces
Demolition work may only be performed
of other machines if these are protected by
with earth-moving machines where there
overhead guards (FOPS).
is no danger to personnel.
If a cab does not have the required
protection, the driver of this vehicle must
leave the driver’s seat when the working
12 Working in the vicinity of
equipment has to be slewed overhead.
underground power lines
The vehicles must be loaded in such a
manner as to ensure that there is no Before commencing excavating work
overloading and no material can be lost using earth-moving machines, it must be
during travel. The vehicle must be loaded determined whether any underground
from the lowest possible height. power lines are present in the intended
working zone which may present a danger
At dumping points, earth-moving machines to personnel.
may only be operated when suitable
measures have been taken to prevent If underground power lines are present,
rolling or falling. their exact position and course must be
determined in consultation with the
proprietor or operator of the lines, and the
necessary safety precautions decided and
10 Guides implemented.
Guides must be easily recognizable, e.g. The course of power lines in the work area
by means of reflective clothing. They must must be clearly marked, under
remain within the machine operator’s field supervision, before commencing any
of sight. excavation work. If the position of lines
cannot be determined, search ditches
While guiding the machine, guides must must be dug - manually, if needed.
not be given other jobs which may distract
If underground power lines are
them from their task.
encountered unexpectedly or they or their
protective covers are damaged, the
machine operator must discontinue work
immediately and notify the supervisor.
11 Danger of falling objects

1.200.02/01.2007
13 Working in the vicinity of overhead
In the observation of safety distances, all
power lines
working movements of the earth-moving
machine, e.g. positions of the boom,
When the earth-moving machine is being
swinging ropes and the dimensions of
used in the vicinity of overhead power
attached loads must be taken into
lines and trolley wires, a safety distance
consideration. Uneven ground which
which varies depending upon the nominal
would cause the earth-moving machine to
voltage of the overhead line must be
be inclined and thus nearer to overhead
maintained between the lines and the
lines must also be taken into account.
earth-moving machine and its working
equipment, in order to prevent current During work in windy conditions, both
overspill. This also applies to the distance overhead lines and working equipment
between these lines and attached may swing out, thus reducing the safety
implements or loads. distance.
The safety distances specified below must If it is impossible to maintain sufficient
be complied with: distance from overhead power lines and
trolley wires, the plant operator must
Nominal voltage Safety distance consult with the proprietor or operator of
the overhead lines to find other safety
in metres precautions to prevent current overspill.
Such measures could be, e.g.
- 1000 V 1.0 m
- Switching off the current
over 1 kV - 110 kV 3.0 m
- Re-routing the overhead line
over 110 kV - 220 kV 4.0 m - Cabling, or
- Limiting the work zone of earth-moving
over 220 kV - 380 kV 5.0 m machines.
nom. voltage unknown 5.0 m

Typ/Model/Type Datum/Edition/Date

General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille

Safety and Accident Prevention 1.200.03

14 Operation in closed rooms aid of a fixing device (rope, chain, etc.),
whereby the assistance of personnel is
If earth-moving machines are used in required to attach and release the load.
closed rooms, these areas must be
Such work covers, for example, the lifting
sufficiently ventilated and special
and lowering of pipes, heavy machine
regulations observed.
parts or containers with earth-moving
machines.
Earth-moving machines may only be used
15 Work stoppages for crane operations if the prescribed
safety devices are present and in full
Before rest periods and at the end of the working order. For earth-moving
working day, the driver of the earth-moving machines, these are:
machine must park the machine on ground - Safe fastening points for lifting device
with sufficient load capabilities and is as - Table of carrying capacity
even as possible, and must secure it - Overload warning device*
against movement. - Hose rupture safety valve for boom cy-
Before rest periods and at the end of the linder*
working day, the driver must lower the *only in case of an admissible carrying
working equipment onto the ground or capacity of more than 1000 kg
secure it so that it cannot move about. Loads must be attached in such a way that
The driver must not leave the earth- they cannot slip or fall out.
moving machine if the working equipment Personnel guiding the machine and
has not been lowered to the ground or attaching loads must always remain in the
secured. machine operator’s field of sight.
Earth-moving machines may only be The machine operator must carry loads as
parked in places where they do not close to the ground as possible and
present an obstacle, e.g. on the prevent them from swinging.
construction site or to plant traffic. Warning
devices, e.g. triangles, warning cordons, Earth-moving machines may only travel
flashing or hazard lights are to be used if with an attached load if the path of travel is
necessary. fairly level.
Before leaving the control console, the When earth-moving machines are used for
driver must bring all working equipment crane operations, personnel attaching
into home position and apply the brakes. loads may only approach the boom from
the side and with the machine operator’s
If the driver is leaving the earth-moving permission. The machine operator may
machine unattended, he must first turn off only give his permission if the earth-
the drive motors and ensure that they moving machine is standing still and the
cannot be started up by unauthorized working equipment is not in motion.
persons (remove ignition key for example).
Do not use fixing devices (ropes, chains)
16 Crane operations which are damaged or of inadequate
dimensions. Protective gloves must
Crane operations are the hoisting, always be worn when working with fixing
transporting and lowering of loads with the devices.

1.200.03/01.2007
17 Assembly, maintenance, repair case of maintenance or repair work which
cannot be performed without the engine/
Earth-moving machines may only be motor running.
assembled, converted or disassembled Depressurize the hydraulic system when
under the guidance of a suitable person carrying out maintenance and repair jobs.
designated by the plant operator and To do this, lower the working equipment to
following the manufacturer’s operating the ground with the engine turned off and
instructions. operate all hydraulic control levers until the
After every change of attachment, the hydraulic system is depressurized.
operator has to ensure the correct Before working on the electrics or when
fastening and / or lock of the quick performing arc-welding on the machine,
exchange device. the connection to the battery must be
Work on braking, steering, hydraulic and interrupted.
electric systems of the earth-moving When disconnecting the battery, first the
machine may only be carried out by expert negative pole then the positive pole must
personnel specially trained in these areas. be disconnected. The battery must be re-
Stability must be ensured at all times connected in reverse order.
during work on earth-moving machines. During repair work around the battery, the
The working equipment must be secured battery must be covered with insulating
against movement by lowering them to the material; tools should never be placed on
ground or equivalent measures, e.g. stays, or near the battery.
trestles. When the engine is running, the Protective devices of moving machine
insecured articulation area of loaders with parts may only be opened or removed
articulated steering must not be entered. when the drive has been switched off and
When jacking up earth-moving machines, cannot be switched on again by
jacking devices must be positioned so that unauthorized persons. Protective devices
they cannot slip. Jacks must be positioned are e.g. engine/motor covers, doors,
and applied absolutely straight, without protective grating, trim.
tilting. Upon completion of assembly,
Raised earth-moving machines must be maintenance or repair work, all protective
supported by suitable structures such as devices must once more be attached in
crosswise stacks of planks, square timbers the proper manner.
or steel trusses. Load-bearing parts of earth-moving
Earth-moving machines which are raised machines may only be welded following
with working equipment must be stabilized consultation with the manufacturer and in
by a supporting structure immediately after accordance with recognized welding
lifting. Do not work under earth-moving principles.
machines which are only supported by the
hydraulics.
Overhead guards (FOPS) must not be
The engine/motor must be turned off prior welded or drilled in any way which could
to all maintenance and repair work. These impair their sturdiness.
requirements may only be ignored in the

Typ/Model/Type Datum/Edition/Date

General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille

Safety and Accident Prevention 1.200.04

Alterations, such as welding of the Before setting off, the route to be taken
hydraulic system, may only be undertaken must be examined to determine whether
with the manufacturer’s permission. the roads are wide enough, entrances and
passages under bridges are large enough
and that roads and bridges have sufficient
Before commencing work on the hydraulic carrying capacity.
system, the pilot pressure, back pressure
and pressure inside the tank must be let 19 Monitoring and inspections
off.
Lubricants cannot be taken internally and The machine must be thoroughly
repeated skin contact should be avoided. inspected by an authorized and trained
There is no special danger to health if person according to the safety regulations
lubricants are used correctly. Please follow valid in your country:
the safety recommendations issued by the
mineral oil companies. •prior to the first commissioning and prior
to re-commissioning after major changes
Only the hoses specified by the •at least once a year
manufacturer may be used. •periodically according to the operating
Hydraulic hoses must be routed and conditions and the conditions in the
operator’s company
assembled by expert personnel.
Never smoke or handle open flames near The inspection report is to be put in writing
or around the fuel tank and batteries. and kept for future reference.
Furthermore, prior to each work shift, the
machine operator must check the earth-
18 Towing, loading, transportation moving machine according to the
inspection chart.
The towing of earth-moving machines may Hydraulic hoses must be replaced as soon
only be done with towing devices as the following damages are recognized:
sufficiently dimensioned.
- Damages to the outer layer which reach
The fixing devices specified by the the intermediate layer
manufacturer must be employed. - Embrittled patches on the outer layer
For loading and transportation, earth- - Deformations when under pressure or
moving machines and all necessary without pressure which differ from the
auxiliary equipment must be secured original shape of the installed hose
against unwanted movement. - Leakages
- Damages to hose fittings or to the
The travelling gear and track-laying gear connection between the fitting and the
of earth-moving machines must be hose
sufficiently cleaned of mud, snow and ice
to ensure that ramps can be driven up The coolant level must only be checked
without risk of slipping. when it has cooled down; the cap must be
turned carefully in order to bleed off
When the earth-moving machine is excess pressure.
transported on lorries, flat-bed trailers or
by rail, it has to be carefully secured with Prior to operations, the machine operator
wheel chocks and tie-downs at the must check the function of the safety
fastening points. devices.

1.200.04/01.2007
The machine operator must advise the
21 Emergency exit
supervisor immediately - and the person
relieving him, should there be a change of
operators - with regard to any The windscreen acts as an emergency
shortcomings. exit. If a front guard is fitted or this exit can
no longer be used for any other reason, an
In the event of shortcomings which emergency hammer must be affixed at an
jeopardize the operating safety of the easily accessible place inside the driver’s
earth-moving machine, it must not be used cab.
until these have been eliminated.

20 Fire protection 22 Other dangers

Failure of the hydraulics

A fire extinguisher has to be
stored in the operator’s cab. A If the hydraulic system fails due to a
fire extinguisher symbol has to standstill of the diesel engine, a
be applied. defectiveness of the hydraulic pump or a
hydraulic oil leakage, only the emergency
functions „lower working equipment“ are
possible.

Typ/Model/Type Datum/Edition/Date

General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille

Safety and Accident Prevention 1.200.05

Gewinde Kolbenmutter Anziehdrehmoment Nm
Thread of nut Tightening torques Nm
Filetage d’écrou Couples de serrage Nm
M 18x2 200
M 20x2 260
M 22x2 410
M 24x2 450
M 27x2 810
M 30x2 1050
M 35x1,5 730
M 36x2 1075
M 36x3 1550
M 39x3 1700
M 40x1,5 730
M 42x2 1400
M 42x3 1850
M 48x3 2050
M 56x2 1600
M 60x2 1800
M 70x2 2500
M 80x2 2900
M 90x2 3200

Typ/Model/Type Datum/Edition/Date
General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Tightening torques, piston nuts 1.500.01
 Führungsbüchse
Gland
Douille

Hydraulikzylinder ∅ Gewinde - Führungsbüchse Anziehdrehmomente Nm

Hydraulic cylinder ∅ Thread - Bushing Tightening torques Nm
Vérin hydraulique ∅ Filetage - Douille Couples de serrage Nm

35/45 M50x2 200 - 230

50 M56x2 230 - 265
55 M60x2 250 - 290
63 M68x2 290 - 335
70 M75x2 330 - 380
70 M80x2 360 - 415
80 M85x2 390 - 450
90 M95x2 450 - 520
95 M100x2 480 - 550
100 M105x2 520 - 600
105 M110x2 550 - 635
110 M115x2 590 - 680
115 M120x2 630 - 725
125 M130x2 690 - 795

1.500.01/01.2007
Pictograms
001 - 099 General control
100 - 119 Loader
120 - 139 Excavator
140 - 149 Backhoe excavator
150 - 159 Universal-mounted excavator / loader
160 - 179 Walking excavator
180 - 199 Tunnelling and mining machines / Rail-road excavator
200 - Maintenance, safety, etc. in general

Symbol Description Symbol Description

001 Battery charge 012 Hydraulic oil, hydraulic oil
indicator level

002 Pre-heat 013 Hydraulic oil temperature

003 Engine oil pressure 014 Hydraulic oil filter

clogging indicator
004 Engine oil temperature 015 Horn

005 Engine oil level 016 Operational status,

operating hours

006 Coolant temperature 017 Parking brake

007 Coolant level 018 Brake accumulator

pressure

008 Air filter 019 Excavator brake

009 Fuel, fuel level 020 Service brake

010 Fan, 021 Hazard warning system

Heater / ventilation

011 Windscreen wash/ 022 Direction indicator,

wipe system left/right

Typ/Model/Type Datum/Edition/Date
Pictograms 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
General 1.500.50
 Symbol Description Symbol Description
023 Working floodlights 039 Speed control

024 Upper beam indicator 040 Oscillating axle lock

025 Direction of travel 041 Steering inversion

forward/reverse

026 Rotating beacon 042 All-wheel steering

crab / round steer

027 Light, lower beam 043 Rocker pedal for travel

028 Central grease system 044 Only shift when machine

is at standstill

029 Lashing points 045 High gear

030 Overload warning 046 Cabin lift / lower

device / Overload
warning indicator
031 Suspension point for 047 Steering control display
loading by crane

032 Travel speed, fast 048 First aid kit

033 Travel speed, slow 049 Fire extinguisher

034 Working hydraulics 050 Switch-over monitor for

cut-off, excavator; operating hours and time
loader / crane
035 Unlocked 051 Swing limitation, engine
stop override

036 Locked 052 Switch for all-wheel

steering

037 Float position 053 Interior lighting

038 Dozer blade 054 Reset hydraulic pulley

block (crane)

1.500.50/01.2007
 Symbol Description Symbol Description
055 Quick movement 071 Danger of crushing
hoisting winch

056 Cable uncoil limit switch 072 Danger of injury

057 Auxiliary winch 073 Observe notes in

operating instructions

058 Magnet system 074

059 Hydraulic rock breaker 075 Linde - no load

automatics

060 Electric boom height 076 Remote control

limitation

061 Undercarriage- 077 Warning - general

adjustment

062 Switch-over swing 078 Temperature - General

speed, engine speed
adjustment
063 Free fall mode 079

064 Grab rotation 080

065 Bucket return 100 Control by Joystick

positioning, lifting frame
height limitation

066 Ride control system 101

067 Bucket return 102 Quick mount-hitch lock

positioning

068 Hydraulic oil level 103

070 Safety distance, 104 Water pump for sweeper

see item 202

Typ/Model/Type Datum/Edition/Date
Pictograms 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
General 1.500.51
 Symbol Description Symbol Description
105 Warning lamp gearbox 151 Universal-mounted
excavator/ loader (AL)
controls
ISO control system right
120 Control 152 Universal-mounted
excavator/ loader (AL)
ISO control system-left
controls
Schaeff control system-
right Schaeff control system left
121 Control 153 Universal-mounted
excavator/ loader (AL)
ISO control system right
controls
Schaeff control system right
122 Control 154 Universal-mounted
excavator/ loader (AL)
Schaeff control system
controls
left
Outrigger right
123 Control 155 Universal-mounted
excavator/ loader (AL)
Intermediate boom
controls
(articulated boom type)
Outrigger left
124 Control 160 Control
telescopic stick in / out Outrigger leg left

125 Control 161 Control

articulation „Knickmatik“ Wheel outrigger - left

126 Switch-over rock 162 Control

breaker / grapple
Outrigger leg right

127 Control 163 Control

dozer blade Wheel outrigger - right

128 Switch-over (HR 12) 164 Steering

Bucket - rocker breaker
small / rock breaker big

140 Shifting of slide bearing 165 Wheel lock (HS 41)

150 Universal-mounted 166 Free wheel (HS 41 M)

excavator/ loader (AL)
controls
ISO control left

Symbol Description Symbol Description

1.500.51/01.2007
167 Outriggers spread 200 Grease gun

168 Outriggers lift / lower 201 Danger

169 Steering mode switch 202 On the machine:

HS 41 MM caution, safety distance
In the operating manual:
warning

170 Outrigger left 203 Note

171 Outrigger right 204 Soot filter

R
180 Switch-over 205 Particle filter
diesel drive

181 Switch-over
electric drive

182 Diesel engine

ignition lock

183 Pony truck IN

184 Pony Truck OUT

185 Electric motor START

186 Electric motor

emergency OFF

187 Cable drum (cable

winch)

Typ/Model/Type Datum/Edition/Date
Pictograms 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
General 1.500.52
 Minimum basic equipment

test port 8 L
part no. 5 066 234 200 pilot pressure
“working hydraulics“
2X control pressure
“travel hydraulics“
screwed fitting ELSD 8 L etc.
part no. 1 919 060 351

test port 10 L
part no. 5 066 234 230
brake pressure
1X
etc.
screwed fitting ELSD 10 L
part no. 1 919 060 352

control pressure
test port M 12x1,5
regulation start
part no. 5 066 253 605
2X housing pressure
seal ring 18x12x1,5
“travel hydraulics“
part no. 1 636 815 453
etc.

nut 8 L
part no. 1 911 060 154 brake inching
plug 1X
part no. 1 928 000 944 etc.
screwed fitting G 8 L
part no. 1 915 000 418

Measuring hoses (Minimeß)

L = 2000mm part no. 5 066 253 600 L = 2500mm part no. 5 066 314 010
L = 3200mm part no. 5 066 314 040 L = 5000mm part no. 5 066 314 055
L = 6000mm part no. 5 066 314 070

Typ/Model/Type Datum/Edition/Date
General 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Test ports 1.600.01
 01 General

1.650.01 Drift Values

Drift values in mm / minute

Machinery type Lift cylinder Tilt cylinder

TL 65 3,0 5,5
TL 70 3,0 5,5
TL70s
TL 80 3,0 5,5
TL80 AS
TL 100 3,5 6,0
TL 120 3,5 6,0
TL 160 3,5 3,0
TL 210
TL 260 3,5 3,0
TL 310

Intermediate
Machinery type Boom cylinder Dipper stick cylinder
boom cylinder
TW 70 GA 3,0 3,0 4,0
TW 85 Mono 3,5 5,5
TW 85 GA+Ci 3,5 2,5 5,5
TW 110 GA 3,0 2,5 5,0
TC 60 Mono 3,0 3,0
TC 75 Mono 3,5 5,5
TC 75 Ci 3,5 2,5 5,5
TC 125 GA 3,0 2,5 5,0
TC 125 Mono 3,0 5,0

Service - Handbuch Deutschland Datum: 01.09.2011

TL/ TC / TW Seite 01/02
01 Allgemein

Drift values in mm / minute

Intermediate
Machinery type Boom cylinder Dipper stick cylinder
boom cylinder
TC 15 5,0 6,5
TC 16 5,0 6,5
TC 16 Twin Drive 5,0 6,5
TC 20 5,0 6,5
TC 25 2,0 2,0
TC 29 4,0 7,0
TC 35 4,0 7,0
TC 37 4,0 6,5
TC 48 3,0 3,0
TC 50

Test conditions

1. Hydraulic oil temperature approx. 50 - 60 °C.

2. Fit test port with gauge on the cylinder.

3. Retract and extend cylinder several times and operate working equipment to its
maximum reach until the gauge indicates a load pressure of 100 bar (if necessary
charge with weight).

4. Measure piston rod length of cylinder

5. Measure piston rod length again after 5 minutes

6. The difference converted into 1 minute is the drift of the cylinder

7. The values indicated are valid for hydraulic oil 10 W 40 (viscosity at 50°C approx.
35 mm2/s (cST)

There may be differences if hydraulic oil with a different specification is used.

Datum:01.09.2011 Deutschland Service - Handbuch

Seite 02/02 TL / TC / TW
Temp. °C Temp. °F Temp. °C Temp. °F Temp. °F Temp. °C Temp. °F Temp. °C
-19 -2,20 21 69,80 -19 -28,33 21 -6,11
-18 -0,40 22 71,60 -18 -27,78 22 -5,56
-17 1,40 23 73,40 -17 -27,22 23 -5,00
-16 3,20 24 75,20 -16 -26,67 24 -4,44
-15 5,00 25 77,00 -15 -26,11 25 -3,89
-14 6,80 26 78,80 -14 -25,56 26 -3,33
-13 8,60 27 80,60 -13 -25,00 27 -2,78
-12 10,40 28 82,40 -12 -24,44 28 -2,22
-11 12,20 29 84,20 -11 -23,89 29 -1,67
-10 14,00 30 86,00 -10 -23,33 30 -1,11
-9 15,80 31 87,80 -9 -22,78 31 -0,56
-8 17,60 32 89,60 -8 -22,22 32 0,00
-7 19,40 33 91,40 -7 -21,67 33 0,56
-6 21,20 34 93,20 -6 -21,11 34 1,11
-5 23,00 35 95,00 -5 -20,56 35 1,67
-4 24,80 36 96,80 -4 -20,00 36 2,22
-3 26,60 37 98,60 -3 -19,44 37 2,78
-2 28,40 38 100,40 -2 -18,89 38 3,33
-1 30,20 39 102,20 -1 -18,33 39 3,89
0 32,00 40 104,00 0 -17,78 40 4,44
1 33,80 50 122,00 1 -17,22 50 10,00
2 35,60 60 140,00 2 -16,67 60 15,56
3 37,40 70 158,00 3 -16,11 70 21,11
4 39,20 80 176,00 4 -15,56 80 26,67
5 41,00 90 194,00 5 -15,00 90 32,22
6 42,80 100 212,00 6 -14,44 100 37,78
7 44,60 110 230,00 7 -13,89 110 43,33
8 46,40 120 248,00 8 -13,33 120 48,89
9 48,20 130 266,00 9 -12,78 130 54,44
10 50,00 140 284,00 10 -12,22 140 60,00
11 51,80 150 302,00 11 -11,67 150 65,56
12 53,60 200 392,00 12 -11,11 200 93,33
13 55,40 300 572,00 13 -10,56 300 148,89
14 57,20 400 752,00 14 -10,00 400 204,44
15 59,00 500 932,00 15 -9,44 500 260,00
16 60,80 600 1112,00 16 -8,89 600 315,56
17 62,60 700 1292,00 17 -8,33 700 371,11
18 64,40 800 1472,00 18 -7,78 800 426,67
19 66,20 900 1652,00 19 -7,22 900 482,22
20 68,00 1000 1832,00 20 -6,67 1000 537,78

Datum/Edition/Date
Umrechnungstabelle / Conversion table
08/2008
Benennung/Descrition/Dénomination Blatt/Page/Feuille

Einheiten / Units 1.800.01

Kilometers Miles per Kilometers Miles per Miles per Kilometers Miles per Kilometers
per hour hour (mph) per hour hour (mph) hour (mph) per hour hour (mph) per hour
(km/h) (km/h) (km/h) (km/h)
1 0,6 110 68,3 1 1,6 110 177,1
2 1,2 120 74,5 2 3,2 120 193,2
3 1,9 130 80,7 3 4,8 130 209,3
4 2,5 140 87,0 4 6,4 140 225,4
5 3,1 150 93,2 5 8,1 150 241,5
6 3,7 160 99,4 6 9,7 160 257,6
7 4,3 170 105,6 7 11,3 170 273,7
8 5,0 180 111,8 8 12,9 180 289,8
9 5,6 190 118,0 9 14,5 190 305,9
10 6,2 200 124,2 10 16,1 200 322,0
20 12,4 210 130,4 20 32,2 210 338,1
30 18,6 220 136,6 30 48,3 220 354,2
40 24,8 230 142,9 40 64,4 230 370,3
50 31,1 240 149,1 50 80,5 240 386,4
60 37,3 250 155,3 60 96,6 250 402,5
70 43,5 260 161,5 70 112,7 260 418,6
80 49,7 270 167,7 80 128,8 270 434,7
90 55,9 280 173,9 90 144,9 280 450,8
100 62,1 290 180,1 100 161,0 290 466,9

bar PSI bar PSI

1 14,50 210 3045,79
2 29,01 220 3190,83
3 43,51 230 3335,87
4 58,02 240 3480,90
5 72,52 250 3625,94
6 87,02 260 3770,98
7 101,53 270 3916,02
8 116,03 280 4061,06
9 130,53 290 4206,09
10 145,04 300 4351,13
20 290,08 310 4496,17
30 435,11 320 4641,21
40 580,15 330 4786,24
50 725,19 340 4931,28
60 870,23 350 5076,32
70 1015,26 360 5221,36
80 1160,30 370 5366,39
90 1305,34 380 5511,43
100 1450,38 390 5656,47
110 1595,41 400 5801,51
120 1740,45 410 5946,55
130 1885,49 420 6091,58
140 2030,53 430 6236,62
150 2175,57 440 6381,66
160 2320,60 450 6526,70
170 2465,64 460 6671,73
180 2610,68 470 6816,77
190 2755,72 480 6961,81
200 2900,75 490 7106,85

1.800.01/08.2008
Cubic meter Cubic feet Cubic Cubic Cubic Cubic Cubic Cubic Cubic feet
(m³) (ft³) yards (yd ) feet (ft³) yards (yd ) meter (m³) yards (yd3) meter (m³)
3 3
(ft³)
0,1 3,53 0,13 1 0,04 0,03 0,1 0,08 2,70
0,2 7,06 0,26 2 0,07 0,06 0,2 0,15 5,40
0,3 10,59 0,39 3 0,11 0,08 0,3 0,23 8,10
0,4 14,13 0,52 4 0,15 0,11 0,4 0,31 10,80
0,5 17,66 0,65 5 0,19 0,14 0,5 0,38 13,50
0,6 21,19 0,78 6 0,22 0,17 0,6 0,46 16,20
0,7 24,72 0,92 7 0,26 0,20 0,7 0,54 18,90
0,8 28,25 1,05 8 0,30 0,23 0,8 0,61 21,60
0,9 31,78 1,18 9 0,33 0,25 0,9 0,69 24,30
1 35,31 1,31 10 0,37 0,28 1 0,76 27,00
2 70,63 2,62 20 0,74 0,57 2 1,53 54,00
3 105,94 3,92 30 1,11 0,85 3 2,29 81,00
4 141,26 5,23 40 1,48 1,13 4 3,06 108,00
5 176,57 6,54 50 1,85 1,42 5 3,82 135,00
6 211,89 7,85 60 2,22 1,70 6 4,59 162,00
7 247,20 9,16 70 2,59 1,98 7 5,35 189,00
8 282,52 10,46 80 2,96 2,27 8 6,12 216,00
9 317,83 11,77 90 3,33 2,55 9 6,88 243,00
10 353,15 13,08 100 3,70 2,83 10 7,65 270,00
20 706,29 26,16 200 7,41 5,66 20 15,29 540,00
30 1059,44 39,24 300 11,11 8,50 30 22,94 810,00
40 1412,59 52,32 400 14,81 11,33 40 30,58 1080,00
50 1765,74 65,40 500 18,52 14,16 50 38,23 1350,00
60 2118,88 78,48 600 22,22 16,99 60 45,87 1620,00
70 2472,03 91,56 700 25,93 19,82 70 53,52 1890,00
80 2825,18 104,64 800 29,63 22,65 80 61,16 2160,00
90 3178,33 117,72 900 33,33 25,49 90 68,81 2430,00
100 3531,47 130,80 1000 37,04 28,32 100 76,46 2700,00

Datum/Edition/Date
Umrechnungstabelle / Conversion table
08/2008
Benennung/Descrition/Dénomination Blatt/Page/Feuille

Einheiten / Units 1.800.02

Newton per Pound per Pound per Pound per Pound per Newton per Pound per Newton per Pound per
meter (Nm) Inch (lbf/in) foot (lbf/ft) Inch (lbf/in) foot (lbf/ft) meter (Nm) foot (lbf/ft) meter (Nm) Inch (lbf/in)
1 8,86 0,74 1 0,08 0,11 1 1,36 12,00
2 17,71 1,48 2 0,17 0,23 2 2,71 24,00
3 26,57 2,21 3 0,25 0,34 3 4,07 36,00
4 35,42 2,95 4 0,33 0,45 4 5,42 48,00
5 44,28 3,69 5 0,42 0,56 5 6,78 60,00
6 53,13 4,43 6 0,50 0,68 6 8,13 72,00
7 61,99 5,16 7 0,58 0,79 7 9,49 84,00
8 70,84 5,90 8 0,67 0,90 8 10,85 96,00
9 79,70 6,64 9 0,75 1,02 9 12,20 108,00
10 88,55 7,38 10 0,83 1,13 10 13,56 120,00
20 177,10 14,75 20 1,67 2,26 20 27,12 240,00
30 265,65 22,13 30 2,50 3,39 30 40,67 360,00
40 354,20 29,50 40 3,33 4,52 40 54,23 480,00
50 442,75 36,88 50 4,17 5,65 50 67,79 600,00
60 531,30 44,25 60 5,00 6,78 60 81,35 720,00
70 619,86 51,63 70 5,83 7,91 70 94,91 840,00
80 708,41 59,00 80 6,67 9,03 80 108,47 960,00
90 796,96 66,38 90 7,50 10,16 90 122,02 1080,00
100 885,51 73,76 100 8,33 11,29 100 135,58 1200,00
200 1771,01 147,51 200 16,67 22,59 200 271,16 2400,00
300 2656,52 221,27 300 25,00 33,88 300 406,75 3600,00
400 3542,03 295,02 400 33,33 45,17 400 542,33 4800,00
500 4427,54 368,78 500 41,67 56,46 500 677,91 6000,00
600 5313,04 442,54 600 50,00 67,76 600 813,49 7200,00
700 6198,55 516,29 700 58,33 79,05 700 949,07 8400,00
800 7084,06 590,05 800 66,67 90,34 800 1084,65 9600,00
900 7969,57 663,81 900 75,00 101,64 900 1220,24 10800,00
1000 8855,07 737,56 1000 83,33 112,93 1000 1355,82 12000,00

Liter gal (US) gal (US) Liter

1 0,26 1 3,79
2 0,53 2 7,57
3 0,79 3 11,36
4 1,06 4 15,14
5 1,32 5 18,93
6 1,59 6 22,71
7 1,85 7 26,50
8 2,11 8 30,28
9 2,38 9 34,07
10 2,64 10 37,85
20 5,28 20 75,71
30 7,93 30 113,56
40 10,57 40 151,42
50 13,21 50 189,27
60 15,85 60 227,12
70 18,49 70 264,98
80 21,13 80 302,83
90 23,78 90 340,69
100 26,42 100 378,54
200 52,83 200 757,08
300 79,25 300 1135,62
400 105,67 400 1514,16
500 132,09 500 1892,71
600 158,50 600 2271,25
700 184,92 700 2649,79
800 211,34 800 3028,33
900 237,75 900 3406,87
1000 264,17 1000 3785,41 1.800.02/08.2008
Tightening torque TL 65 - 70s - TL80 - TL100

Note: When using Loctite thread lock, make sure that the threads are clean and free of grease and oil.

Pump attachment: Bolt/screw type: Torque:

Clutch on Flywheel M8 8.8 (8x) 25 Nm
Clutch hub on pump shaft thread pin M12x22 50 Nm
Pump flange on clutch housing M10 8.8 (12x) 46 Nm
Travel pump on pump flange M16 8.8 (2x) 170Nm
Loader pump on travel pump M10 (Allen screw 8.8) (2x) 45 Nm
Loader pump on travel pump (TL100) M12 x35 8.8 (2x) 80 Nm

Front axle:
Front axle on front carriage M20x90 8.8 (8x) 395 Nm

Internal gear of planetary gear M10 12.9 79 Nm

on axle

Drum Brake:
Brake support on axle M12 (Allen screw 10.9) 115 Nm

Disc Brake:
Brake support on axle M14 10.9 185 Nm
Brakedisc on cardan shaft M10 10.9 17 Nm
Brake calliper (Park and Service) M16 310 Nm
on support

Attention, check Axletype and Version!

APR 715 or 720 Version:
Drive Flange Bolt M20x1,5 12.9 400 Nm
on king pinion or
Locknut 600 Nm

MTL3015 or 3020 Version:

Drive flange Locknut 24x2 450 Nm
on king pinion

Rear axle: Bolt/screw type: Torque:

King pin on Rear carriage:

Flange bolts: M12 “Verbus-Rip”

replace by Flange bolts: M12x40 (2x) M12x50 (4x) 8.8 79 Nm

(use Nordlock washers Part No: 1 990 707 023
to make sure that the bolt can´t come loose)

Internal gear of planetary gear M10 12.9 79 Nm

on axle

Typ/Model/Type Datum/Edition/Date
TL 65 - 70s - TL80 - TL100 02.2011

Benennung/Description/Dénomination Blatt/Page/Feuille
Tightening torques 1.900.24
Cardan shaft: Bolt/screw type: Torque:
Flange bolts front axle M8 10.9 37Nm
Flange bolts rear axle M10 10.9 67Nm

Wheeles:
Wheel nuts (TL65) M18x1,5 325 Nm
Wheel nuts M20x1,5 460 Nm

Articulation:
Cover of swing bearing (TL65) M10x25 8.8 46 Nm
Cover of swing bearing M10x35 10.9 (Allen screw) 69 Nm
Bolts of steering cylinder pins M12x30 8.8 (+ Loctite 242) 80 Nm

Swing Loader TL70s: Bolt/screw type: Torque:

Swing bearing of loading frame M16x60 10.9 (18x / 9x) 330 Nm

Hydraulic cylinders: Piston nut : Guide bushing:

Steering cylinder (all Models) M22x2 410Nm + Loctite 242 390-450Nm

Only for machines with parallel kinematic:

TL65:
Lifting cylinder M36x2 1550Nm + Loctite 242 M95x2 450-520 Nm
Shovel cylinder M27x2 810Nm + Loctite 242 M85x2 390-450 Nm

TL70s:
Lifting cylinder M27x2 810Nm + Loctite 242 M85x2 390-450 Nm
Shovel cylinder M27x2 810Nm + Loctite 242 M95x2 450-520 Nm

TL80:
Lifting cylinder M42x3 1850Nm + Loctite 242 M110x2 550-635 Nm
Shovel cylinder M30x2 1050Nm + Loctite 242 M95x2 450-520 Nm

TL100:
Lifting cylinder M42x3 1850Nm + Loctite 242 M120x2 630-725 Nm
Shovel cylinder M36x3 1550Nm + Loctite 242 M110x2 550-635 Nm

Hyraulic cylinder nuts/wrench size/torque table

Thread size: Part Number nut: Wrench size: Torque: Add loctite 242:
M18x2 1 212 251 817 27 mm 200 Nm yes
M22x2 1 212 251 819 32 mm 410 Nm yes
M24x2 1 212 251 821 36 mm 450 Nm yes
M27x2 1 212 251 824 41 mm 810 Nm yes
M30x2 1 212 251 826 46 mm 1050 Nm yes
M36x3 1 212 251 832 55 mm 1550 Nm yes
M39x3 1 212 251 834 60 mm 1700 Nm yes
M42x3 1 212 251 836 65 mm 1750 Nm yes
M48x3 1 212 251 840 75 mm 1800 Nm yes

1.900.24/02.2011
Tightening torque TL210 - TL260 (from TL02600135)

Note: When using Loctite thread lock, make sure that the threads are clean and free of grease and oil.

Pump attachment: Bolt/screw type: Torque:

Clutch on Flywheel 3/8“-16UNC-11/4“ (8X) 40 Nm
Clutch hub on pump shaft Thread pin M14x16 70 Nm
Pump flange on clutch housing M10x35 8.8 (12x) 30 Nm
Travel pump on pump flange M20x45 8.8 (4x) 380 Nm
Loader pump on travel pump M16x45 8.8 (2x) 115 Nm

Front axle:
Front axle on front carriage M30x2x280 8.8 (8x) 1500 Nm

Internal gear of planetary gear mount with Loctite 242 1st step 330 Nm
2nd step 385 Nm
Drive flange cardan shaft mount with Loctite 242 880-1100Nm
on pinion shaft (resulting in 120-180Ncm rolling moment)

Differential housing mount with Loctite 242 78 Nm

Axle flared tube 300 Nm

Rear axle:
Rear axle support frame on rear carriage M30x150 10.9 (4x) 2000 Nm

Internal gear of planetary gear mount with Loctite 242 1st step 330 Nm
on axle 2nd step 385 Nm

Differential housing mount with Loctite 242 78Nm

Axle flared tube 300Nm

Cardan shaft flange on mount with Loctite 242 300-350 Nm

gear output shaft

Rear axle center bolt M14x40 123Nm

Hydr. motor 140 on gear M16x50 (cylinder screw 10.9)200Nm

Hydr. motor 80 on gear M12x45 (cylinder screw 8.8) 79Nm

Cardan shaft:
Flange bolts M12x35 8.8
need to be replaced by Flange bolts: M12x1,25x35 10.9 110Nm
TL310 M12x1,25x40 10.9 110Nm

Wheels:
Wheel nuts M22x1.5 610 Nm

Typ/Model/Type Datum/Edition/Date
TL210 - TL260 02.2011
Benennung/Description/Dénomination Blatt/Page/Feuille
Tightening torques 1.900.30
Articulation:
Covers of swing bearings M12x40 10.9 (cylinder screw) 120 Nm
Screws of steering cylinder pins M12x30 (with Loctite 242) 80 Nm

Hydraulic cylinders: Piston nut : Guide bushing:

Steering cylinder M30x2 1050Nm + Loctite 242 390-450Nm
Lift cylinder M48x3 2050Nm + Loctite 242 M12x40 12.9 (12x) 155Nm
Bucket cylinder M60x2 1800Nm + Loctite 242 M12x50 10.9 (18x) 120Nm

Hyraulic cylinder nuts/wrench size/torque table

Thread size: Part Number nut: Wrench size: Torque: Add loctite 242:
M18x2 1 212 251 817 27 mm 200 Nm yes
M22x2 1 212 251 819 32 mm 410 Nm yes
M24x2 1 212 251 821 36 mm 450 Nm yes
M27x2 1 212 251 824 41 mm 810 Nm yes
M30x2 1 212 251 826 46 mm 1050 Nm yes
M36x3 1 212 251 832 55 mm 1550 Nm yes
M39x3 1 212 251 834 60 mm 1700 Nm yes
M42x3 1 212 251 836 65 mm 1750 Nm yes
M48x3 1 212 251 840 75 mm 1800 Nm yes

1.900.30/02.2011
Tightening torques TW70

Note: When using Loctite thread lock, make sure that the threads are clean and free of grease and oil.

Pump attachment (Yanmar engine): Bolt/screw type: Torque:

Secure all screws/bolts using Loctite 242!
Clutch on Flywheel M14x45 8.8 (3x) 170 Nm
Pump flange on clutch housing M10x40/45 8.8 (12x) 45 Nm
Travel pump on pump flange M16x40 (cyl. screw)8.8 (2x) 170 Nm
Working pump flange on travel pump M12x25 (cyl. screw)8.8 (2x) 80 Nm
Working pump on working pump flange M16x60 m. hex. nut (2x)

Cooler:
Cooler support on engine TW70 (Yanmar) M10x35 8.8 (8x) 46 Nm
Fan on water pump TW70 (Yanmar) M8x70 8.8 (4x) 23 Nm

Slewing gear:
Slew ring on undercarriage M16x70 10.9 (24x) 325 Nm
Slew ring on uppercarriage M16x70 10.9 (24x) 325 Nm
Swing gear on uppercarriage M16x35/40 10.9 (8x) 325 Nm
Caution — The contact faces of the screw heads must be of bright metal!

Swing motor on swing gear cylinder screws 130 Nm

Rotary transfer on uppercarriage M12x40 12.9 (6x) 165 Nm
Torque support on rotary transfer M16x50 10.9 (2x) 325 Nm

Counter weight:
Attachment of counter weight TW70 M20x70 8.8 (1x top) 300 Nm
M20x180 8.8 (2x bottom) 300 Nm
M16x50 8.8 (1x right) 200 Nm

Wheel nuts:
TW70 M22x1,5 610 Nm

Front axle TW70:

Axle on chassis M20x120 10.9 (4x) 490 Nm
Internal gear of planetary gear mount with Loctite 242 90-100 Nm
on axle
Drive flange cardan shaft mount with Loctite 270 80-120 Nm
on pinion shaft
Plate for plunger cylinder M12x60 8.8 (3x) 80 Nm
on axle

Rear axle TW70:

Axle on chassis M20x180 8.8 (8x) 400 Nm
Internal gear of planetary gear mount with Loctite 242 90-100 Nm
on axle stub
Drive flange cardan shaft mount with Loctite 270 80-120 Nm
on output shaft
Travel motor M12x45 8.8 (4x) 80 Nm

Typ/Model/Type Datum/Edition/Date
TW70 07.2010
Benennung/Description/Dénomination Blatt/Page/Feuille
Tightening torques 1.900.49
Cardan shaft: Bolt/screw type: Tightening torque:
Flange screws, rear: M8x20 10.9 (8x) 35 Nm
Flange screws, front: M10x30 10.9 (8x) 69 Nm

Hydraulic cylinders on articulated boom:

Hydraulic cylinders: Piston nut : Guide bushing:

Dozer blade cylinders M30x2 1050Nm + Loctite 270 M105x2 520-600Nm
Pipe safety valve in cylinder 25Nm
Articulation cylinder M36x3 1550Nm + Loctite 270 M12x40 12.9 (10x) 155Nm
Boom cylinder M36x3 1550Nm + Loctite 270 M12x40 12.9 (10x) 155Nm
Intermediate boom cyl. M30x2 1050Nm + Loctite 270 M10x30 10.9 (10x) 55Nm
Dipper cylinder M36x3 1550Nm + Loctite 270 M12x40 12.9 (10x) 155Nm
Bucket cylinder M30x2 1050Nm + Loctite 270 M10x30 10.9 (10x) 55Nm

1.900.49/07.2010
Tightening torques TW85, 110

Note: When using Loctite thread lock, make sure that the threads are clean and free of grease and oil.

Pump attachment TW85 20km/h: Bolt/screw type: Torque:

Secure all screws/bolts using Loctite 242!
Clutch on Flywheel M10x35 8.8 (8x) 49 Nm
Clutch hub on pump shaft clamp bolt 86 Nm
Pump flange on clutch housing M10x25 (10x) 45 Nm
Travel pump on pump flange M16x50 (cyl. screw) 10.9 (2x) 290 Nm
Working pump on travel pump M16x50 (2x) 200 Nm

Pump attachment TW85 36km/h:

Secure all screws/bolts using Loctite 242!
Clutch on Flywheel M10x20 8.8 (8x) 45 Nm
Pump flange on clutch housing M10x25 (10x) 45 Nm
Travel pump on pump flange M16x50 (cyl. screw) 8.8 (2x) 200 Nm
Working pump on travel pump M16x50 (2x) 200 Nm

Pump attachment TW110:

Secure all screws/bolts using Loctite 242!
Flywheel clutch M10x35 8.8 (8x) 49 Nm
Clutch hub on pump shaft clamp screw 70 Nm
Pump flange on clutch housing M10x25/30 (10x) 45 Nm
Travel pump on pump flange M20x1.5x45 10.9 (4x) 400 Nm
Working pump on travel pump M20x1.5x45 10.9 (4x) 400 Nm

Gear pump on Deutz engine:

TW 85 (dual pump) M10x35 M10x185 10.9 (2x) 70 Nm
TW 110 (triple pump) M10x265 10.9 (2x) 70 Nm

Cooler:
Cooler support on engine TW85/110 M16x60 10.9 (4x) 290 Nm
Fan on water pump TW85/100 M8 8.8 (4x) 30 Nm

TW85 - Slewing gear:

Slew ring on chassis M16x80 10.9 (30x) 325 Nm
Slew ring on superstructure M16x80 10.9 (30x) 325 Nm
Swing gear on superstructure M16x120 8.8 Cyl bolt (12x) 195 Nm
Caution — The contact faces of the screw heads must be of bright metal!

Swing motor on swing gear M10x30 10.9 (4x) Cyl bolt 72 Nm

Rotary transfer on uppercarriage M12x40 12.9 (6x) 165 Nm
Torque support on rotary transfer M16x50 10.9 (2x) 325 Nm

Typ/Model/Type Datum/Edition/Date
TW85, 110 04.2011
Benennung/Description/Dénomination Blatt/Page/Feuille
Tightening torques 1.900.51
TW110 - Slewing gear: Bolt/screw type: Torque:
Slew ring on chassis M16x80 10.9 (24x) 325 Nm
Slew ring on superstructure M16x80 10.9 (24x) 325 Nm
Swing gear on superstructure M16x45 (12x) Cyl bolt 195 Nm
Caution — The contact faces of the screw heads must be of bright metal!

Swing motor on swing gear M10x30 10.9 (4x) Cyl bolt 72 Nm

Rotary joint on superstructure M12x40 12.9 (6x) 165 Nm
Torque support on rotary joint M16x50 10.9 (2x) 325 Nm

Rear weight:
Attachment of rear weight TW85 M20x60 8.8 (1x top) 300 Nm
M20x180 8.8 (2x bottom) 300 Nm
M20x50 8.8 (1x right) 300 Nm
Attachment of rear weight TW110 M20x120 8.8 (3x top/bottom)385 Nm
(from TW01100100 to TW01100559) M20x50 8.8 (1x right) 300 Nm

Wheel nuts:
TW85, 110 M22x1.5 610 Nm

Front axle TW85/110:

Axle on chassis M16x110 8.8 (4x) 200 Nm
Internal gear of planetary gear mount with Loctite 242 1st step 120 Nm
on axle stub 2nd step 280 Nm
Drive flange cardan shaft mount with Loctite 242 280-310 Nm
on pinion shaft
Cardan shaft flange bolts: M10x30 10.9 (8x) 69 Nm

Rear axle TW85/110:

Axle on chassis M20x210 8.8 (8x) 400 Nm
Intenal gear of planetary gear mount with Loctite 242 1st step 120 Nm
on axle stub 2nd step 280 Nm
Drive flange cardan shaft mount with Loctite 242 280-310 Nm
on pinion shaft
Cardan shaft flange screws M10x30 10.9 (8x) 69 Nm

1.900.51/04.2011
TW85 Articulated boom:
Hydraulic cylinders: Piston nut: : Guide bushing:
Dozer blade cylinders M30x2 1.050Nm + Loctite 270 M105x2 520-600Nm
Hose rupture valve in cylinder 25Nm
Articulation cylinder M36x3 1.550Nm + Loctite 270 M12x40 12.9 (10x) 145Nm
Boom cylinder M42x3 1.850Nm + Loctite 270 M12x40 12.9 (12x) 155Nm
Intermediate boom cyl. M36x3 1.550Nm + Loctite 270 M12x40 12.9 (12x) 155Nm
Stick cylinder M42x3 1.850Nm + Loctite 270 M12x40 12.9 (12x) 155Nm
Bucket cylinder M42x3 1.850Nm + Loctite 270 M10x30 10.9 (12x) 55Nm

TW110 Articulated boom:

Hydraulic cylinders: Piston nut: Guide bushing:
Dozer blade cylinders M36x3 1.550Nm + Loctite 270 M115x2 630-725Nm
Hose rupture valve in cylinder 25Nm
Articulation cylinders M42x3 1.850Nm + Loctite 270 M12x40 12.9 (12x) 155Nm
Boom cylinder M50x2 Nm + Loctite 270 M12x40 12.9 (16x) 155Nm
Intermediate boom cyl. M36x3 1.550Nm + Loctite 270 M10x40 10.9 (12x) 80Nm
Stick cylinder M56x2 1.600Nm + Loctite 270 M12x40 12.9 (12x) 155Nm
Bucket cylinder M56x2 1.600Nm + Loctite 270 M12x40 12.9 (12x) 55Nm

Hyraulic cylinder nuts/wrench size/torque table

Thread size: Part Number nut: Wrench size: Torque: Add loctite 242:
M18x2 1 212 251 817 27 mm 200 Nm yes
M22x2 1 212 251 819 32 mm 410 Nm yes
M24x2 1 212 251 821 36 mm 450 Nm yes
M27x2 1 212 251 824 41 mm 810 Nm yes
M30x2 1 212 251 826 46 mm 1050 Nm yes
M36x3 1 212 251 832 55 mm 1550 Nm yes
M39x3 1 212 251 834 60 mm 1700 Nm yes
M42x3 1 212 251 836 65 mm 1750 Nm yes
M48x3 1 212 251 840 75 mm 1800 Nm yes

Typ/Model/Type Datum/Edition/Date
TW85, 110 04.2011
Benennung/Description/Dénomination Blatt/Page/Feuille
Tightening torques 1.900.52
02 Technical Data R
_____________________________________________________________________________________________________________________________________________________________________________________

Subgroups list Technical Data

Machine type Serial-Number File Number

SKL 200 (SKL873SP) 0100 > 2.13.05-06

TL 65 (SKL824) 0100 > 0328 2.22.01-02

TL 65 0329 > 0451 2.22.20-21
TL 65 0452 > 2.22.22-23

TL 80 (SKL834) 0100 > 0750 2.24.01-02

TL 80 0751 > 1180 2.24.03-04
TL 80 1181 > 2.24.20-21
TL 80 TL08020100 > 2.24.30-31

TL 80 AS 0100 > 0146 2.25.01-02

TL 80 AS 0147 > 2.25.20-21

TL 100 (SKL844) 0100 > 0452 2.26.01-02

TL 100 0453 > 0646 2.26.03-04
TL 100 0647 > 2.26.20-21

TL 120 (SKL854) 0100 > 0279 2.27.01-02

TL 120 0280 > 2.27.20-21

TL 160 (SKL160) 0100 > 0198 2.28.01-02

TL 160 0199 > 2.28.20-21

TL 210 0100 > 0138 2.29.01-02

TL 210 0139 > 2.29.20-21

TL 260 (SKL260) 0100 > 0134 2.30.01-02

TL 260 0135 > 0185 2.30.03-04
TL 260 0186 > 2.30.20-21

TL 310 0100 > 2.31.01-02

TL 70 (SKS634) 0100 > 0205 2.37.01-02

TL 70 0206 > 0249 2.37.03-04
TL 70 0250 > 0362 2.37.20-21
TL 70 0363 > 2.37.22-23

Date: 01-September-2011 Germany Service manual

Page 01/02 All types of machines
 R
02 Technical Data
_________________________________________________________________________________________________________________________________________________________________________________________________________

Subgroups list Technical Data

Machine type Serial-Number File Number
TW 70 (HML23) 0100 > 0231 2.49.50-51
TW 70 0232 > 2.49.60-61

TW 85 (HML32) 0100 > 0447 2.51.03-04

TW 85 0448 > 2.51.20-21

TW 110 (HML42) 0100 > 0339 2.53.02-03

TW 110 0340 > 0559 2.53.20-21

TC 60 (HR20) 0100 > 2.60.01-02

TC 75 (HR32) 0100 > 1039 2.65.11

TC 75 1040 > 2.65.20

TC 125 (HR42) 0100 > 0312 2.67.02

TC 125 0313 > 2.67.20

TC 29 (HR14) 0100 > 0808 2.76.03

TC 29 0809 > 2.76.04

TC 35 (HR16) 0100 > 0556 2.78.03

TC 35 0557 > 2.78.04

TC 48 (HR18) 0100 > 0578 2.80.02

TC 48 0579 > 2.80.03

TC 15 0100 > 0162 2.90.02

TC 15 0163 > 0181 2.90.03
TC 15 0182 > 2.90.20

TC 16 0100 > 0732 2.91.02

TC 16 0733 > 0884 2.91.03
TC 16 0885 > 2.91.20

TC 20 0100 > 0492 2.92.01

TC 20 0493 > 0808 2.92.02
TC 20 0809 > 2.92.20

TC 25 0100 > 2.93.20

TC 37 (HR3.7) 0100 > 0428 2.97.01

TC 37 0429 > 2.97.02

TC 50 (HR5.0) 0100 > 0352 2.99.01

TC 50 0353 > 2.99.20

Service manual Germany Date: 01-September-2011

All types of machines Page 02/02
DIESEL ENGINE
Manufacturer: Perkins
Type: 1106C-E60TA
Performance acc. to DIN 70020: kW/PS 106 / 144 at 2,200 min-1
Construction: 6 cylinders in line
Cooling: water
Injection: direct injection
Spec. fuel consumption: g/kWh 220
Capacity: cm³ 6,000
High idle: min-1 2,350 +50
Low idle: min-1 750 +50
Tappet clearance - inlet cold: mm 0.20
Tappet clearance - outlet cold: mm 0.45
Further data: see engine instruction book

ELECTRIC SYSTEM
Voltage: V 24
Battery: V/Ah/A 2 x 12 / 105 / 760
Alternator: V/A 24 / 80
Starter: V/kW/PS 24 / 4.5 / 6.1
Starting aid: glow system
Lighting: acc. to German motor vehicle
construction and use regulation
and Euronorm

TRANSMISSION
Travel pump: type A 4 VG 125 DA with pressure cut-off
Displacement: max. cm³/rev. 125
Travel motor: type A 6 VM 160 DA 6
Displacement: max. cm³/rev. 160

TRAVEL RANGE
4 pre-selectable travel ranges, electro-hydraulically operated:
SKL 200: 20 km/h - version
Gearbox position 1, tortoise / rabbit: km/h 0 to 7 / 0 to 15
Gearbox position 2, tortoise / rabbit: km/h 0 to 10 / 0 to 20
SKL 200: 40 km/h - version
Gearbox position 1, tortoise / rabbit: km/h 0 to 7 / 0 to 16
Gearbox position 2, tortoise / rabbit: km/h 0 to 16 / 0 to 40
Cardan shaft rev. at 20 km/h - version adjustment at nominal speed
tortoise / rabbit
tyres 1./2. gear / 1./2. gear
standard: 20.5-25 12PR SGLD/L-2 Good Year: min-1 450 / 660 800 / 1,170
option: 20.5 R25 XHA TL Michelin: min-1 450 / 660 800 / 1,170
20.5-25 12PR E91TL Dunlop: min-1 450 / 660 820 / 1,200
555/70 R25 XHF Michelin: min-1 450 / 660 840 / 1,230
20.5 R25 EM RL-2 Good Year: min-1 450 / 660 800 / 1,170
Cardan shaft rev. at 40 km/h - version adjustment at nominal speed
tortoise / rabbit
tyres 1./2. gear / 1./2. gear
standard: 20.5-25 12PR SGLD/L-2 Good Year: min-1 450 / 1,035 1,015 / 2,330
option: 20.5 R25 XHA TL Michelin: min-1 450 / 1,035 1,015 / 2,330
20.5-25 12PR E91TL Dunlop: min-1 450 / 1,035 1,040 / 2,380
555/70 R25 XHF Michelin: min-1 450 / 1,035 1,065 / 2,450
20.5 R25 EM RL-2 Good Year: min-1 450 / 1,035 1,015 / 2,330

Typ/Model/Type Datum/Edition/Date
SKL 200 (SKL873) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Technical Data 2.13.05
PRESSURE AND SETTING VALUES travel
Suction pressure: max. bar - 0.25
Charge pressure (high idle): bar 32 ±1
High pressure (safety valves): bar 480
Pressure cut-off: bar 440 ±10
Case pressure: max. bar 2.5
Regulation start (DA-motor): bar 220 (motor can be stalled up to
2,100 -50 min-1)
Start-up speed: min-1 1,150 ±50
Engine stalling (tortoise): min-1 2,000 -100 at full speed and 220 bar HP
Brake inching beginning / end: bar 5 / 13

STEERING
Steering unit: type Rexroth LAGU 320/160-12/LD 240-
175
Servo selector valve: type Rexroth 7730
Steering pump: make Brueninghaus (see working hydraulics)
Steering pressure: bar 205 +10/-5 (LS eff. 175 bar)
Supplementary steering (shift pressure) bar 20 ±2

WORKING HYDRAULICS
Working and steering pump: make Brueninghaus/Rexroth
type A10 VO 71 DFR 1
Displacement: cm³/rev. 71
ltr./min 156
Stand-by pressure (flow controller): bar 32 +2
Servo-controlled valve: type PRSV C01
Control valve: type Rexroth 3 M6-15

PRESSURE AND SETTING VALUES working

LS pressure relief valve: bar 250
Line relief pressures:
- lifting frame lift: bar 280 +10
- lifting frame lower: bar anti-cavitation
- shovel dump in: bar 280 +10
- shovel dump out: bar 280 +10
- additional control circuit: bar 230 +10 / 230 +10

WORKING CYCLES
Lifting frame lift: s 6.3
Lifting frame lower: s 4.3
Shovel dump in: s 1.3
Shovel dump out: s 1.4

AXLES
Front axle with self-locking diff., 20 km/h - version: make/type DANA 176 / 348
Rear axle with self-locking diff., 20 km/h - version: make/type DANA 360 / 176 / 70
Lock value: max. 45%
Front axle with self-locking diff., 40 km/h - version: make/type DANA 176 / 348
Rear axle with self-locking diff., 40 km/h - version: make/type DANA 360 / 176 / 69

2.13.05/01.2007
BRAKE SYSTEM
Service brake (four-wheel-brake): hydraulic 2-circuit brake, oil-immersed
disks of both axles
Parking brake (hydraulic hand brake valve): spring-loaded brake acting on the disks
of both axles
Additional brake: hydrostatic by closed circuit of the
transmission
Brake pump (accessory drive): make Cassappa PLP 20.11.2
Displacement: cm³/rev. 11
ltr./min. 24
Brake pressure (service brake): max. bar 60 +6
Accumulator charge valve: make Rexroth type LT 13
Cut-in / cut-off pressure: bar 120 - 150
Sequence valve (pressure sequence valve): bar Δp 13 (e.g. 60 bar brake pressure
means 60 bar at the inching valve and
47 bar at the brake)
Opening pressure (parking brake): bar 15
Setting value, parking brake: bar 25

LUBRICANTS
Engine: see engine instruction book
Hydraulic oil: see Schaeff hydraulic oil recommendation
table
Transmission oil: MIL-L 2105 B or API-GL 5,
SAE 85 W 90 LS or SAE 90 LS
Multi-purpose grease: acc. to DIN 51825. Dripping point over
170° C. With lithium.
Brake medium: hydraulic oil

MAINTENANCE PARTS see instruction book

CAPACITIES ltr.
Engine oil - change: approx. 15.0 engine oil (+ 2 x 0.5 l filter)
Hydraulic oil (tank and system): approx. 170.0 hydraulic oil
Hydraulic oil (change): approx. 130.0 hydraulic oil
Fuel tank: approx. 210.0 diesel
Front axle - central housing: approx. 11.5 transmission oil
Front axle - wheel hub: approx. 2.35 transmission oil, each
Rear axle - central housing: approx. 10.5 transmission oil
Rear axle - reduction gearbox: approx. 3.4 transmission oil
Rear axle - wheel hub: approx. 2.35 transmission oil, each
Service brake: connected to the hydraulic system
Cooling agent: approx. 46.0 water with anti-corrosive
and anti-freeze agent

Typ/Model/Type Datum/Edition/Date
SKL 200 (SKL873) 01.2007
Benennung/Description/Dénomination Blatt/Page/Feuille
Technical Data 2.13.06
DIESEL ENGINE
Manufacturer: Deutz
Type: F4M 2011
Performance according to
(ECE-R24/ISO1585/ISO9249): kW 37 at 2,300 min-1
Construction: 4 cylinders in line
Cooling: external oil cooling
Injection: direct injection
Capacity: cm³ 3,100
High idle: min-1 2,450 +50
Low idle: min-1 850 +50
Spec. fuel consumption under full load: g/kWh 216
Tappet clearance - inlet cold: mm 0.30
Tappet clearance - outlet cold: mm 0.50
Torque of cylinder head studs Nm 30 / 80 / 160
(only in case of repair): Tightening angle 90°
Further data: see engine instruction book or chapter 3

ELECTRICAL SYSTEM
Voltage: V 12
Battery: V/Ah/A 12 / 80 / 720 (EN)
Generator: V/A 14 / 95
Starter: V/kW/PS 12 / 2.3 / 3.1
Cold start aid: heater plug
Lighting: acc. to German motor vehicle construction and use
regulation (“StVZO”) and Euronorm.
H4 halogen headlamp.
Two working lights at the front.

TRANSMISSION
Travel pump: type A 4 VG 40 DA with pressure cut-off
Displacement: max. cm³/rev. 40
Travel motor 20/36 km/h version: type A 6 VM 55 DA 2
Displacement 20/36 km/h version: max. cm³/rev. 55

TRAVEL RANGE
Two/ four pre-selectable travel ranges, electro-hydraulically controlled:
TL 65: 20 km/h - version:
tortoise / rabbit km/h 0 to 7.0 / 0 to 20
TL 65 S: 36 km/h - version:
Gearbox position 1, tortoise / rabbit: km/h 0 to 6.5 / 0 to 18
Gearbox position 2, tortoise / rabbit: km/h 0 to 13 / 0 to 36

Cardan shaft rev. at 20 km/h - version adjustment at nominal speed

tortoise / rabbit
and standard tyres 365/70 R18: min-1 650 / 1,985
12,5-18: min-1 650 / 1,985
335/80 R18: min-1 650 / 1,940

Cardan shaft rev. at 36 km/h - version adjustment at nominal speed

tortoise / rabbit
1./2. gear / 1./2. gear
and standard tyres 365/70 R18: min-1 630 / 1,290 1,750 / 3,565
12,5-18: min-1 630 / 1,290 1,750 / 3,565
335/80 R18: min-1 630 / 1,290 1,710 / 3.490

Typ/Model/Type Datum/Edition/Date
TL 65 from s/n.: TL00650100 to 328 01.2007
(SKL 824 / SKL 824 S)
Blatt/Page/Feuille
Benennung/Description/Dénomination
Technical Data 2.22.01
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