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Terex TW85 Operating Instructions Manual

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tW85
Wheeled Excavator

OPERATING INSTRUCTIONS

EN
Language version
:
2010-01
Edition
:
5780211153
Order number
:
TW00850448>
From vehicle ID No
.:
Translation of the original operating instructions

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Summary of Contents for Terex TW85

  • Page 1: Operating Instructions

    Wheeled Excavator OPERATING INSTRUCTIONS Language version 2010-01 Edition 5780211153 Order number TW00850448> From vehicle ID No Translation of the original operating instructions...
  • Page 2 Terex GmbH Geschäftsbereich Terex Schaeff Schaeffstr. 8 74595 Langenburg Germany Phone +49(0)7905/58-0 Fax +49(0)7905/58-114 www.terex.com E-mail: info@terex.com Please complete before commissioning the wheeled excavator: Vehicle model: ................Vehicle ID No.: ................Year of construction: ............... Commissioned on: ..............Dealer: This operating manual is protected by limited copyright. It may be reproduced for and used by the drive /...

  • Page 3: Table Of Contents

    4.2.1 Starting the engine ...........................36 4.2.2 Monitoring during operation......................37 4.2.3 Switching off the engine ........................38 4.3 Driver's seat, steering wheel height and tilt adjustment................39 4.4 Heating / Ventilation / Air-conditioning ....................40 4.5 Light switch .............................41 4.6 Front windshield ............................41 TW85...
  • Page 4 7.9.7 Hydraulic oil tank ..........................89 7.9.8 Hydraulic oil return filter........................90 7.9.9 Hydraulic oil suction filter........................91 7.9.10 Hydraulic oil tank - breather ......................92 7.9.11 Bleeding the plunger cylinders .......................93 7.9.12 Hose-rupture safety valves of support legs..................93 7.9.13 Axles...............................94 7.9.14 Brakes ............................98 7.9.15 Wheels............................100 TW85...
  • Page 5 9.1 Electrical system ...........................113 9.2 Immobilizer............................114 9.2.1 Activating the immobilizer.......................114 9.2.2 Deactivating the immobilizer ......................114 9.2.3 Learning a new key ........................114 9.2.4. Learning multiple new keys ......................115 9.2.5 Clearing learned keys........................115 9.2.6 Security functions ...........................115 9.2.7 Fault causes ...........................116 TW85...
  • Page 6 Table of contents TW85...

  • Page 7: Introduction 1

    Introduction 1 1 Introduction You decided to buy a Terex TW85 Wheeled Excavator. The confidence placed in this model will be rewarded efficient economical performance of the machine. This operating manual contains all the information and instructions that are required to handle the machine correctly.

  • Page 8: Warranty And Maintenance

    Strictly observe safety instructions. Insist that only original Terex spare parts are used in the event of any repair work. In this way, you will have a product of lasting high quality, Symbol “Warning” thereby ensuring that your machine maintains its original condition.

  • Page 9: Environmental Standards

    Absorbent materials and removed soil must be disposed of properly. The environmental standards Engine oil pressure currently valid must be observed. Coolant temperature Air filter Fuel, fuel level Blower Heating/ventilation Air-conditioning Windshield washer and wiper system Horn Travel motion alarm TW85...
  • Page 10 Danger of crushing Travel speed Danger of injury FAST Travel speed, SLOW The relevant notes in the operating instructions should be observed Driving with accelerator pedal – apportionable driving Grease gun Lubricating point Steering reversal Working hydraulics shut-off Engine speed setting TW85...

  • Page 11: Safety And Accident Prevention 2

    The EC declaration of conformity only applies if the earth-moving machine is used in accordance with the operating instructions. It includes the use of original Terex work attachments and other work attachments, which are mentioned in the operating instructions or in other Terex documentation for application at this earth- moving machine.

  • Page 12: Intended Use

    This risk is borne solely by the user. Strict compliance with operating maintenance instructions and the performance of maintenance work, as well as adherence to the maintenance intervals is also part of intended use. TW85...

  • Page 13: General Safety Notes

    • 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 so that they cannot slam shut. TW85...

  • Page 14: Danger Zone

    • 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. TW85...

  • Page 15: Travel Operation

    Outside areas covered general traffic regulations, e.g. on factory premises, traffic regulations should be applied in the proper manner. This should also apply with regard to drivers’ licenses. TW85...

  • Page 16: Guides

    See regulations book "Demolition work" (ZH 1/614) published German Tiefbau- Berufsgenossenschaft (Civil Engineering Employer’s Liability Insurance Association). TW85...

  • Page 17: Working In The Vicinity Of Overhead Power Lines

    Such measures could be, e.g. • Switching off the current, • Re-routing the overhead line, • Cabling, or • Limiting the operating zone of earth-moving machines TW85...

  • Page 18: Crane Operations

    Loads must be carried as close to the ground as possible and be prevented from swinging. Earth-moving machines may only move with an attached load if the path of travel is fairly level and if the machine operator’s view of the driving zone is guaranteed. TW85...

  • Page 19: Recovery, Loading, Transportation

    Alterations, such as welding of the hydraulic are large enough and that roads and bridges have system, are only to be undertaken with the sufficient carrying capacity. manufacturer’s permission. TW85...

  • Page 20: Monitoring And Inspections

    - and his replacement, if there is a change of operator - with regard shortcomings. In the event of shortcomings which jeopardize the operating safety of the earth-moving machine, it is not to be used until these have been eliminated. TW85...

  • Page 21: Technical Data 3

    Technical data 3 3 Technical data 3.1 Views Three-piece articulated boom (TPA) 3880 2930 5400 3260 6450 4080 7500 4680 4810 Fig. 3 Digging envelope TW85...
  • Page 22 3 Technical data Circular boom HM32-004 8090 Fig. 4 Digging envelope, working envelope TW85...
  • Page 23 Technical data 3 Monobloc boom with dipperstick 2,000 mm 4230 2930 4030 2320 3910 5060 6010 3500 4640 Fig. 5 Digging envelope TW85...
  • Page 24 3 Technical data Monobloc offset boom 4270 2930 4070 2270 5100 3870 6060 Offset boom straight drawn. Fig. 6 Digging envelope HM32-007 Fig. 7 Digging zone TW85...
  • Page 25 Technical data 3 HM32-008 1500 180° Hüllkreis Fig. 8 Working envelope Working envelope Mono-LS 2000 2960 1665 3045 Working envelope 4460 3165 4545 180° Working envelope 5920 3330 6090 360° TW85...

  • Page 26: Engine

    Suction filter in the form of a tank insert filter. Travel speed Forward - Reverse TW85, TW85 AL TW85 (Four-wheel (High-speed version) steering) Travel range I...

  • Page 27: Brakes

    (High-speed version) Multiple disk brake running in oil bath in center housing of front axle and on hub of rear axle TW85 AL (Four-wheel steering) Multiple disk brakes running in oil bath in center housing of front and rear axle...

  • Page 28: Hydraulic System

    Operating range 50-45° C Knickmatik Bend mechanism for the lateral parallel adjustment of the boom axle at total digging depth to the right and left. Lateral adjustment to the right: 990 mm Lateral adjustment to the left: 870 mm TW85...

  • Page 29: Axles

    Technical data 3 Priority valve Priority supply of hydraulic oil to steering. Steering TW85, TW85 Fully-hydraulic, proportionally jointed front axle, by means of a steering control device and a steering cylinder integrated in the axle. Steering TW85 AL Electrically preselectable steering type...

  • Page 30: Tires

    Hydraulic oil, tank and system approx. 190.0 Hydraulic oil Hydraulic oil tank approx. 125.0 Hydraulic oil (change quantity) Steering front axle, TW85, TW85 AL center approx. Gearbox oil housing Steering front axle, TW85 approx. Gearbox oil center housing Steering front axle, TW85, TW85 AL approx.

  • Page 31: Consumable Specifications

    Diesel fuel EN 590 Before using RME fuels ASTM D975 1-D / 2-D (rape oil methyl ester), it is essential to consult your responsible Terex dealer for further details. Engine EO 1540 A Engine oil SAE 15W-40 See also engine manufacturer’s...

  • Page 32: Permissible Loads In Compliance With German Road Traffic Regulations (Stvzo)

    1942 Smallest turning radius over outside edge of tires, 6700 6700 6700 6700 TW85, TW85 , TW85 AL-normal steering Smallest turning radius over outside edge of tires, 4000 4000 4000 4000 TW85 AL with 4WS All dimensions and weights are based on the standard version.

  • Page 33: Excavator Equipment

    The weight of the work attachment must be deducted from the stated payload. (weight see type label) Carrying capacity table with the following equipment: • without bucket with quick-attach system • Twin tires 8.25-20 with filling rings • full tank, with driver TW85...
  • Page 34 L o a d r a d i u s f r o m c e n t e r o f r i n g g e a r Height hook longt. trans- longt. trans- longt. trans- longt. trans- longt. trans- verse verse verse verse verse -1.0 TW85...
  • Page 35 1.88 0.95 1.06 1.13 0.79 0.85 2.57 1.23 2.13 0.92 1.04 1.11 0.74 0.82 5.06 1.49 3.20 1.06 2.26 0.82 1.26 1.33 0.89 0.95 0.67 0.73 -1.0 4.69 1.44 3.06 1.00 2.03 0.74 1.28 1.31 0.89 0.95 0.69 0.71 TW85...

  • Page 36: Work Attachments

    0.385 900* 0.385 Ditch-cleaning bucket 1500* 0.270 Swing bucket 1500* 0.345 1500* 0.345 Clamshell grab type GM 2 0.135 0.170 0.220 0.260 * = These work attachments are not road driving approved! -Further work attachments available on request! - TW85...

  • Page 37: Supports

    • Cutting units -Further attachments available on request! - Any modifications of Terex 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.

  • Page 38: Operation

    4 Operation 4 Operation 4.1 Operating controls The following list includes non-standard equipment! HM32-0101 010831 Fig. 10.1 Operation TW85...
  • Page 39 Travel direction preselection – forward/neutral/reverse Engine speed setting (manual throttle) Temperature control Heating Battery main switch Power socket Electrical refueling pump (option) Uppercarriage - locking pin Radio Power socket Service ladder (climbing flap) Changeover switch Fresh air / circulating air TW85...
  • Page 40 4 Operation 35 37 39 36 38 51 52 53 54 71 72 73 TW85-0102-N TW85AL TW85 59 60 61 62 63 59 60 61 62 63 TW85S 58 59 65 66 62 63 Fig. 10.2 Instruments and operation TW85...
  • Page 41 Working floodlight, boom Pre-heat/ starter switch Rear fog lamp Fan switch - heating Option – Steering reversal Option – air conditioner Option – Change-over "ISO" to "SAE" control Windshield wiper and washer system Working hydraulics shut-off Rock breaker/auxiliary fitting TW85...

  • Page 42: Engine

    “1” or “0”, and pause for at least 1 minute before trying again. Repeat the start-up procedure. Do not drive the engine at full throttle straight away. Drive with restraint until the operating temperature of the engine has been reached. HM32-011 Fig. 11 Operation TW85...

  • Page 43: Monitoring During Operation

    When the hydraulic oil is cold, the hydraulic oil filter clogging indicator may light up briefly. It will go out once the operating temperature is reached. • If the air filter service indicator lamp (12/29) lights up, perform the necessary air filter maintenance. TW85...

  • Page 44: Switching Off The Engine

    Do not switch the engine off when running at full throttle, but allow it to run for a short time at low revs without load. • Turn the ignition key (12/48) to Position "0". • The engine stops automatically. TW85...

  • Page 45: Driver's Seat, Steering Wheel Height And Tilt Adjustment

    Tilt adjustment of steering wheel • Push down lever (14/7) • Adjust steering-wheel tilt • Release lever 49 50 Steering wheel height adjustment • Push up lever (14/7) • Adjust steering-wheel height • Release lever HM32-014 010831 Fig. 14 Operation TW85...

  • Page 46: Heating / Ventilation / Air-Conditioning

    2-3 minutes to allow the hot air (stored heat) to escape. • Keep windows and doors closed. • It is recommended to cool down the vehicle interior temperature by no more than 6 to 8°C below outside temperature. TW85...

  • Page 47: Light Switch

    • Pull the window back approx. 10 cm. vue vers l’avant • Lock the lever in the guide rod. view to the front Ansicht nach vorn Ansicht nach oben view to the top vue vers le haut HR32-015 Fig. 16 Front windshield TW85...

  • Page 48: Travel Operation

    (For example, in the Federal Republic of Germany, StVZO and StVO). TW85 AL: While driving on roads, the all- wheel steering must be deactivated. See chapter 4.7.2 36 38 4.7.1 Driving...
  • Page 49 • Switch on the working hydraulics (18/52) • TW85, TW85 : Travel range switch (18/58) to "work" (turtle) • TW85 AL: Travel range switch (18/64) to "work" (turtle normal steering or 4WS or "crab steering") • TW85 : Select speed range I (18/65) Observe the indicator light (17/67) •...

  • Page 50: Steering

    In the event of steering malfunctions, determine the cause immediately (see Trouble-Shooting Table chap. 8) and call for service personnel if necessary. TW85, TW85 The wheeled excavator is equipped with a fully- hydraulic jointed front axle and an emergency steering system.
  • Page 51 "straight position." • Straight-ahead control lamp (19/35) for front axle lights up • Straight-ahead control lamp (19/34) for rear axle lights up HM32-019-N • Travel range / steering type switch (19/64) set Fig. 19 Operation to crab steering TW85...

  • Page 52: Brakes

    • Swing upper carriage to travel position and peg out with upper carriage swing lock bolts (20/21) • TW85 AL – Set to "normal steering" (see Chapter 4.7.2 Steering) HM32-020-N • Boom up until color marking on the slewing Fig.
  • Page 53 • Close the cab door Drive carefully down gradients, do not press accelerator pedal down to the stop. Before switching out of fast gear into the HM32-022 slow gear, the travel speed must be Fig. 23 Pincer tube for grab reduced. TW85...

  • Page 54: Switching Off The Machine (Parking)

    • Raise exit barrier (25/6) • Windows and doors must be closed and/or locked. • Battery main switch (25/18) set to “0” if necessary If necessary, use chocks to stop the machine from rolling away. HM32-025 Fig. 25 Operation TW85...

  • Page 55: Working Operation Of The Machine 5

    Only in this way is an optimal stability achieved. HM32-030 • Before activation of the "swivel upper carriage" Fig. 30 Operation work function, the upper carriage must be unlocked (30/21) TW85...

  • Page 56: Shifting Of Excavator At High Engine Speed

    Danger of accident! Foot on brake pedal (31/12) Release excavator brake (31/11) 11 12 Switch off the pendulum axle locking (31/62) Switch travel direction (31/15) Ease off brake pedal until machine rolls HM32-031 Fig. 31 Operation TW85...

  • Page 57: Operation Of Work Functions

    To avoid the uppercarriage from drifting sideways when starting to swing, the additional hydrostatic swing brake must be operated. To this purpose, actuate key button (32/69) and keep it actuated until the uppercarriage starts to swing. HR32-032 Fig. 32 Operation TW85...

  • Page 58: Operation (Mono) - Articulation

    When using wide work attachments, e.g. ditch cleaning bucket, pivoting bucket, wide backhoe bucket special attachments, the driver must exercise particular caution when working with the Knickmatik. It can cause damage to persons and/or property. HM32-034 Fig. 34 Operation TW85...

  • Page 59: Operation - Support Legs / Support Plate

    HM32-035 Fig. 35 Operation 5.3.5 Operation – front dozer blade (option) • Change-over switch (36/61) – front dozer blade / support leg, left links left links left gauche HM32-036 Fig. 36 Operation TW85...

  • Page 60: Operation - Additional Control Circuit

    • To do so, set switch for pendulum axle locking to "ON" (38/62) • The indicator light in the switch lights up red. After completing the special work, set switch pendulum axle locking immediately back to "OFF." HM32-038 Fig. 38 Operation TW85...

  • Page 61: Changing Work Attachments

    It may consequently be necessary to carry out readjustments (e.g. to the pressure control valves). TW85...

  • Page 62: Assembly Of Work Attachments

    • The control rod must be kept in the operator’s Fig. 40 Quick-attach system cab. 5.4.2.1 Hydraulic quick-attach system (option) If this Terex machine is equipped with a hydraulic quick-attach system HS 08-3 then the following must be operated. • Two-handed operation (safety switching) is required to operate this.

  • Page 63: Clamshell Grab

    • Connect the swivel motor to the couplings (51/1-additional control circuit) "Open/Close" function to the couplings 51/2- bucket cylinder). When the grab has been dismantled, re- rechts open the ball valves (51/3). right droite HM32-041 Fig. 41 Additional control circuit TW85...

  • Page 64: Hydraulic Rock Breaker

    The pressure force must be applied axial to the rock breaker and perpendicular to the surface of the material. Improper use may lead to severe damage to the rock breaker, holder and HM32-042 the excavator itself. Fig. 42 Additional control circuit TW85...

  • Page 65: Using The Machine For Crane Operations

    A load falling against the cable Fig. 43 Operation • Pulling up at an angle • Moving the earth moving equipment to an area where the ground slopes more • Wind load Avoid these hazards by using the machine cautiously and prudently. TW85...
  • Page 66 • The safety instructions given in chapter 2.16 must Load warning indicator (43/40) rises to the red range. be observed. • An acoustic warning signal (continuous noise) sounds. Overload warning device is working. TW85...

  • Page 67: Recovery And Transport Of The Machine 6

    • Open the "Travel" oil circuit so that the hydrostatic transmission no longer acts as an auxiliary brake. TW85 • Manual transmission to idle position TW85, TW85 AL, TW85 • Release the spring-loaded cylinder. Towing lugs: Front: on the attachment breaker Rear: Eye bolts right and left on under carriage Max.
  • Page 68 Front axle Pull or push switch rod (47/1) to idle position (center position) with appropriate tool. The preselected gear is automatically engaged upon starting the diesel engine and the hydraulic system. HM32-047-N Fig. 47 Manual transmission - idle position TW85...
  • Page 69 • The spring brake cylinder is released with a strong strike from below on the quick release sleeve (48-1/1) toward the cylinder. To activate the spring brake cylinder, release the parking brake. Quick release sleeve locks in place independently. Fig. 48-1 Spring-loaded cylinder New version TW85...

  • Page 70: Loading The Machine Using A Crane

    Be aware of the total transport height. Risk of accident when driving in tunnels, under bridges, etc.! Main dimensions Transport position 6,300 mm 2,450 mm 2,930 mm HM32-051 Fig. 51 Lashing for transport TW85...

  • Page 71: Maintenance And Care 7

    Every 1,000 operating hours After every 1,000 operating hours Chapter 7.8.4 Every 2,000 operating hours After every 2,000 operating hours Chapter 7.8.4 The first date to arrive always applies also applicable if new or overhauled diesel engines are put into operation. TW85...

  • Page 72: Regular Oil Analysis

    500 running hours • Engine oil: 100 running hours Based on the first results, the laboratory recommends the interval for the next sampling. Ask your Terex dealer for an information booklet detailing the scope and procedures of the oil analysis. TW85...

  • Page 73: Inspection Parts And Aids

    MPS085004C Service package every 500-hour-inspection MPS085005C Service package every 1000-hour-inspection MPS085006C Extras Terex hydraulic oil, mineral 4 312 005 050 Terex hydraulic oil, bio-degradable For further information, please contact your Terex dealer Transmission oil (SAE 85 W 90 LS) 4 314 005 775...

  • Page 74: Care And Cleaning

    • When installing the battery, ensure good driving functions carried out. contact of terminal connections. • Only tighten terminal screws so that they are “hand-tight”, to prevent deformation of the terminal cones! TW85...
  • Page 75 A = Summer diesel Petrol shall not be added. B = Winter diesel Danger of explosion! C = Super diesel D = Added proportion of petroleum E = Outside temperature TW85...

  • Page 76: Checking, Maintenance And Inspection Plans

    7 Maintenance and care 7.8 Checking, maintenance and inspection plans 7.8.1 Initial inspection (hand-over inspection) HM32-053-N Fig. 53 Initial inspection TW85...
  • Page 77 Test run, hydraulic function check and test work. Visual inspection of all hoses, pipes, cylinders, etc. for leak tightness Check function of electrical indicating and warning elements, as well as the light system Sign hand-over card and return to manufacturer TW85...

  • Page 78: Daily And Weekly Tasks

    7 Maintenance and care 7.8.2 Daily and weekly tasks Inspection and maintenance jobs to be performed by service personnel HM32-054 Fig. 54 Inspection and maintenance plan TW85...
  • Page 79 Check correct function of pneumatic springs of service covers and front windshield Check function, condition and completeness of safety equipment Check function “Shut-off of the working hydraulics by maintenance ladder” Lubricate the machine according to overview of lubricating points 7.8.3 TW85...

  • Page 80: Overview Of Lubricating Points

    7 Maintenance and care 7.8.3 Overview of lubricating points Replace defective grease nipples immediately and check if grease passes through! HM32-055 011206 20 21 25 26 Fig. 55 Lubrication plan TW85...
  • Page 81 Door hinges for maintenance ladder Special equipment Clamshell grab Swing bucket Hydraulic cylinders of swing bucket In the case of special operating conditions, e.g. working on sandy ground, the lubrication intervals should be shortened, in order to encourage self-cleaning of bearing points. TW85...

  • Page 82: Inspection Plan

    Check electrical indicating and warning elements as well as lighting equipment. Check smooth running of operator controls and adjust if necessary Check function of hydraulic axle locking and bleed 7.9.11 plunger cylinders Check correct function of steering TW85...
  • Page 83 Sign inspection card and return to manufacturer 1) at least every 2 years 2) Extension of oil change intervals according to oil sample analysis and laboratory report For further information see section 7.3. 3) under warranty 4) every 5 years or 5,000 running hours TW85...

  • Page 84: Inspection And Maintenance Work

    • Top engine oil up to the “MAX” mark on the dipstick • Start the engine and run at idle speed for approx. 2 min. • Stop the engine. • Check the oil level and top up if necessary TW85...

  • Page 85: Engine Oil Filter

    • With one more half turn, tighten the filter cartridge. HR42-042 • After a test run, check the tightness of the Fig. 58 Engine oil filter engine oil filter cartridge. TW85...

  • Page 86: Cooling System - Combined Hydraulic Oil/Water/Charge Air Cooler

    • If necessary, e.g. in case of an oiled cooler, clean with cold cleaner or a steam jet device. HR32-045 • After cleaning, the engine must be brought to Fig. 60 Cooler operating temperature in order to dry the cooler. TW85...
  • Page 87 Technical data section 3.9) and close the cap. • Start the engine and bring to operating temperature; turn off the engine and allow to HR32-046 cool. • Check the coolant level and top up (several Figure 61 Engine block times, if necessary). TW85...

  • Page 88: Fuel System

    • After a test run, check for tightness. Fig. 63 Fuel filter Fuel tank • Drain water from the fuel tank via the drain plug (64/1). • Clean the filler screen (64/2) and check for damage. HM32-064-1 Fig. 64 Fuel tank TW85...
  • Page 89 • Check that the filter insert is undamaged and that there is no dirt on the inside. • The insert is ready to be re-installed. TW85...

  • Page 90: Air Filter, Air Intake

    Hold tight with the right hand on the support HM42-066 handle (66/2) and step onto the upper stage of the ascent. Fig. 66 Air filter maintenance • The air filter cartridge (66/3) can be changed while standing on the ascent. TW85...
  • Page 91 • after 2 years of operation at the latest • if the service indicator switches on after the main cartridge has just been serviced HM32-067 • if the main cartridge is damaged Fig. 68 Operation • if the safety cartridge is defective TW85...
  • Page 92 • Grasp the safety cartridge (69/3) by the two clips (69/6), withdraw by moving slightly to and fro, and dispose of it. HM32-068 • Insert a new safety cartridge and check that it is correctly positioned. Fig. 69 Air filter • Re-install the main cartridge. TW85...
  • Page 93 Tears and HR32-054 perforations in the paper bellows can be determined using a torch. Fig. 70 Cleaning the main cartridge Never continue to use damaged main cartridges. If in doubt, use a new one. TW85...

  • Page 94: V-Belt

    Tensioning V-belts – Generator • Slacken the fastening screws (71/3, x3) of the generator (71/5). HR42-056 • Adjust the generator using the screw (71/4) until Fig. 71 V-belt the V-belt tension is correct. • Re-tighten the fastening screws (71/3). TW85...

  • Page 95: Hydraulic Oil Tank

    • Fill with clean hydraulic oil up to the correct 5 = Drain level on the sight glass (74/1). • Re-mount the filter cover. • Screw back in the breather. • Check the tightness of filter and drain plug. TW85...

  • Page 96: Hydraulic Oil Return Filter

    • Install the filter bowl in the tank, together with the new insert. • Apply a light coat of grease to the cover and tighten the cover by hand. • Screw back in the breather. • Check the tightness of the filter. HR32-062 Fig. 76 Return filter TW85...

  • Page 97: Hydraulic Oil Suction Filter

    O-ring (77/3) is in exactly the right position. • Retighten the filter cover with auxiliary tool. HM32-077 • Screw back in the breather. Fig. 77 Suction filter • Check the tightness of the filter by means of a test run. TW85...

  • Page 98: Hydraulic Oil Tank - Breather

    7.9.10 Hydraulic oil tank - breather • Remove the breather (74/2), replace it by a new one and tighten so that it is hand-tight. Replace the filter if the cap is dirty, e.g. due to oil fumes. HM32-074 Fig. 74 Hydraulic oil tank TW85...

  • Page 99: Bleeding The Plunger Cylinders

    • Switch off the engine; switch on the ignition. • Operate the support leg’s control lever. The function is correct when the controls do not move the support leg! HM32-079 Fig. 79 Plunger cylinder TW85...

  • Page 100: Axles

    • Screw back on the drain plug carefully. • Pour in oil using the filling hole (81/3) until oil HM32-081-N escapes from the inspection hole (81/1). Front axle differential Fig. 81 • Carefully close the filling and inspection plugs. TW85...
  • Page 101 • Flush out the axle if necessary. HML32AL • Carefully close the drain plugs. • Pour in oil using the filling hole (82/3) until oil escapes from the inspection hole (82/1). • Carefully close the filling and inspection plugs. HM32-082-N axle differential Fig. 82 Rear TW85...
  • Page 102 • Flush the transmission if necessary. • Screw back on the drain plug carefully. HML32S • Pour in oil using the filling and inspection hole (83/1) until oil escapes. • Carefully close the filling and inspection plug. HM32-083-N Fig. 83 Transmission TW85...
  • Page 103 Maintenance and care 7 7.9.13.4 Wheel hub Front axle TW85, TW85 , TW85 AL and rear axle TW85 ALChecking oil level wheel combined inspection, filling and drain hole. • Move the wheel hub to the inspection position. • Remove the screw plug, check and top up oil if required.

  • Page 104: Brakes

    7.9.14 Brakes Vorderachse/Front axle - HML32, HML32AL, HLM32S Hinterachse/Rear axle - HML32AL Front axle TW85, TW85 , TW85 AL and rear axle TW85 AL Checking function of brake disc play • Apply the parking brake (86/63). • Open the inspection hole (85/1).
  • Page 105 Dispose of according to regulations! • Close bleeder screws. • Open bleeder screws (TW85, TW85 - 87/3; TW85AL – 87/4) on the two brake housings of the rear axle one after the other until the braking...

  • Page 106: Wheels

    (type A 22) daily, and subsequently at regular intervals, and tighten to the required torque if necessary. Fastening torque: 610 Nm When changing a wheel, always tighten the wheel nuts to the specified torque crosswise in several steps TW85...

  • Page 107: Swing Gear

    (90/3) mounted in the driver’s cab and through a lubricating pipe (90/4). • Slowly slew the uppercarriage to the left and right, and lubricate it thoroughly until both gaskets (90/5) have a collar of fresh grease. HM32-090 Fig. 90 Swing connection TW85...
  • Page 108 Damaged screws must be replaced by new ones! • All accessible screws must be examined to ensure that they are tightened to the torques specified in figure 91. M A = 325 Nm M A = 325 Nm HM32-091-N Fig. 91 Tightening torques TW85...

  • Page 109: Cab Ventilation Dust Filter

    Fig. 92 Cleaning the dust filter for cab ventilation 7.9.19 Windshield washer system • Topping up the windshield washer tank (93/1) as required. • Add antifreeze when temperatures are around or below freezing. HM32-093 Fig. 93 Windshield washer tank TW85...

  • Page 110: Electrical Equipment

    Ensure that the negative terminal is attached to the negative pole (-) and the positive terminal to the positive pole (+). • Install cover (94/1). In winter, in particular, take care to ensure that the HM32-094 02-11-07 battery is well charged. Fig. 94 Battery TW85...

  • Page 111: Taking Out Of Service

    • Seal off the air intake opening of the air filter suction filters as well as breathers have been out of use for more than 6 months, they must system and the exhaust pipe opening. be replaced. • Lubricate machine according lubrication plan. TW85...
  • Page 112 7 Maintenance and care TW85...

  • Page 113: Troubleshooting 8

    Mechanical fault Repair 8.5 Parking brake without function Spring-loaded brake mechanically Activate spring-loaded brake unblocked Hydraulic fault in spring-loaded brake Repair actuation 8.6 Insufficient performance of swing brake Brake pads worn Change brake pads Fault when actuating the brake Repair TW85...

  • Page 114: No Zero Position Of Travel Direction

    Check, re-adjust or repair Adjusting motor not adjusting Adjustment start is set too high. Mechanical damage on controller or adjustment. Adjust or call Service Agent Internal damage to variable displacement Replace unit pump or variable displacement motor TW85...

  • Page 115: Hydrostatic Travel Drive Works In One Direction Only

    Check pressure and troubleshoot interrupted Mechanical damage variable Check, call Service Agent if necessary displacement pump and/or engine Internal damage to variable displacement Replace unit completely pump or variable displacement motor Mechanical connection between variable Check, repair displacement motor and axle interrupted TW85...

  • Page 116: Excavator Installation Not Working

    Top up hydraulic oil to the mark Incorrect hydraulic oil Quality of hydraulic oil must conform to our recommendation Air in hydraulic system Tighten connections with engine off and system relieved of pressure Oil cooler dirty or damaged Clean, check and replace if necessary TW85...

  • Page 117: Uppercarriage Slewing Too Far

    8.18 Faults in the overload warning device No optical display Overload warning sensor or display module defective. Call Service Agent No acoustic warning Overload warning sensor is not switched on. Overload warning sensor or display module defective. Call Service Agent TW85...

  • Page 118: Faults In The Electrical System

    Determine the fault or source of the problem, get problem fixed by specialist if necessary Starting system does work Check charge capacity of battery. satisfactorily Test starter function. Check connection and condition of power and battery ground cables Check function of ignition lock, replace if necessary TW85...

  • Page 119: Appendix 9

    K 02 Starting relay auxiliary fitting K 03 Preheat relay Travel, parking brake, reverse Working floodlight, front travel spotlight, brake light Working floodlight, rear switch assigned (Air-conditioning Working hydraulics option) Brake light Flasher transmitter Warning blinker High beam light TW85...

  • Page 120: Immobilizer

    15. This makes it necessary to first open the mechanical locking system before the electronic key is inspected. A manipulation of the immobilizer with the ignition deactivated is thereby impossible. TW85...

  • Page 121: Learning Multiple New Keys

    • All learned keys are cleared and all available keys can be relearned. • The master key code is not deleted during the clearing process. This function is only available if the control unit relay additionally connected to terminal 30. TW85...

  • Page 122: Fault Causes

    Key to be learned does not have transponder Defective antenna Learning time for key in ignition too short Clearing of learned keys not possible No or incorrect master key used (red grip) Time for master key in ignition lock too short Defective antenna TW85...
  • Page 123 3. Warranty • Explanation of warranty stipulations • Explanation of inspection cards and note on maintenance and inspection plan. • Explanation of how to fill out the warranty/handing-over card correctly and how to return to Terex...
  • Page 124 I n s p e c t i o n p l a n O = Checking, maintenance X = Replace Operating hours W o r k t o b e c a r r i e d o u t b y t r a i n e d s p e c i a l i s t d e a l e r p e r s o n n e l Perform work with machine at operating temperature after every...

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