tc20

Crawler Excavators
CRAWLER EXCAVATORS

OPERATING INSTRUCTIONS
tc20

Language versio: EN

Edition: 2012-09

Order number: 5780210563

From vehicle ID No: TC00200809>

Original operating instructions

 ®
Terex Deutschland GmbH
Geschäftsbereich Compact
Kraftwerkstraße 4
74564 Crailsheim
Germany
Phone +49(0)7951 9357-0
Fax +49(0)9357-671
E-Mail: info@terex-compact.com
www.terexconstruction.com

Please complete before commissioning the crawler 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 /
plant operator.
 Table of contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Warranty and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Notes on using the Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Regulations concerning environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Safety and Accident Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.1 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Preliminary remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 General safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7 Transport of persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.9 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.10 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.11 Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.12 Danger of falling objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.13 Working in the vicinity of underground power lines . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.14 Working in the vicinity of overhead power lines . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.15 Operation in closed spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.16 Work stoppages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.17 Load hook applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.18 Change of work attachments, maintenance, repair . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.19 Recovery, Loading and Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.20 Monitoring and inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.21 Fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.22 Notes concerning residual dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.1 Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1.1 Digging envelope with 1 100 mm and 1 300 mm dipperstick . . . . . . . . . . . . . . . . . . . 21
3.1.2 Views with cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.4 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.6 Fuels, lubricants, and coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6.1 Fluid capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6.2 Fuel, lubricant, and coolant specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.7 Specific ground pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.8 Sound level values, vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.9 Dimensions and operating weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.10 Carrying capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.11 Working range for grab operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.12 Work attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.13 Optional accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
4.1 Initial familiarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2 Display elements and operator controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Operating Manual Crawler Excavator TC20 3

Table of Contents
4.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3.2 Monitoring the machine during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3.3 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4 Driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.5 Heating/ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.6 Front window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.7 Driving and steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.8 Track width adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.9 Operations with rubber crawler chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.10 Switching off the machine (parking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5 Working operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 Work functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1.1 Mode of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1.2 Work function: Articulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1.3 Work function: Dozer blade and track width adjustment . . . . . . . . . . . . . . . . . . . . . 49
5.1.4 Work function: Additional control circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.2 Changing work attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.2.1 Installation and removal of work attachments . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.2.2 Hydraulically actuated additional work attachments . . . . . . . . . . . . . . . . . . . . . . . 52
5.2.3 Clamshell grab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.2.4 Hydraulic rock breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.3 Removing the cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6 Recovery, Loading and Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.1 Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2 Loading the machine by use of a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7 Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.1 Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.2 Regular oil analyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.3 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.4 Inspection parts and aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.5 Care and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.6 Notes for winter operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.7 Checking, maintenance and inspection plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.7.1 Initial inspection (Handing-over inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.7.2 Daily and weekly tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.7.3 Overview of lubricating points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.7.4 Inspection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.8 Inspection and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.8.1 Opening and closing the engine hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.8.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.8.3 Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.8.4 Engine - cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.8.5 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.8.6 Air filter, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.8.7 V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.8.8 Valve lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.8.9 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.8.10 Hydraulic oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.8.11 Hydraulic oil return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4 Operating Manual Crawler Excavator TC20

 Table of contents
7.8.12 Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.8.13 Crawler gear units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.8.14 Brake valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.8.15 Crawler chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.8.16 Swing bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.8.17 Swing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.8.18 Windshield washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.8.19 Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.9 Immobilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.9.1 Preservation (temporary immobilization ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.9.2 During immobilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.9.3 After immobilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8 Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
8.1 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.2 Table of faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
9.1 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.2 Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.3 Handing over the Machine and Instructing the Operator . . . . . . . . . . . . . . . . . . . . . . . 95
9.4 Maintenance and Inspection Plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Operating Manual Crawler Excavator TC20 5

Table of Contents

6 Operating Manual Crawler Excavator TC20

 Introduction 1

1 Introduction

You have chosen a Terex TC20 crawler excavator.

The confidence placed in this model will be rewarded

by the efficient and economical performance of the
machine.

These Operating Instructions contain all information

necessary for the correct use of the machine.

This Instruction Book is intended for use by personnel

responsible for operation, maintenance, repair and
supervision of the machine.

Please read it carefully before putting the machine

into operation and make sure that it is kept at hand at
all times.

Should you need further explanations or should

anything be unclear, please contact your dealer 1
immediately.

Special equipment and attachments are not included

in these Operating Instructions.

We reserve the right to make improvements on the

machine within the scope of impending technical
developments, without incurring any obligation to
change these Operating Instructions.

Attention HR1.6-05-01

Any modifications of Terex products and their

Fig. 1 Type label
equipment using extras and work
attachments which are not included in our
product range require our written approval. If
our approval is not sought, our warranty
expires, as does our product liability for any
resulting consequential damage.

Please state the vehicle type and vehicle

identification number when making inquiries or
orders, and in all written correspondence.

Attention
The vehicle identification number of the
machine is stamped onto the type label (1/1).

Operating Manual Crawler Excavator TC20 7

1 Introduction
1.1 Warranty and maintenance 1.2 Copyright

The warranty period covers twelve months, beginning This Operating Manual is copyrighted. It must not be
with the day the machine is handed over or put into copied, disseminated or used for competitive
operation. purposes, either fully or in part, without prior written
permission.
Safe working conditions and good working order of
the machine are prerequisites for efficient work. Your
Terex crawler excavator fulfils these requirements
when correctly handled and when serviced and 1.3 Notes on using the Operating
maintained as specified. Instructions
Careful observation of the machine whilst in function
Presentation of Figures and Positions
and the use of the specified lubricants will prevent
malfunction. (1/1) = Figure 1, Item number 1
Trained specialist personnel are responsible for any
Presentation of cross references to Chapters and
servicing of the machine which requires expert
activities
knowledge. Inspections and repairs must therefore be
carried out by your dealer’s customer service. Î 1.3, 8 = Chapter/Section 1.3, Page 8
In respect of possible claims for damages during the
Pictogram "Danger to life"
warranty period, all work specified in the maintenance
and inspection plan must be carried out at the
Danger to life
specified intervals.
This indicates a potential danger represented
After the warranty period, too, regular maintenance by the machine which, if appropriate
must be performed in order to ensure that the precautions are not taken, may result in
machine is constantly in good working order and death.
enjoys a reasonable service life.

Insist that only original Terex spare parts are used in Pictogram "Danger of injury/machine damage"
the event of any repair work. In this way, you will have
a product of lasting high quality, thereby ensuring that Danger of injury/machine damage
your machine maintains its original condition. This indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury, or
property/equipment damage.

Pictogram "Attention"

Attention
This symbol is employed for information
containing important notes about the correct
use and/or how to proceed. Non-compliance
may lead to malfunction.

8 Operating Manual Crawler Excavator TC20

 Introduction 1
1.4 Regulations concerning
environmental protection

Applicable environmental requirements must be

observed for all tasks performed on and with the
machine.

During installation, repair and maintenance tasks,

particular care must be taken that substances that
would damage the environment such as
– lubricating greases and oils
– hydraulic oils
– fuels
– coolant
– cleaning fluids containing solvents

do not seep into the ground or the sewerage system.

These substances must be kept, transported,

collected and disposed of in suitable containers.

If the substances listed above do reach the soil, the

leak or outlet must be stopped immediately and the
fluid must be cleaned up with a suitable absorbent
material. If necessary, the soil involved must be
removed. Absorbent materials and removed soil must
be disposed of properly. Applicable environmental
requirements must be observed.

Operating Manual Crawler Excavator TC20 9

1 Introduction
1.5 Pictograms

The following Table explains the meaning of the

pictograms which may be attached to your machine.

Symbol Description Symbol Description

Danger to life Windshield washer and wiper system

On machine: Travel speed, FAST

Caution, safety distance
In Operating Instructions:
Danger of injury/machine damage
Attention Travel speed, SLOW

Battery charge indicator Horn

Preheating Working floodlight(s)

Engine oil pressure Rotating beacon

Engine oil level Dozer blade

Coolant temperature Hydraulic rock breaker

Air filter Working hydraulics shut-off

Fuel, fuel level Fire extinguisher

Hydraulic oil Danger of injury

Hydraulic oil level

Hydraulic oil filter clogging indicator Observe notes in Operating Instructions

Fan for heating/ventilation Grease gun

Air conditioning system

Tab. 1 Pictograms on the machine

10 Operating Manual Crawler Excavator TC20

 Safety and Accident Prevention 2

2 Safety and Accident Prevention

2.1 Declaration of Conformity

Declaration of Conformity
The machine complies with the
fundamental requirements stipulated in
the applicable European guidelines.
Conformity has been proven. The
respective documents and the original of
the Certificate of Conformity are kept by
the manufacturer.
A copy of the Certificate of Conformity is
attached to the sales documents.

EC declaration of conformity
according to the machinery directive 2006/42/EC
1. We hereby declare that the earth-moving machine of type TC 20:
Crawler excavator: TC 20
Vehicle ID No.: TC0020
Actual productivity: 13.1 kW

2. complies with all the relevant requirements of Machinery Directive 2006/42/EC.

3. The machine also complies with the relevant requirements of the following directives:
2004/108/EC (EMC), 2000/14/EC Annex VIII (noise emission), 97/68/EC (exhaust
emissions)

4. Representative sound power level:

92.9 dB (A)

5. Guaranteed sound power level:

93 dB (A)

6. Applied harmonized standards:

EN ISO 12100
EN 474-1
EN 474-5

7. Document editor, who is authorized to compile technical documentation:

Maik Schulze, Kraftwerkstr. 4, D-74564 Crailsheim, Germany

8. Conformity assessments according to RL 2000/14/EC appendix VIII and voluntary type

examination by: DGUV Test testing and certification office
Technical Committee
Landsberger Straße 309
D-80687 Munich, Germany
Notified Body number: 0515

The EC declaration of conformity only applies if the earth-moving machine is used in accordance
with the operating instructions. It includes the use of original Terex work attachments and other
work attachments, which are mentioned in the operating instructions or in other Terex
documentation for application at this earth-moving machine.
Replaceable equipment manufactured by Terex or third party manufacturers may only be installed
and used if the installation at the affected earth-moving machine is performed by Terex. In all other
cases, special written approval is required from Terex.

Date of the declaration of conformity 01.12.2011

Crailsheim

Operating Manual Crawler Excavator TC20 11

2 Safety and Accident Prevention
2.2 Preliminary remarks 2.3 Proper use

Before putting the earth-moving machine into The earth-moving machine with standard bucket
operation, read these Operating Instructions carefully equipment is intended solely for work which is
and strictly observe the indicated references for safe suitable for the function of the machine and its work
operation. implements.

National safety regulations - e.g. the Accident Such work involves loosening, taking up, transporting
Prevention Regulations, “Earth-Moving Machinery” and dumping soil, rock or other materials as well as
(VBG 40) and “Vehicles” (VBG 12) in the Federal loading these materials on trucks, conveyor belts or
Republic of Germany - must also be complied with other means of transport.
when operating the earth-moving machine.
The assembly of special work implements such as
In addition to the Operating Instructions, legal clamshell grab, hydraulic rock breaker, etc. allows the
regulations governing road traffic and road safety machine to perform above mentioned work.
measures must also be observed. Such requirements
could also apply in respect of handling hazardous Any usage above and beyond that specified here, e.g.
goods or the wearing of personal safety gear, for the transport of persons or the transport of loading
example. material and any non-compliance with the
manufacturer’s instructions is regarded as improper
Furthermore, safety laws governing work in particular use. The supplier cannot be held responsible for any
locations (tunnels, adits, quarries, pontoons, damage resulting from improper use. This risk is
contaminated areas, etc.) must likewise be observed. borne solely by the user.

Compliance with the Operating and Maintenance

Instructions, the performance of maintenance work as
specified and adherence to replacement intervals all
form part of the concept of proper use.

12 Operating Manual Crawler Excavator TC20

 Safety and Accident Prevention 2
2.4 General safety notes 2.5 Operation

– It is important to refrain from any working methods Earth-moving machines are only to be independently
which impair safety. operated and serviced by persons who:
– The earth-moving machine may only be operated – are physically and mentally suitable
with cabin or canopy.
– have been instructed in the operation or
– The earth-moving machine is only to be used if it maintenance of earth-moving machines and have
is in a safe, operational condition. demonstrated this ability to the plant operator
– The manufacturer’s instructions must be complied – can be expected to perform their allocated duties
with for operation, maintenance, repair, assembly, reliably.
and transportation.
All such persons must be of the legal minimum age.
– The plant operator must provide additional special
safety instructions, wherever necessary, for They must be designated by the plant operator to
specific local conditions. operate or service the earth-moving machine.

– The Operating Instructions and any information Operating equipment and controls are only to be
pertaining to safety must be carefully kept in the operated from the driver’s seat.
driver's cabin.
The earth-moving machine is only to be ascended
– The Operating Instructions and safety notes must and entered using the entrances and surfaces
be complete and fully readable. intended for this purpose.
– Safety equipment on earth-moving machines must It is the driver’s responsibility to ensure that the
not be deactivated or removed. operator’s stand, entrances and other surfaces of the
– Protective clothing must be worn during operation. earth-moving machine which have to be stepped on
Rings, scarves and unbuttoned jackets are to be are kept free of dirt, grease, oil, ice, and snow.
avoided. Protective goggles, protective boots,
helmets, gloves, reflecting jackets, ear-muffs, etc.
may be required.
– Before commencing work, information must be
obtained on first aid and possible means of rescue
(emergency ambulance, fire brigade, helicopters).
– A check must be carried out to ensure that the first
aid box is at hand and that its contents comply with
regulations.
– Personnel must be aware of the location and
method of operation of the fire extinguishers on
the earth-moving machine as well as on-site fire-
warning and fire-fighting equipment.
– Loose parts such as tools or other accessories
must be secured to the earth-moving machine.
– Open doors, windows, covers, flaps, etc. must be
closed or secured against slamming shut if in an
open condition.

Operating Manual Crawler Excavator TC20 13

2 Safety and Accident Prevention
2.6 Danger zone 2.8 Stability

– Nobody must be allowed to remain in the danger – The earth-moving machine must be used, driven
zone of an earth-moving machine. and operated in such a manner that its stability
against overturning is ensured at all times.
– The danger zone encompasses the area around
the earth-moving machine in which persons may – The machine operator must drive at speeds which
be injured by movements of the earth-moving are suitable for local conditions.
machine during operation, its work implements
– The permitted payload of the earth-moving
and attachments, or by swinging out or falling
machine must not be exceeded.
loads.
– The earth-moving machine must remain at a
– The machine operator is only to work the earth-
sufficient distance from the edges of quarries, pits,
moving machine if nobody is in the danger zone.
mounds and slopes to ensure there is no risk of
– The machine operator must give a warning signal falling. If this is not possible, it must be secured to
to persons who may be in danger. prevent rolling or slipping.
– The machine operator must stop work with the
earth-moving machine if someone remains in the
danger zone despite the warning.
– To ensure no danger of crushing, a sufficient
safety distance (min. 0.5 m) must be kept from
solid objects, e.g. buildings, excavation slopes,
scaffolding, other machines, etc.
– If the above safety distance cannot be maintained,
the area between solid objects and the working
zone of the earth-moving machine must be
blocked off.
– If conditions are such that the machine operator’s
view of the driving and working zone is restricted,
he must be guided or the driving and working zone
must be marked by a solid barricade.

2.7 Transport of persons

The transport of persons on the machine is forbidden.

14 Operating Manual Crawler Excavator TC20

 Safety and Accident Prevention 2
2.9 Driving 2.10 Operation

Before putting the earth-moving machine into Daily before commencing work and after every
operation, the driver's seat, mirrors and operator change of work attachments, the machine operator
controls must be adjusted so as to ensure safe must check the correct fastening of the work
working. attachment as well as the correct lock of the quick-
attach system (QAS). Work attachments are to be
A safety belt (seat belt), if installed, must always be carefully moved at low height. During this check
fastened. nobody must be allowed to remain in the danger zone
The windows must be clean and free of ice. of the earth-moving machine.

Driving tracks must be designed so as to ensure The machine operator may only swing the work
smooth, safe operation, i.e. they must be sufficiently equipment over occupied drivers' seats, operator
wide, on ground which has as few slopes as possible consoles and workplaces of other machines if these
and sufficient carrying capacity. Downhill tracks must are protected by canopies (FOPS).
be set out in such a way that earth-moving machines If a cabin does not have the required protection, the
can be safely braked. driver of this vehicle must leave the operator’s stand
Downhill tracks must be set out in such a way that while the work equipment is being swung overhead.
earth-moving machines can be safely braked. The vehicles must be loaded in such a manner as to
Before driving downhill, the appropriate gear for the ensure that there is no overloading and no material
terrain must be selected and the gear lever not be can be lost as long as the machine is moving. The
moved during downhill travel (road or off-road gear). vehicle must be loaded from the lowest possible
height.
On steep drops and uphill gradients, the load must be
carried on the uphill side, if possible, in order to At dumping points, earth-moving machines may only
increase stability. be operated if suitable measures have been taken to
prevent rolling or falling.
The carrying capacity of bridges, cellar roofs, vaults,
etc. must be verified before the earth-moving
machine can drive over them.
2.11 Guides
The internal dimensions of constructions must be
noted before entering underground passages, Guides must be easily recognizable, e.g. by means of
tunnels, etc. reflective clothing. They must remain within the
machine operator’s field of vision.
It is the plant operator's responsibility to ensure that
equipment such as first-aid box, warning triangle, While guiding the machine, guides shall not be given
hazard lights are kept with the earth-moving machine other jobs which may distract them from their task.
according to the traffic regulations valid in the user’s
country and that the driver has the appropriate license
as required by the national traffic laws of the country
in question.

Outside areas covered by general traffic regulations,

e.g. on construction sites, traffic regulations should be
applied in the proper manner. This should also apply
with regard to drivers’ licenses.

Operating Manual Crawler Excavator TC20 15

2 Safety and Accident Prevention
2.12 Danger of falling objects 2.14 Working in the vicinity of overhead
power lines
Earth-moving machines are only to be used where
there is a danger of falling objects if the operator’s If the earth-moving machine is being used in the
stand has a canopy (FOPS). A front guard must be vicinity of overhead power lines and trolley wires, a
employed if there is a risk of materials breaking safety distance which varies depending on the
through into the cabin. nominal voltage of the overhead line must be
maintained between the lines and the earth-moving
In front of walls e.g. of stacked materials, earth-
machine and its work equipment, to prevent current
moving machines must be positioned and operated in
overspill. This also applies to the distance between
such a way that the driver's seat and entry to the
these lines and attached implements or loads.
driver's seat are not situated on the side facing the
wall. The safety distances specified below must be
complied with.
Demolition work is only to be performed by earth-
moving machines where there is no danger to Nominal voltage Safety distance
persons and if the machine is equipped with canopy, in kV in meters
cabin-mounted front guard and the appropriate work –1 1.0
implement. >1 to 110 3.0
See regulations book "Demolition work" (ZH 1/614) >110 to 220 4.0
published by the German Tiefbau- >220 to 380 5.0
Berufsgenossenschaft (Civil Engineering Employer’s nominal voltage unknown 5.0
Liability Insurance Association).
Tab. 2 Prescribed safety distances

In the observation of safety distances, all working

2.13 Working in the vicinity of movements of earth-moving machines, e.g. positions
underground power lines of the work equipment and the dimensions of
attached loads must be taken into consideration.
Uneven ground which would cause the earth-moving
Before commencing excavating work using earth-
machine to be inclined and thus nearer to overhead
moving machines, it must be determined whether any
lines must also be taken into account.
underground power lines are present in the intended
working zone which may present a danger to During work in windy conditions, both overhead lines
persons. and work equipment may swing out, thus reducing the
safety distance.
If underground power lines are present, their exact
position and course must be determined in If it is impossible to maintain sufficient distance from
consultation with the proprietor or operator of the overhead power lines and trolley wires, the plant
lines, and the necessary safety precautions decided operator must consult with the proprietor or operator
and implemented. of the overhead lines to find other safety precautions
to prevent current overspill. Such measures could be,
The course of power lines in the work area must be e.g.
clearly marked, under supervision, before
commencing any excavation work. If the position of – Switching off the current,
lines cannot be determined, search ditches must be
– Re-routing the overhead line,
dug - manually, if need be.
– Cabling, or
If underground power lines are encountered
unexpectedly or they or their protective covers are – Limiting the work zone of earth-moving machines.
damaged, the machine operator must discontinue
work immediately and notify the supervisor.

16 Operating Manual Crawler Excavator TC20

 Safety and Accident Prevention 2
2.15 Operation in closed spaces 2.17 Load hook applications

If earth-moving machines are to be used in closed Load hook applications are the hoisting, transporting
spaces, these areas must be sufficiently ventilated and lowering of loads with the aid of a fixing device
and special regulations observed. (rope, chain, etc.), whereby the assistance of
personnel is required to attach and release the load.
Such work covers e.g. the lifting and lowering of
pipes, tubbing rings or containers using earth-moving
2.16 Work stoppages
machines.

Before rest periods and at the end of the working day, Earth-moving machines are only to be used for load
the driver of the earth-moving machine must park the hook applications if the prescribed safety devices are
machine on ground which has sufficient carrying present and in full working order. For earth-moving
capacity and is as level as possible, and must secure machines, these are:
it against unintended movement.
– Secure attachment of loading implements
Before rest periods and at the end of the working day, – Table of carrying capacity
the driver must lower the work equipment onto the
ground or secure it so that it cannot move. – Overload warning device 1

The driver is not to leave the earth-moving machine if – Hose-rupture valve on boom cylinder 1
the work equipment has not been lowered to the 1
Only if the permissible carrying capacity exceeds 1000 kg.
ground or secured.
Loads must be attached in such a way that they
Earth-moving machines are only to be parked in cannot slip or fall out.
places where they do not present an obstacle to
others, e.g. on the construction site or to plant traffic. Personnel guiding the machine and attaching loads
Warning devices, e.g. triangles, warning cordons, must always remain in the machine operator’s field of
flashing or hazard lights are to be used if necessary. vision.

Before leaving the operator stand, the driver must The machine operator must carry loads as close to
bring all operating equipment and controls into home the ground as possible and prevent them from
position, switch off the working hydraulics and apply swinging.
the brakes. Earth-moving machines may only move with an
If the driver is leaving the earth-moving machine attached load if the path of travel is fairly level.
unattended, he must first turn off the engine and If earth-moving machines are used for load hook
ensure that it cannot be started up by unauthorized applications, personnel attaching loads is only to
persons (e.g. removing ignition keys). approach the boom from the side and with the
machine operator’s permission. The machine
operator is only to give his permission if the earth-
moving machine is standing still and the work
equipment is not in motion.

Do not use fixing devices (ropes, chains, shackles)

which are damaged or of inadequate dimensions.
Protective gloves must always be worn when working
with fixing devices.

Operating Manual Crawler Excavator TC20 17

2 Safety and Accident Prevention
2.18 Change of work attachments, • Before working on the electrics or when
maintenance, repair performing arc-welding on the machine, the
connection to the battery must be disconnected.
Earth-moving machines are only to be converted, • When disconnecting the battery, first the negative
maintained or serviced under the guidance of a pole then the positive pole must be disconnected.
suitable person designated by the plant operator and The battery must be re-connected in reverse
following the manufacturer’s Operating Instructions. order.

After every change of work attachments, the driver • During repair work around the battery, it must be
must convince himself that the quick-attach system is covered with insulating material. Tools should
correctly fastened and locked never be placed on or near the battery.

Work on e.g. Protective devices of moving machine parts are only

to be opened or removed after the drive has been
– braking, switched off and cannot be switched on again by
– steering, unauthorized persons. Protective devices are e.g.
engine/motor covers, doors, protective grating, trim.
– hydraulic and
Upon completion of assembly, maintenance or repair
– electric systems
work, all protective devices must once more be
of the machine is only to be carried out by expert attached in the proper manner.
personnel specially trained in these areas.
Load-bearing parts of earth-moving machines are
Stability must be ensured during all type of work on only to be welded following consultation with the
the machine at all times. manufacturer and in accordance with recognized
welding principles.
The machine must be suitably secured by chocks so
that it cannot roll away whenever work is performed, Protective structures (ROPS; FOPS) are not to be
particularly under the machine. welded or drilled in any way.

The work equipment must be secured against Alterations, such as welding of the hydraulic system,
movement by lowering it to the ground or equivalent are only to be undertaken with the manufacturer’s
measures, e.g. cylinder supports, trestles. As long as permission.
the engine is running, the unprotected working range
Before commencing work on the hydraulic system,
must not be entered.
the operating pressure, pilot pressure, back pressure
When jacking up earth-moving machines, jacking and pressure inside the tank must be let off.
devices must be positioned so that they cannot slip.
Swallowing lubricants as well as long and repeated
Jacks must be positioned and applied absolutely
skin contact can be hazardous to health and should
straight, without tilting.
therefore be avoided. When used properly, there is no
Raised earth-moving machines must be supported by particular danger to health. The safety specification
suitable structures such as crosswise stacks of sheets from the mineral companies must be
planks, square timbers or steel trusses. observed.

Earth-moving machines which are raised with work Only the hoses specified by the manufacturer may be
equipment must be stabilized by a supporting used.
structure immediately after lifting. Work under raised
Hydraulic hoses must be routed and assembled by
machines which are only supported by their
expert personnel.
hydraulics is forbidden.
In the vicinity of fuel or batteries, smoking and naked
The engine/motor(s) must be turned off prior to all
flames are prohibited.
maintenance and repair work. These requirements
may only be ignored in the case of maintenance or
repair work which cannot be performed without the
engine/motor(s) running.

When performing maintenance and repair work on

the hydraulic system, the hydraulic system must be
relieved of pressure. With the engine turned off, lower
the work equipment to the ground and actuate all
hydraulic control levers until there is no more
pressure in the hydraulic system.

18 Operating Manual Crawler Excavator TC20

 Safety and Accident Prevention 2
2.19 Recovery, Loading and Hydraulic hoses must be replaced as soon as the
Transporting following damage is recognized:
– Damage to the outer layer which reaches the
Earth-moving machines are only to be loaded onto intermediate layer,
recovery vehicles if adequate towing vehicles are
– Embrittled patches on the outer layer,
used.
– Deformations when under pressure or without
The tow fixing points specified by the manufacturer pressure which differ from the original shape of the
must be employed. installed hose,
For loading and transportation, earth-moving – Leaks,
machines and all necessary auxiliary equipment must
be secured against unwanted movement. – Damage to hose fittings or to the connection
between the fitting and the hose.
The traveling gear and crawler unit of earth-moving
machines must be sufficiently cleaned of mud, snow The coolant level may only be checked after the
and ice to ensure that ramps can be driven up without engine has cooled down; the cap must be turned
risk of slipping. carefully in order to let off excess pressure.

When transporting the earth-moving machine on Prior to operations, the machine operator must check
trucks, flatbed trailers, or by rail, it must be sufficiently the function of the safety devices.
secured with chocks and by attachment to the lashing The machine operator must advise the supervisor
points. immediately - and his replacement, if there is a
Before setting off, the route to be taken must be change of operator - with regard to any shortcomings.
examined to determine whether the roads are wide In the event of shortcomings which jeopardize the
enough, entrances and passages under bridges are operating safety of the earth-moving machine, it is not
large enough and that roads and bridges have to be used until these have been eliminated.
sufficient carrying capacity.

2.20 Monitoring and inspections

The machine must be submitted to a general

inspection according to the regulations in force in the
user's country (e.g. Accident Prevention Regulations
in Germany); this inspection must be carried out by an
expert (e.g. machine engineer or machine foreman):
– before the machine is put into operation for the first
time and before the machine is again put into
operation after essential modifications have been
made
– at least once a year
– in the meantime, according to operating conditions
and local environments

The results of this inspection have to be recorded in

writing and this record kept until the next inspection
takes place.

Prior to every work shift, the machine operator must

check the earth-moving machine according to the
inspection and maintenance plan.

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2 Safety and Accident Prevention
2.21 Fire protection

• Switch off the engine when filling the fuel tank and
take special care as long as the engine is hot.
• Never smoke or handle open flames whilst
refueling the tank of the machine.

The fire extinguisher must be kept in the

cabin.

The fire extinguisher symbol must be

attached.

2.22 Notes concerning residual dangers

Failure of hydraulic system

If the hydraulic system fails because the diesel engine

is not running, the hydraulic pump is damaged or
hydraulic oil has been lost, only the EMERGENCY
function "Lower work equipment" can still be
performed.

20 Operating Manual Crawler Excavator TC20

 Technical Specifications 3

3 Technical Specifications

3.1 Views

3.1.1 Digging envelope with 1 100 mm and

1 300 mm dipperstick

2740
2290

2
4

3
3

25°

0
1

4200
2

4370
3
4
5

Optional 2600 960

2720 1130
Extra-long dipperstick
3130 1770
3250 1970
3620 2300
3740 2500
4

4
1

1
0
1

4200
2

4370
3
4
5

1990 2850
2110 3050
2210 3070
2330 3270

Fig. 2 Digging envelope

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3 Technical Specifications
3.1.2 Views with cabin

2290
HR2.0-04-03

R1160
B A
1000
1340

Fig. 3 Views with cabin

A) Total width of uppercarriage
B) Total width of dozer blade

22 Operating Manual Crawler Excavator TC20

 Technical Specifications 3

420 550

60°

60°
C

1340 mm D

2560 mm
A

2800 mm B

Fig. 4 Slew circle

A = slew circle 180°

B = slew circle 360° – bucket heaped

C = loading position – max. height

D = undercarriage extended

E = dimensions when working with Knickmatik

Operating Manual Crawler Excavator TC20 23

3 Technical Specifications
3.2 Engine

Engine
Manufacturer Mitsubishi
Type L3E four-stroke diesel engine
Design 3 cylinders in line
Displacement 952 cm3
Power in accordance with ISO 9249 13.1 kW / 2250 min-1
Permissible inclined positions continuously 25° on all sides; briefly 30° (max. 30 minutes)
Specific fuel consumption 272 g/kWh
Practical fuel consumption approx. 3.3 l/hr at medium load
Cooling Water-antifreeze mixture for all-year operation
Heating Warm water with 2-speed fan
Max. torque 54.9 / 2100 min-1
Tab. 3 Technical specifications - Engine

3.3 Electrical system

Electrical system
Operating voltage 12 V
Battery 12 V – 74 Ah
Generator 12 V – 40 A
Starter 12 V – 1.7 kW
Tab. 4 Technical specifications - Electrical system

3.4 Chassis

Chassis
Crawler-type undercarriage Maintenance-free crawler-type undercarriage.
Idler suspension with hydraulic crawler-chain tension.
Travel speeds Forward - Reverse
0 – 2.4 km/h
Max. hill climbing ability 60 %
Power transmission Two-stage hydrostatic travel drive with axial piston variable-displacement motor
Optional: Two-stage hydrostatic travel drive and reduction gear directly acting on crawler-chain sprockets.
Travel brake valves for downhill driving.
Chain width Steel or rubber, 230 mm
Overall length of chassis 1 490 mm
Track width adjustment Horizontally adjustable crawler frames.
Hydraulically adjustable from driver's seat.
Range of adjustment, outside edge of crawler chains:
990 – 1340mm
Driving – steering Independent individual control of crawler chains, also counterwise thanks to
dual-circuit hydraulic system. 2 combined hand levers/ foot pedals for operation.
Tab. 5 Technical specifications - Chassis

24 Operating Manual Crawler Excavator TC20

 Technical Specifications 3
3.5 Hydraulic system

Hydraulic system
Excavator hydraulics Dual fixed-displacement pump with power switch.
Pump capacity: 1 x 33.6 l/min
1 x 19.2 l/min
Max. pressure: 180 bar
Excavator installation Hydraulically pilot-operated control valve for the functions "boom, dipperstick, bucket, uppercarriage,
slewing"; Proportional control of all functions.
Pilot pressure 28 bar with pressure accumulator
Additional control Control circuit for grab, rock breaker, etc.
circuit
Capacities available: 33 l/min at 100 bar
30 l/min at 140 bar
max. 180 bar
Open return
Hydraulic filter Full-flow return filter installed in the oil tank.
Hydraulic cylinders Double-acting work cylinders, partially with end-position damping.
Swing drive Hydrostatic, swing motor and drive pinion on internally toothed ring gear of swing bearing.
Swing range: 360° unlimited
Swing speed: 0 – 10 rpm
Additional spring-loaded multi-disk brake serving as parking brake:
- by operating the push-button on the left-hand joystick
- with the diesel engine switched off and ignition OFF.
Knickmatik®: On the right: swing angle 60°
On the left: swing angle 60°
Bend mechanism for the lateral parallel adjustment of the boom axle at total digging depth, left/right
by approx. 420/550 mm.
Dozer blade Hand lever providing sensitive control, independent from drive.
Dozer blade with pluggable extensions with full support function.
Width 1 340 mm
Height 235 mm
Lift below road level 160 mm
Lift above road level 200 mm
Slope angle 25°
Tab. 6 Technical specifications - Hydraulic system

Operating Manual Crawler Excavator TC20 25

3 Technical Specifications
3.6 Fuels, lubricants, and coolants

3.6.1 Fluid capacities

All values stated are approximate. The level marking is always the decisive factor.

Fluid capacities in liters Fuels and lubricants

Fuel 30.0 Diesel
Engine oil, engine and filter 3.1 + 0.5 HD-oil (change quantity)
Hydraulic oil, tank and system 35.0 Hydraulic oil
Hydraulic oil tank 25.0 Hydraulic oil (change quantity)
Crawler gear units 0.3 each Transmission oil
Swing gear 0.1 Transmission oil
Coolant 4.2 Water with anti-corrosion agent and antifreeze1
Tab. 7 Fluid capacities
1 The mixture ratio must be adjusted to the level of antifreeze required.

26 Operating Manual Crawler Excavator TC20

 Technical Specifications 3
3.6.2 Fuel, lubricant, and coolant specifications

Prescribed fuels, lubricants, and coolants

for Central Europe
Application Code Designation Specification, standards, Remarks
designation Quality
according to
Bi 1
Engine – Diesel fuel EN 590 Attention
ASTM D975 1-D / 2-D Before using RME fuels
(rape oil methyl ester), it is
essential to consult your
responsible Terex dealer
for further details.
Engine EO 1540 A Engine oil SAE 15W-40 See also engine manufacturer's
API CF4 Operating Manual.
Cooling for SP-C Coolant Antifreeze based on See also engine manufacturer's
Engine ethylene glycol Operating Manual.
Hydraulic HYD 1040 Hydraulic oil or HVLP 46 The following viscosity limit values
system multi-grade or must be observed (according to
engine oil SAE 10W-40 ASTM 445):
at 100 °C min. 8 mm2/s (cSt)
at –10 °C approx. 1500 mm2/s (cSt)
BIO-E-HYD- Biodegradable Filling according to customer The same viscosity specifications
HEES hydraulic oil on specifications. Brand label on apply as for mineral hydraulic oils.
synthetic ester machine.
base
Machine damage Attention
caused by non-mixable bio When changing from
oils. mineral to biodegradable
hydraulic oils, the tank and
• Do not mix bio oils from
hydraulic system must be
different
completely drained,
manufacturers.
cleaned and flushed.
For further details before
changing oils, please
consult your responsible
Terex dealer.
Transmission(s) GO 90 LS Transmission oil SAE 85W-90LS Alternative recommendation:
API-GL 5 SAE 80-90LS
Lubricating MPG-A Multi-purpose, K2K-30
points lithium DIN 51825
-soap based
grease
Tab. 8 Fuel, lubricant, and coolant specifications
1
In conformity with the regulation lubricants of the Main Association of the German Building Industry e.V.

Operating Manual Crawler Excavator TC20 27

3 Technical Specifications
Alternative recommendation for other
temperature ranges

Engine oil Hydraulic oil

according to API CG 4 or CF 4 and ACEA E3 or E2 according to DIN 51524.T3 HVLP

Ambient temperature Ambient temperature

Fig. 5 Recommended viscosity classes for engine oil Fig. 6 Recommended viscosity classes for hydraulic oil

3.7 Specific ground pressure

Specific ground pressure 1

with rubber crawler chain
with cabin 0.30 da N/cm2
with canopy 0.29 da N/cm2
with steel crawler chain
with cabin 0.31 da N/cm2
with canopy 0.30 da N/cm2
Tab. 9 Specific ground pressure
1 Specifications without driver

3.8 Sound level values, vibration

Sound level values Driver's cabin Canopy

Guaranteed sound power level LWA 93 dB (A) LWA 93 dB (A)

Sound pressure level (at driver's ear) LpA 77 dB (A) LpA 78 dB (A)
Tab. 10 Sound level values in compliance with directive 2000/14/EC and EN 474

Vibration
Effective values of acceleration below 0.5 m/s2 for entire body
and 2.5 m/s2 for upper limbs
Tab. 11 Vibration values in compliance with directive 2002/44/EC and EN 474

28 Operating Manual Crawler Excavator TC20

 Technical Specifications 3
3.9 Dimensions and operating weights
1
Weight Excavator equipment LS LS
1100 mm 1300 mm
Machine weight: 1 950 kg Digging depth2 2 300 mm 2 500 mm
with 400-mm bucket, control circuit for work Deepest bucket hinge point 2
1 770 mm 1 970 mm
attachments, open return, without driver, with
rubber crawler and cabin
Transport weight with tank half full, w/ quick- 1 900 kg Maximum possible height 3 620 mm 3 740 mm
attach system, w/out bucket
Cabin 180 kg Dump height2 2 600 mm 2 720 mm
Canopy 80 kg Maximum height of bucket hinge 3 130 mm 3 250 mm
point2
Dimensions Maximum reach 4 200 mm 4 370 mm
Total width (crawler-type undercarriage 1 000 mm Bucket angle of rotation 192° 192°
retracted)
Total length (travel position) 2 680 mm Ripping force1 11 000 N 9 700 N
Total length (transport position) 4235 mm Breakout force1 15 700 N 15 700 N
Total height (travel position) 2 390 mm
Height (cabin roof) 2 290 mm
Uppercarriage tail swing 1 160 mm
Ground clearance 170 mm
Drawbar pull 1st speed range 1 500 daN
Drawbar pull 2nd speed range 730 daN
Tab. 12 Dimensions and operating weights
1
Values are theoretical according to DIN 24086.
2
Dimensions apply to machine standing on level ground, but can be increased by tilting the machine using the blade.

Operating Manual Crawler Excavator TC20 29

3 Technical Specifications
3.10 Carrying capacity

The stated carrying capacities in tons (t) were

determined according to ISO 10567 and include a
stability factor of 1.33 or 87% of the hydraulic lifting-
load capacity.

Attention
The dead-weight of the work attachment
must be deducted from the stated payload.

Carrying capacity tables with the following

equipment:
– boom
– with quick-attach system
– without bucket
– rubber crawler chain, 230 mm wide
– full tank, with driver

Permissible values Load radius from center of ring gear in meters

crawler chain retracted 1.5 2.0 2.5 3.0 3.5
and dipperstick 1100 mm longt. trans- longt. trans- longt. trans- longt. trans- longt. trans-
verse verse verse verse verse
A -- -- -- -- 0,40 0,32 0,38 0,25 -- --
2.0
V -- -- -- -- 0,39 0,31 0,37 0,24 -- --
A -- -- 0,66 0,44 0,44 0,31 0,38 0,24 0,31 0,19
Height 1.0
V -- -- 0,65 0,43 0,43 0,30 0,37 0,23 0,30 0,18
of bucket pivot
A -- -- 0,74 0,40 0,52 0,29 0,39 0,23 0,28 0,18
in meters 0.0
V -- -- 0,63 0,38 0,45 0,27 0,38 0,21 0,27 0,17
A 0,99 0,56 0,64 0,39 0,42 0,29 0,30 0,23 -- --
-0.75
V 0,98 0,53 0,63 0,37 0,40 0,27 0,30 0,21 -- --
Tab. 13 Table of carrying capacity in tons
A) supported by dozer blade

V) movable

Permissible values Load radius from center of ring gear in meters

crawler chain extended 1.5 2.0 2.5 3.0 3.5
and dipperstick 1100 mm longt. trans- longt. trans- longt. trans- longt. trans- longt. trans-
verse verse verse verse verse
A -- -- -- -- 0,40 0,40 0,38 0,35 -- --
2.0
V -- -- -- -- 0,39 0,38 0,37 0,33 -- --
A -- -- 0,66 0,52 0,44 0,44 0,38 0,36 0,31 0,30
Height 1.0
V -- -- 0,65 0,50 0,43 0,42 0,37 0,34 0,30 0,29
of bucket pivot
A -- -- 0,74 0,58 0,52 0,43 0,39 0,33 0,28 0,28
in meters 0.0
V -- -- 0,72 0,56 0,50 0,40 0,38 0,31 0,27 0,27
A 0,99 0,99 0,64 0,64 0,42 0,33 0,30 0,25 -- --
-0.75
V 0,98 0,74 0,63 0,47 0,40 0,31 0,30 0,23 -- --
Tab. 14 Table of carrying capacity in tons

A) supported by dozer blade

V) movable

30 Operating Manual Crawler Excavator TC20

 Technical Specifications 3

Permissible values Load radius from center of ring gear in meters

crawler chain retracted 1.5 2.0 2.5 3.0 3.5
and dipperstick 1300 mm longt. trans- longt. trans- longt. trans- longt. trans- longt. trans-
verse verse verse verse verse
A -- -- -- -- 0,46 0,32 0,38 0,25 -- --
2.0
V -- -- -- -- 0,36 0,31 0,30 0,24 -- --
Height A -- -- 0,66 0,44 0,44 0,31 0,38 0,24 0,31 0,19
1.0
of bucket V -- -- 0,41 0,43 0,36 0,30 0,27 0,23 0,22 0,18
pivot A -- -- 0,74 0,40 0,52 0,29 0,39 0,23 0,28 0,18
in meters 0.0
V -- -- 0,49 0,38 0,38 0,27 0,29 0,21 0,19 0,17
A 0,99 0,56 0,64 0,39 0,42 0,29 0,30 0,23 -- --
-0.75
V 0,74 0,53 0,47 0,37 0,40 0,27 0,30 0,21 -- --
Tab. 15 Table of carrying capacity in tons

A) supported by dozer blade

V) movable

Permissible values Load radius from center of ring gear in meters

crawler chain extended 1.5 2.0 2.5 3.0 3.5
and dipperstick 1300 mm longt. trans- longt. trans- longt. trans- longt. trans- longt. trans-
verse verse verse verse verse
A -- -- -- -- 0,46 0,45 0,38 0,35 -- --
2.0
V -- -- -- -- 0,36 0,38 0,30 0,32 -- --
Height A -- -- 0,66 0,52 0,44 0,44 0,38 0,36 0,31 0,30
1.0
of bucket V -- -- 0,41 0,48 0,36 0,38 0,27 0,29 0,22 0,25
pivot A -- -- 0,74 0,58 0,52 0,43 0,39 0,33 0,28 0,28
in meters 0.0
V -- -- 0,49 0,49 0,38 0,40 0,29 0,31 0,19 0,22
A 0,99 0,99 0,64 0,64 0,42 0,42 0,30 0,30 -- --
-0.75
V 0,74 0,74 0,47 0,47 0,40 0,40 0,30 0,30 -- --
Tab. 16 Table of carrying capacity in tons
A) supported by dozer blade

V) movable

Operating Manual Crawler Excavator TC20 31

3 Technical Specifications
3.11 Working range for grab operations

Danger of injury
due to overturning hazard of machine.
• For safety reasons, ensure that the
indicated reach distances are not
exceeded when the grab is full.

45° 45°

B
max. 3,0 m

90°

H
R
13
0 8

Fig. 7 Working range of grab

A) Maximum reach
B) Restricted reach

32 Operating Manual Crawler Excavator TC20

 Technical Specifications 3
3.12 Work attachments

Standard Quick-attach mounting

Width in mm Capacity in Width in mm Capacity in
liters liters
Bucket 220 21 – –
Bucket with ejector 220 21 – –
Bucket – – 250 22
Bucket with ejector – – 250 25
Bucket 260 25 – –
Bucket with ejector 260 25 – –
Bucket 300 29 300 26
Bucket with ejector 300 29 300 32
Bucket 400 40 400 38
Bucket – – 500 49
Bucket 600 61 600 60
Ditch-cleaning bucket 850 72 – –
Ditch-cleaning bucket 1 000 85 1 000 –
Swing bucket 850 47 850 –
Swing bucket 1 000 56 1 000 –
Clamshell grab type GL1 – – 250 –
Hydraulic rock breaker type SH 50/SMS – – – –
Tab. 17 Work attachments

Attention
Additional work attachments available from
the manufacturer.

Operating Manual Crawler Excavator TC20 33

3 Technical Specifications
3.13 Optional accessories

– Mechanical quick-attach system for work

attachments
– Hydraulically telescopic undercarriage with dozer
blade extension
– Canopy (weight reduction: 100 kg)
– Dipperstick 1300 mm
– FOPS-skylight guard
– Rear-end protection
– Cabin-mounted working floodlights, front/rear
– Boom-mounted working floodlight
– Yellow rotating beacon
– Travel motion alarm (acoustic signal)
– Crane lifting beam
– Floor plates rubberized for steel crawler chains
– Quick-mounting adapter for hydraulic rock breaker
– Catalytic converter
– Electric drive
– Biodegradable oil
– Immobilizer
– Electrical refueling pump
– Radio
– Cutting unit

Attention
Additional accessories available from the
manufacturer.

Machine damage
due to unauthorized alterations to the design,
additional equipment and work attachments
of Terex products.
• Please note that any modification requires
the written approval from the
manufacturer. If our approval is not
sought, our warranty expires, as does our
product liability for any resulting
consequential damage.

34 Operating Manual Crawler Excavator TC20

 Operation 4

4 Operation

4.1 Initial familiarization

• If you are not familiar with the operator controls

and display elements of this machine, read this
Chapter carefully before operating the machine.

This Chapter deals with all functions.

• Before driving and working with the machine it is
necessary to thoroughly familiarize yourself with
the display elements and operator controls.
• Each time before putting the machine into
operation it must be subjected to a thorough visual
inspection. Ensure that there is no damage, loose
or missing screws, oil accumulations, oil or fuel
leakage. Shortcomings must be remedied
immediately. In the event of shortcomings which
jeopardize the operating safety, the machine must
not be put into operation until these have been
eliminated.
• Before putting the machine into operation, the
inspections according to Î 7.7, 61 must be
carried out.

Operating Manual Crawler Excavator TC20 35

4 Operation
4.2 Display elements and operator
controls

16 5 6 7

2
15
17
2
9
12

1 10
8

4/4
h.
3
13

14
11
HR2.0-04-08

Fig. 8 Operator controls

1 Operation – excavator installation
2 OFF switch – excavator hydraulics / exit barrier
3 Brake – swing motion of uppercarriage
4 Operation – articulation
5 Crawler unit, left
6 Crawler unit, right
7 Additional control circuit – rock breaker, etc.
8 Operation – dozer blade up / down or track width adjustment smaller / larger (in connection with changeover level
pos. 17)
9 Manual throttle
10 Operation – excavator installation
11 Fuse and relay box
12 Change-over "ISO" to "SAE" control (option)
13 Vandalism guard (canopy only) (option)
14 Windshield washer fluid tank
15 Horn
16 Storage space for control rod of quick-attach system
17 Change-over – dozer blade / track width adjustment (optional)

36 Operating Manual Crawler Excavator TC20

 Operation 4

23 18 21 22 33

2
R
4
4/

90°
0

h.

HR3.7-03-102

20 19 25 24 27 28 29 30 34 32 26

Fig. 9 Operator controls

18 Battery charge indicator (red)
19 Preheating monitor (yellow)
20 Engine oil pressure indicator (red)
21 Air filter clogging indicator (yellow)
22 Hydraulic oil filter clogging indicator (yellow)
23 Fuel gauge
24 Operating-hour meter
25 Coolant temperature (red)
26 Power socket
27 Travel, FAST/SLOW (option)
28 Windshield wiper and washer system (only for the cab)
29 Working floodlight(s)
30 Heating/ventilation (only for the cab)
31 -
32 Rotating beacon (option)
33 Glow plug and starter switch (ignition lock)
34 Travel motion alarm ON/OFF (option)

Operating Manual Crawler Excavator TC20 37

4 Operation
4.3 Engine

4.3.1 Starting

Attention
Each time before putting the machine into
operation, the inspections according to
(Î 7.7, 61) must be carried out.

Danger to life
due to presence in the danger zone.
• Before switching on the engine always
ensure that no-one is in the danger zone of
the machine.

• All gearshift levers in neutral position.

• Insert ignition key in glow plug and starter switch
2 2
(10/33).
9
• Turn ignition key clockwise to Position "1"; the
indicator lamps (10/18,10/20) light up.
• Pre-heating starts; the indicator lamp (10/19)

0
lights up.

4/
4
h.
• Move manual throttle (10/9) to full-throttle position.

R
• After the indicator lamp (10/19) has gone out, turn
the glow plug and starter switch to Position "2". As
soon as the engine is running, turn the ignition key
back to Position "1" and decrease the revs to low
idle speed. The indicator lamps should go out. 18 33
• If the engine has not started after max. 30
seconds, turn the ignition key to "1" or "0", and 0
1
pause for at least 1 minute before trying again;
2
repeat the start-up procedure. R
4
4/
0

• If the engine has not started after 4 start-up

h.

procedures, determine the source of fault.

HR1.6-04-11
Engine damage
20 19
Avoid damaging the engine by:
• not driving the engine at full throttle straight Fig. 10 Starting the engine
away.
• driving with restraint until the engine has
reached its operating temperature.

38 Operating Manual Crawler Excavator TC20

 Operation 4
4.3.2 Monitoring the machine during operation

The machine is fitted with a warning buzzer emitting a

signal if the following malfunctions occur:
– Insufficient engine oil pressure (11/20)
– Air filter clogging indicator (11/21)
– Excessively high coolant temperature (11/25)

Engine damage
due to fault which has not been remedied.
• The fault must be remedied before
restarting the engine and operating the
machine again.

• As soon as the warning buzzer sounds, check

which indicator lamp is activated and proceed
accordingly.
• If the battery charge indicator (11/18) or the engine 9
oil pressure indicator lamp (11/20) lights up, switch
off the engine immediately and determine the
cause. If necessary, call for service personnel.

0
• If the air filter maintenance indicator (11/21) lights

4/
4
h.
up, perform the necessary maintenance work.
• If the permitted coolant temperature (11/25) is

R
exceeded, stop work, open the engine hood and
keep the engine running at idle speed to allow it to
cool down. Once the engine has cooled down, turn
it off and determine the cause. If necessary, call
for service personnel. 18 21 22 33
• If the hydraulic oil filter clogging indicator (11/22)
lights up, replace the filter element and determine
the cause of clogging. R
4
4/
0

Attention
h.

If the hydraulic oil is cold, the hydraulic oil filter

clogging indicator may light up briefly. It will go HR1.6-05-11

out once the operating temperature has been

reached. 20 25

Fig. 11 Monitoring and switching off the engine

4.3.3 Switching off

Attention
Do not switch off the engine when running at
full throttle, but allow it to run for a short time
without load at low idle-running speed.

• Move the manual throttle (11/9) to low idle

position.
• Turn the ignition key (11/33) to Position "0".
• The engine stops automatically.

Operating Manual Crawler Excavator TC20 39

4 Operation
4.4 Driver's seat

The comfort seat meets international quality and

safety standards (Fig. 12).

1. Horizontal adjustment
2. Handle for weight adjustment – the driver's weight
can be adjusted for in 9 stages (10 kg each).
Move the weight adjustment handle clockwise
until the stop; the weight adjustment mechanism
automatically switches to the 50-kg position
3. Seat-back inclination adjustment
3
2
1 HR5.0_5.1_6

Fig. 12 Driver's seat

4.5 Heating/ventilation
1
Heating
• Before putting the heater into operation, the hot
water supply (13/1) in the engine compartment
must be opened.
• The heater fan, which is connected to the coolant
circuit, is switched on and off using the switch
(14/30).
• Hot air is distributed and aimed as desired via a
windshield nozzle in the pedal console and by
adjusting the air vent on the seat console.

HR2.0-01-13

Fig. 13 Heating
Ventilation
• In ventilating mode the hot water supply (13/1)
remains turned off.
• The fan is switched on and off using the switch
(14/30).
R
4
4/

• Air is distributed and aimed as desired via a

0

windshield nozzle in the pedal console and by

h.

adjusting the air vent on the seat console.

HR3.7-03-15

30

Fig. 14 Ventilation

40 Operating Manual Crawler Excavator TC20

 Operation 4
4.6 Front window

• To open the windshield, release the two levers

(15/1).
• Pull the window back and up at the same time.
• Lock the window in the upper position using the
levers (15/1). 1

HR5.0_7.1_2_1

Fig. 15 Front window

Operating Manual Crawler Excavator TC20 41

4 Operation
4.7 Driving and steering

Danger to life
C A
due to incorrect operation.
• Always observe that the direction of travel
always relates to the undercarriage (drive
at the rear, dozer blade in front)

Attention D B
The engine must be switched off before lifting
the exit barrier (16/2) and leaving the
5 6
machine.

Driving 2

– Rocker pedal / hand lever (16/6) for right-hand 2

crawler chain:
A) forward

0
B) reverse

4/4
h.
– Rocker pedal / hand lever (16/5) for left-hand

R
crawler chain:
C) forward
D) reverse

Driving forward or reverse

• Move the rocker pedal / hand lever on the right
(16/6) and the left (16/5) equally forward or
backward.

Cornering
• Reduce the speed of one crawler chain according
to the curve.

Spot-turning
• Operate the rocker pedal / hand lever for the right
and left-hand crawler chains in an opposed
manner.

Turning over one crawler chain

• Operate the rocker pedal / hand lever for the right
or left-hand crawler chain.

HR1.6-03-17

Fig. 16 Driving and steering

42 Operating Manual Crawler Excavator TC20

 Operation 4
4.8 Track width adjustment

Attention
The hydraulic track width adjustment must be
carried out on a plane and paved surface.

Danger of injury
due to incorrect operation of the control.
• Before actuating the lever (17/8) for
“Dozer blade/Track width adjustment”,
check the position of the changeover lever
(17/17).
• Familiarize yourself with the control. 17

• Change-over lever (17/17) in position “Track width

adjustment”.
8

4/
4
Attention

h.
If ground conditions are unfavorable, the
crawler unit should be slackened.

R
• Pull lever (17/8) backward, track width is retracted.
HR2.0-04-19
• Push lever (17/8) forward, track width is extended.
Fig. 17 Actuation of hydraulic track width adjustment
• Move the change-over lever (17/17) back to
position "Dozer blade".

Operating Manual Crawler Excavator TC20 43

4 Operation
4.9 Operations with rubber crawler
chains

Attention
This crawler excavator can be equipped with
either steel or rubber crawler chains.
If the excavator is equipped with rubber
crawler chains, work on paved roads, within
buildings, etc. can be performed without
damaging the road ways.

When using rubber crawlers, the following points

have to be observed:
– The rubber crawler chain must have the correct
tension. Incorrect crawler chain tension is
detrimental to travel performance and adds to the
wear of the crawler chain.
– Do not drive or turn over sharp edges or stairs
since the crawler chain is stressed only on special
points (18/A) and fissuring or cracking of the
rubber and the steel insert may occur.
– Prevent stones and other substances from getting A
into the crawler chain as they may cause the
crawler chain to be extended or damaged.
– Do not undertake any sharp turns on surfaces with
a high friction resistance such as rough concrete.
– Avoid that the rubber crawler chain is
contaminated by fuel or oil and clean immediately
if this has occurred.
– When working on salt water beaches, the rubber
crawler chains must be thoroughly cleaned every
day using clean water. The steel insert in the A
rubber crawler chains may be damaged due to
corrosion.

HR1220

Fig. 18 Operations with rubber crawler chains

44 Operating Manual Crawler Excavator TC20

 Operation 4
4.10 Switching off the machine
(parking)

• Park the machine on a preferably level, solid

ground. 2
• Lower the work attachment onto the ground.
• Lower the dozer blade. 2
• Turn off the engine and remove the ignition key
(19/33).
• Apply and lock the vandalism guard (19/13)

4/
4
(optional in case of canopy).

h.
• Raise the working hydraulics shut-off / exit barrier 13
(19/2).

R
• Windows and doors must be closed and/or locked.
• Secure the machine against rolling away.
33

R
4
4/
0

h.

HR1.6-03-21

Fig. 19 Switching off the machine (parking)

Operating Manual Crawler Excavator TC20 45

4 Operation

46 Operating Manual Crawler Excavator TC20

 Working operation 5

5 Working operation

The excavator is equipped as standard with an "ISO"-

control (function of control levers 20/1 and 20/10) on
which the following description is based.

There is the option to fit the excavator with a

switchable control system for the work equipment.
Switching is accomplished by operating the lever
(20/12).

Danger to life
due to incorrect operation of the control 2
system.
• Check your excavator to see which control 2
system is installed (only ISO-control or ISO 12
and SAE-control systems).
• If you can choose between ISO and SAE, 1
10

0
check which control system (ISO or SAE)

4/
4
h.
is activated before working with the
excavator.

R
• Familiarize yourself with the control
system.
HR1.6-03-22

Danger of injury
Fig. 20 Operating the exit barrier
due to uncontrolled movements of the
machine.
• When lifting and lowering the exit barrier,
ensure that no other control levers and/or
pedals are operated.

Attention
If the exit barrier (20/2) is lifted, all travel and
work functions are deactivated.

Before working with the excavator:

• Memorize the lever controls well.
• Start at low engine speed when familiarizing
yourself with the controls.

Operating Manual Crawler Excavator TC20 47

5 Working operation
5.1 Work functions

5.1.1 Mode of operation

Danger to life
due to incorrect operation of the control
system.
• Before working with the excavator check
if the ISO or SAE control system (option)
is activated.
• Familiarize yourself with the control
system.

1 10
Danger of injury 3 12
due to uncontrolled movements of the
machine.
• For special jobs it is necessary to
additionally lock the uppercarriage by

4/
4
applying a brake. To do so, press and hold

h.
the push-button (21/3).

R
• (Option) Select the desired mode of operation of
the work equipment using the lever (21/12).
A = ISO control system HR1.6-03-23

B = SAE control system Fig. 21 Checking the mode of operation

5.1.2 Work function: Articulation

Danger to life
due to lack of care when using extra-wide
work attachments (e. g. ditch-cleaning
buckets, swing buckets, extra-wide buckets,
special attachments). 4
• Exercise special caution when using the
Knickmatik system.
0

4/
4
h.

HR1.6-03-24
Fig. 22 Operation of articulation

48 Operating Manual Crawler Excavator TC20

 Working operation 5
5.1.3 Work function: Dozer blade and track
width adjustment

Dozer blade

Danger of injury
due to incorrect operation of the control
system.
• Before commencing work, check if the
control is in position "Dozer blade" or
"Track width adjustment" (23/17).

• Pull lever (23/8) backward, dozer blade moves up.

• Push lever (23/8) forward, dozer blade moves
down.

Hydraulic track width adjustment

17
Danger of injury
17
due to incorrect operation of the control
system.
• Before commencing work, check if the
17
control is in position "Dozer blade" or
"Track width adjustment" (23/17).
• After adjusting the track width, move the
change-over lever (23/17) back to position
"Dozer blade". 8

4/
4
h.
• Change-over lever (23/17) in position "Track width
adjustment".
R

• Slacken the crawler chain if required.

• Pull lever (23/8) backward, track width is retracted. HR1.6-04-25

• Push lever (23/8) forward, track width is extended.

Fig. 23 Operating the dozer blade / hydraulic track width
• Move the change-over lever (23/17) back to adjustment
position "Dozer blade".

Operating Manual Crawler Excavator TC20 49

5 Working operation
5.1.4 Work function: Additional control circuit

The additional control circuit is operated using the

right-hand rocker pedal (24/7).

4/
4
h.

R
HR1.6-03-26

Fig. 24 Operation of additional control circuit

5.2 Changing work attachments

Various work attachments are available to achieve

maximum utilization of the machine for a variety of
applications.

The machine may be equipped with a quick-attach

system to shorten the time it would take to install
attachments.

Attention
Under special circumstances it is possible to
use the work attachments of predecessor
models for our machines. When mounting the
work attachments of predecessor models
they may have to be adjusted and/or may be
subject to utilization restrictions.
• It is essential to consult your dealer before
mounting such a work attachment.

Danger of injury
due to attachments tilting and overturning.
• If work attachments are not used, they
must be secured with wedges or similar.

50 Operating Manual Crawler Excavator TC20

 Working operation 5
5.2.1 Installation and removal of work
attachments

Attention
Ensure that the bearings of the quick-attach
system and work attachment and/or the
dipperstick, bucket rod and work attachment
are clean.

Changing procedure using the quick-attach

system

Attention
concerning hydraulically actuated additional
work attachments. 1

• Release the pressure in the hydraulic

system.
• Disconnect the hydraulic connection.

• Lower the work attachment onto the ground and

position so that it cannot tilt.
• Open the quick-attach system using the control
rod (25/1) until the locking pins are completely
retracted.
• Move the quick-attach system out of the work HR1228
attachment.
Fig. 25 Quick-attach system
• Check the function of the quick-attach system lock
and grease the pins if necessary.
• Attach another work attachment and close the
quick-attach system until the locking pins are
completely extended and the lock has engaged.
• Keep the control rod in the storage space (26/16) 16
inside the driver's cabin.

Procedure for changing work attachments

without quick-attach system

Attention
concerning hydraulically actuated additional
work attachments.
0

• Disconnect the hydraulic connection

4/
4
h.

(hydraulic system must be without

pressure).
R

• Lower the work attachment onto the ground and

position so that it cannot tilt.
HR1.6-04-28

• Remove the pins connecting the work attachment Fig. 26 Storage space for control rod
to the dipperstick and the bucket rod.
• Attach another work attachment.

Operating Manual Crawler Excavator TC20 51

5 Working operation
5.2.2 Hydraulically actuated additional work
attachments

• Mechanical installation is similar to the attachment

of a bucket with or without quick-attach system.
• The hydraulic pressure supply is connected to the
lines of the additional control circuit (27/1) by 2
means of a coupling. 1

5.2.3 Clamshell grab

Changing procedure using the quick-attach right

system 3

• Attach the clamshell grab and close the quick-

attach system until the locking pins are completely
extended.

Machine damage
4
due to the bucket cylinder piston rod not
having fully retracted.
• Ensure that the bucket cylinder piston rod
1
is fully retracted.
left
2
• Fully retract the bucket cylinder piston rod and HR1.6-04-29

close the ball valve (27/3). Fig. 27 Additional control circuit

• Connect the swivel motor to the couplings (27/1
additional control circuit) and the "Open/Close"
function to the couplings (27/2 bucket cylinder).

Attention
• After the clamshell grab has been
removed, re-open the ball valve (27/3).

Changing procedure without quick-attach system

(clamshell grab attached directly)

Machine damage
due to the bucket cylinder piston rod not
having fully retracted.
• Ensure that the bucket cylinder piston rod
is fully retracted and close the ball valve
(27/3).

• Connect the grab to the dipperstick using the

suspension pin and secure.
• Connect the swivel motor to the couplings (27/1
additional control circuit) and the "Open/Close"
function to the couplings (27/2 bucket cylinder).

Attention
• After the clamshell grab has been
removed, re-open the ball valve (27/3).

52 Operating Manual Crawler Excavator TC20

 Working operation 5
5.2.4 Hydraulic rock breaker

Attaching the hydraulic rock breaker

Machine damage
due to inappropriate hydraulic rock breaker.
– Only use rock breakers approved by
Terex.
– The Mounting & Operating Instructions of
the hydraulic rock breaker manufacturer
must be observed.
– Neither the permissible capacity in liters in
the rock breaker supply line nor the
permissible operating pressure of the rock
breaker (= pressure at rock breaker entry
during operations) must be exceeded.
If malfunctions occur, the max. pressure of
the additional control circuit is limited to
180 bar (operating pressure of machine).
– When working in or under water, special
rock breaker types must be used.

• Mechanical installation is similar to the attachment

of a bucket with or without quick-attach system.
• The hydraulic pressure supply is connected to a
line of the additional control circuit (28/1) by 2
means of a coupling. 1
• Connect the return line to the coupling (28/4) of the
"open return".

Hydraulic rock breaker operations right

3
Machine damage
due to improper use.
Ensure that the rock breaker is always used
properly; improper use may lead to severe
damage to the rock breaker, holder and the 4
excavator itself.
• The notes and instructions provided by the
hydraulic rock breaker manufacturer must
1
be observed.
left
2 HR1.6-04-29
Maintenance of the hydraulic rock breaker
Fig. 28 Additional control circuit
• Maintenance of the hydraulic rock breaker must be
performed according to the instructions of the
hydraulic rock breaker manufacturer.

Operating Manual Crawler Excavator TC20 53

5 Working operation
5.3 Removing the cabin

For particular operations it is better to work without

cabin.

Attention
In order to dismount the cabin and to install
the canopy, the original Terex crane lifting
beam should be used (weight of the cabin
approx. 180 kg). A

Danger to life
due to falling objects. A B
• If you work without cabin, the canopy has
to be mounted.

Removing the cabin

• Open the cabin door and engage in support.
A B
• Remove the floor mat and the floor panel in front
of the seat console inside the cabin.
• Remove the front panel of the seat console, both
4/4

0
h.

right-hand and left-hand side.

A
• Remove the rear cover.
• Loosen the cable connections leading towards the
cabin.
• If a radio is installed, it must be removed along A B
with the console. Unplug the antenna and
loudspeaker cables from the radio and draw back
the cables. A B
1 5
• Screw the crane lifting beam onto the cabin using
the 4 bolts. 2 2
4
• Remove the fastening screws (29/1 - 4 pcs.) with 4
washers (29/2) (screwing 29/A). 3
• Remove the nuts (29/5 - 2 pcs.) (screwing 29/B). 3

• Unhinge the cabin using a crane and place it

carefully down onto the ground.
• Put on the canopy and fasten (tightening torque HR2.0-02-29

MA = 80 Nm). Fig. 29 Attachment of the cabin

• Plug in the cable for the working floodlight(s). A) Screw

• Re-install the rear cover, front panel and floor mat. B) Nut

Attention
For the removal of the canopy and re-
installation of the cabin, proceed in the same
manner as above but in reverse order.

54 Operating Manual Crawler Excavator TC20

 Recovery, Loading and Transporting 6
6 Recovery, Loading and Transporting

6.1 Recovery
2
Attention
We recommend recovering the machine
using a crane.

2
The following towing lugs are available if the machine
has to be pulled for recovery:
– Lug (30/1) on chassis 1
– Two drilled holes (30/2) on dozer blade
2

HR2.0-01-30

Fig. 30 Towing lugs

6.2 Loading the machine by use of a 1

crane

Attention
Only use the original Terex crane lifting beam
for the cabin or the canopy.

Machine damage
due to exceeding the maximum weight-lifting
capacity.
• Ensure that the weight-lifting capacity of 1
the crane is at least 2500 kg.

HR1.6-04-34
• Empty and fold in the bucket.
Fig. 31 Crane suspension
• Position the work equipment to be pointing straight
ahead.
• Raise the boom.
• Retract the dipperstick.
• Stop the engine.
• Leave the excavator and close the doors.
• Screw the crane lifting beam (31/1) onto the cabin
or the canopy using the 4 bolts.
• Attach the excavator to the crane lifting beam in
the correct manner.

Operating Manual Crawler Excavator TC20 55

6 Recovery, Loading and Transporting
6.3 Transport
1 1 2
• During transport on a flat bed trailer, by truck and
rail, etc., the machine must be properly lashed at
the marked points (chassis 32/1 and dozer blade
32/2) and be secured with chocks.
• Lower the dozer blade and position the work
equipment on the ground.

Danger to life
due to disregarding the total transport height.
HR2.0-01-32-1
• Be aware of the total clearance height 1 1 2
when driving in tunnels, under bridges, etc.
Fig. 32 Lashing the machine
Danger of injury
due to uncontrolled movements of the
machine.
• For loading and transportation purposes,
adjust the machine to a wide track width.

Loading the machine onto a truck (Fig. 33)

• Connect the loading platform (ramp) to the
excavator (max. angle 15°).
• Secure the machine to be loaded with chocks
against rolling away.
HR3.7-03-36
• Drive the machine in reverse onto the truck and
drive it forward when unloading it from the truck.
• Carefully lash the machine for transport. Fig. 33 Loading the machine onto a truck

56 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7

7 Care and Maintenance

The good operating condition and life expectancy of

machines are largely influenced by care and
maintenance.

For this reason, it is in every machine owner’s interest

to perform the specified maintenance work and
comply with the service intervals. This Chapter deals
in detail with periodic maintenance, inspection and
lubricating tasks.

The type-specific maintenance and inspection plan

lists all work to be performed on the machine at
regular intervals. Maintenance and inspection plans
for this purpose are contained in every Instruction
Book.

It is essential that the recommendations in the

Chapter "Safety and Prevention of Accidents" are
observed (Î 2, 11).

7.1 Intervals

Initial inspection once before first putting into operation Î 7.7.1, 61

Daily jobs Every 10 operating hours or every work shift 1 Î 7.7.2, 62
Weekly jobs Weekly or after 50 operating hours 1
Î 7.7.2, 62
100 operating hours once after first putting into operation 2 Î 7.7.4, 66
Every 500 operating hours After every 500 operating hours Î 7.7.4, 66
Every 1000 operating hours After every 1000 operating hours Î 7.7.4, 66

Tab. 18 Intervals
1
whichever comes first
2
also applicable if new or overhauled diesel engines are put into operation.

Operating Manual Crawler Excavator TC20 57

7 Care and Maintenance
7.2 Regular oil analyses

Oil analyses are not intended as a substitute for the

oil change intervals but – apart from a possible
reduction of maintenance costs and as a form of
preventive maintenance – they take into account the
increasing environmental awareness.

Advantages of an oil analysis

– Extension of the oil change intervals under
standard or light-duty operating conditions.
– Minimum wear of high-quality components with
optimum use of the lubricants.
– Periodic laboratory analyses enable an early
detection of imminent damage.
– Repairs performed before they actually become
absolutely necessary help prevent serious and
unexpected damage.
– Sequential damage can be avoided.

How often should the oil be analyzed?

Periodic oil analyses reveal trends in the condition of

the oil and the machine. The oils should be analyzed
at the following intervals:
– Hydraulic oil: 1 000 operating hours
– Transmission oil: 500 operating hours
– Engine oil: 100 operating hours

Based on the first results, the laboratory recommends

the interval for the next sampling. Ask your Terex
dealer for an information booklet detailing the scope
and procedures of the oil analysis.

7.3 Warranty

During the warranty period thorough inspections are

stipulated which are obligatory and must be carried
out by trained specialist dealer personnel.

Attention
The inspections are obligatory and must be
paid for. The performance of inspections as
specified must be confirmed on the
inspection cards in the warranty/handing-
over certificate.
If omitted, this may affect the warranty
covered by us.

58 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
7.4 Inspection parts and aids

Tab. 19 --

Attention
Maintenance and wearing parts for
inspections should be ordered well in
advance.
Contact your dealer!

Lubricants
– The machine’s life expectancy and operating
condition largely depend on the use of the
specified lubricants and compliance with the
service intervals.
– If lubricants which do not conform to our
recommendations are used, consequential
damage may occur for which we will not assume
liability, even inside the warranty period.
– Observe the specifications for fuels, lubricants,
and coolants (Î 3.6, 26).

Operating Manual Crawler Excavator TC20 59

7 Care and Maintenance
7.5 Care and cleaning

Attention Engine oil

The machine must be cleaned on a suitable – The oil viscosity (SAE class) should be selected
surface with an oil separator. according to the ambient temperature at the
machine's place of operation.
• Neither a steam-jet appliance nor a high-pressure
Coolant
cleaning apparatus may be used for cleaning
during the first two months after the machine has – Before the beginning of the cold season, check
been used for the first time, or when newly the level of antifreeze and adjust in line with the
painted, to ensure that the paint can harden ambient temperature if necessary. At the factory,
sufficiently. the antifreeze protection is set to approx. –40 °C.
• Do not use aggressive detergents for cleaning the
Condition of the battery
machine. We recommend using commercially
available cleaning agents for passenger cars. – A good cold start performance requires a well-
charged battery. By warming the battery to
• When cleaning with a steam-jet appliance, the hot
approx. +20 °C (remove the battery after the
water jet should not exceed 80 °C and a spray
engine has been turned off and store it in a warm
pressure of 70 bar.
room), the minimum starting temperatures can be
• Linings (insulating materials, etc.) should not be lowered by 4 – 5 °C.
exposed directly to water, steam or high-pressure
– When installing the battery, ensure good contact
jets.
of terminal connections.
• When cleaning with water or steam jets, take care
– Only tighten terminal screws so that they are
not to spray exhaust-gas and air filter openings.
"hand-tight", to prevent deformation of the
• When cleaning the engine with water or steam terminal cones.
jets, do not expose sensitive engine parts, such as
generator, cabling, oil pressure switches, etc. Fuel
directly to the jet.
• Only use commercially available brand-named
• After each wet clean, the machine must be diesel fuel with a sulfur content of less than 0.5 %.
lubricated in accordance with the lubricating plan
and a test of all work cycles, support and driving Use only winter diesel fuel in winter to prevent line
functions carried out. connections becoming blocked through paraffin
deposits. At very low temperatures, troublesome
deposits may also occur when winter diesel is used.

7.6 Notes for winter operation

The following points - and the relevant notes in the

Engine Instruction Book - should be observed during
winter operation:

Hydraulic oil
– If the machine is not used for longer periods at
temperatures around and below freezing, warm it
up by running the engine at medium speed
(approx. 3 – 5 min).

60 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
7.7 Checking, maintenance and inspection plans

7.7.1 Initial inspection (Handing-over

inspection)

13

4/4
h.

R
HR2.0-01-34

8 6 9 7 3 2 1 5 4/13

Fig. 34 Initial inspection

Work to be carried out by trained dealer service

personnel.

Activities Chapter
1 Check whether machine-specific Operating Manual is in the machine.
2 Check the engine oil level. Î 7.8.2, 68
3 Check the hydraulic oil level. Î 7.8.9, 80
4 Check the fuel level. Î 7.8.5, 72
5 Check the coolant level. Î 7.8.4, 70
6 Check the oil level in the crawler gear units. Î 7.8.13, 83
7 Check the oil level in the swing gear Î 7.8.17, 86
8 Check the crawler-chain tension. Î 7.8.15, 84
9 Check the battery fluid level and charge. Î 7.8.19, 87
10 Grease machine (all lubricating points). Î 7.7.3, 64
11 Test run, hydraulic function check and test work.
12 Visual inspection for tightness of all hoses, pipes, cylinders, etc.
13 Check function of electrical indicating and warning elements, and the lighting system.
14 Initial delivery/handing-over certificate and return to manufacturer.
Tab. 20 Work involved in initial inspection

Operating Manual Crawler Excavator TC20 61

7 Care and Maintenance
7.7.2 Daily and weekly tasks

Inspection and maintenance jobs to be performed by

operating personnel.

18

15

16

HR2.0-04-37

5/17

11

13

14
R
4/4
0

h.

12

19

Fig. 35 Inspection and maintenance plan

62 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7

Daily Chapter
1 Check the hydraulic oil level. Î 7.8.9, 80
2 Check the engine oil level. Î 7.8.2, 68
3 Check the fuel level (fuel gauge on instrument panel). Î 7.8.5, 72
4 Check windshield washer-fluid level. Î 7.8.18, 86
5 Check crawler-chain tension of rubber chains. Î 7.8.15, 84
6 General visual inspection for material cracks, external damage, completeness, etc.
7 Check for leaks in pipes, hoses, control unit, hydraulic pumps, cylinders, etc.
Attention
The screw-in couplings must be locked when tightening hose or line connections to prevent
rotation.
8 Check function of electrical indicating and warning elements, and the lighting system.
9 Check smooth running of operator controls.
10 Grease machine according to overview of lubricating points. Î 7.7.3, 64
Tab. 21 Daily tasks

Weekly Chapter
11 Clean the cooling fins of the water cooler and the hydraulic oil cooler Î 7.8.4, 70
Machine damage Î 7.8.10, 81
due to strong accumulation of dust.
• Shorten the cleaning intervals.
12 Check whether there is water in the fuel line of the water separator and if necessary, drain. Î 7.8.5, 73
13 Check the coolant level. Î 7.8.4, 70
14 Clean the dust ejection valve on the air filter. Î 7.8.6, 74
Machine damage
due to strong accumulation of dust.
• Shorten the cleaning intervals.
15 Check the function of the front windshield.
16 Check that door catches function perfectly.
17 Check the crawler-chain tension of the steel chains. Î 7.8.15, 84
18 Check bearing bushings and pins/bolts of the work equipment.
19 Check the function, condition and completeness of safety devices (e.g. exit barrier, etc.).
20 Grease machine according to overview of lubricating points. Î 7.7.3, 64
Tab. 22 Tasks to be performed weekly

Operating Manual Crawler Excavator TC20 63

7 Care and Maintenance
7.7.3 Overview of lubricating points

Machine damage
due to damaged lubricating nipples.
• Replace damaged grease nipples
immediately and check if grease passes
through.

7 8 9

3
3 1
21

2
1
10
11

12

14 13 16

R
4/4

25
0

h.

HR2.0-04-38

17 18

Fig. 36 Overview of lubricating points

64 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
• Grease all lubricating points with multi-purpose
grease.

Attention
The intervals stated are valid for single-shift
operation.
• Shorten the lubrication intervals for special
operations, e.g. on sandy ground in order
to achieve self-cleaning of the bearing
points.

Item Lubricating point Number daily weekly Chapter

1 Bucket rod – bucket and/or quick-attach system 1 X
2 Dipperstick – bucket and/or quick-attach system 1 X
3 Bucket cylinder – Bucket rod – Tilt lever 3 X
4 Dipperstick – tilt control lever 1 X
5 Bucket cylinder – Dipperstick 1 X
6 Dipperstick cylinder – Dipperstick 1 X
7 Boom – Dipperstick 1 X
8 Dipperstick cylinder – Boom 1 X
9 Boom cylinder – Boom 1 X
10 Boom cylinder – Slewing column 1 X
11 Slewing column – Boom 1 X
12 Articulated cylinder – Slewing column 1 X
13 Uppercarriage – Slewing column 2 X
14 Dozer blade cylinder 2 X
15 -
16 Ring gear – bearing races 2 X Î 7.8.16, 85
17 Ring gear – Toothing 1 X Î 7.8.16, 85
18 Articulated cylinder – uppercarriage (open cabin floor) 1 X
19 - -
20 - -
21 Quick-attach system 2 X
Machine damage
For lubrication, place the bucket on the ground, open
the quick-attach system (the pins must be fully
retracted) - and start to lubricate. Close the quick-
attach system.
22 - -
Item Special equipment
25 Clamshell grab 11 X
Tab. 23 Lubricating points

Operating Manual Crawler Excavator TC20 65

7 Care and Maintenance
7.7.4 Inspection Table

Work to be carried out by trained dealer service

personnel.

O = Checking, maintenance operating hours min. min.

X = Replace 2x 1x
Perform work with machine at operating temperature after eve- eve- eve- annu- annu- Chapter
100 ry ry ry ally ally
300 600 1200
1 Check whether machine-specific Operating Manual is in the O O
machine.
2 Change engine oil. X X X Î 7.8.2, 68
3 Change the engine oil filter. X X X Î 7.8.3, 69
4 Drain water from the fuel tank. O O O Î 7.8.5, 72
5 Change fuel filter. X X X Î 7.8.5, 72
6 Check air intake. O O Î 7.8.6, 74
7 Replace air filter main cartridge. according to the X Î 7.8.6, 74
service indicator
8 Replace the air filter safety cartridge. as required 1 Î 7.8.6, 74
9 Clean cooling fins of the hydraulic oil cooler. O O O Î 7.8.10, 81
Machine damage
due to strong accumulation of dust.
• Shorten the cleaning intervals.
10 Clean cooling fins of the water cooler. O O O Î 7.8.4, 70
Machine damage
due to strong accumulation of dust.
• Shorten the cleaning intervals.
11 Check level of antifreeze in the coolant. O Î 7.8.4, 70
12 Change the coolant. as required 1 Î 7.8.4, 70
13 Check V-belt tension. O O Î 7.8.7, 76
14 Check engine mount and pump attachments. O O
15 Check engine speed adjustment, upper and lower idling speeds. O O
16 Check valve lash on the engine and adjust if necessary. O O O Î 7.8.8, 79
17 Check injection nozzles. O
18 Check injection pump. O
19 Check acid level and battery connections. O O Î 7.8.19, 87
20 Check condition of crawler chains. O O Î 7.8.15, 84
21 Check secure fastening of crawler-chain sprocket, crawler gear units O O
and hydraulic motor.
22 Check smooth running of bottom and top rollers. O O
23 Check bearing bushings and pins/bolts of work equipment and O O
adjust until they are without play.
24 Check electrical indicating and warning elements and lighting O O
equipment.
25 Check smooth running of operator controls and adjust if necessary. O O
Tab. 24 Inspection plan
1
At least every two years.
2 Extension of oil change intervals according to oil sample analysis and laboratory report Î 7.2, 58.
3 Within warranty.

66 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7

O = Checking, maintenance operating hours min. min.

X = Replace 2x 1x
Perform work with machine at operating temperature after eve- eve- eve- annu- annu- Chapter
100 ry ry ry ally ally
300 600 1200
26 Check for leaks in all pipes, hoses, control valves, hydraulic pumps, O O
cylinders, etc.
Attention
The screw-in couplings must be locked when tightening
hose and line connections to prevent rotation.
27 Check or change the hydraulic oil. O O X2 X Î 7.8.9, 80
28 Replace the hydraulic oil return filter insert. X according to X Î 7.8.11, 82
service
indicator
29 Replace breather. X X Î 7.8.12, 82
30 Check or replace oil of crawler gear units. X O X X Î 7.8.13, 83
31 Check secure fastening of swing bearing attachment. O O O Î 7.8.17, 86
32 Check that the ring gear attachment screws are securely fastened. O O O Î 7.8.16, 85
33 Grease machine according to overview of lubricating points. O O Î 7.7.3, 64
34 Check function, condition and completeness of safety devices. O O
35 Check function of brake valves. O O Î 7.8.14, 83
36 Hydraulic function check with pressure function test. O O
37 Test run and test work. O O
38 Initial inspection card and return to manufacturer. O O3 Î 7.3, 58
Tab. 24 Inspection plan
1
At least every two years.
2
Extension of oil change intervals according to oil sample analysis and laboratory report Î 7.2, 58.
3
Within warranty.

Operating Manual Crawler Excavator TC20 67

7 Care and Maintenance
7.8 Inspection and maintenance work

7.8.1 Opening and closing the engine hood

Danger of injury
due to unlocked engine hood.
1
Ensure that the engine hood lock snaps into
place correctly when opening the engine
hood.

Machine damage
due to securing device which has not been
unlocked.
• Before closing the engine hood, push lever
(37/1) upward.

Fig. 37 Closing the engine hood

7.8.2 Engine oil

Checking the engine oil level

• The oil level must be checked daily before start-up
with the machine standing on level ground.
• Insert the oil dipstick (38/3) until the stop. The 3
notches on the dipstick indicate the minimum and
maximum oil levels. 4
• Top up engine oil if necessary. Open the filler neck 2
(38/2) and add oil using a clean container. Close
the filler neck again.

1
HR1.6-01-41

Fig. 38 Engine oil

68 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
Changing the engine oil

Attention
• Collect the waste oil in a suitable container
and dispose of in compliance with 3
regulations.
4
• Run the engine until it reaches operating 2
temperature, engine oil temperature approx.
80 °C.
• Park the machine on a level surface.
• Stop the engine.
• Place suitable drip pans under the opening.
1
• Screw the oil drain hose onto the oil-change valve
(39/1). HR1.6-01-41

Danger of scalding Fig. 39 Engine oil

due to hot oil getting into contact with skin or

eyes.
• Wear appropriate protective clothing and
safety goggles.

• Remove the oil drain hose and screw the

protective cap onto the valve (39/1).
• Change the engine oil filter (Î 7.8.3, 69).
• Replenish engine oil via the oil filler neck (39/2) to
the "MAX" mark on the oil dipstick (39/3).

7.8.3 Engine oil filter

The engine oil filter must be replaced every time the

engine oil is changed.
• Unscrew the filter cartridge (40/4) using a 3
tightening scrap wrench or similar tool and dispose
of in compliance with regulations. 4
• Clean the filter head and check its condition. 2

• Wet the seal ring with oil and tighten firmly by

hand.
• Check the tightness of the engine oil filter
cartridge.

1
HR1.6-01-43

Fig. 40 Engine oil

Operating Manual Crawler Excavator TC20 69

7 Care and Maintenance
7.8.4 Engine - cooling system

Checking the coolant level

Danger of scalding
due to hot oil getting into contact with skin or
eyes.
• Only check the coolant level after the
engine has cooled down.
• Wear appropriate protective
clothing/safety goggles.

• Release pressure from the cap (41/1).

1
• Remove cap (41/1) and check the water level.
• The water level must be up to the overflow pipe 2
(41/2).
• If required, top up with a mixture of water and
antifreeze (50 %/50 %).

Water cooler – cleaning the cooling fins

Machine damage
due to overheated engine.
• Clean the cooler thoroughly.
HR1.6-04-43
• Clean the water cooler from the outlet side with
compressed air. Fig. 41 Water cooler

Clean with cold detergent or a steam-jet appliance if

required, e.g. if there is oil in the cooler.
• Park the machine on a cleaning area equipped
with an oil separator.
• Clean the machine using a steam-jet appliance.
• After cleaning, run the engine until it reaches
operating temperature to dry the cooler.

70 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
Changing coolant

Danger of scalding
1
due to hot oil getting into contact with skin or
eyes. 2
• Only change coolant after the engine has
cooled down.
• Wear appropriate protective clothing and
safety goggles.

• Park the machine on a level surface.

• Place a drip pan under the engine and cooler.
• Before removing the cooler cap (42/1), release
pressure from the cap.
HR1.6-04-43
• Open the drain valve (43/1) on the cooler and
drain coolant. Fig. 42 Water cooler
• Unscrew the water-drain plug (43/2) on the
cylinder block and drain coolant. 2
• If necessary, flush the cooling system with clean
water.
• Refit the drain plug to the engine and close again
the drain valve on the cooler.
• Fill the cooling system with coolant and close the
cooler with the cap (42/1).
• Start the engine and bring to operating
temperature; turn off the engine and allow to cool.
• Check the coolant level and top up coolant 1
(several times, if necessary).
HR1.6-01-46

Fig. 43 Changing coolant

Operating Manual Crawler Excavator TC20 71

7 Care and Maintenance
7.8.5 Fuel system

Checking the fuel level

• Check the fuel level using the fuel gauge (44/23).
• In order to prevent condensation from forming
23
before the machine is next put into operation, top
up fuel every day after use (45/1).

4
4/
0

h.
HR3.7-03-49

Fig. 44 Checking the fuel level

HR2.0-04-47

Fig. 45 Fuel tank

Replacing the fuel filter

Attention
• Collect the fuel in a suitable container.

• Unscrew drainage unit (46/1).

• Loosen and remove filter unit (46/2).
2
• Collect any escaping fuel. 1
• Screw the drainage unit (46/1) to the new filter
unit.
• Install new fuel filter.
• Check for leakages.

Attention
Fig. 46 Replacing the fuel filter
The fuel system does not have to be vented.

72 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
Venting the fuel system

Note
• The fuel system must be vented if the fuel
tank has been completely emptied.

• Fill the fuel tank.

• Operate the pump (47/2) at the fuel filter (47/1) 1
until fuel flows through the fuel filter. 2
Draining the fuel system
• Place a suitable container under the opening of
the water separator.
• Unscrew the drain valve (47/3) until fuel flows out
of it.
• Remove the container and dispose of the fuel.

Fig. 47 Venting and draining the fuel filter

Operating Manual Crawler Excavator TC20 73

7 Care and Maintenance
7.8.6 Air filter, air intake

Machine damage
due to dust being drawn into the engine.
• All maintenance work on the air intake
system must be carried out with the engine
off.
• Do not start the engine while the filter
cartridge is removed.

Cleaning the dust ejection valve

The dust ejection valve (48/1) is largely maintenance-
free.
• Any baked-on dust can be removed by squeezing
the valve together.

Cleaning or replacing the air intake

• Clean impurities (leaves, etc.) from the air intake
section in front of the air filter.
• Check the air filter attachment for damage and
repair or replace if necessary.
• Check the tightness of the air duct after the air
filter.
• Examine rubber parts for damage and replace if 1 HR12-03-53
necessary.
Fig. 48 Cleaning the dust ejection valve

74 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
Cartridge maintenance intervals
The air filter main cartridge must be replaced if, during
operation, the filter maintenance indicator lamp
(49/21) in the instrument panel lights up.
21
Attention
A brief delay in maintenance does not result
in lower filter efficiency.
R

4
4/
Replace the air filter safety cartridge:

h.
– after the third maintenance of the main cartridge
– after 2 years of operation at the latest HR3.7-04-54

– if the service indicator switches on after the main

cartridge has just been serviced
– if the main cartridge is damaged
– if the safety cartridge is damaged. Fig. 49 Maintenance switch indicator lamps

Changing the main cartridge

• Open the tension brackets (50/5) and remove the
cover (50/1) along with the dust ejection valve.
• Withdraw the dirty air filter cartridge (50/2) by
carefully turning and tilting and dispose of it.
• Note down the date of maintenance on the safety
cartridge. 5

• Clean the filter housing (50/4) with a damp cloth,

especially the seal area for the air filter cartridge.
• Check whether the new air filter cartridge is
damaged.

Machine damage 4 3 2 1
due to dust being drawn into the engine. HR1253

• Do not install damaged air filter cartridges.

Fig. 50 Changing air filter cartridges
• Mount the air filter cartridge into the filter housing
by slightly turning.
• Re-mount the cover along with the dust ejection
valve to the bottom and re-fasten with tension
brackets (50/5).

Operating Manual Crawler Excavator TC20 75

7 Care and Maintenance
Changing the safety cartridge
• Remove main cartridge (51/2).
• Remove the safety cartridge (51/3) by carefully
turning and tilting and dispose of it according to
regulations.
• Clean the filter housing (51/4) with a damp cloth,
especially the seal area for the cartridges. 5

• Install the new safety cartridge in the filter housing

by slightly turning it.
• Install the main cartridge in the filter housing.
• Re-mount the cover (51/1) along with the dust
ejection valve to the bottom and re-fasten with 4 3 2 1
tension brackets (51/5).
HR1253

7.8.7 V-belt
Fig. 51 Changing air filter cartridges
Danger of injury
due to rotating V-belts.
• Only check and tension V-belts with the
engine off.
• Secure the engine against unauthorized
starting.

• Check the entire V-belt for damage (visual

inspection). Replace damaged or worn V-belts
immediately.

Checking V-belt tension

Attention
We recommend checking the V-belt tension
using a V-belt belt tensioner gauge.
• Check the tension in accordance with the
manufacturer’s Operating Instructions.

76 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
Checking without a belt tensioner gauge
• Press the V-belt with your thumb in the middle of
the greatest free length, and measure the V-belt
sag.

Attention
Using medium thumb pressure of approx.
45 N (approx. 4.5 kg), the V-belt sag should
equal 10 mm.

Tensioning the V-belt

• Stop the engine and remove the ignition key.
• Open the engine hood. 1
• Slacken the fastening screw (52/1) of the 14Nm
generator.
• Rotate the generator until the tension is correct.
• Re-tighten the fastening screws 52/1 and 52/2 of
the generator. 2
• Check the tension again. 22Nm
10
mm
• Close the engine hood.

HR1.6-04-53

Fig. 52 Tensioning the V-belt

Operating Manual Crawler Excavator TC20 77

7 Care and Maintenance
Changing V-belts
• Open the engine hood.
• Disconnect the battery. 1
• Loosen the fastening screw of the protective grill 14Nm
(option) and remove the protective grill (option).
• Loosen the clamping bolt (53/1) of the generator
and remove the V-belt.
• Slightly press the water cooler to the right and take 2
out the V-belt above the fan blade. 22Nm
10
• Mount the new V-belt and tighten according to mm
instructions.
• Re-mount the screw of the protective grill (option).
• Re-connect the battery. HR1.6-04-53

• Check the correct function of the fan blade.

Fig. 53 Changing V-belts
• Perform a test run.
• After 15 minutes, check the tension of the new V-
belts and adjust if necessary.

78 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
7.8.8 Valve lash

• Test the valve lash (54/1) on a cold engine by

placing a feeler gauge between the upper part of
the tappet (54/3) and the rocker arm (54/2).

The correct valve lash is as follows:

Inlet valve = 0.25 mm
Exhaust valve = 0.25 mm

Attention
The 1st cylinder is located at the front on the
fan side of the engine.
Firing sequence: 1 – 3 – 2
6
• Remove the valve cover
2
• Turn the crankshaft clockwise until the valves 5
intersect at the 1st cylinder.
4
• The markings (54/6) on the housing and V-belt 1
pulley must coincide. Check the overlapping of the
valve by moving the crankshaft by approx. 20° in
both directions. The rocker arm must not move.
3
• If the rocker arm moves, the crankshaft must be
turned further by one full turn (360°).
• In this position, check the valve lash of the valves
on the 1st cylinder.
HR1258
Attention
If necessary, adjust the valve lash as follows: Fig. 54 Adjusting the valve lash

• Slacken lock nut (54/4).

• Using a screwdriver, adjust the setting
screw (54/5) in such a way that the correct
valve lash (54/1) is obtained after the lock
nut is tightened.

• To adjust the other cylinders, turn the crankshaft

further by 240° in each case.
Order of adjustment = firing sequence
• Check and adjust the valves as specified for the
1st cylinder.
• Re-install the valve cover.

Operating Manual Crawler Excavator TC20 79

7 Care and Maintenance
7.8.9 Hydraulic oil tank

Checking the hydraulic oil level

• Remove the return filter cover (55/2).
• Check the oil level using the sight glass (55/3) and
replenish hydraulic oil if necessary.
1
Attention
2
The excavating equipment must be extended
and lowered to the ground.
• Ensure that the hydraulic oil level lies
between the two markings.
3

Changing the hydraulic oil

Attention
• Only change the hydraulic oil when it is at
operating temperature.
HR1.6-04-56

• Retract all hydraulic cylinders.

Fig. 55 Checking the hydraulic oil level, changing the
• Stop the engine. hydraulic oil
• Unscrew the breather (55/1).
• Place suitable drip pans under the opening.

Danger of scalding
due to hot oil getting into contact with skin or
eyes.
• Wear appropriate protective
clothing/safety goggles.

• Unscrew the drain plug (56/1) from the hydraulic

oil tank and drain oil into clean containers.

Attention
• Dispose of the waste oil according to
regulations.

• Screw back on the drain plug carefully.

• Loosen the return filter cover.
• Fill up with clean hydraulic oil until the correct level
on the sight glass (55/3) is reached.
1
• Re-mount the filter cover. HR1.6-04-57
Fig. 56 Drain plug
• Screw back in the breather.

80 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
7.8.10 Hydraulic oil cooler

Machine damage
due to overheated engine.
• Clean the cooler thoroughly.

• The hydraulic oil cooler (57/1) is cleaned from the

outlet side using compressed air.

Clean with cold detergent or a steam-jet appliance if

required, e.g. if there is oil in the cooler.
• Park the machine on a cleaning area equipped
with an oil separator.
1
• Clean the machine using a steam-jet appliance.
HR1.6-04-58
• After cleaning, run the engine until it reaches
operating temperature to dry the cooler.
Fig. 57 Hydraulic oil cooler

Operating Manual Crawler Excavator TC20 81

7 Care and Maintenance
7.8.11 Hydraulic oil return filter

Attention
• After a larger repair job, renew the filter 1
insert following the test run. 2
• Damaged hydraulic attachments may
shorten the operating life of the return filter.

Changing the filter insert 3

• Switch off the engine.

Attention
Always place a receptacle for the collection of
waste oil under the working area when
draining oil or removing the filter insert.
HR1.6-04-56

Fig. 58 Hydraulic oil tank

• Remove the cover (59/1) of the return filter (58/2)

using an auxiliary tool and unscrew. 1
• Check the condition and O-rings of the cover. 2

• Pull out the filter element and dispose of according

to regulations.
• Clean the filter bowl if necessary.
• Check O-rings and replace any damaged part.
• Check the condition of the clogging indicating
sensor.
• Insert a new filter element.
• Apply a light coat of grease to the cover and
tighten the cover by hand.
• Check the tightness of the filter.

7.8.12 Breather

• Remove the breather (58/1), replace it by a new

filter and tighten so that it is hand-tight.

Attention
The breather must also be replaced if it is
dirty, for example due to hydraulic oil vapor.
Fig. 59 Return filter

82 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
7.8.13 Crawler gear units

Checking the oil level

– Move the crawler gear unit to the inspection
position.
– Remove the inspection screws (60/2) and top up
oil up to bottom edge of the drill holes if required.

Carrying out an oil change

Attention A 3
• Dispose of waste oil in compliance with
regulations.

• The oil must be changed at operating temperature

with the machine parked on level ground.
• Position the transmission in such a way that the
drain plug (60/1) is right at the bottom. 2

• Open the filler/inspection plug (60/2) on the

transmission.
• Open the drain plug (60/1) and catch any escaping
oil. B
• Flush out the transmission with flushing oil if
necessary.
1
• Carefully re-insert the drain plug with sealing tape
and top up transmission oil using the
filler/inspection plug (60/2) until oil escapes from
the hole.
• Carefully re-insert the filler/inspection plug with
HR1.6-06-63
sealing tape.
Fig. 60 Crawler gear units
7.8.14 Brake valves A) Filling and inspection position
B) Drain position
Function check
• Move both levers equally forward into the
"Machine rolling" position.
• Move both levers to neutral position at the same
time.
The machine should brake in a constant manner
and must not drift sideways.

Operating Manual Crawler Excavator TC20 83

7 Care and Maintenance
7.8.15 Crawler chains

Checking the crawler chain tension

• This check must be carried out on a level surface.
• Slew the uppercarriage by 90° and lift on one side
until the crawler is free above ground.

• The sag of the crawler chain between lower roller

and crawler chain (Fig. 61, distance "a") should
a
be:
Steel chain approx. 25 – 35 mm 2
Rubber chain approx. 15 – 20 mm
.

Tensioning the crawler chain grease

1
• Remove the covers on the right-hand and left-
hand side of the crawler frame and re-tension the
crawler chain using the hand grease gun via the
grease nipple (61/1).
• Move the crawler chain and check the crawler- HR2.0-01-61

chain tension again. Fig. 61 Crawler chain tension

Attention
in case of new rubber crawler chains.
• Check the sag of the rubber chains on the
first day of operation 2 - 3 times and
retension if necessary.

Releasing the crawler chain tension

Danger of injury
due to grease spurting out under pressure.
• Wear appropriate protective clothing and
safety goggles.
• Release the crawler chain tension slowly
and carefully.

• Slowly loosen the valve (61/2) with the grease

nipple and let grease drain out until the correct
crawler chain tension is obtained.
• Re-tighten the valve using the grease nipple.
• Remove any grease and dispose of according to
regulations.
• Move the crawler chain and check the crawler-
chain tension again.

84 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
7.8.16 Swing bearing

Lubrication of toothing R
4/4

0
h.

The grease nipple (62/1) mounted on the left side

inside the cabin lubricates the toothing of the ring gear
via a nozzle tube (62/2). To do so:
• Slowly slew the uppercarriage and lubricate it
thoroughly at the same time using a grease gun.

Lubrication of bearing races

1
The bearing races are lubricated via the lubricating 4
nipples (62/3) mounted on the ring gear. To do so:
• Slowly slew the uppercarriage and lubricate it
thoroughly until the gasket has a collar (62/4) of
fresh grease.
3
4
Checking the secure fastening of the swing
bearing
2
Attention
• When mounting for the first time, the bolts
must again be checked after 100 operating
hours. HR1.6-05-63

Fig. 62 Ring gear

The following assembly conditions are prerequisites
for an optimum bolted connection on the chassis and
the uppercarriage:
– The contact faces of bolts must be of bright metal,
i.e. absolutely free from grease and paint.
– The thread and the bolt head must not be MA = 125 Nm
damaged. A
MA = 125 Nm
MA = 64 Nm
Machine damage
MA = 64 Nm
due to damaged screws/bolts. C 8
6

• Replace damaged screws/bolts

immediately.
2

B 4
• All screws/bolts must be examined to ensure that
6
they are tightened to the torques specified in
8
Fig. 63. HR1.6-04-64

Checking the swing bearing attachment

• All screws/bolts must be examined to ensure that Fig. 63 Swing bearing
they are tightened to the torques specified in A) Uppercarriage
Fig. 63.
B) Chassis
C) Oval hole (x3) (below the oval cover)

Operating Manual Crawler Excavator TC20 85

7 Care and Maintenance
7.8.17 Swing gear

Attention
The swing gear has lifetime lubrication. Oil
changes are therefore unnecessary.

HR2.0-03-66

Fig. 64 Swing gear

7.8.18 Windshield washer system

• Top up the windshield washer tank (65/14) as

required.
• Add antifreeze when temperatures are around or
below freezing.

4/
4
h.

R
14
HR1.6-04-68

Fig. 65 Washer-fluid container

86 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
7.8.19 Electrical equipment

Battery
The battery (66/1) is located under the floor panel on
the left-hand side inside the cabin.

Attention R

4/4
0

h.
The instructions of the battery manufacturer
must be observed when using the battery for
the first time.

• Only check the battery with the engine switched

off.
• The acid level should be approx. 10 mm above the
plates. If necessary, top up with pure distilled 1
water. HR1.6-04-63

Attention
In the case of maintenance-free batteries, Fig. 66 Battery
this check is not necessary.

Operating Manual Crawler Excavator TC20 87

7 Care and Maintenance
Removing the battery
• Open the cabin floor.
• First disconnect the battery ground cable (-), then
the positive cable (+). 1
• Slacken the clamping bracket (67/1).
• Lift out the battery.

Installing the battery

• Place the battery into the machine.
• Secure with the clamping bracket.
• Connect first the positive battery cable, then the
ground cable.

HR1.6-05-70
Machine damage
due to reverse of terminals.
Fig. 67 Removing the battery
• Ensure that the negative terminal is
connected to the negative pole (-) and the
positive terminal to the positive pole (+).

• Close again the cabin floor.

Attention
In winter, in particular, the battery charge
should be closely monitored.

Checking the lighting and warning equipment

• Check the function of the lighting equipment.
• Check the function of the indicator lamps.
• Check the function of the warning equipment.

88 Operating Manual Crawler Excavator TC20

 Care and Maintenance 7
7.9 Immobilization

7.9.1 Preservation (temporary immobilization ) 7.9.2 During immobilization

Machine damage
When the machine is out of use for 6 months, after
due to damage from storage (e.g. corrosion this time all assemblies must be brought to operating
damage) during shutdown periods over three temperature and maneuvered for
months. approx. 15 minutes.
• Perform the preservation measures.
Beforehand, the anti-corrosion coat must be
Preservation measures: removed from the piston rods, and the openings of
• We recommend keeping the machine in a dry, the air filter system and the exhaust pipe freed.
dust-free room during the storage period. After the maneuvering cycle, preserve the machine
• Thoroughly clean the inside and outside of the once more as previously described.
machine, including the engine.
• Lubricate the machine according to the 7.9.3 After immobilization
lubrication plan.
Before putting the machine into operation once
• Check the oil levels of all assemblies such as more, the following measures must be carried out:
transmission(s), etc. and top up if necessary.
• Anti-corrosion coat must be cleaned from the
• Check the hydraulic oil level and top up if piston rods.
necessary.
• Seal off the air intake opening of the air filter and
• Repair any paint damage. the exhaust pipe opening.
• Fill the diesel tank completely, to prevent • Check the condition of the air filter main cartridge
corrosion of the tank walls. and the safety cartridge and replace if necessary.
• Check the antifreeze level in the coolant and • Clean the machine with a neutral detergent.
adjust if necessary.
• Check and, where required, re-charge and re-
• Perform all preservation measures specified in install the battery.
the diesel engine Operating Manual.
• Carry out all measures for putting the diesel
• Ensure that the crawler chain tension engine back into operation listed in the Engine
corresponds to the prescribed value and protect Operating Manual.
rubber crawler chains from direct sunlight.
• Lubricate the machine according to the
• Treat bare piston rods with a commercially lubrication plan.
available anti-corrosion agent.
• Remove and clean the battery and keep it If the machine has been out of use for more than
according to regulations in a dry - in winter, frost- 6 months
proof - room. Coat connections with a little pole – The oil in the assemblies such as axles,
grease. transmission(s), etc. must be changed.
• Seal off the air intake opening of the air filter – Replace hydraulic oil filters (suction and return
system and the exhaust pipe opening. filters, breathers, if installed).

Operating Manual Crawler Excavator TC20 89

7 Care and Maintenance

90 Operating Manual Crawler Excavator TC20

 Trouble-shooting 8

8 Trouble-shooting

Operating problems are often the result of incorrect

handling of the machine, the use of unsuitable
materials or irregular maintenance.

The following Table presents a summary of a range of

problems and their probable causes.

If a problem can only be eliminated through repair,

then your responsible Service Agent must be called
in.

8.1 Engine

All faults in the diesel engine must be examined as

described in their specific Engine Operating
Instructions.

During the warranty period, malfunctions must be

dealt with by your responsible Service Agent or a
specialist workshop.

8.2 Table of faults

Possible cause Remedy

Machine fails to drive
Engine damaged. Check engine.
Too little hydraulic oil in tank. Top up hydraulic oil to recommended mark.
Hydraulic pump has failed. Have pump checked for mechanical damage by specialist.
Replace hydraulic pump completely.
Clutch or pump drive damaged. Replace pump drive.
Determine cause of damage.
Main relief valve damaged or wrongly adjusted. Replace main relief valve.
Insufficient driving performance
Insufficient engine power. Check diesel engine.
Main relief valves damaged or wrongly adjusted. Check pressure, re-adjust valves, replace if necessary.
Oil loss in rotary joint. Re-seal rotary joint.
Crawler chains tensioned too tightly. Check crawler-chain tension and reduce if required.
Excavator installation not working
Exit barrier lifted and/or shutoff valve damaged. Lower exit barrier and/or check shutoff valve; replace or repair if
required.
Oil supply to hydraulic pump interrupted. Check lines.
Hydraulic pump has failed. Have hydraulic pump checked by specialist and replace if necessary.
Main relief valves have failed or are wrongly Check main relief valve and replace if necessary.
adjusted.
Decrease in machine's performance
Insufficient engine power. Check diesel engine.
Insufficient hydraulic oil level. Top up hydraulic oil to the recommended mark.
Pump is sucking in air. Re-tighten hose connections. Replace O-ring or seals.
Insufficient operating pressure. Re-adjust main relief valves or replace if required.
Machine working too slowly and hydraulic oil is becoming too hot
Tab. 25 Table of faults

Operating Manual Crawler Excavator TC20 91

8 Trouble-shooting

Possible cause Remedy

Incorrect adjustment of main relief valves or valves Re-adjust main relief valves or replace if required.
are damaged.
Hydraulic pump worn. Replace hydraulic pump.
Incorrect hydraulic oil. Quality of hydraulic oil must conform to our recommendation.
Insufficient oil level. Top up oil to mark on sight glass.
Oil cooler dirty or damaged. Clean, check and replace if necessary.
Air in hydraulic system. Tighten connections with engine off and system relieved of pressure.
Uppercarriage slewing too far
Secondary valves damaged or wrongly adjusted. Re-adjust secondary valves; replace if required.
Swing motor is leaking – internal wear. Replace hydraulic motor.
Working cylinders not operating satisfactorily
Seals in cylinders worn. Re-seal cylinder(s).
Secondary valves damaged or wrongly adjusted. Check secondary valves and replace completely if required.
Main relief valves wrongly adjusted. Check main relief valves and replace if required.
Faults in the electrical system
Outside and/or internal lighting without function. Check cables, connections, bulbs, and fuses.
Windshield wiper not working. Check cables, connections, and fuses. Examine windshield wiper for
mechanical damage, replace if necessary.
Windshield washer system not working. Check water level. Check cables, connections and fuse.
Check water pump and water pipes and replace if necessary.
Horn not responding. Check cables, connections and fuses, replace horn if necessary.
Warning/indicating elements are imprecise. Determine the fault or source of the problem and eliminate it, call
service personnel if necessary.
Tab. 25 Table of faults

92 Operating Manual Crawler Excavator TC20

 Appendix 9

9 Appendix

9.1 Electrical system

Fig. 68 Fuse and relay box – assignment diagram

Item Amps Assigned to

FA 30 A Main fuse
FB 60 A Pre-heating fuse
F1 5A Instrument cluster 15, immobilizer 15
F2 10 A Fuel pump, generator
F3 15 A Working floodlights, front
F4 15 A Working floodlights rear, boom
F5 10 A Travel fast/slow, travel motion alarm
F6 10 A Swing brake, dozer blade
F7 15 A Heater fan
F8 15 A Washer and wiper system
F9 10 A Horn, radio 15
F10 20 A Optional: 2nd control circuit, optional: electrical seat, air conditioning system
F11 5A Instrument cluster 30, immobilizer 30
F12 10 A Interior light, radio 30, rotating beacon
F13 15 A Socket
F14 15 A Optional: refueling pump optional: 30
K1 – Main relay
K2 – Swing brake
K3 – Front dozer blade
K10 – Glow plug timing unit
K12 -- Time relay engine shut-off
Tab. 26 Assignment

Abbrev. Color Abbrev. Color Abbrev. Color Abbrev. Color

bg beige dgr dark gray hbr light brown rt red
bl blue ge yellow hgr light gray sw black
br brown gn green hr light red vie violet
dbl dark blue gr gray nt natural colors ws white
dbr dark brown hbl light blue or orange
Tab. 27 Cable and plug colors

Operating instructions TC20 crawler excavator 93

9 Appendix
9.2 Immobilizer

Note
The immobilizer is self-activating; that is,
without additional activation or divergent
actions.
If the mechanical start switch is in
position "0" (terminal 15 off), the
immobilizer is generally activated.

• Set the start switch key to position "0".

• The immobilizer is automatically activated after
5 sec.
• The immobilizer becomes and remains activated if
the key remains inserted in position "0".

Deactivating the immobilizer

Note
The immobilizer is deactivated if a valid
mechanical key and a valid electronic key
(transponder) are present.

• Set the start switch key to position “1”.

• The transponder is not read until the mechanical
key in the start switch has activated terminal 15.
This makes it necessary to first open the
mechanical locking system before the electronic
key is inspected. A manipulation of the immobilizer
with the ignition deactivated is thereby impossible.

94 Operating instructions TC20 crawler excavator

 Handing over the Machine and Instructing the Operator 3. Warranty
– Explanation of warranty offered by manufacturer.
The following checklist should be followed when handing over the machine to the
operator: – Explanation of inspection cards and note on maintenance and inspection plan.
– The warranty/handing-over card must be filled out correctly and sent back to the
1. Operating Manual manufacturer.
Go through the Operating Instructions (page by page) and explain them in detail
through practical training on the machine. Items which are particularly important
include:
– Accident Prevention Regulations published by the employers liability insurance
associations in the users country
– Technical Specifications
– Operator controls, indicating and warning elements
– Checks before putting the machine into operation
– Diesel engine running-in instructions Crawler Excavator
– Starting and stopping the diesel engine
– Explanation of hydrostatic crawler drive
– Driving TC20
– Recovery and transport of the machine
– Operation of all functions
– Tensioning crawler chains
– Explanation of maintenance intervals and points according to Maintenance and Maintenance and Inspection Plan
Inspection Plan by demonstrating and explaining maintenance points on machine
(for trained dealer service personnel)
– Lubrication intervals and points of lubrication according to lubrication chart and
demonstration of these points on the machine The careful performance of all prescribed inspections is the best prerequisite for the
machines continuous readiness for operation.
– Handing-over of Diesel Engine Operating Instructions
The inspections are obligatory. If omitted, this may affect the warranty covered by us.
2. Spare Parts List
The following applies to maintenance and inspection work:
– Structure of Spare Parts List, Figures and the associated texts
• The machine must be thoroughly cleaned before inspection takes place.
– Instructions for ordering spare parts - always state the type of machine, the vehicle
• All maintenance work specified should be performed in the prescribed sequence
identification number ("Fz-Id.Nr."), parts designation, complete spare part number,
with the machine at operating temperature.
number of pieces, delivery address, etc.
O = Checking, maintenance operating hours min. min. O = Checking, maintenance operating hours min. min.
X = Replace 2x 1x X = Replace 2x 1x
Perform work with machine at after every every annu- annu- Perform work with machine at after every every annu- annu-
operating temperature 100 500 1000 ally ally
operating temperature 100 500 1000 ally ally
1 Check whether machine-specific Operating O O 24 Check electrical indicating and warning elements O O
Manual is in the machine. and lighting equipment.
2 Change engine oil. X X X 25 Check smooth running of operator controls and O O
3 Change the engine oil filter. X X X adjust if necessary.
4 Drain water from the fuel tank. O O O 26 Check for leaks in all pipes, hoses, control valves, O O
5 Change fuel filter. X X X hydraulic pumps, cylinders, etc.
6 Check air intake. O O Attention
7 Replace air filter main cartridge. according to the X The screw-in couplings must be locked
service indicator when tightening hose and line
connections to prevent rotation.
8 Replace the air filter safety cartridge. as required 1
9 Clean cooling fins of the hydraulic oil cooler. O O O 27 Check or change the hydraulic oil. O O X2 X
28 Replace the hydraulic oil return filter insert. X X X
Machine damage
29 Replace breather. X X
due to strong accumulation of dust.
30 Check or replace oil of crawler gear units. X O X X
• Shorten the cleaning intervals.
31 Check secure fastening of swing bearing O O O
10 Clean cooling fins of the water cooler. O O O attachment.
Machine damage 32 Check that the ring gear attachment screws are O O O
due to strong accumulation of dust. securely fastened.
33 Grease machine according to overview of O O
• Shorten the cleaning intervals.
lubricating points.
11 Check level of antifreeze in the coolant. O 34 Check function, condition and completeness of O O
12 Change the coolant. as required 1 safety devices.
13 Check V-belt tension. O O 35 Check function of brake valves. O O
14 Check engine mount and pump attachments. O O 36 Hydraulic function check with pressure function O O
15 Check engine speed adjustment, upper and lower O O test.
idling speeds. 37 Test run and test work. O O
16 Check valve lash on the engine and adjust if O O O 38 Initial inspection card and return to manufacturer. O O3
necessary. 1
At least every two years.
17 Check injection nozzles. O 2
Extension of oil change intervals according to oil sample analysis and laboratory report Î 7.2, 58.
18 Check injection pump. O 3
Within warranty.
19 Check acid level and battery connections. O O
20 Check condition of crawler chains. O O
21 Check secure fastening of crawler-chain sprocket, O O
crawler gear units and hydraulic motor.
22 Check smooth running of bottom and top rollers. O O
23 Check bearing bushings and pins/bolts of work O O
equipment and adjust until they are without play.
 Index 10

10 Index

A Fire protection . . . . . . . . . . . . . . . . . . . 20
Additional control circuit . . . . . . . . . . . . . . 50 Front window . . . . . . . . . . . . . . . . . . . . 41
Air filter . . . . . . . . . . . . . . . . . . . . . . 74 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 60
Air intake . . . . . . . . . . . . . . . . . . . . . 74 Fuel filter . . . . . . . . . . . . . . . . . . . . . . 72
Articulation . . . . . . . . . . . . . . . . . . . . 48 Fuel system . . . . . . . . . . . . . . . . . . . . . 72
Assignment diagram . . . . . . . . . . . . . . . 93 Fuel tank . . . . . . . . . . . . . . . . . . . . . . 73
B Fuel, lubricant, and coolant specifications . . . . . 27
Battery . . . . . . . . . . . . . . . . . . . . . . . 87 Fuels, lubricants, and coolants . . . . . . . . . 26, 27
Bearing races . . . . . . . . . . . . . . . . . . . 85 G
Biodegradable oils . . . . . . . . . . . . . . . . . 27 Ground pressure . . . . . . . . . . . . . . . . . . 28
Brake valves . . . . . . . . . . . . . . . . . . . . 83 Guides . . . . . . . . . . . . . . . . . . . . . . . 15
Breather . . . . . . . . . . . . . . . . . . . . . . 82 H
Bucket . . . . . . . . . . . . . . . . . . . . . . . 33 Handing-over inspection . . . . . . . . . . . . . . 61
C Heating . . . . . . . . . . . . . . . . . . . . . . . 40
Cabin . . . . . . . . . . . . . . . . . . . . . 22, 54 Hydraulic additional work attachments . . . . . . . 52
Cable and plug colors . . . . . . . . . . . . . . . 93 Hydraulic oil . . . . . . . . . . . . . . . . . 28, 60, 80
Canopy . . . . . . . . . . . . . . . . . . . . . . 16 Hydraulic oil cooler . . . . . . . . . . . . . . . . . 81
Care . . . . . . . . . . . . . . . . . . . . . . 57, 60 Hydraulic oil level . . . . . . . . . . . . . . . . . . 80
Carrying capacity . . . . . . . . . . . . . . . . . 30 Hydraulic oil return filter . . . . . . . . . . . . . . 82
Cartridge maintenance intervals . . . . . . . . . 75 Hydraulic oil tank . . . . . . . . . . . . . . . . . . 80
Change of work attachments . . . . . . . . . . . 18 Hydraulic rock breaker . . . . . . . . . . . . . . . 53
Changing work attachments . . . . . . . . . . . . 50 Hydraulics . . . . . . . . . . . . . . . . . . . 20, 25
Chassis . . . . . . . . . . . . . . . . . . . . . . 24 I
Clamshell grab . . . . . . . . . . . . . . . . 33, 52 Immobilization . . . . . . . . . . . . . . . . . . . 89
Cleaning . . . . . . . . . . . . . . . . . . . . . . 60 Initial inspection . . . . . . . . . . . . . . . . . . . 61
Closed spaces . . . . . . . . . . . . . . . . . . . 17 Inspection plan . . . . . . . . . . . . . . . . . . . 66
Condition of the battery . . . . . . . . . . . . . . 60 Intervals . . . . . . . . . . . . . . . . . . . . . . . 57
Coolant . . . . . . . . . . . . . . . . . . . . 60, 71 ISO control system . . . . . . . . . . . . . . . . . 48
Copyright . . . . . . . . . . . . . . . . . . . . . . 8 L
Crawler chain tension . . . . . . . . . . . . . . . 84 Lighting equipment . . . . . . . . . . . . . . . . . 88
Crawler chains . . . . . . . . . . . . . . . . . . 84 Load hook applications . . . . . . . . . . . . . . . 17
Crawler gear units . . . . . . . . . . . . . . . . . 83 Loading . . . . . . . . . . . . . . . . . . . . . 19, 55
D Lubricants . . . . . . . . . . . . . . . . . . . . . . 59
Daily tasks . . . . . . . . . . . . . . . . . . . 62, 63 M
Danger zone . . . . . . . . . . . . . . . . . . . . 14 Main cartridge . . . . . . . . . . . . . . . . . . . 75
Declaration of Conformity . . . . . . . . . . . . . 11 Maintenance . . . . . . . . . . . . . . . . . . 18, 57
Digging envelope . . . . . . . . . . . . . . . . . 21 Maintenance and Inspection Plan . . . . . . . . . 95
Dimensions . . . . . . . . . . . . . . . . . . . . 29 Maintenance plan . . . . . . . . . . . . . . . . . . 62
Ditch-cleaning bucket . . . . . . . . . . . . . . . 33 Mode of operation . . . . . . . . . . . . . . . . . 48
Dozer blade . . . . . . . . . . . . . . . . . . . . 49 Monitoring . . . . . . . . . . . . . . . . . . . . . 19
Drawbar pull . . . . . . . . . . . . . . . . . . . . 29 O
Driver's seat . . . . . . . . . . . . . . . . . . . . 40 Oil analyses . . . . . . . . . . . . . . . . . . . . . 58
Driving . . . . . . . . . . . . . . . . . . . . . 15, 42 Oil change . . . . . . . . . . . . . . . . . . . . . 83
Dust ejection valve . . . . . . . . . . . . . . . . 74 Oil level . . . . . . . . . . . . . . . . . . . . . . . 83
E Operating weights . . . . . . . . . . . . . . . . . 29
Electrical equipment . . . . . . . . . . . . . . . . 87 Operation . . . . . . . . . . . . . . . . . . . . 13, 35
Electrical system . . . . . . . . . . . . . . . 24, 93 Operator controls . . . . . . . . . . . . . . . . . . 36
Engine . . . . . . . . . . . . . . . . . . . . . 24, 91 Overhead power lines . . . . . . . . . . . . . . . 16
Engine - cooling system . . . . . . . . . . . . . . 70 Overview of lubricating points . . . . . . . . . 64, 65
Engine oil . . . . . . . . . . . . . . . . . . . 28, 69 P
Engine oil filter . . . . . . . . . . . . . . . . . . . 69 Preservation . . . . . . . . . . . . . . . . . . . . 89
Engine oil level . . . . . . . . . . . . . . . . . . 68
Q
Environmental protection . . . . . . . . . . . . . . 9
Quick-attach system . . . . . . . . . . . . . . 51, 52
F R
Filter insert . . . . . . . . . . . . . . . . . . . . 82
Recovery . . . . . . . . . . . . . . . . . . . . 19, 55
Fire extinguisher . . . . . . . . . . . . . . . . . . 20
Relay box . . . . . . . . . . . . . . . . . . . . . . 93

Operating Manual Crawler Excavator TC20 97

10 Index
Repair . . . . . . . . . . . . . . . . . . . . . . . . 18
Rubber crawler chains . . . . . . . . . . . . . . . 44
S
SAE control system . . . . . . . . . . . . . . . . . 48
Safety cartridge . . . . . . . . . . . . . . . . . . . 76
Safety distance from overhead power lines . . . . 16
Service packages . . . . . . . . . . . . . . . . . . 59
Slew circle . . . . . . . . . . . . . . . . . . . . . 23
Sound level values . . . . . . . . . . . . . . . . . 28
Stability . . . . . . . . . . . . . . . . . . . . . . . 14
Starting the engine . . . . . . . . . . . . . . . . . 38
Steering . . . . . . . . . . . . . . . . . . . . . . . 42
Swing bearing . . . . . . . . . . . . . . . . . . . 85
Swing gear . . . . . . . . . . . . . . . . . . . . . 86
Switching off the engine . . . . . . . . . . . . . . 39
Switching off the machine . . . . . . . . . . . . . 45
T
Table of carrying capacity . . . . . . . . . . . . . 30
Table of faults . . . . . . . . . . . . . . . . . . . . 91
Technical Specifications . . . . . . . . . . . . . . 21
Toothing . . . . . . . . . . . . . . . . . . . . . . 85
Track width adjustment . . . . . . . . . . . . . . . 49
Transport . . . . . . . . . . . . . . . . . . . . 19, 56
Trouble-shooting . . . . . . . . . . . . . . . . . . 91
U
Underground power lines . . . . . . . . . . . . . . 16
V
Valve cover . . . . . . . . . . . . . . . . . . . . . 79
Valve lash . . . . . . . . . . . . . . . . . . . . . . 79
V-belt . . . . . . . . . . . . . . . . . . . . 76, 77, 78
V-belt tension . . . . . . . . . . . . . . . . . . . . 76
VBG 12 . . . . . . . . . . . . . . . . . . . . . . . 12
VBG 40 . . . . . . . . . . . . . . . . . . . . . . . 12
Vehicle identification number . . . . . . . . . . . . 7
Ventilation . . . . . . . . . . . . . . . . . . . . . 40
Venting the fuel system . . . . . . . . . . . . . . . 73
Views of the machine . . . . . . . . . . . . . . . . 21
W
Warning equipment . . . . . . . . . . . . . . . . . 88
Warranty . . . . . . . . . . . . . . . . . . 8, 34, 58
Water cooler . . . . . . . . . . . . . . . . . . . . 70
Weekly tasks . . . . . . . . . . . . . . . . . . 62, 63
Windshield washer system . . . . . . . . . . . . . 86
Winter operation . . . . . . . . . . . . . . . . . . 60
Work attachments . . . . . . . . . . . . . . . . . 33
Work stoppages . . . . . . . . . . . . . . . . . . 17
Working Operation . . . . . . . . . . . . . . . 15, 47
Working range for grab . . . . . . . . . . . . . . . 32

98 Operating Manual Crawler Excavator TC20