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Terex TC 16 TC16 Compact Crawler Excavator Service Repair Manual.pdf
- 1. SERVICE - MANUAL R TW 70 TW 85 TW 110 TC 60 TC 75 TC 125 TC 29 TC 35 TC 48 TC 15 TC 20 TC 37 TC 50 TC 25 TL 60 TL 65 TL 80 TL 80AS TL 100 TL 210 TL 120 TL 260 TL 160 TL 310 SKL 200 TL70s TC 16 List of Contents 1 General 2 Technical Data 3 Diesel Engine 4 Hydraulic System 5 Setting Instructions 6 Functional Description 7 Electrical System 8 Maintenance 9 Operation 10 Options 11 Repair Instructions 12 BDE/Special tooling 01.2012
- 2. Typ/Model/Type Mitsubishi S 3 L (TC25) Datum/Edition/Date 01.2008 Benennung/Description/Dénomination Antriebsmotor Blatt/Page/Feuille 3.600.01
- 4. Typ/Model/Type Mitsubishi S4L (TC29, TC35, TC37) Datum/Edition/Date 01.2008 Benennung/Description/Dénomination Diesel engine Blatt/Page/Feuille 3.600.02
- 5. CYLINDER HEAD Loosening of the bolts - sequence - Tightening of the bolts - sequence - Tightening torque, cylinder head bolts: 88 ± 5 Nm Technical Data Valve clearance, cold 0.25 mm inlet & exhaust Injection pressure 140 bar + 5 bar Compression pressure new 30 bar lower limit: 27 bar Injection timing 17° before top dead centre Oil pressure, service temperature 3.5 bar ± 0.5 bar Tightening torques: Bolts/nuts in general Thread Quality class 4 Quality class 7 M 6 4 Nm 9 Nm M 8 11 Nm 18 Nm M 10 21 Nm 35 Nm M 12 35 Nm 64 Nm M14 60 Nm 93 Nm Typ/Model/Type Mitsubishi SL-Series Datum/Edition/Date 01.2008 Benennung/Description/Dénomination Diesel engine Blatt/Page/Feuille 3.600.03
- 7. Injection nozzles - injection figures good ⎜ ← bad, replace → ⎜ Injection nozzle Typ/Model/Type Mitsubishi SL- Series Datum/Edition/Date 01.2008 Benennung/Description/Dénomination Diesel engine Blatt/Page/Feuille 3.600.04 filter fuel pump from fuel tank overflow pipe to fuel tank fuel injection nozzle injection pipe injection pump threaded sleeve injection nozzle compl. spacer pin spring washer body leak-off pipe
- 8. Oil circuit Water circuit 3.600.04/01.2008 oil pressure switch oil filter pressure relief valve oil pump main oil gallery drain plug oil screen cooler fan bypass hose thermostat water pump
- 9. starter water pump fuel injection nozzle oil filler plug intake manifold fuel injection pump ventilation pump fuel system engine serial number flywheel housing oil drain plug oil pressure switch oil dipstick thermostat fan oil pan oil filter alternator v-belt pulley on crankshaft exhaust manifold fuel filter coolant drain plug Typ/Model/Type Datum/Edition/Date Mitsubishi S 4 Q 01.2007 Blatt/Page/Feuille Benennung/Description/Dénomination Diesel engine 3.800.01
- 10. CYLINDER HEAD Tightening order of bolts Tightening torque of cylinder head studs: 118 ± 5 Nm Technical Data Tappet clearance cold 0.25 mm inlet & exhaust Injection pressure 120 bar + 10 bar Compression pressure new 30 bar Lower limit: 26 bar Injection timing 22° before top dead centre Oil pressure, service temperature 2 - 4 bar (under load) ± 0,5 bar Tightening torques: bolts / nuts, general Thread Quality class 4 Quality class 7 M 6 4 Nm 9 Nm M 8 11 Nm 18 Nm M 10 21 Nm 35 Nm M 12 35 Nm 64 Nm M 14 60 Nm 93 Nm 3.800.01/01.2007
- 11. Fuel feed Fuel filter • Slacken the ventilation plug (A) of the fuel filter (B) by means of an open end wrench. • Put a clean cloth around the ventilation plug (A) to collect the escaping fuel, then operate the feed pump (C) as shown in the illustration. • The ventilation plug (A) is to be closed when the fuel escapes from the ventilation without bubbles. If the fuel pump valve is dirty and the fuel cannot be fed through the fuel filter, the ventilation plug as well as the feed line of the fuel filter are to be dismounted and cleaned with compressed air. • To unlock the fuel pump cover (D), turn it to the left. • Operate the fuel feed pump (C) ap- proximately 20 times, then turn the cover (D) to the right and lock. Mitsubishi S 4 Q Datum/Edition/Date Typ/Model/Type 01.2007 Benennung/Description/Dénomination Blatt/Page/Feuille Diesel engine 3.800.02
- 12. Remove fuel lines • Remove pipe clamp (E) from the injection lines (F). Unscrew lines (F) at the injection pump and at the injection nozzles (G). • Unscrew the drain oil lines (H) at the injection nozzles (G) by slackening the nuts (J). Mount protective caps to protect the fuel system against dirt or foreign particles at the pump and injection nozzles ! Removal of the injection nozzles • Screw out the injection nozzles (G) of the engine by means of a socket wrench. Remove the injection nozzle seals with a wire or a screwdriver and dispose of according to regulations. 3.800.02/01.2007
- 13. Injection nozzles - injection figures Good ⎜ ← Bad, replace → ⎜ Injection nozzle housing washer spring pin spacer injection nozzle, cpl. Typ/Model/Type Mitsubishi S 4 Q Datum/Edition/Date 01.2007 Benennung/Description/Dénomination Diesel engine Blatt/Page/Feuille 3.800.03 threaded sleeve
- 14. Removal of the injection pump • Check the alignment of the marking on the injection pump with the marking on the flange. • Remove the front cover of the injection pump gear. • Make markings (K) at the idler gear and injection pump gear. • Slacken the bolts of the intermediate flange and remove the injection pump including the intermediate flange and gear. Make sure that the engine does not turn after the removal of the injec- tion pump. To remove the gear of the injection pump, slacken the nut of the gear prior to the removal of the pump. Check the injection timing • Adjust the piston no. 1 to top dead centre. 3.800.03/01.2007 flange marking injection pump marking injection pump gear
- 15. • Turn the crankshaft approximately 30° counter-clockwise, facing the engine front side (fan side). Then slowly turn clockwise up to 20° before top dead centre until the marking on the crankshaft V-belt pulley is in line with the one of the control housing. • Remove the maintenance cover from the fuel injection pump. • Make sure that the flat side „A“ of the circlip aligns with marking „E“ on the setting plate. If this is alright, the injection timing is adjusted correctly. • If the flat side „A“ is not in alignment with line „E“, the nuts holding the injection pump are to be slackened and the pump is to be turned in such a manner that the markings align. • Hold the injection pump in that position and tighten the nuts. Typ/Model/Type Mitsubishi S 4 Q Datum/Edition/Date 01.2007 Benennung/Description/Dénomination Diesel engine Blatt/Page/Feuille 3.800.04 flange marking flange marking injection pump marking
- 16. Engine control The setting data of the injection system depends on the performance, speed (rpm) and specification of the engine. For the correct data, please refer to the do- cumentation of the engine manufacturer. 1) Adjustment of the first piston to top dead centre in compression stroke a) Turn the crankshaft clockwise (with a view of the engine front side) until the „O“ at the crankshaft V-belt pulley is in line with the marking. b) Press the inlet and outlet rocker at the first cylinder downward. Tappets must be free. 2) Check of the injection timing a) Remove the retainer ring of the valve holder for the first cylinder at the injection pump. b) Dismount the valve holder (1) for the first cylinder. Remove the piston of the pressure valve (2) and the spring (3). c) Re-mount the valve holder (1). d) Mount the overflow pipe on the valve holder (1) for the first cylinder. e) Turn the crankshaft until the piston of the first cylinder is 60° before top dead centre. f) Turn the crankshaft in engine turning direction by operating the hand feed pump until the fuel flow from the overflow pipe stops. g) Check injection timing (marking on the crankshaft V-belt pulley of the crankshaft). Typ/Model/Type Mitsubishi S 4 Q Datum/Edition/Date 01.2007 Benennung/Description/Dénomination Engine control Blatt/Page/Feuille 3.800.05
- 17. 3) Adjustment of the injection timing a) If the injection timing must be changed, turn the injection pump as shown in the illustration opposite. b) Only the setscrew for max. engine speed is sealed. c) If this setting is checked and adjusted, please ensure that there is somebody near the engine to be able to operate the engine cut-off mechanically in case of engine overspeeding. d) A marking unit at the injection pump flange changes the injection timing by 6° to the crankshaft angle. Off-load min. speed (idle running speed) and max. speed setting For inspections and settings warm the engine up thoroughly until the coolant and engine oil temperatures are higher than 70°C (158° F). 3.800.05/01.2007 a) The off-load min. speed (idle running speed) as well as the max. speed of each engine are set on the test bench in the factory. The setscrew for max. speed is sealed. These settings are to be performed by an authorised workshop only. b) After removing the leaden seals and adjusting the regulator, all visisble stops are to be sealed as though they would have been sealed by the factory. c) It is decisive for the settlement of warranty claims whether the stop screw leaden seals are alright or not. d) When this setting is checked and adjusted, please make sure that there is somebody near the engine in order to be able to stop engine mechanically in case of engine overspeeding. injection timing earlier injection timing later
- 18. 1) Engine start-up a) Set speed adjusting lever to high idle running speed. Actuate starter. b) The engine fires from a crankshaft speed of 150 min-1 . When the engine is running, the speed is to be held between 800 and 1,000 min-1 . c) When the engine is running with constant speed, the speed adjusting lever is to be brought into idle running position. 2) Set off-load low idle running speed a) Hold the speed adjusting lever in off- load min. speed position and set low idle running speed by means of the setscrew (2) b) Engine speed increase: Turn the setscrew of the low idle running speed clockwise. To be performed by trained and qualified personnel only: c) In case of speed variations (fluctuations of the engine), turn the setscrew (3) of the idle running speed spring clockwise to increase the spring preload. In case of a critical speed (speed resulting in bad engine vibrations due to torsional oscillations), a higher or lower speed range is to be chosen. An excessive spring preload results in engine overspeeding with the load decreasing. Make sure that this is prevented. Mitsubishi S 4 Q Datum/Edition/Date 01.2007 Engine control Blatt/Page/Feuille 3.800.06
- 19. 3) Set max. output (capacity) To be performed by trained and qualified personnel only: a) Bring speed adjusting lever into full load position and load engine with its indicated output. b) While the engine is running with constant speed, adjust the full load stop screw in such a manner that the engine achieves its indicated output. c) If the full load stop screw is turned counter-clockwise, the capacity is reduced, and the engine speed is lowered. If the full load stop screw is turned clockwise, the capacity is increased, and the exhaust gas values deteriorate. This setting can only be performed on the test bench as it is sealed by the factory. 3.800.06/01.2007
- 20. Oil circuit valve tappet pressure valve oil pump oil main distribution intake manifold drain plug engine oil filter crankshaft control gears camshaft rocker arm piston Water circuit radiator fan waterpump thermostat Datum/Edition/Date Typ/Model/Type Mitsubishi S 4 Q 01.2007 Blatt/Page/Feuille Benennung/Description/Dénomination 3.800.07 Diesel engine
- 21. Yanmar 4 TNV 88 Typ Motor Datum Model Engine Edition Type Moteur Date Tipo Motor Fecha 01.2007 Benennung Technische Daten Specification data Blatt Description Page Dénomination Feuille Denominación Página 3.900.01 Kolben (Piston) Nockenwelle (Cam Shaft) Ölwanne (Oil Pan) Kurbelwelle (Crank Shaft) Stößel (Tappet) Generator Thermostat (Cooling Water Thermostat) Auslasskrümmer (Exhaust Manifold) Kurbelgehäuseentlüftung (Breether) Einspritzdüse (Fuel Injection Valve) Ventil (Valve) Kipphebel (Rocker Arm) Zylinderkopf (Cylinder Head) Einlasskrümmer (Intake Manifold) Kraftstoffilter (Fuel Filter) Schwungrad (Flywheel) Ölmesstab (Oil-Level Gauge) Einspritzpumpe (Injection Pump) Ölfilter (Oil Filter) Yanmar 4TNV88
- 22. Ventilspiel einstellen: Valve clearence adjustment: Einstellungen bei kaltem Motor. Adjustments to do when engine is cold. Zündreihenfolge: 1-3-4-2 Firing order: Ventilspiel bei OT bzw. Überschneidung des 1. Zylinders (Schwungradseite) an folgenden Ventilen Einstellbar. Valve clearence to be adjust at TDC respectively overlap of cylinder 1 (flywheelside) at following valves. Zylinder Nummer : Cylinder No. : 1 2 3 4 Ventil Valve EIN IN AUS OUT EIN IN AUS OUT EIN IN AUS OUT EIN IN AUS OUT Zylinder 1 OT No.1 TDC X X X X Zylinder 1 überschneidung No. 1 overlap X X X X Ventilspiel : 0,15 - 0,25 mm Valve clearence : 0,15 – 0,25 mm Typ/Model/Type Yanmar 4TNV88 Datum/Edition/Date 01.2007 Benennung/Description/Dénomination Antriebsmotor Engine Blatt/Page/Feuille 3.900.02
- 24. 3.900.03/01.2007
- 25. Düsennadel (Nozzle valve) Düsenkörper (Nozzle body) Düse (Nozzle) Überwurfmutter (Nozzle case nut) 39.2 - 44.1 Nm Ventilplatte (Valve stop spacer) Druckbolzen (Nozzle spring seat) Ventilfeder (Nozzle spring) Ausgleichsscheibe (Adjustin shim) Düsenhalter (Nozzle holder) Rücklaufleitung (Fuel return line) Einspritzdüse (Fuel injector) Einspritzdruck: 210+10 bar (Injection pressure) Typ/Model/Type Yanmar 4TNV88 Datum/Edition/Date 01.2007 Benennung/Description/Dénomination Antriebsmotor Engine Blatt/Page/Feuille 3.900.04
- 27. 3.900.05/01.2007
- 29. 3.900.06/01.2007
- 30. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it. GET MORE OTHER MANUALS https://www.aservicemanualpdf.com/ GET MORE OTHER MANUALS https://www.aservicemanualpdf.com/
- 32. 3.900.07/01.2007