Terex TV800 Operators Instruction Book Download Page 1

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TEREX, Central Boulevard, ProLogis Park, Coventry CV6 4BX, England

Tel.: +44 (0)2476 339400 - Fax: +44 (0)2476 339500

www.terexce.com - Email : [email protected] - [email protected]

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents
are known to the State of California to cause
cancer, birth defects, and other reproductive harm.

CALIFORNIA

Proposition 65 Warning

Battery posts, terminals and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm.

Wash hands after

handling.

WARNING

Noise Level at Drivers Ear

Exceeds 85dB(A)

Dealer Stamp

Operators Instruction Book

TV800, TV800H, TV900

Tandem Vibratory Roller

Kubota Engine - Poclain Drive Motors

Publication No. 0102GB-5 April 2011

For Machines with Danfoss Drive Motors Refer to 0102GB-4 - August 2010

Original Instructions

Summary of Contents for TV800

Page 1: ...roductive harm CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling WARNING Noise Level at Drivers Ear Exceeds 85dB A Dealer Stamp Operators Instruction Book TV800 TV800H TV900 Tandem Vibratory Roller Kubota Engine Poclain Drive Mot...

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Page 3: ...1 Table of Contents TV800 TV800H TV900 Roller ...

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Page 5: ... Hydraulic Fluid 3 5 Fluid Levels 3 5 Frozen Battery Electrolyte 3 5 Fires 3 5 Water Cooled Engines 3 5 Lubricants 3 6 Hygiene 3 6 Storage 3 6 Handling Oil 3 6 New Oil 3 6 Old Oil 3 6 First Aid Oil 3 7 Swallowing Oil 3 7 Skin Contact 3 7 Eye Contact 3 7 Oil or Fuel Spillage 3 7 Fires 3 7 Gradients 3 8 Slopes Diagram A 3 8 Maximum Slope Gradient Diagram B 3 8 Gradients 3 9 Crossing Gradients Diagra...

Page 6: ...ery Charge 5 6 C Water Temperature 5 6 D Cold Start Heater 5 6 E Oil Pressure 5 6 F Indicator Light 5 6 Start Switch 5 6 Work Lights When fitted 5 7 Hazard Lights Switch When Fittted 5 7 Direction Indicator Switch When Fitted 5 7 Warning Horn 5 8 Drive Control Lever 5 9 Drive Control Lever Functions 5 9 Drive Control Lever 5 10 Vibration Button 5 10 Hand Throttle 5 10 Single or Double Drum Vibrati...

Page 7: ...Transportation Transportation 8 1 Loading on to a Lorry Trailer using Ramps 8 1 Unloading 8 1 Transportation 8 2 Loading or Unloading using a Crane 8 2 Articulation Lock 8 2 Transportation 8 3 Tie Down Points 8 3 9 Maintenance Maintenance and Lubrication 9 1 Safety Signs 9 1 Hydraulic Oil Under Pressure 9 1 Cleaning 9 2 Vehicle Machine Battery End of Life Disposal 9 2 Battery 9 3 Battery Isolator ...

Page 8: ...stem 9 13 Tank Removal 9 13 Filter 9 13 Tank Refitting 9 13 Drum Mountings 9 14 Centre Pivot steering Ram 9 14 Drive Pump Pivot 9 15 Scraper Blades 9 15 ROPS 9 16 Introduction 9 16 Attachments and or Modifications 9 16 Maintenance 9 16 Repair 9 16 Seat Belts 9 17 Important Facts about Seat Belts 9 17 Seat Belt maintenance Guidlines 9 17 Service Schedule 9 18 Recommended Lubricants 9 19 Scrapping t...

Page 9: ...2 Introduction TV800 TV800H TV900 Roller ...

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Page 11: ... the Manufacturer in writing immediately invalidates the Manufacturers warranty and product liability for any resulting consequential damage Safety Alert System Intended Use This machine has been designed and tested to carry out the function of compacting materials of the non cohesive bituminous and granular varieties If used correctly they will provide an effective and safe means of compaction an...

Page 12: ...ed All claims during the warranty period will only be accepted if the recommended maintenance and service work has been carried out at the specified intervals It is important regular maintenance and service work is carried out after the warranty period has expired to ensure the machine is safe to use and does not cause unnecessary downtime and expense Modifications to this machine and or changes t...

Page 13: ...00H TV900 Commercial Name Same as model type Terex United Kingdom Limited hereby declares that the above piece of machinery is in conformity with the relevant provisions of Machinery Directive 2006 42 EC Terex United Kingdom Limited hereby declares that the above piece of machinery is in conformity with the provisions of the following other EC directives Noise Equipment Used Outdoors 2000 14 EC Em...

Page 14: ...Introduction TV800 900 Roller 0102 5 April 2011 2 4 ...

Page 15: ...3 Safety TV800 TV800H TV900 Roller ...

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Page 17: ...with the machine you must be thinking what hazards there may be and how to avoid them b Safety Alert Symbol DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which if not avoided may result in minor or moderate...

Page 18: ... Dust Mask A dust mask must be worn when site conditions dictate Respirator A respirator must be worn when site conditions dictate Protective Clothing Protective clothing must be worn when site conditions dictate Safety Glasses Safety glasses must be worn at all times to prevent eye injury from flying objects High Visibility Clothing High visibility clothing must be worn at all times when operatin...

Page 19: ...e before refuelling If there is a spillage mop it up and do not start the engine until it is safe again Do not smoke when refuelling The exhaust gets extremely hot Do not place anything on top of it and keep all combustible materials clear Do not attempt any maintenance on a hot engine Do not clean or inspect the machine with the engine running Do not operate the machine if it damaged improperly a...

Page 20: ... functioning in a rollover cannot be over emphasized Through periodic inspections cracks loose bolts damage and other normal wear and tear related problems can be eliminated before they become serious Proper inspection and maintenance procedures can ensure that ROPS will perform the life saving function they are designed for and expected to do b Seat Belt A seat belt is provided for operator safet...

Page 21: ...r charged Never jump start a machine with a frozen battery To help prevent freezing keep the battery fully charged b Fires Using water to extinguish an oil fire could spread the fire or give you a shock from an electrical fire Use a carbon dioxide dry chemical or foam extinguisher whilst waiting for the fire brigade Keep fire extinguisher seviceable and have it checked regularly b Water Cooled Eng...

Page 22: ...b Handling Oil See also First Aid Oil on Page 3 7 New Oil There are no special precautions needed for the handling or use of new oil other than the normal care and hygiene practices Old Oil Observe the following precautions Avoid prolonged excessive or repeated skin contact with used engine oil Apply a barrier cream to the skin before handling used engine oil Note the following when removing engin...

Page 23: ...f excessive skin contact wash with soap and water Eye Contact In the case of eye contact flush with water for 15 minutes If the irritation persists get medical attention Oil or Fuel Spillage Absorb with sand or a locally approved brand of absorbent granules Scrape up and dispose of in a chemical disposal area b Fires Extinguish with carbon dioxide dry chemical or foam ...

Page 24: ... ascending or descending a gradient the front of the roller MUST ALWAYS face the top of the incline Maximum Slope Gradient Diagram B Maximum gradient X without vibration 40 21 8º 1 in 2 5 Maximum gradient X with vibration 30 b ALWAYS Reverse Down Inclines A 0102 3 001 0102 3 002 B X ...

Page 25: ...dients Diagram C Never drive across a gradient Although the machine may appear stable crossing a gradient depending on the surface the roller may begin to slide down the gradient out of control especially if vibration is being used b NEVER Drive Across Gradients 0102 3 003 C ...

Page 26: ...chine when on a gradient Crush Hazard Crushing can result in serious injury or death Transport Lock Fit transport lock before lifting Lift Point Entanglement Hazard Contact with rotating parts can result in serious injury Keep away from fan and belt when engine is running Stop Engine and Remove Start Key before servicing Crush Hazard Machine movement can cause serious injury or death Stay away fro...

Page 27: ...y Description of Symbols and Pictorials Used on Safety Signs Read Instruction Manual before performing maintenance or repair Keep clear of rotating parts Contact with rotating parts will result in injury or death Stop engine when working in this area ...

Page 28: ...2 2184 8002 2399 8002 2400 8002 2343 20 A 8002 2622 8002 2284 8002 2533 8002 2506 8002 2519 8002 2535 8002 2511 6 8002 2533 8002 2526 STOP 8002 2288 Benford Ltd Prologis Park 8002 2517 MAX 8002 2545 40 21 8 1 in 2 5 o 8002 2282 8002 2839 1 2 3 8 9 10 14 15 16 18 19 21 22 7 17 20 4 5 11 12 23 24 13 ...

Page 29: ... Warning 10 Read Manual Before Releasing Brakes 11 Ear Protection Must Be Worn At All Times 12 Lift Point Fit Articulation Before Lifting 13 Gradient Instructions 14 Diesel Fuel Filler Point 15 Hydraulic Oil Filler Point 16 Danger Moving Parts Stop Engine Before Maintenance 17 Hot Surface Keep Clear 18 Tie Down Points 19 Danger Crush Hazard Keep Clear Of Crush Zone 20 Vehicle Sound Power Level 21 ...

Page 30: ...Safety TV800 900 Roller 0102 3 November 2009 3 14 Blank Page ...

Page 31: ...4 Installation TV800 TV800H TV900 Roller ...

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Page 33: ...s machine Check general condition of the machine has it been damaged during delivery Raise folding ROPS if fitted and install all pins and locking rings Fit flashing beacon to ROPS Check fluid levels see Pre Start Checks on page 4 2 Articulation Lock If the machine has been delivered by a lorry or trailer the articulation lock B may have been fitted This must be released before the machine is used...

Page 34: ... 13 or better Check all instruments alarm buzzers and warning lights function correctly Check all controls function correctly Check all lights and road traffic indicators if fitted function correctly Note When filling fuel tank make sure the tank is filled when the engine is cold and the machine is in a well ventilated area with the engine stopped using clean fuel and container It is advisable to ...

Page 35: ...5 Description TV800 TV800H TV900 Roller ...

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Page 37: ...5 1 TV800 900 Roller 0102 5 April 2011 Description TV800 0102 5 001 ...

Page 38: ...via a push pull cable It controls the speed forward and reverse movement of the machine and also the machines braking system Braking System The roller brakes are integral with the drive motors The brakes are spring applied and hydraulically released using pressure from the auxiliary pump The hydraulic pressure is controlled by a solenoid valve operated by the drive control lever Normally the solen...

Page 39: ...cs to be activated 1 or isolated 2 When the battery is isolated the key may be removed to prevent theft or unauthorised use of the machine Anti Theft Cover A metal cover A is fitted over the control panel to help prevent theft and unauthorised use of the machine This can be secured in place by fitting a padlock through the pin B The cover must be removed and placed in its storage position before t...

Page 40: ...ng the electrical supply All machines have a 20Amp circuit breaker A to protect the standard circuit machines with full RTA lighting have an extra 30Amp circuit breaker B Emergency Stop Button The RED emergency stop switch A when pressed will immediately stop the engine and all electrical hydraulic systems will stop functioning To release turn the switch knob in the direction of the arrow embossed...

Page 41: ...tted 10 Switch Hydraulic Breaker When Fitted 3 Warning Light Battery Charge 11 Switch Pressure Sprinklers When Fitted 4 Emergency Stop Button 12 Switch Lighting When Fitted 5 Warning Light Engine Oil Pressure 13 Switch Indicators When Fitted 6 Warning Light Cold Start 14 30A Circuit Breaker Lighting When Fitted 7 Warning Light Coolant Temperature 15 Switch Hazard Warning Lights When Fitted 8 Hour ...

Page 42: ... is running the temperature is too high The engine must be stopped immediately and the cause investigated D Cold Start Heater When the start key switch is turned to the start position this light will come on Do not attempt to start the engine until this light goes out E Oil Pressure This warning light will come on when the start switch is turned to the start position and will go out when the engin...

Page 43: ...he hazard lights switch A is pressed all four indicator lights and the switch will flash Press the switch a second time to turn the lights off Direction Indicator Switch When Fitted The indicator switch B is turned to the left or right to operate the direction indicators The indicator warning light will flash when the indicators are operating If the warning light flashes faster than normal check f...

Page 44: ...0 900 Roller 0102 5 April 2011 5 8 Warning Horn A warning horn is provided to alert others of the machines presence The horn is sounded by pressing the button A located in the centre of the steering wheel A 0102 5 019 ...

Page 45: ...the operator out of the Neutral position to release the brakes before the lever can be moved forward or backwards When the lever is returned to the neutral position the brakes are applied Drive Control Lever Functions The functions of the drive control lever are shown on a decal positioned on the machine and replicated below NOTICE When Changing Direction Ensure The Lever Does Not Enter The Neutra...

Page 46: ...e A is positioned to the right of the drivers seat The hand throttle has 3 set positions 1 Idle 2 Low Frequency Vibration 3 High Frequency Vibration When the throttle lever is moved from Idle position 1 and passes through position 2 the lever is automatically locked in position 2 by a spring loaded pin To continue moving the lever the release collar B must be lifted to release the pin and allow th...

Page 47: ...d the filler cap A is located under the lockable arm rest Gravity System Sprinkler Valve The sprinkler valve is controlled by a knob B located to the rear of the drive control lever Turning the knob anti clockwise opens the valve and allows water to discharge through the brass spray bars Turning the knob clockwise shuts off the supply Pressurised Sprinkler System Option The pressurised sprinkler s...

Page 48: ...drive and allows the hydraulic breaker outlets to be used If the drive control lever is moved with the breaker in use the engine will stop Hydraulic Breaker Connections The connections for the hydraulic breaker are fitted at the side of the machine The outlets have quick release couplers B C and have a maximum flow of 30 litres min 0102 5 017 A 0102 5 015 B C ...

Page 49: ...s fitted to the machines ROPS and is controlled by switch C The Flashing Beacon is easily removed to prevent theft or vandalism by slackening nut B and lifting the beacon off its mounting stem When the beacon has been removed the top of the mounting stem is covered by pulling the rubber stem cap F over the mounting stem E 0102 5 021 A B C F E 0102 5 022 ...

Page 50: ...OPS Other than checking for loose fastenings corrosion and damage the ROPS is maintenance free Folding ROPS The optional Folding ROPS comprises of two sections A B and is pivoted at seat level to allow the ROPS to be tipped backwards to reduce the transportation height not the working height It is secured in the raised position by a locking pin C and linch pin D b Under No Circumstances Modify The...

Page 51: ...6 Inspection TV800 TV800H TV900 Roller ...

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Page 53: ... Operators Inspection is to keep the machine in proper working condition and to detect any signs of malfunction during normal operation between scheduled maintenance intervals Read the Safety Section of this manual before performing the inspection While it may not be the operators responsibility to perform mechanical maintenance the operator must be thoroughly familiar with the machine and its pro...

Page 54: ...Manual Present and legible 5 Seat Belt Working and undamaged 6 Seat Interlock Check for correct operation 7 Battery Check Electrolyte Level 8 Water Tank Check level 9 Fuel Tank Check level 10 Hydraulic Oil Check level 11 Engine Oil Check Level 12 Engine Coolant Check level Only with engine cold 13 Air Cleaner Check blockage indicator and squeeze dust ejector 14 Lighting if fitted Check operation V...

Page 55: ...7 Operating Instructions TV800 TV800H TV900 Roller ...

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Page 57: ...s for damage hydraulic hose end fittings for leakage hose outer covers for ballooning etc Check engine and hydraulic oil levels make sure the engine and hydraulic tank are filled using clean oil and a clean container Check fuel tank is full make sure the tank is filled when the engine is cold and the machine is in a well ventilated area with the engine stopped using clean fuel and container It is ...

Page 58: ...Ensure the machine is parked on firm level ground Remove the flashing beacon Remove the two linch pins C from the locking pins D Remove the pins D Carefully pull the top half of the ROPS A backwards and lower into the travelling position Replace pins and fix in position using the linch pins To return the ROPS to its operational position reverse the above procedure b Only Lower the ROPS when Transp...

Page 59: ...d personal injury Before dismounting ensure the machine is parked safely and is on firm level ground The direction lever is in NEUTRAL and the engine has been stopped b Do Not use steering wheel drive control lever etc when mounting or dismounting Use Footsteps and Handles provided b Ensure the steps handles and Operators footplate are kept free from mud oil ice etc b DO NOT jump from the machine ...

Page 60: ...ust the seat characteristics to the weight of the operator Turning the knob clockwise adjusts the seat for the larger person and anticlockwise for the smaller person When the knob B is turned the pointer E moves to allow the operator to select the correct weight from the scale F Back Rest Angle Adjustment Lifting lever C allows the back of the seat to be pushed forwards or backwards to suit the op...

Page 61: ...r buckle B into the outer buckle A until it locks into position Adjust by pulling the belt through buckle B until it is a firm comfortable fit across the hips To remove the seat belt press the button C and pull inner buckle B away from outer buckle A b Seat Belt must be locked in position across the Operators hips BEFORE operating the machine 0102 7 005 A B C ...

Page 62: ... to the Start position and release the key as soon as the engine starts When the engine is running ensure the battery charge warning light is out To Stop The Engine Return the throttle to Idle Position 1 Turn the start key switch anticlockwise to the Off position NOTICE Do Not Crank Engine For More Than 10 seconds NOTICE Do Not Use Starting Sprays To Assist Engine Starting NOTICE Do Not Let Engine...

Page 63: ...er to enter the Neutral gate The parking brake will be applied Parking The Roller Select a flat level site where the roller will cause least obstruction to others Remove start key Chock drums if necessary Fit anti vandal cover and lock in place If parking over night and there is a possibility of frost the water tank must be drained NOTICE When Changing Direction Do Not Allow Lever To Enter NEUTRAL...

Page 64: ... or high frequency vibration Position 2 or 3 Move control lever to Half Speed gate Press button on control lever to switch on vibration To stop vibration press the button on the control lever a second time NOTE If the control lever is moved into the Neutral or Full Speed gates while vibrating vibration will stop NOTICE Do Not Use Vibration On Hard Surfaces ...

Page 65: ...A Fit battery isolator key C into tow valve and turn fully clockwise to Tow position 1 Move the steering from side to side to generate enough hydraulic pressure to release the brakes The roller is now ready for towing To Re instate the Brakes Turn the key in the tow valve fully anti clockwise to the Drive position 2 Remove key and refit to battery isolator switch Check the brakes are working corre...

Page 66: ...Operating Instructions TV800 900 Roller 0102 5 April 2011 7 10 Blank Page ...

Page 67: ...8 Transportation TV800 TV800H TV900 Roller ...

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Page 69: ...use the drums to develop flat spots which will affect the finish when rolling soft surfaces Damage may be caused to the vibration isolation mounts Fit articulation lock see Articulation Lock page 8 2 Secure the machine to the lorry chassis using chains straps or ropes of sufficient strength attached to the machine See Securing Roller page 8 3 Unloading When unloading from a lorry trailer strong lo...

Page 70: ...in line Fit the articulation lock before lifting the machine see Articulation Lock Note Other Methods of Lifting Are Not Recommended Articulation Lock The articulation lock A must be fitted whenever the machine is lifted clear of the ground or when placed on a lorry or trailer for transporting Remove the R clip from the outer pin B and lift the pin out Swing the lock bar A round to line up with th...

Page 71: ...A are provided one on each of the drum side plates Use chains ropes or straps of sufficient strength to hold the roller safely in all circumstances When the roller has been secured to the lorry trailer bed chocks should be nailed in position to prevent movement as shown below 0102 8 004 0102 8 005A A A ...

Page 72: ...Transportation TV800 900 Roller 0102 5 April 2011 8 4 Blank Page ...

Page 73: ...9 Maintenance TV800 TV800H TV900 Roller ...

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Page 75: ...itted to prevent the possibility of crushing Ensure all guards and covers removed during maintenance are replaced before the machine is put back into work Safety Signs All safety signs fitted to the machine must be legible Use mild soap and water to clean safety signs DO NOT use solvent based cleaners because they may damage the safety sign material All safety signs MUST be replaced immediately th...

Page 76: ...referable to use a biodegradable cleaner Do not use solvents or like products which can damage rubber and plastics Vehicle Machine Battery End of Life Disposal When the battery reaches the end of its useful life it must be removed from the machine and recycled in an approved way in accordance with local environmental regulations This service is usually offered by battery vendors Machine users that...

Page 77: ... Battery Removal Remove the Negative battery lead C and then the Positive battery lead D from the battery A Remove the 2 bolts holding the battery strap B Remove strap Lift battery out using handles provided Battery Replacement Before replacing the battery ensure the battery area and the battery are clean and free from corrosion Refit the battery Refit the battery strap and secure with the 2 bolts...

Page 78: ...cleaner G must not be cleaned it must be renewed when necessary Thoroughly clean air cleaner body E and end cap D Reassemble by reversing the above procedures Air Filter Cleaning Air cleaner elements should be cleaned by blowing gently with an airline from inside or tapping gently against a firm object NOTICE Check Air Inlet System Daily For Air Leaks 0102 9 004 E A D B F C G NOTICE Maximum engine...

Page 79: ...ne is cold is just below the seam of the tank C Coolant When adding coolant ensure it is a mixture of water and antifreeze to the correct ratio for the temperature range that the machine is to be used in See 10 Specifications section for correct mixture ratios b DO NOT Remove The Filler Cap When The Engine Is HOT 0102 9 013 B A C b NEVER start engine without coolant in the cooling system Never rem...

Page 80: ...day this will prevent condensation forming in the tank overnight or during long periods of inactivity Fuel Filter Servicing is limited to changing the filter Unscrew the filter canister A Dispose of the filter canister in an environmentally safe way Smear the rubber ring on the new filter canister with grease Screw the filter canister A on to the filter and hand tighten only do not use grips etc t...

Page 81: ...hine on firm level ground 2 Stop the engine and let the machine stand for a few minutes to allow the oil to drain into the engine sump 3 Remove engine dipstick A wipe clean with paper replace the dipstick Remove and check the oil level on dipstick 4 If the oil level is below the MIN level E remove the engine oil filler cap C and add clean fresh oil of the correct grade to the engine While adding o...

Page 82: ...g sealing washer and refit the drain plug and tighten See Engine Oil Level Checking for filling instructions Start engine and check for leaks Hydraulic Oil Checking Level The hydraulic oil tank is located under the rear of the front chassis frame It has a combined filler cap and dip stick To check the level Unscrew the filler cap A and wipe the dipstick with clean paper Put the dipstick back into ...

Page 83: ... correct alignment Refit and tighten cap screws Hydraulic Tank Draining Before draining the hydraulic oil tank the machine should be run to enable the oil temperature to increase which will allow the oil to drain more easily The oil should be warm NOT HOT Clean the area around the drain plug Loosen the drain plug B Position a suitable under the tank to catch the oil Remove the drain plug and allow...

Page 84: ...late Remove the hoses Drain the tank refer to page 9 9 Remove the 6 bolts and washers fixing the suction strainer plate B to the tank A Lift the suction strainer plate away from the tank taking care that dirt or fragments of the gasket do not enter the tank Unscrew the old suction strainers D and discard Suction Strainers Refitting Remove all traces of old gasket from the top of the tank and the s...

Page 85: ...from underneath the machine Plug the hose unions in the top of the tank and thoroughly clean outside of tank Remove suction strainer plate E and drain plug D Remove all traces of gasket from the suction strainer plate and tank face Thoroughly wash inside of tank with a suitable solvent and allow to dry Clean and refit drain plug using a new sealing washer Replace both suction strainers on strainer...

Page 86: ...ly 50mm 2ins from the bottom of the filler neck Re fit filler cap C and tighten Close arm rest and lock Draining Drain the tank by opening the sprinkler valve or by disconnecting the quick release coupling on the base of the water tank Testing Water Flow Open the valve and check that water flows through every hole in each spray bar If water does not flow check the filter and spray bars for obstruc...

Page 87: ...m of the tank Remove the water tank by pulling it rearwards Filter Unscrew the cap D at the base of the tank and remove it complete with the water outlet connection and filter Wash the filter with clean running water If the filter is damaged or severely blocked replace it Wash the tank out thoroughly with clean water Refit the filter assembly and cap D Tank Refitting Refit the water tank into the ...

Page 88: ...ing must be replaced Centre Pivot steering Ram The centre pivot and steering ram pivots are lubricated through the grease nipples A Ensure all surplus grease is removed NOTICE DO NOT Allow Diesel or Hydraulic Oil to come into contact with the mountings because the rubber will be damaged 0102 9 021A A b Always Fit Articulation Lock Before Working In Area Of Centre Pivot 0102 0 024 A A A A A A ...

Page 89: ...move surplus grease and refit protective cap Scraper Blades Four scraper blades A are fitted one at the front and rear of each drum Each blade is held in contact with the drum by springs that provide automatic tensioning of the blade The only maintenance required is the replacement of the rubber blades when worn out or damaged 0102 9 026 A 0102 9 025A A A ...

Page 90: ...missing resilient mounts Excessive motion or rattling during operation are indications of a problem The mounts should be disassembled and repaired if required Missing or damaged mounting hardware bolts nuts washers etc should be replaced Bolts should be checked for correct torque settings Cracks in ROPS FOPS structure and mounting system The machine should be cleaned and disassembled as necessary ...

Page 91: ...delines detail how to Inspect seat belt for cuts fraying extreme or unusual wear of the webbing etc and damage to the buckle retractor hardware or other factors which indicate that seat belt replacement is necessary 1 Check the webbing Pull the webbing completely out of the belt retractor and inspect the full length of the webbing for cuts wear fraying dirt and stiffness If a belt shows any cuts f...

Page 92: ...hours and including Check the start inhibitor is working and adjusted correctly Drain fuel filter Lubricate the centre pivot Lubricate drive pump lever cable pivot Oil all control pivots control levers etc Check and clean water sprinkler system filter Check tightness of all hydraulic fittings Check tightness of all nuts and bolts including engine mountings Check clean and protect battery connectio...

Page 93: ...Maintenance Recommended Lubricants Application Type Quantity Engine Oil Shell Rimula R3 X 15 W40 5 1 Litres Hydraulic Oil Shell Tellus T46 25 0 Litres Fuel Diesel 22 0 Litres Vibration Bearings EP2 Grease General Greasing Multi Purpose Grease ...

Page 94: ...n them or have residual flammable liquids on them Fire extinguishers must be readily available if cutting welding equipment is to be used Fluids must be drained off into suitable containers and if possible recycled or otherwise disposed of in an environmentally friendly way in accordance with local regulations Where possible recyclable materials should be separated out and processed in accordance ...

Page 95: ...10 Specifications TV800 TV800H TV900 Roller ...

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Page 97: ...ns Introduction All dimensions are in metric mm weights in kilograms and capacities in litres unless otherwise stated Imperial equivalents are shown in brackets This section also contains details of electric and hydraulic circuits and fixing torque data ...

Page 98: ... 5 April 2011 10 2 Machine Dimensions A B C D E I J H J F G A B C D E F G H I J K TV800 550 1260 1860 205 10 1530 2400 35 800 870 370 TV800H 550 1260 1860 205 10 1530 2400 35 800 870 370 TV900 550 1260 1860 205 10 1530 2400 35 900 970 370 ...

Page 99: ... Hydrostatic Hydrostatic Hydrostatic Driven Drum Front and Rear Front and Rear Front and Rear Maximum Speed km h 8 0 8 0 8 0 Gradability No Vibration 40 40 40 Gradability With Vibration 30 30 30 Brakes Service Brake Hydrostatic Hydrostatic Hydrostatic Parking Brake Hydro Mech Hydro Mech Hydro Mech Vibration System Drive System Hydrostatic Hydrostatic Hydrostatics Vibrating Drums Both Rear Both Rea...

Page 100: ...1 A rated sound pressure level at operator station A rated sound power of machine LpAd LWAd TV800 86 4dB 106 dB TV800HS 86 4dB 106 dB TV900 86 4dB 106 dB Operation Value Uncertainty Hand Arm Vibration as defined in EN474 1 Stone road Type Two High Frequency 4 66 m s2 2 33 Stone road Type Two Low Frequency 2 62 m s2 1 31 Asphalt Travel roading 2 58 m s2 1 29 Whole body vibration values as defined i...

Page 101: ...atio ºC ºF 16ºC 60ºF 27ºC 81ºF 38ºC 100ºF 20 1 5 9 15 8 S G 1 032 S G 1 030 S G 1 028 25 1 4 12 10 4 S G 1 041 S G 1 037 S G 1 033 33 3 1 3 19 2 2 S G 1 054 S G 1 049 S G 1 044 50 1 2 37 34 6 S G 1 080 S G 1 074 S G 1 068 Use good quality Ethylene Glycol Check concentration regularly ...

Page 102: ... 7 Switch Engine Oil Pressure P Purple 8 Switch Engine Temperature R Red 9 Engine Glow Plugs S Slate 10 Engine Glow Plug Timer U Blue 11 Warning Light Lighting T Turquoise 12 Warning Light Battery charge W White 13 Warning Light Engine Temperature Y Yellow 14 Warning Light Engine Glow Plug 15 Warning Light Engine Oil Pressure 16 Warning Light Direction Indicators 17 Diode 3 Amp in panel 18 Circuit...

Page 103: ...10 7 TV800 900 Roller 0102 5 April 2011 Specifications Electrical Circuit 10 9 11 12 13 8 16 15 14 7 6 17 5 20 A B C 4 19 A B 18 21 3 1 2 ...

Page 104: ...2 Relay G Green 3 Anti Start Module K Pink 4 Brake Solenoid LG Light Green 5 Capacitor 100u N Brown 6 Vibration Button O Orange 7 Vibration Solenoid P Purple 8 Vibration Flip Flop Relay R Red 9 Half Speed Switch On Main Controller S Slate 10 Drive Switch On Main Controller U Blue 11 Switch Seat T Turquoise 12 Horn W White Y Yellow ...

Page 105: ...10 9 TV800 900 Roller 0102 5 April 2011 Specifications Electrical Circuit 7 8 6 9 5 10 4 2 3 11 1 12 ...

Page 106: ...2 Beacon G Green 3 Pump Water K Pink 4 Alarm Reverse LG Light Green 5 Work Lights Front N Brown 6 Work Lights Rear O Orange 7 Switch Work Lights A Off B Side Front C Rear P Purple 8 Relay 1 Pole R Red 9 Switch Reverse Alarm S Slate 10 Controller Water Pump U Blue 11 Potentiometer T Turquoise 12 Switch Breaker A Off B On W White Y Yellow ...

Page 107: ...10 11 TV800 900 Roller 0102 5 April 2011 Specifications Electrical Circuit 6 5 7 A B C 8 8 4 9 10 3 11 2 1 12 A B ...

Page 108: ...ts Side Front B Black 2 Light Number Plate G Green 3 Lights Side Rear K Pink 4 Indicator Lights Left Hand Front Rear LG Light Green 5 Indicator Lights Right Hand Front Rear N Brown 6 Flasher Unit O Orange 7 Switch Work Indicators A Left B Off C Right P Purple 8 Switch Hazard Lights R Red S Slate U Blue T Turquoise W White Y Yellow ...

Page 109: ...10 13 TV800 900 Roller 0102 5 April 2011 Specifications Electric Circuit RTA Lights Only 1 2 3 4 5 6 7 8 A B C ...

Page 110: ...ne Kubota 2 Vibration Pump 3 Drive Pump 4 Drive Motor Front 5 Drive Motor Rear 6 Brake Valve 7 Vibration Motor Front 8 Vibration Motor Rear 9 Valve Single Dual Drum Vibration Selection 10 Vibration Valve 11 Orbitrol Steering Unit 12 Steering Ram 13 Hydraulic Tank 14 Flushing Valve ...

Page 111: ... 900 Roller 0102 5 April 2011 Specifications Hydraulic Circuit R 1 X L L X 1 R ORIFICE 1 2MM B A L1 S BRAKE T CP ORB T P R L P2 P1 T1 T2 10BAR 285BAR PRV B T A bar 17 2 5BAR 3 BAR 1 3 2 4 5 6 7 8 9 10 11 12 13 14 ...

Page 112: ...a 2 Vibration Pump 3 Drive Pump 4 Drive Motor Front 5 Drive Motor Rear 6 Brake Valve 7 Vibration Motor 8 Vibration Motor Rear 9 Valve Single Dual Drum Vibration Selection 10 Vibration Valve 11 Orbitrol Steering Unit 12 Steering Ram 13 Hydraulic Tank 14 Breaker Valve 15 Hydraulic Breaker 16 Flushing Valve ...

Page 113: ...02 5 April 2011 Specifications Hydraulic Circuit Breaker Option ORIFICE 1 2MM 160 Bar B A L1 S BRAKE T CP ORB T P R L P2 P1 T1 T2 10BAR 285BAR PRV P2 P1 T2 T1 TO 2 5BAR 3 BAR B T A bar 17 16 2 1 3 6 4 7 5 13 9 8 10 11 12 14 15 ...

Page 114: ...Colour Bolt Finish 8mm 8 8 Grade Cadmium Correct Tightening Torque 23 5 x 0 8 18 8 Nm Standard Nut and Bolt Torque Figures Nm Material Grade ISO Dia mm Pitch 8 8 10 9 12 9 8 1 25 23 5 33 39 10 1 25 46 8 65 8 79 12 1 75 87 7 132 147 8 14 2 0 131 5 185 222 16 2 0 206 290 348 18 2 5 253 355 426 20 2 5 402 566 678 Correction Factors for Plate Finishes Finish Correction Factor Self Colour 1 0 1 0 0 8 Z...

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Terex TV800, Operators Instruction Book

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