The maintenance manual will provide your full and accurate information for TLB840 backhoe loaders Terex. This manual contains all the necessary technical information and diagnostic procedures concerning the loader, allowing the servicing technicians to work in safety and guarantee that the equipment remains perfectly efficient throughout its working life.
A maintenance manual is a full complect that includes detailing hydraulic and electrical diagrams, photos, pictures, step by step instruction, instructions for assembling and disassembling the engine parts, brakes, lubrication, frame fuel system, battery... etc.
This is the same manual as the manual given to official dealer workshops. The manual covers all the repair procedures you will ever need. This manual is presented in PDF format so you can find the information you need and print all the text or individual pages. For convenience, we recommend using Adobe PDF Reader to ensure the correct display of all graphics. Please read through these instructions and familiarize yourself with them before actually using Terex equipment.
Models:
TLB840SM / TLB840PS
Table of Contents:
- GENERAL INFORMATION
- GENERAL INFORMATION
- GENERAL SAFETY
- ACCESSORIES
- REMOVAL AND INSTALLATION — STANDARD LOADER BUCKET FROM
- QUICK ATTACH UNIT
- REMOVAL AND INSTALLATION — 7 IN 1 LOADER BUCKET FROM A QUICK ATTACH UNIT
- REMOVAL AND INSTALLATION — QUICK ATTACH LOADER UNIT
- SPECIFICATIONS — ACCESSORIES
- DESCRIPTION AND OPERATION — HOSE BURST VALVES
- REMOVAL AND INSTALLATION—LOADER BEAM HYDRAULIC CYLINDERS BURST VALVES
- REMOVAL AND INSTALLATION — LOADER BUCKET CROWD HYDRAULIC CYLINDER
- BURST VALVE
- REMOVAL AND INSTALLATION — BACKHOE DIPPER ARM CYLINDER BURST VALVE
- REMOVAL AND INSTALLATION — BACKHOE BOOM CYLINDER BURST VALVE
- SPECIFICATIONS — HOSE BURST VALVES
- BUCKETS
- REMOVAL AND INSTALLATION — STANDARD LOADER BUCKET
- REMOVAL AND INSTALLATION — MULTI PURPOSE LOADER BUCKET
- REMOVAL AND INSTALLATION — MULTI PURPOSE LOADER BUCKET CLAMPING CYLINDER
- DISASSEMBLY AND ASSEMBLY — MULTI-PURPOSE LOADER BUCKET
- DISASSEMBLY AND ASSEMBLY — MULTI-PURPOSE LOADER BUCKET CLAMPING
- CYLINDER
- SPECIFICATIONS — BUCKETS
- DIGGER QUICK ATTACH
- REMOVAL AND INSTALLATION — QUICK ATTACH BACKHOE BUCKET
- REMOVAL AND INSTALLATION — BACKHOE QUICK ATTACH UNIT
- REMOVAL AND INSTALLATION — BACKHOE QUICK ATTACH UNIT HYDRAULIC CYLINDER
- SPECIFICATIONS — DIGGER QUICK ATTACH
- DIGGER BOOM AND DIPPER STICK
- REMOVAL AND INSTALLATION — STANDARD BACKHOE BUCKET
- REMOVAL AND INSTALLATION — BACKHOE BOOM
- REMOVAL AND INSTALLATION — BACKHOE DIPPER ARM
- REMOVAL AND INSTALLATION — TRANSPORT LOCK
- REMOVAL AND INSTALLATION — BOOM SWING TOWER
- DISASSEMBLY AND ASSEMBLY — EXTENDABLE DIPPER ARM HYDRAULIC CYLINDER
- GENERAL PROCEDURE — BACKHOE CONTROL LEVER ADJUSTMENT
- GENERAL PROCEDURE — AUXILIARY FUNCTION/TELESCOPIC DIPPER CONTROL PEDAL
- ADJUSTMENT
- SPECIFICATIONS — DIGGER BOOM AND DIPPERSTICK
- DIGGER SWING SYSTEM
- REMOVAL AND INSTALLATION — MAST CASTING
- REMOVAL AND INSTALLATION — MAST CASTING CLAMP SEALS
- REMOVAL AND INSTALLATION — STABILIZER LEG (CENTRE MOUNT)
- REMOVAL AND INSTALLATION — STABILIZER LEG (CENTRE MOUNT) CYLINDER
- REMOVAL AND INSTALLATION — STABILIZER LEG (SIDE SHIFT)
- REMOVAL AND INSTALLATION — STABILIZER LEG HYDRAULIC CYLINDER (SIDESHIFT)
- DISASSEMBLY AND ASSEMBLY — DIPPER HYDRAULIC CYLINDER
- DISASSEMBLY AND ASSEMBLY — BACKHOE BUCKET HYDRAULIC CYLINDER
- DISASSEMBLY AND ASSEMBLY — BOOM HYDRAULIC CYLINDER
- DIGGER SWING SYSTEM (Continued)
- DISASSEMBLY AND ASSEMBLY — SLEW HYDRAULIC CYLINDER
- DISASSEMBLY AND ASSEMBLY — STABILIZER HYDRAULIC CYLINDER (SIDESHIFT)
- DISASSEMBLY AND ASSEMBLY — STABILIZER LEG HYDRAULIC
- CYLINDER (CENTREMOUNT)
- GENERAL PROCEDURE — CHECKING AND ADJUSTING THE BUCKET END
- WEAR PADS ON EXTENDABLE DIPPER
- GENERAL PROCEDURE — CHECKING AND ADJUSTING THE EXTENDABLE
- DIPPER BUCKET END SIDE WEAR PADS
- GENERAL PROCEDURE — CHECKING AND ADJUSTING THE BOOM END WEAR PADS
- GENERAL PROCEDURE — CHECKING AND ADJUSTING THE EXTENDABLE DIPPER
- BOOM END SIDE WEAR PADS
- GENERAL PROCEDURE — STABILIZER LEG WEAR PADS (SIDESHIFT)
- GENERAL PROCEDURE — STABILIZER LEGS CONTROL LEVER ADJUSTMENT
- SPECIFICATIONS — DIGGER SWING SYSTEM
- MAIN HYDRAULICS
- HYDRAULIC SCHEMATICS
- DIAGNOSING AND TESTING — HYDRAULICS/PRESSURE TESTING
- DIAGNOSING AND TESTING — HYDRAULIC OIL CONTAMINATION
- REMOVAL AND INSTALLATION — HYDRAULIC OIL RESERVOIR
- REMOVAL AND INSTALLATION — OIL COOLER
- REMOVAL AND INSTALLATION — HYDRAULIC PUMP
- REMOVAL AND INSTALLATION — BACKHOE CONTROL VALVE BANK
- REMOVAL AND INSTALLATION — BACKHOE SERVO CONTROL VALVE BANK
- REMOVAL AND INSTALLATION — LOADER CONTROL VALVE
- REMOVAL AND INSTALLATION — RIDE CONTROL VALVE
- DISASSEMBLY AND ASSEMBLY — HYDRAULIC PUMP
- DISASSEMBLY AND ASSEMBLY — BACKHOE CONTROL VALVE
- DISASSEMBLY AND ASSEMBLY — LOADER CONTROL VALVE
- DISASSEMBLY AND ASSEMBLY — RIDE CONTROL VALVE
- GENERAL PROCEDURE — HYDRAULIC CYLINDER INSPECTION
- GENERAL PROCEDURE — CLEANING THE HYDRAULIC SYSTEM
- GENERAL PROCEDURE — FLUSHING WATER FROM THE HYDRAULIC SYSTEM
- GENERAL PROCEDURE — RELEASING THE HYDRAULIC SYSTEM PRESSURE
- GENERAL PROCEDURE — HYDRAULIC CYLINDER RING LUG EXTRACTION
- SPECIFICATIONS — MAIN HYDRAULIC SYSTEM
- LOADER
- REMOVAL AND INSTALLATION — FRONT LOADER BEAM
- REMOVAL AND INSTALLATION — LOADER BEAM HYDRAULIC CYLINDER
- REMOVAL AND INSTALLATION — FRONT LOADER HYDRAULIC CROWD CYLINDER
- REMOVAL AND INSTALLATION — LOADER BUCKET POTENTIOMETER
- DISASSEMBLY AND ASSEMBLY — LOADER BUCKET HYDRAULIC CYLINDER
- DISASSEMBLY AND ASSEMBLY — LOADER BEAM HYDRAULIC CYLINDER
- GENERAL PROCEDURE — ANTI ROLLBACK ADJUSTMENT
- GENERAL PROCEDURE — RETURN TO DIG ADJUSTMENT
- SPECIFICATIONS — LOADER
- OPERATORS ENVIRONMENT
- REMOVAL AND INSTALLATION — CAB
- REMOVAL AND INSTALLATION — CAB HEATING AND AIR CONDITIONING UNIT
- REMOVAL AND INSTALLATION — DRIVER SEAT (ALL MODELS)
- REMOVAL AND INSTALLATION — JOYSTICK AND HOSES
- REMOVAL AND INSTALLATION — SERVO CONTROLS
- SPECIFICATIONS — OPERATORS ENVIRONMENT
- ELECTRICS
- DIAGNOSING AND TESTING — STARTING SYSTEM
- DIAGNOSING AND TESTING — CHARGING SYSTEM
- DIAGNOSING AND TESTING — BATTERY
- REMOVAL AND INSTALLATION — BATTERY (SINGLE)
- REMOVAL AND INSTALLATION — BATTERY (TWIN)
- REMOVAL AND INSTALLATION — STARTER MOTOR
- REMOVAL AND INSTALLATION — STARTER MOTOR SOLENOID
- REMOVAL AND INSTALLATION — ALTERNATOR
- REMOVAL AND INSTALLATION — FRONT WIPER MOTOR
- REMOVAL AND INSTALLATION — REAR WIPER MOTOR
- REMOVAL AND INSTALLATION — INDICATOR SWITCH AND FORWARD/REVERSE SWITCH
- GENERAL PROCEDURE — BATTERY ISOLATION
- GENERAL PROCEDURE — BATTERY CHARGING
- SPECIFICATIONS — ELECTRICS
- FUSE AND RELAY INFORMATION
- WIRING DIAGRAM — TRANSMISSION
- WIRING DIAGRAM — POWER SUPPLY
- WIRING DIAGRAM — OPERATORS ENVIRNOMENT
- WIRING DIAGRAM — HYDRAULIC SYSTEMS
- CHASSIS AND BODYWORK
- REMOVAL AND INSTALLATION — REAR FENDER
- REMOVAL AND INSTALLATION — HARDNOSE
- REMOVAL AND INSTALLATION — BONNET
- SPECIFICATIONS — CHASSIS AND BODYWORK
- FRONT AXLE AND STEER SYSTEM
- DESCRIPTION AND OPERATION — TWO-WHEEL STEER
- REMOVAL AND INSTALLATION — STEERING COLUMN
- REMOVAL AND INSTALLATION — ORBITROL STEERING MOTOR
- REMOVAL AND INSTALLATION — TIE ROD END
- SPECIFICATIONS — STEERING
- DESCRIPTION AND OPERATION — FOUR-WHEEL DRIVE FRONT AXLE
- DIAGNOSING AND TESTING — FOUR-WHEEL DRIVE FRONT AXLE
- REMOVAL AND INSTALLATION — FOUR-WHEEL DRIVE FRONT AXLE
- REMOVAL AND INSTALLATION — STEERING CYLINDER GROUP
- DISASSEMBLY AND ASSEMBLY — STEERING CYLINDER GROUP
- DISASSEMBLY AND ASSEMBLY — EPICYCLIC REDUCTION GEAR GROUP
- DISASSEMBLY AND ASSEMBLY — WHEEL HUB GROUP
- DISASSEMBLY AND ASSEMBLY — AXLE HOUSING GROUP
- DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL SUPPORT GROUP
- DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP
- DISASSEMBLY AND ASSEMBLY — PINION GROUP
- GENERAL PROCEDURE — TOE-IN ADJUSTMENT
- GENERAL PROCEDURE — STEERING ANGLE ADJUSTMENT
- GENERAL PROCEDURE — DRAINING AND FILLING THE FRONT AXLE HOUSING OIL
- GENERAL PROCEDURE — DRAINING AND FILLING THE HUB OIL
- SPECIFICATIONS — FOUR-WHEEL DRIVE FRONT AXLE
- WHEELS AND TYRES
- SAFETY PRECAUTIONS — WHEELS AND TYRES
- REMOVAL AND INSTALLATION — FRONT WHEEL
- REMOVAL AND INSTALLATION — REAR WHEEL
- SPECIFICATIONS — WHEELS AND TYRES
- DRIVETRAIN AND BRAKES
- DESCRIPTION AND OPERATION — HYDRAULIC BRAKING SYSTEM
- REMOVAL AND INSTALLATION — PARKING BRAKE CABLE
- REMOVAL AND INSTALLATION — MASTER CYLINDER
- REMOVAL AND INSTALLATION — BRAKE FLUID RESERVOIR
- GENERAL PROCEDURE — BRAKE BLEEDING
- SPECIFICATIONS — BRAKES
- DESCRIPTION AND OPERATION — FOUR-WHEEL DRIVE REAR AXLE
- DIAGNOSING AND TESTING — TWO - WHEEL STEER REAR AXLE
- REMOVAL AND INSTALLATION — TWO WHEEL STEER REAR AXLE
- DISASSEMBLY AND ASSEMBLY — BRAKES
- DISASSEMBLY AND ASSEMBLY — FLANGE GROUP
- DISASSEMBLY AND ASSEMBLY — WHEEL HUB AND REDUCTION GEAR
- DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL SUPPORT GROUP
- DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL GROUP
- DISASSEMBLY AND ASSEMBLY — PINION GROUP
- DISASSEMBLY AND ASSEMBLY — DIFFERENTIAL LOCKING GROUP
- GENERAL PROCEDURE — DRAINING AND FILLING THE REAR AXLE HOUSING OIL
- SPECIFICATIONS — TWO-WHEEL STEER REAR AXLE
- DESCRIPTION AND OPERATION — SYNCHROSHUTTLE TRANSMISSION – CARRARO
- DIAGNOSING AND TESTING — SYNCHROSHUTTLE TRANSMISSION – CARRARO
- DIAGNOSING AND TESTING — SYNCHROSHUTTLE TRANSMISSION – CARRARO PRESSURE
- TESTING
- REMOVAL AND INSTALLATION — SYNCHROSHUTTLE TRANSMISSION — CARRARO
- DISASSEMBLY AND ASSEMBLY — PLUGS AND FILTERS
- DISASSEMBLY AND ASSEMBLY — TRANSMISSION OIL PUMP
- DISASSEMBLY AND ASSEMBLY — SAHR BRAKE SOLENOID VALVE
- DISASSEMBLY AND ASSEMBLY — HYDRAULIC CONTROL VALVE
- DISASSEMBLY AND ASSEMBLY — FOUR WHEEL DRIVE SOLENOID VALVE
- DISASSEMBLY AND ASSEMBLY — TRANSMISSION HOUSING (4WD)
- DISASSEMBLY AND ASSEMBLY — INPUT SHAFT AND IDLER SHAFT
- DISASSEMBLY AND ASSEMBLY — SHAFTS C AND B
- DISASSEMBLY AND ASSEMBLY — FOUR WHEEL DRIVE SHAFT (E)
- DISASSEMBLY AND ASSEMBLY — SAHR BRAKE GROUP
- DISASSEMBLY AND ASSEMBLY — MANUAL PARKING BRAKE
- DISASSEMBLY AND ASSEMBLY — PIPES
- DISASSEMBLY AND ASSEMBLY — SPEED CONTROLS
- GENERAL PROCEDURE — NEGATIVE PARKING BRAKE
- SPECIFICATIONS — SYNCHROSHUTTLE TRANSMISSION — CARRARO
- DESCRIPTION AND OPERATION – CARRARO SERVO POWER SYNCHRO TRANSMISSION
- DIAGNOSING AND TESTING — CARRARO SERVO POWER SYNCHRO TRANSMISSION
- DIAGNOSING AND TESTING — CARRARO SERVO POWER SYNCHRO TRANSMISSION
- PRESSURE TESTING
- REMOVAL AND INSTALLATION — CARRARO SERVO POWER SYNCHRO TRANSMISSION
- DISASSEMBLY AND ASSEMBLY — FILTERS
- DISASSEMBLY AND ASSEMBLY — TRANSMISSION OIL PUMP
- DISASSEMBLY AND ASSEMBLY — SWITCHES AND SENSORS
- DISASSEMBLY AND ASSEMBLY — SAHR BRAKE SOLENOID VALVE
- DISASSEMBLY AND ASSEMBLY — SAHR BRAKE GROUP
- DISASSEMBLY AND ASSEMBLY — HYDRAULIC CONTROL VALVE
- DISASSEMBLY AND ASSEMBLY — MANUAL PARKING BRAKE
- DISASSEMBLY AND ASSEMBLY — FRONT HALF-HOUSING
- DISASSEMBLY AND ASSEMBLY — REAR COVER SHAFTS
- DISASSEMBLY AND ASSEMBLY — GEAR PISTONS
- DISASSEMBLY AND ASSEMBLY — INPUT SHAFT AND IDLER SHAFT
- DISASSEMBLY AND ASSEMBLY — SHAFTS C AND B
- DISASSEMBLY AND ASSEMBLY — FOUR WHEEL DRIVE SHAFT (E)
- DISASSEMBLY AND ASSEMBLY — SHIFT RAILS — FORKS
- GENERAL PROCEDURE — NEGATIVE PARKING BRAKE
- SPECIFICATIONS — CARRARO SERVO POWER SYNCHRO TRANSMISSION
- ENGINE
- DESCRIPTION AND OPERATION — ENGINE
- REMOVAL AND INSTALLATION — ENGINE
- REMOVAL AND INSTALLATION — RADIATOR
- REMOVAL AND INSTALLATION — FUEL TANK
- REMOVAL AND INSTALLATION — AIR CLEANER
- REMOVAL AND INSTALLATION — EXHAUST PIPE
- REMOVAL AND INSTALLATION — EXHAUST SILENCER
- GENERAL PROCEDURE — THROTTLE ADJUSTMENT
- GENERAL PROCEDURE — DRAINING, FILLING AND BLEEDING THE COOLING SYSTEM
- SPECIFICATIONS — ENGINE
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