Tunnel Heading and Loading Machine

itc120 f8

OPERATOR’S MANUAL

Language version: AN
Edition: 06.2012
Code number: 6246.054.790
Valid for serial N° 120 F8 #0479
Original – Operator’s manual
 ITC SA
Inter Techno Commerce S.A
122, rue de la Fusion
CH 1920 – Martigny – Switzerland
 +41 277 222 191
 +41 277 222 185

www.itcsa.com
e-mail : info@itcsa.com

German quality product manufactured by

Terex GmbH
Schaeffstrr.8
PF. 61
D-74595 Langenburg

Please before first delivery; enter the information of tunnel loading machine:

Machine model: ITC120N F8

Machine-Ident.-N°: 0120N / 0479

Construction year: 2012

Date of first delivery: EXW 06.2012 on site: ……………………

Dealer:

This documentation is reduced copyright. It may be multiplied and used for the driver / operator.
 Table of Contents 1
1 Table of contents
1 Table of contents ................................................................................................... 3
2 Foreword ................................................................................................................ 1
2.1 Concerning these operating instructions ....................................................................................... 1
2.2 Notes on using the operating manual ............................................................................................ 3
2.3 Intended use .................................................................................................................................. 4
2.4 Unintended use .............................................................................................................................. 4
2.5 Warranty......................................................................................................................................... 4
2.6 Declaration of Conformity .............................................................................................................. 5
3 Safety ...................................................................................................................... 6
3.1 General safety notes .............................................................................................................. 6
3.1.1 Safety symbol .................................................................................................................. 6
3.1.2 Hazard classification........................................................................................................ 6
3.1.3 Description of symbols and hazard pictorials .................................................................. 7
3.2 Location of the safety signs.................................................................................................... 8
3.2.1 Pictograms....................................................................................................................... 9
3.3 Personal safety..................................................................................................................... 10
3.3.1 Personal protection equipment...................................................................................... 10
3.4 Work zone safety.................................................................................................................. 11
3.4.1 General work zone regulations and safe work practices .............................................. 11
3.4.2 Deactivation and protection against re-activation ......................................................... 11
3.5 General safety notes ............................................................................................................ 12
3.6 Operation.............................................................................................................................. 13
3.7 Danger zone......................................................................................................................... 14
3.8 Transport persons ................................................................................................................ 14
3.9 Stability ................................................................................................................................. 14
3.9.1 Stability on slopping ground .......................................................................................... 14
3.10 Driving ................................................................................................................................ 15
3.11 Operation............................................................................................................................ 15
3.11.1 Machine deployment ................................................................................................... 16
3.11.2 Rock breaker employment........................................................................................... 17
3.12 Guides ................................................................................................................................ 18
3.13 Danger of falling objects..................................................................................................... 18
3.14 Working in the vicinity of underground power lines ........................................................... 18
3.15 Working in the vicinity of overhead power lines ................................................................. 19
3.16 Operation in closed spaces................................................................................................ 20
3.17 Work stoppages ................................................................................................................. 20
3.18 Change of work attachments, maintenance, repair ........................................................... 21

Model ITC 120N / 0479

1 Table of Contents

3.19 Recovery, Loading and Transporting................................................................................. 23

3.20 Monitoring and inspections ................................................................................................ 23
3.21 Fire protection .................................................................................................................... 24
3.22 Notes concerning residual dangers ................................................................................... 24
3.22.1 Failure of hydraulic system.......................................................................................... 24
3.23 Special hints for operation with Hydraulic Rock Breaker ................................................... 24
4 Initial installation and settings ........................................................................... 26
4.1 Initial familiarization...................................................................................................................... 26
4.1.1 Handing over the Machine and instruction the Operator ...................................................... 26
5 Tunnel Heading Machine description ................................................................ 27
5.1 Overviews of the tunnel heading machine................................................................................... 27
5.1.1 Views of the emergency stop and main switch ..................................................................... 29
5.2 Announcement and control elements in the operator’s cab ........................................................ 30
5.2.1 Driver’s Station ...................................................................................................................... 30
5.2.2 Display and Operating Elements........................................................................................... 32
5.2.3 Fuse and relay....................................................................................................................... 34
5.2.4 Driver’s Seat .......................................................................................................................... 38
5.3 Identification plate ........................................................................................................................ 39
5.3.1 Battery main switch ............................................................................................................... 39
5.3.2 Display................................................................................................................................... 40
5.3.3 Electric configuration of the Displays .................................................................................... 49
5.3.4 Customized changes of the display configuration................................................................. 53
5.3.5 Resetting of Display configuration......................................................................................... 55
5.3.6 Display for camera system .................................................................................................... 56
5.4 Extinguisher system..................................................................................................................... 56
6 Maintenance ......................................................................................................... 57
6.1 General ........................................................................................................................................ 57
6.2 Care and cleaning........................................................................................................................ 57
6.3 Inspection intervals ...................................................................................................................... 58
6.3.1 Regular Oil Analyses............................................................................................................. 60
6.3.2 Warranty ................................................................................................................................ 60
6.4 Inspection Means......................................................................................................................... 61
6.4.1 Service Parts ......................................................................................................................... 61
6.4.2 Fuels, lubricants and coolants............................................................................................... 62
6.5 Lubrication.................................................................................................................................... 65
6.5.1 Central lubrication system ..................................................................................................... 65
6.5.2 Rock breaker lubrication system ........................................................................................... 67
6.5.3 Lubrication plan ..................................................................................................................... 67
6.6 Initial Inspection (Transfer Inspection)......................................................................................... 73
6.6.1 Initial inspection ..................................................................................................................... 73

Model ITC 120N / 0479

 Table of Contents 1
6.6.2 Daily and Weekly Work ......................................................................................................... 74
6.6.3 Inspection Schedule Diesel engine ....................................................................................... 78
6.6.4 Inspection plan machine........................................................................................................ 79
6.7 Maintenance and inspection work ............................................................................................... 81
6.7.1 Diesel engine......................................................................................................................... 82
6.7.2 Engine cooling system .......................................................................................................... 88
6.7.3 Air intake system ................................................................................................................... 91
6.7.4 Fuel System........................................................................................................................... 95
6.7.5 V-belt ..................................................................................................................................... 99
6.7.6 Crawler Travel gear............................................................................................................. 101
6.7.7 Travel-drive gear unit .......................................................................................................... 107
6.7.8 Hydraulic System ................................................................................................................ 108
6.7.9 Additional control circuit (Option) ........................................................................................ 114
6.7.10 Electrical Equipment.......................................................................................................... 115
6.7.11 Cable reel .......................................................................................................................... 118
6.7.12 Boom equipment ............................................................................................................... 119
6.7.13 Transfer Belt Conveyor ..................................................................................................... 120
6.8 Immobilization ............................................................................................................................ 123
6.8.1 Preservation (temporary immobilization)............................................................................. 123
6.8.2 While being taken out of service ......................................................................................... 124
6.8.3 After the machine had been taken out of service................................................................ 124
6.8.4 To remove waste................................................................................................................. 124
7 Operation............................................................................................................ 125
7.1 Before operation ........................................................................................................................ 125
7.2 Running...................................................................................................................................... 127
7.2.1 Starting and stopping the engine ........................................................................................ 129
7.2.2 Electric motor operation start and stop ............................................................................... 130
7.2.3 Driving and steering ............................................................................................................ 131
7.2.4 Monitoring during operation ................................................................................................ 134
7.2.5 Parking ................................................................................................................................ 138
7.2.6 Shut-down in case of emergency (emergency-stop) .......................................................... 139
7.2.7 Start up after emergency (emergency-stop) ....................................................................... 139
7.2.8 Operating the excavator equipment .................................................................................... 140
7.2.9 Changing work attachments................................................................................................ 145
7.2.10 Notes for winter operation ................................................................................................. 147
8 Transport ............................................................................................................ 151
8.1 Salvaging the Machine............................................................................................................... 151
8.2 Lifting the Machine with a Crane ............................................................................................... 153
8.3 Transporting the Machine .......................................................................................................... 154
9 Technical Data ................................................................................................... 155
9.1 Views.......................................................................................................................................... 155

Model ITC 120N / 0479

1 Table of Contents

9.1.1 Front, top, left and right side views with F8 boom geometry............................................... 155
9.2 Technical data............................................................................................................................ 156
9.2.1 Operating data..................................................................................................................... 156
9.2.2 Diesel Drive ......................................................................................................................... 156
9.2.3 Electrical Drive .................................................................................................................... 157
9.2.4 Brake ................................................................................................................................... 157
9.2.5 Hydraulic System ................................................................................................................ 158
9.2.6 Travel gear .......................................................................................................................... 158
9.2.7 Conveyor ............................................................................................................................. 159
9.2.8 Lighting system ................................................................................................................... 159
9.2.9 Operating............................................................................................................................. 160
9.2.10 Boom equipment ............................................................................................................... 160
9.3 Pressure measurement table..................................................................................................... 161
10 Trouble shooting and fault rectification ........................................................ 162
10.1 Who is allowed to rectify malfunctions..................................................................................... 162
10.2 Before trouble shooting and fault rectification ......................................................................... 162
10.3 Trouble shooting and fault rectification .................................................................................... 163
11 Service and spare parts information.............................................................. 168
11.1 Spare parts............................................................................................................................... 168
11.2 Service ..................................................................................................................................... 169
12 Standards and regulations.............................................................................. 170
12.1 Applicable standards and regulations...................................................................................... 170
12.2 Acquisition of standards and regulations ................................................................................. 170
13 Index ................................................................................................................. 171

Model ITC 120N / 0479

 Foreword 2
2 Foreword
2.1 Concerning these operating instructions
Economic operation This operating manual contains important information for safe, proper and
economical operation of the tunnel heading machine. Strict compliance
with these instructions helps to avoid dangers, to reduce repair costs and
downtimes and to enhance the reliability and service life of the tunnel
heading machine.

Reading the operating in- Read these operating instructions thoroughly to become acquainted with
struction correct handling and operation.

Deployment location These operating instructions must always be available at the deployment
location of the tunnel heading machine.

Technical modifications Items described in this manual are subject to change without prior notifi-
cation.

Copyright This Operating Manual is copyrighted. It must not be copied, dissemi-

nated or used for competitive purposes, either fully or in part, without prior
written permission.

Model ITC 120N / 0479 1

2 Foreword

Definition of the target The contents of these Operating Instructions are aimed at a diverse target
groups audience. The level of knowledge each target group must have is defined
here. Be physically and mentally fit and suitable.
All target groups must have read these Operating Instructions and under-
stood their contents.

Operating personnel must • be of the legal minimum age.

• have been instructed in handling the tunnel heading machine.
• have proven their ability to operate the tunnel heading machine to the
operating company.
• have been appointed by the operating company to operate the tunnel
heading machine.
• be familiar with the country-specific accident-prevention regulations.

Maintenance personnel must • be physically and mentally fit and suitable.

• be of the legal minimum age.
• know the maintenance points on the tunnel heading machine.
• have proven their ability to operate the tunnel heading machine to the
operating company.
• have been appointed by the operating company to operate the tunnel
heading machine.
• know the country-specific environmental regulations for the disposal
of lubricants. See chapter "Regulations concern environmental pro-
tection".

Service personnel must

• be physically and mentally fit and suitable.
• be of the legal minimum age.
• have sound school education and vocational training.
• have been trained by TEREX for service work on the tunnel heading
machine.
• must have been trained in the rules and procedures related in case
of malfunction.

2 Model ITC 120N / 0479

 Foreword 2
2.2 Notes on using the operating manual
The safety symbol is used to warn you of potential personal injury. Ob-
serve all instructions that follow this safety symbol in order to avoid poten-
tial injuries or death.

1 2
Structure of safety notes

3
Type of danger
Consequence of danger
Action against danger 4

6 5

1 Safety symbol
2 Signal word danger level
3 Type and source of the danger
4 Possible consequence of danger
5 Measures for hazard prevention
6 Safety symbol

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

Model ITC 120N / 0479 3

2 Foreword

2.3 Intended use

The tunnel heading machine with standard bucket equipment is intended
solely for work which is suitable for the function of the machine and its
work implements. The TEREX tunnel heading machine ITC 120N is solely
intended for the following types of work:
• Loosening of materials at the face, profiling of tunnel cross-sections
as well as digging and mucking out of the tunnel floor.
After installation of additional approved special work attachments, such as
e. g. :
• Hydraulic rock breaker
• Cutting units
• Cutter-crushers
• Etc…
The equipment can be used for core ITC 120N sponging applications.
Strict compliance with the operating and maintenance instructions and the
performance of maintenance work, as well as adherence to the mainte-
nance intervals is also part of intended use. The operator must also follow
the enclosed operating instructions for externally supplied components.

2.4 Unintended use

Using the TEREX Tunnel heading machine Model ITC 120N for the fol-
lowing types of work is considered unintended:
• Transport of persons
• Transport of payload
• Lifting platform applications
• Load hook applications
• Working in explosion-hazard atmospheres
The supplier cannot be held responsible for any damage resulting from
improper use. This risk is borne solely by the user.

2.5 Warranty
The warranty period covers 12 months, beginning with the day the ma-
chine is handed over or put into operation.

4 Model ITC 120N / 0479

 Foreword 2
2.6 Declaration of Conformity
The tunnel heading machine meets the general requirements of the appli-
cable European directives.
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 docu-
ments.

Model ITC 120N / 0479 5

3 Safety

3 Safety
3.1 General safety notes

3.1.1 Safety symbol

The safety symbol is used to warn you of potential personal injury. Ob-
serve all instructions that follow this safety symbol in order to avoid po-
tential injuries or death.

3.1.2 Hazard classification

Indicates an imminently hazardous situation which, if the safety regula-
Danger
tions are not observed, will result in death or serious injury.

Indicates a potentially hazardous situation which, if the safety regulations

Warning are not observed, may result in death or serious injury.

Caution Indicates a potentially hazardous situation which, if the safety regulations

are not observed, may result in property or equipment damage, or minor
or moderate personal injury.

Caution without safety sym- Indicates a potentially hazardous situation which, if the safety regulations
bol are not observed, may result in property or equipment damage.

6 Model ITC 120N / 0479

 Safety 3

3.1.3 Description of symbols and hazard pictorials

The symbols used in this Manual and on the tunnel heading machine
identify the following hazards:

Warning of hazardous spot

If the required precautionary measures are not taken, death, personal
injury, and substantial property or equipment damage may occur.

Warning of hazardous electric voltage

If the required precautionary measures are not taken, high electric volt-
age, high load currents (on terminals, capacitors, housing parts and
printed circuit boards) may lead to death, physical injury or considerable
property damage.

Warning of explosion danger

If the required precautionary measures are not taken, death burns or
blindness may occur through explosive gasses or contact with caustic
acids.

Warning against danger of burning

If the required precautionary measures are not taken, personal injury
caused by burning may occur.

Warning of crushing danger

If the required precautionary measures are not taken, personal injury due
to crushing may occur.

Warning of suspended load

If the required precautionary measures are not taken, death, personal
injury, and substantial property or equipment damage may occur due to
suspended or falling loads.

Warning of hazardous dusts

If the required precautionary measures are not taken, personal injury
caused by inhaling hazardous dusts may occur.

Warning of pollution
If the required precautionary measures are not taken, these substances
may cause serious environmental damage.

Model ITC 120N / 0479 7

3 Safety

3.2 Location of the safety signs

The safety signs are located in the following positions on the tunnel head-
ing machine:

Figure 1 Location of the safety label

1 Warning of a danger place – Keep safety distance

2 Warning of electrical tension

3 Hearing protection

4 First assistance box (location, box not supplied)

5 Fire extinguisher, (location, not supplied)

8 Model ITC 120N / 0479

 Safety 3
Servicing and replacing safety signs
• The safety of the operator always has to come first.
• Safety signs must always be kept in good condition and legible.
• Replace any safety sign which has been damaged or disappeared.
• Use mild detergents and water to clean the safety signs.
• Do not use any solvent containing cleansers.
• Always specify machine serial number and language when ordering
safety signs.

3.2.1 Pictograms
The following pictograms may be attached to the tunnel heading ma-
chine:
Pictograms Description Pictograms Description
Sense of rotation
of hydraulic oil Air filter
cooler

Yellow revolving Fuel

light Fuel level

Run speed Hydraulic oil

Slow (Tortoise) Hydraulic oil level

Hydraulic oil tem-

Conveyor chain
perature

Hydraulic oil filter

V-belt monitoring
Clogging indicator

Hydraulic oil filter

Horn
Clogging indicator
Operational sta-
tus indicator, Points of fastening
operation hours

Cooling agent Towing points for

temperature crane loading

Cooling agent First assistance box

level first aid box

Battery charge
Fire extinguisher
indicator

Pre-heating Work spotlight

Engine oil pres- Run speed

sure Fast (Hare)

Washing pane Ventilation

Option Option

Model ITC 120N / 0479 9

3 Safety

3.3 Personal safety

The Operating Instructions and the symbols described have to be read
and understood by all persons working on and with the tunnel heading
machine.

3.3.1 Personal protection equipment

The mandatory signs used in this Manual and on the tunnel heading ma-
chine require the following safety measures:

Work with protective clothing

If the required protective clothing is not worn during work, personal injury
may result.

Working with protective gloves

If the required protective gloves are not worn during work, hand injuries
may result.

Working with protective glasses

If the required protective goggles are not worn during work, eye injuries
or a total loss of sight may result.

Working with hearing protection

If the required hearing protection is not worn during work, health defects
may result.

Working with respiratory protection

If the required respiratory protection is not worn during work, health de-
fects may result.

Working with face protection

If the required face protection is not worn during work, eye injuries or a
total loss of sight may result.

10 Model ITC 120N / 0479

 Safety 3
3.4 Work zone safety

3.4.1 General work zone regulations and safe work practices

Read the operating instructions thoroughly and follow the notes on safe
operation before starting up the tunnel heading machine.
In addition to the operating instructions observe also the national legal
and miscellaneous regulations applicable at the deployment location of
the tunnel heading machine.
• Working safety
• Accident prevention
• Safeguarding your health
• Environmental protection
• Public roadways
Such duties could also apply in respect of e. g. handling hazardous
goods or the wearing of personal safety gear.
Furthermore, safety laws governing work in particular locations (tunnels,
adits, quarries, pontoons, contaminated areas, etc.) must likewise be
observed, e.g.:
• Working around tracks (BGV D33)
• Construction work (BGV C22)
• Safety rules for construction work under ground (BGR 160)
• Tunneling machines (DIN EN 12111)
The stipulated safety requirements must also be observed when working
in explosion-hazard atmospheres.
The customer and the operator of the tunnel heading machine are held
responsible for compliance with the safety rules. The customer must in
any case become familiar with the locally valid rules and regulations.

3.4.2 Deactivation and protection against re-activation

Ensure all the following safety instructions are read prior to using or ser-
vicing the tunnel heading machine, to avoid personal injury:
• Before breaks and the end of work park the tunnel heading machine on
a solid and level ground.
• The tunnel heading machine is only to be parked in places where it
does not obstruct e. g. the public traffic or the construction site traffic.
• Lower the work equipment to the ground by supporting it on the bucket.
• Lower the dozer blade.
• Shut down the engine and pull out the ignition key.
• Put the left exit barrier in upright position.
• Interrupt the machine circuit on the main battery switch at the left below
the driver's seat.
• Close or lock doors and panels.
• Secure the tunnel heading machine through warning equipment, e.g.
triangles, warning cordons, flashing or hazard lights.

Model ITC 120N / 0479 11

3 Safety

3.5 General safety notes

Do not undertake any working procedures that might impair your safety.
• The tunnel heading machine is only to be used if it is in a safe, op-
erational condition.
• The manufacturer’s instructions must be complied with for operation,
maintenance, repair, assembly, and transportation.
• The plant operator must provide additional special safety instruc-
tions, wherever necessary, for specific local conditions.
• The Operating Instructions and any information pertaining to safety
must be carefully kept in the driver's cab.
• The Operating Instructions and safety notes must be complete and
fully readable.

Before starting work • Before starting work become acquainted with the First Aid and Rescue
Possibilities (Emergency Doctor, Fire Brigade and Rescue Services).
• Check that the first aid kit is available and properly stocked.
• Become familiar with the location and the operation of fire extinguishers
on the tunnel heading machine, as well as the local fire alarm and fire
fighting facilities.
• Fasten any loose parts, e. g. tools and other accessories.
• Close all doors, windows, hoods, flaps, or secure these in open condi-
tion against unintended closing.

During work • Never make any safety features ineffective and do not remove any safe-
ty features.
• Wear protective clothing for operation. Take off rings, scarves and open
jackets. Protective goggles, protective boots, helmets, gloves, reflecting
jackets, earmuffs, etc… may be required for certain work.

12 Model ITC 120N / 0479

 Safety 3

Regulations concerning envi- • Comply with the valid environmental regulations when working on or
ronmental protection with the tunnel heading machine.
• Take special care that no environmentally harmful substances, like lu-
brication grease and oils, hydraulic oils, fuels, coolants and solvent con-
taining cleaning fluids do not seep into the ground or the sewer when
performing installation, repair and maintenance work. These sub-
stances must be collected, transported, kept and disposed of in suitable
containers.
• If the substances listed above enter into the soil, the leak or outlet must
be stopped immediately and the fluid must be cleaned up with a suit-
able absorbent material. If necessary, the soil involved must also be
removed.
• Properly dispose of binding agent and excavated material, comply with
valid environmental regulations.

3.6 Operation
• Operate the control equipment only from the driver's seat.
• To access and exit the tunnel heading machine, use only the steps and
surfaces provided for this purpose
• Make sure that the operator’s stand, access steps and other walk-on
surfaces on the tunnel heading machine, are kept free of dirt, grease,
oil, ice, and snow.
• Make sure
• That the rear-view mirrors are always clean and properly adjusted al-
lowing the operator to still see the left and the right rear end of the
tunnel heading machine from his seat.
• That the headlights and hazard lights are clean and in working order
• That the warning equipment (backing/reversing alarm, engine start-
up) is working.

Model ITC 120N / 0479 13

3 Safety

3.7 Danger zone

Nobody must be allowed to remain in the danger zone of tunnel heading
machine.
The danger zone encompasses the area around the tunnel heading ma-
chine in which persons may be injured by movements of the tunnel head-
ing machine during operation, its work implements and attachments, or
by swinging out or falling loads.
• The machine operator may only work the with the tunnel heading ma-
chine if nobody is in the danger zone.
• The machine operator must give a warning signal to persons who may
be in danger.
• Stop work with the tunnel heading machine if persons remain in the
danger zone despite the warning.
• To avoid danger of crushing, a sufficient safety distance (min. 0.55 m)
must be kept from solid objects, e. g. buildings, excavation slopes, scaf-
folding, or other tunnel excavators, etc.
• If the safety distance cannot be kept, fence off the area between solid
construction elements and the working range of the tunnel heading ma-
chine.
• 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 secured by means of a solid barricade.

3.8 Transport persons

• The tunnel heading machine must not be used to transport persons.

3.9 Stability
• The tunnel heading machine must be used, driven and operated in such
a manner that its stability against overturning is ensured at all times.
• Match the travel speed to the local conditions.
• Do not exceed the permissible load for the tunnel heading machine.
• Keep the tunnel heading machine away from the edges of quarries, pits,
mounds and slopes, to ensure there is no risk of falling. If this is not
possible, the tunnel heading machine must be secured to prevent roll-
ing or slipping.

3.9.1 Stability on slopping ground

There is danger of overturning on sloped base.
There is particular danger when working (digging and lifting) on soft
bases if the blade is used to increase standing stability.
An increased degree of caution is required on slopes over 10° (17.6%).
The tilt angle increases when driving over obstacles one-sided.

14 Model ITC 120N / 0479

 Safety 3
Maximum inclination • Test the standing stability of the machine before beginning work.
• Observe the stability specifications. See chapter 6.7.6 ‘’Crawler travel
gear’’ page 101. The stability specifications are based on a level, solid
and even base.
All stability calculations must be made with a horizontally positioned ma-
chine on a uniform and solid ground. If the machine is used while working
under conditions that do not meet this requirement (such as loose and
irregular ground, no horizontal position, side loads, etc.) these conditions
must be taken into consideration by the operator.
• Secure the machine against rolling or sliding.
• In the case of adjustable running gear, ensure that the crawler unit is
moved out.
• Begin work slowly.

3.10 Driving
• The tunnel heading machine may not travel on public roadways.
• Before putting the tunnel heading machine into operation, the driver's
seat, mirrors and operator controls must be adjusted so as to ensure
safe working.
• Always wear the seat belt.
• Keep windows clean and free of ice.
Driving tracks must be designed so as to ensure smooth, safe operation,
i.e. they must be sufficiently wide, on ground which has as few slopes as
possible and sufficient carrying capacity. Downhill tracks must be set out
in such a way that earth-moving machines can be safely broken.
Downhill tracks must be set out in such a way that the tunnel heading
machine can be safely broken.
• Before driving downhill, the appropriate gear for the terrain must be
selected and the gear lever not be moved during downhill travel (road
or off-road gear). On steep drops and uphill gradients, the load must be
carried on the uphill side, if possible, in order to increase stability.
• The carrying capacity of bridges, cellar roofs, vaults, etc. must be veri-
fied before the earth-moving machine can drive over them.
• Check the clear dimensions of constructions before entering into sub-
ways, tunnels, etc.
It is the plant operator's responsibility to ensure that equipment such as
first-aid box, warning triangle, hazard lights are kept with the earth-
moving machine 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 factory
premises, traffic regulations should be applied in the proper manner. This
should also apply with regard to drivers’ licenses.

3.11 Operation
• Daily before commencing work and after every change of work attach-
ments, a check must be carried out to ensure that the work attachment
is correctly fastened, and the quick-mount hitch is properly locked.
Move the working attachment carefully in low height. During this check
nobody must be allowed to remain in the danger zone of the earth-
moving machine.

Model ITC 120N / 0479 15

3 Safety

• The machine operator may only swing the work equipment over occu-
pied drivers' seats, operator consoles and workplaces of other ma-
chines if these are protected by canopies (FOPS).If the operator’s stand
does not have the required protection, the driver of this vehicle must
leave the operator’s stand while the work equipment is being swung
overhead.
• At dumping points, the tunnel heading machine may only be operated if
suitable measures have been taken to prevent rolling or falling.

3.11.1 Machine deployment

• Do not perform quick and jerky working movements (fast acceleration
and sudden braking) when the work equipment is swiveled to the side
and extended since this makes the machine laterally unstable causing
danger of tipping over.
• Rocking the machine back and forth with the work equipment through
repeated alternating movements is not allowed since this presents dan-
ger to tipping over.
• When working with the work equipment, you may only press it into the
rock walls to be removed with the force of the bucket/hydraulic cylinder.
Never use the travel gear for working (to dig out the excavation), since
the developing leverage may cause damages to hydraulic cylinders,
joint pins or the steel structure of the work equipment through such
force.
• When ripping, preferably press the work equipment at a right angle into
the working surface. After penetrating, the material is to be “dug out” by
retracting the removal equipment and not by moving the entire boom.
• Do not drive with the work equipment against obstacles (e.g. shaft
face), since the hydraulic cylinders, joint pins or the steel structure may
otherwise be damaged.
• Do not use the work equipment for striking (e.g. on embedded seams or
against the shaft floor), since the hydraulic cylinders, joint pins or the
steel structure may otherwise be damaged. This applies in particular to
the end positions of the work equipment when it has driven against the
mechanical limit stops.
• Do not carry out any working movements of the work equipment in ex-
treme positions against the mechanical limit stops (toggle lever effect).
• Do not transport any loads with the work equipment. The machine is not
approved for lifting operations. The mounting of working platforms is not
permitted.
• When working the ground, always work from one point of impact; the
excavation can be expanded from the there. The continuous expansion
of an excavation produces higher headways than constantly switching
to several points of impact.

16 Model ITC 120N / 0479

 Safety 3
3.11.2 Rock breaker employment
• Compliance with the several items mentioned here serves to avoid
damage when achieving optimal application of the hammer.
• The hammer operating manual must generally be observed when using
the hammer in order to prevent hazards and damage to the rock
breaker and tunnel heading machine.
• The hammer thrust may only be applied with the hammer advance cyl-
inder (stroke) and not through other working cylinders. This prevents
unnecessary force from acting on the chisel and the boom equipment.
• Levering material loose and general material removal is not permitted
with the chisel.
• Moving the excavation equipment in extreme positions against the me-
chanical end stops (toggle lever effect) is not permitted.
• Tunneling applications create more force on the hammer housing than
during normal operations. Increased wear on the hammer may there-
fore occur.
• The hydraulic hammer must be regularly inspected for chisel bushing
wear and tightness.
• The danger of chisel breakage increases in the case of worn guide
bushings. In addition, the danger of percussion piston damage in-
creases when this meets an uneven chisel.

Cutting unit application • Always follow the operating instructions of the cutting unit when working
with it to avoid hazards and damage to the cutting unit and the work
equipment.

3.11.3 Cable Reel

The following items must be observed when operating the machine with a
cable reel attached:
Inspect the cable reel daily for proper functionality before beginning work.
Inspect the condition of the reeled cable. If the cable is reeled more on
one side, unwind cable and properly re-reel.
Inspect functionality and lubricate the cable guide arm and the reel.
Monitor the unwinding of the cable when traveling forward.
Monitor the winding of the cable when traveling backward.
Never completely unwind the cable (leave 2 coils on the reel)
Check cable return force with cable wound up.
Attention! Damages to the cable do not fall under the warranty!

Model ITC 120N / 0479 17

3 Safety

3.12 Guides
Guides must be easily recognizable, e.g. by means of reflective clothing.
They must remain within the machine operator’s field of vision.
While guiding the machine, guides shall not be given other jobs which
may distract them from their task.

3.13 Danger of falling objects

• If there is danger of falling objects use the tunnel heading machine only
if the driver's seat is protected by a FOPS (Falling Object Protection
Structure) canopy. A front guard must be employed if there is a risk of
materials breaking through into the cab.
• When operating the tunnel heading machine in front of walls, e. B. with
stacked material, position the machine so that the operator's stand and
the access steps are not on the side of the tunnel heading machine fac-
ing the wall.
• Only use the tunnel heading machine for demolition work if no persons
are endangered and if the tunnel heading machine is equipped with a
protective roof (FOPS) and front protection mounted to the operator's
stand. See the regulations pamphlet "Demolition work" (BGI 665) pub-
lished by the German ‘’Tiefbau-Berufsgenossenschaft’’ (Civil Engineer-
ing Employer’s Liability Insurance Association).

3.14 Working in the vicinity of underground power lines

• Before commencing excavating work with the tunnel heading machine,
determine whether any underground power lines are present in the in-
tended working zone which may present a danger to persons.
• If underground power lines are present, their exact position and course
must be determined in consultation with the proprietor or operator of the
lines, and the necessary safety precautions decided and implemented.
• Before starting any earth work clearly mark the route of lines in the con-
struction site area under supervision. If the position of lines cannot be
determined, search ditches must be dug - manually, if need be.
• In case of unexpected detection or damaging of underground power
lines or their protective coverings stop work immediately and inform the
supervisor.

18 Model ITC 120N / 0479

 Safety 3
3.15 Working in the vicinity of overhead power lines
If the tunnel heading machine is being used in the vicinity of overhead
power lines and trolley wires, a safety distance which varies depending
on the nominal voltage of the overhead line must be maintained between
the lines and the tunnel heading machine and its work equipment, to
prevent current overspill. This also applies to the distance between these
lines and attached implements or loads.

Specified safe distance The safe distance depends on the rated voltage of the overhead power
line.
Nominal voltage Safe distance
Up to 1’000 V 1.0 m
Over 1 kV 110kV 3.0 m
Over 110kV 220 kV 4.0 m
Over 220 kV 1380 kV 5.0 m
Nominal voltage unknown 5.0 m

Tab 3-1: Specified safe distance

• Also consider all working movements of the tunnel heading machine, e.

g. positions of the work equipment and the dimensions of attached
loads.
• Consider also uneven ground which could cause a slanted position of
the tunnel heading machine and thus bring it closer to the overhead
power line. During work in windy conditions, both overhead lines and
work equipment may swing out, thus reducing the safety distance.
If it is impossible to maintain sufficient distance from overhead power
lines and trolley wires, the plant operator must consult with the proprietor
or operator of the overhead lines to find other safety precautions to pre-
vent current overspill. Such measures could be, e. g.
• Switching off the current,
• Re-routing the overhead line,
• Wiring
• Limitation of the working range of the tunnel heading machine.

Model ITC 120N / 0479 19

3 Safety

3.16 Operation in closed spaces

If tunnel heading machine are to be used in closed spaces, these areas
must be sufficiently ventilated and special regulations observed.

3.17 Work stoppages

• Before rest periods and the end of work park the tunnel heading ma-
chine on a level base of sufficient load bearing capacity and secure it
reliably against unintended moving.
• Before rest periods and the end of work lower the working attachment to
the ground to prevent it from moving.
• Do not leave the tunnel heading machine before you have lowered and
secured the working attachment.
Tunnel heading machine are only to be parked in places where they do
not present an obstacle to others, e.g. on the construction site or to plant
traffic. Warning devices, e. g. triangles, warning cordons, flashing or haz-
ard lights are to be used if necessary.
• Before leaving the operator's stand return all control elements to neutral
position, apply the brakes and switch of the working hydraulics.
• Before exiting the tunnel heading machine shut down the engine and
secures it against unauthorized restarting (e. g. by pulling out the igni-
tion key or disconnecting the battery if necessary).

20 Model ITC 120N / 0479

 Safety 3
3.18 Change of work attachments, maintenance, repair
Tunnel heading machine shall only be converted, maintained or serviced
under the guidance of a suitable person designated by the plant operator
and following the manufacturer’s Operating Instructions.
• After changing the work attachments convince your self of the correct
fastening of the work attachments or locking of the quick-mount hitch.
Work on e. g.
• Brake systems,
• Hydraulic systems,
• Electric systems
Of the tunnel heading machine is only to be carried out by expert person-
nel specially trained in these areas.
Stability must be ensured during all types of work on the tunnel heading
machine at all
• Always secure the machine with wheel chocks against rolling when
working on or especially under the tunnel heading machine.
• Secure the work equipment against movement by lowering it to the
ground or by applying equivalent measures, e. g. cylinder supports,
trestles.
• As long as the engine is running, the unprotected working range must
not be entered.
• Attach the lifting gear for jacking up the tunnel heading machine so that
it cannot slip off. Make sure that the jacks are placed exactly vertically.
• The raised tunnel heading machine must be supported with suitable
structures; e. g. crosswise stacked planks, square timbers or steel
trusses.
• Stabilize the tunnel heading machine, which has been lifted with the
work attachment, immediately after lifting with a supporting structure.
Work under the raised tunnel heading machine is prohibited, if it is only
supported by the on-board hydraulics.
• Shut down the engine before any 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.
• Always depressurize the hydraulic system before starting corresponding
maintenance and repair work. 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.
• Before starting work in the electric system or for welding work on the
machine disconnect the battery connection. In addition, the plug of the
electronic system must be pulled off.
• When disconnecting the battery disconnect the minus pole first and then
the plus pole. Reconnect in reverse order.
• When performing repair work in the area of the battery cover the battery
with insulating material. Do not lay any tools on the battery.
• Open or remove the safety features from moving parts of the machine
only after the machine has been shut down and the drive is properly
secured against unauthorized restarting. Protective devices are e. g.
engine/motor covers, doors, protective grating, trim.

Model ITC 120N / 0479 21

3 Safety

• Upon completion of assembly, maintenance or repair work, all protec-

tive devices must once more be attached in the proper manner.
• Welding work on load-bearing parts of the tunnel heading machine is
only permitted after consultation with the manufacturer and in accor-
dance with recognized welding principles.
• Do not perform welding or drilling work on protective roofs (FOPS).
• Alterations, such as welding of the hydraulic system, are only to be un-
dertaken with the manufacturer’s permission.
• Before commencing work on the hydraulic system, the operating pres-
sure, pilot pressure, back pressure and pressure inside the tank must
be relieved.
• Observe the safety data sheets issued by the mineral oil companies.
Swallowing lubricants as well as long and repeated skin contact can be
hazardous to health and should therefore be avoided. When used prop-
erly, there is no particular danger to health.
• Use only hydraulic hoses specified by the manufacturer.
• Route and assemble hydraulic hoses correctly.
• In the vicinity of fuel or batteries, smoking and naked flames are prohib-
ited. Safe working conditions and good working order of the machine
are prerequisites for efficient work. Your TEREX Tunnel heading ma-
chine model ITC 120N fulfils these requirements when correctly han-
dled and when serviced and maintained as specified:
• Prevent malfunctions by cautiously watching the tunnel heading ma-
chine functions and by using the specified fuels and lubricants.
• Trained specialist personnel shall be responsible for any servicing of
the tunnel heading machine requiring expert knowledge. Inspections
and repairs must therefore be carried out by your dealer’s customer
service.
• Within the warranty period damage claims can only be lodged if the
specified intervals for maintenance and inspection work have been
complied with.
• Regular maintenance must also be performed after the warranty period
in order to ensure that the tunnel heading machine is constantly in good
working order and enjoys a reasonable service life.
• Insist that only original ITC spare parts are used in the event of any
repair work. In this way, you will have a product of lasting high quality,
thereby ensuring that your tunnel heading machine maintains its origi-
nal condition.

22 Model ITC 120N / 0479

 Safety 3
3.19 Recovery, Loading and Transporting
Tunnel heading machine are only to be loaded onto recovery vehicles if
adequate towing equipment is used.
• Use the lifting points specified by the manufacturer.
• For loading and transportation secure the tunnel heading machine and
the required auxiliary devices against unintended movements.
• Clean running gear and chassis of the tunnel heading machine from
slurry, snow and ice, so that loading ramp can be approached without
the risk of slipping.
• For transport by truck, low loader or railway secure the tunnel loading
machine reliably with wheel chocks and by fastening it at the lashing
points.
• Before taking off, the route to be taken must be examined to determine
whether the roads are wide enough, entrances and passages under
bridges are large enough and that roads and bridges have sufficient
carrying capacity.

3.20 Monitoring and inspections

• Have the tunnel heading machine inspected by an expert (e. g. machine
engineer or machine foreman) according to the regulations in force in
the user's country (e.g. Accident Prevention Regulations in Germany):
• Before the machine is put into operation for the first time and after
significant modifications have been made
• At least once a year
• In the meantime, according to operating conditions and local envi-
ronments
• Keep record of the inspection report and file it until the next inspection.
• Before the beginning of the shift check the tunnel heading machine
following the inspection plan.
• Replace hydraulic hoses as soon as the following damage is noticed:
• Damage to the outer layer which reaches the intermediate layer.
• Embitter patches on the outer layer.
• Deformations when under pressure or without pressure which differ
from the original shape of the installed hose.
• Leaks.
• Damage to hose fittings or to the connection between the fitting and
the hose.
• Check the coolant level only with the engine shut down, carefully turn
the cover to relieve overpressure.
• Check the function of the safety devices before using the machine.
• In case of any faults inform the supervisor immediately, at change of
shifts inform also the new operator.

Model ITC 120N / 0479 23

3 Safety

3.21 Fire protection

• Shut down the engine before refueling and take care when the engine is
hot.
• Never smoke or handle open flames whilst refueling the tank of the
machine.
• Keep the fire extinguisher near the operator's stand.
Its location must be identified by the fire extinguisher symbol.

3.22 Notes concerning residual dangers

3.22.1 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.

3.23 Special hints for operation with Hydraulic Rock Breaker

Safety Regulations
These regulations apply to all devices in which energy is transferred to a
tool through a percussion piston. This energy, used for the demolition of
rock and the like, carries with it risks for third parties when handled incor-
rectly. The following instructions must therefore be strictly followed:
• The tool of a hydraulic hammer, regardless of what type, may never be
on the foot or against the body of the operator as long as the hydraulic
connection is not blocked. Hydraulic hammers of all kinds may never be
directed at people with the tool.
• Tools that are worn or damaged at the insertion end or the striking sur-
face may no longer be used.
• Usage of a tool without locking device in the hydraulic hammer is pro-
hibited.
• Only the specified hoses may be used for hydraulic hammers (accord-
ing to the installation manual). The usage of incorrect hose qualities or
pressure ratings can lead to risk of accident.
• The relevant accident prevention regulations in the field of construction
work underground must be followed.
Before using hydraulic hammers, the following must be ensured:
• The operator must be informed with regard to the safety regulations and
must be familiar with the handling of the rock breaker.
• The operator should wear suitable hearing protection when operating
the hammer.
When dismantling a hydraulic hammer, it must be ensured that the con-
nection hoses are closed with plugs and installed stop valves are closed,
in order keep oil contamination and leakage to a minimum.
The operating manual from the hammer manufacturer describes the cor-
rect handling of the hydraulic hammer. It likewise belongs in the opera-
tor’s cab.
The user is responsible in every case for compliance with all safety regu-
lations.
Comply with the Underground Engineering Industrial Safety Council VBG
37 and the safety regulations for construction work underground (ZH
1/486).

24 Model ITC 120N / 0479

 Safety 3
When using a hydraulic hammer outside of the Federal Republic of Ger-
many, the national laws and regulations of the respective user country
must be followed.
Note that safe operation of the hydraulic hammer is only guaranteed
when using original spare parts.
Usage in Accordance with Regulations
the hydraulic hammer is suitable for the following types of work:
Range of application tunnel construction, percussive loosening.
When using/transporting the excavator with a hydraulic hammer at-
tached, the operating manual/operating instructions provided by the
manufacturer of the excavator must also be observed.

Model ITC 120N / 0479 25

4 First installation and attitudes

4 Initial installation and settings

4.1 Initial familiarization
Note
Initial inspection must be carried out before commissioning.
See chapter 6.7 "Maintenance and Inspection work" page 81.
The tunnel heading machine must only be operated by properly trained
and instructed personnel. For this purpose a corresponding instruction
session and training is conducted when the tunnel excavator is handed
over.

4.1.1 Handing over the Machine and instruction the Operator

The following checklist should be followed when handing over the ma-
chine to the operator:

Operating Instructions • 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 employer’s liability
insurance associations in the user’s country
• Technical data
• Operator controls, indicating and warning elements
• Checks before putting the machine into operation
• Engine running-in instructions
• Starting and shutting down the engine
• Explanation of hydrostatic crawler drive
• Driving
• Recovery and transport of the machine
• Operation of all functions
• Tensioning crawler chains
• Explanation of maintenance intervals and points according to Main-
tenance and Inspection Plan by demonstrating and explaining main-
tenance points on machine
• Lubrication intervals and points of lubrication according to lubrication
chart and demonstration of these points on the machine
• Handing over the engine Operating Instructions.

Spare Parts List • Explain the structure of Spare Parts List, Figures and the associated
texts Explain that spare parts orders must always be accompanied by
machine type, vehicle identification number (‘’Fz-Id.Nr.’’), parts designa-
tion, complete spare part number, quantity, delivery address, etc…

Warranty • Explain the warranty conditions.

• Explain the inspections cards with a hint to the maintenance and in-
spection plan.
• Fill the warranty/handing over card correctly and send it back to us.

26 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
5 Tunnel Heading Machine description
5.1 Overviews of the tunnel heading machine

Hydraulic installation:

Fig. 2 Index tunnel heading machine

Model ITC 120N / 0479 27

5 Tunnel Heading Machine description

01 Chassis
02 Cable reel
03 Basic conveyor
04 Conveyor extension (1625mm)
06 Conveyor drive
07 Chain
08 Conveyor hydraulic installation
10 Hydraulic oil tank
11 Fuel tank
14 Driver’s seat
15 Foldable cab
16a Valve assy cpl 6 & 4 SX14
16b Valve assy cpl 7 SX12
19 Conveyor drive motor
23 Electric installations
24 Panels
25 Diesel drive
26 Oil-Air cooler
32 Crawler gear
54 Boom equipment
60 Conveyor ram
61 Apron ram
70 Hydraulic installation – Basic machine
71 Hydraulic installation – Pilot circuit
72 Hydraulic installation - Circulation
74 Electric drive hydraulic installation
75 Diesel drive hydraulic installation
78 Hydraulic installation – Boom equipment
80 Hydraulic installation – Cable reel
90 Tool box

28 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
5.1.1 Views of the emergency stop and main switch

1 2 3

Fig 3 Views of the emergency stop and main switch

1 Emergency stop on right rear of the machine

2 Emergency stop on left rear of the machine
3 Emergency stop on control panel
4 Main switch

Model ITC 120N / 0479 29

5 Tunnel Heading Machine description

5.2 Announcement and control elements in the operator’s cab

5.2.1 Driver’s Station

Figure 5 Operation

Figure 5.3 Main switch

The main switch battery is in the first door, rear of operator’s cab.

30 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
1 a Tool carrier lower
b Tool carrier lift
c King post left
d King post right
e Hydraulic hammer ON / OFF
f TCU ON / OFF
2 a Jib lower
b Jib lift
c Bucket open
d Bucket closed
e Conveyor forward
f Conveyor backwards
G Quick hitch
3 a Crawler left forward
b Crawler left backward
4 a Crawler right forward
b Crawler right backward
5 a Conveyor up
b Conveyor down
6 a Apron left open
b Apron left closed
7 a Apron right open
b Apron right closed
8 Manual lever Diesel engine

9 Armrest blocking hydraulic when

lifted
10 Switch Hammer (Option)
11 Switch TCU (Option)
12 Switch Quick hitch
13 Switch for strobe light in park posi-
tion.
14 Speed of conveyor

Model ITC 120N / 0479 31

5 Tunnel Heading Machine description

5.2.2 Display and Operating Elements

Dash board

Figure 4 Dash board

H01 white OK for start electric motor

H02 red Alarm STOP
H03 red Temperature of cable reel
H04 green OK for start motors
H5 red Hydraulic oil level
H6 red Hydraulic oiltemp. >85°C
H7 red Hydraulic oil filter – clogging – return filter
H8 red Hydraulic oil filter – clogging – pressure filter (Option)
H11 red Battery loading check
H12 red Engine oil pressure
H13 red Dewater fuel filter
H14 red Cooler liquid level
H15 yellow Engine pre heating

32 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
H16 yellow Air filter warning
H51 green OK for start TCU
H52 green OK for start Hammer
P1 Display
P4 Operating hour counter
S0 Selector diesel / electric
S1 Diesel engine ignition key
SN1 Emergency STOP switch
S6 Speed selector
S8 Electric motor STOP
S9 Electric motor START
S20 Flood light front
S21 Flood light rear
S22 Horn
S28 Pony Truck
Console left
S51 TCU forwards
S52 Hammer forwards
S101 Quick hitch (Option)
Joystick left
S17L TCU (Option)
S17R Hammer (Option)
Joystick right
S18L Conveyor forwards
S18R Conveyor backwards
S34 Quick hitch (Option)

Model ITC 120N / 0479 33

5 Tunnel Heading Machine description

5.2.3 Fuse and relay

Electric box I 400 / 110VAC

Fig 6 Electric box I 400 / 110 VAC

Position Design Designation

Q1 3x 125A Main switch 400VAC

F01 3x 20A Transformator protection switch

Q11 4A T01 Transformator 24 VDC prim.

Q12 1,6A T02 Transformator 110 VAC prim.

Q13 2A LG01 Battery load control prim.

F07 4A Fuse 110 VAC

34 Model ITC 120N / 0479

 Tunnel Heading Machine description 5

Electric box II 24 VDC

Fig 7 Electric box II 24 VDC

Position Design Designation
FT10 50A Current alimentation 24 VDC
FT11 6A Disconnection E-motor
FLG01 6A Battery loading current
FD21 7,5A Switch of filling pump
FD25 5A Cancel switch of D-Engine
FD26 5A Release and monitoring E-Engine
F31 …A Reserve
F32 7,5A Fuse Start E-Motor / Emergency STOP
F33 7,5A Hydraulic monitoring
F34 15A Flood light rear
F35 15A Flood light front
F36 15A Cab light
F37 15A Back alarm and yellow revolving light
F38 10A Cable reel control
F39 10A Hydraulic operation and speed
F40 10A Pony-truck / Conveyor
F41 7,5A Speed selector slow / quick
F42 10A TCU / Hammer
F43 10A Horn
F44 10A Control module A11 – A13
F45 10A Option central greasing
F46 3A Camera system
F47 5A Fire extinguisher system
F101 10A Quick hitch system
F102 5A Backwards light
F103 10A Parking brake

Model ITC 120N / 0479 35

5 Tunnel Heading Machine description

Electric box III 24 VDC (slew

plate)

Fig 8 Electric box III 24 VDC (slew plate)

Position Designation

A11 Control module

A12 Control module

A13 Control module
A14 Option control module
P1A Adjustment module of display P1

R12 Terminal resistance CAN

X21 Terminal connector (CAN-H CAN-L)

36 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
Electric box, diesel distribu-
tion

Fig 8 Electric box, diesel distribution

Position Ampere Designation

FD1 125A Diesel engine pre-heating

FD2 50A Electric box alimentation

FD5 15A Option hydraulic oil filling pump
FD22 15A Diesel start
FD23 15A Diesel cancel button

Model ITC 120N / 0479 37

5 Tunnel Heading Machine description

5.2.4 Driver’s Seat

The comfort seat is spring-mounted with oil-pressure-operated shock
absorbers. The seat meets international quality and safety standards.

Figure 13 Operator’s Seat

1 – Armrest blocking
2 – Horizontal adjustment - seat
3 – Weight adjustment
4 – Height and inclination adjustment - seat

38 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
5.3 Identification plate
Vehicle type and vehicle identification number are stamped on the name
plate.
Note
Please state the vehicle type and vehicle identification number
when making inquiries or placing orders, and in all written cor-
respondence.

Figure 1 Identification Plate

5.3.1 Battery main switch

Figure 13.1 Batteries main switch

1 Batteries main switch

Note
The battery main switch interrupts the engine circuit. The en-
gine circuit shall be interrupted during prolonged standstill or at
the end of the shift.

Model ITC 120N / 0479 39

5 Tunnel Heading Machine description

5.3.2 Display
The operation of the display takes place with the four keys as illustrated
in the lower part of the photo 2-1. The keys show the following symbols
starting at the left side:
• Star
• Arrow downwards
• Arrow upwards
• Return
The display has several masks for indicating the engine and sensor val-
ues.
The cyclic mask change can be executed with the two keys indicating the
arrows. The Menu can be activated with the star key. The return key is
used to confirm the warning and error messages. The key with the star is
used as well to go back step by step in the menu mode and close the
menu.

Since the machine can be operated either in Diesel or electrical mode the
display has to indicate the corresponding values depending on the mode.
As soon as the selector switch of the machine is switched on, the display
is automatically activated according to the selected mode. Chapter 5
describes the display mode for Diesel usage and chapter 6 explains the
electric mode.

5.3.2.1 Displayed values in Diesel operation

Mask 1
The values are indicated with a vertical indicator and a round instrument
for the engine drive.
Position Description Value range Normal values
upper left Temperature of 0 - +140 °C 0 - +106 °C
side cooking agent
lower left Petrol gauge 0 – 100 % 20 – 100 %
side
upper right Batteries loading 0 – 40 Volt 10 – 30 Volt
side check
lower right Hydr. oil tem- -999 - +140 °C -20 - +80 °C
side perature gauge
middle Rev-counter 0 – 2500 UPM 0 – 2500 UPM

Illustration 0-1 : Diesel drive gauge 1

40 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
Mask 2 The display is numeric.
Position Description Value range
upper left Hour counter Diesel drive >0h
side
lower left Total working hours >0h
side
upper right Effective fuel consump- > 0 L/h
side tion per hour
lower right Working hours of the >0h
side hammer

Illustration 0-2: Diesel-drive Mask 2

Mask 3 The display is numeric.

Position Description Value range
upper left Position hand accelera- 0 – 100 %
side tion
lower left Rev-counter > 0 UPM
side
upper right Engine Oil pressure 0 – 10 bar
side
lower right Engine air pressure 0 – 5 bar
side

Illustration 0-3: Diesel-drive Mask 3

Model ITC 120N / 0479 41

5 Tunnel Heading Machine description

Mask 4 The display is numeric.

Position Description Value range
upper left Temperature of cooling 0 – 140 °C
side agent
lower left Petrol tank 0 – 100 %
side
upper right Level of cooling agent 0 – 100 %
side
lower right Hydraulic oil temperature -999 - +140 °C
side

Illustration 0-4: Diesel-drive Mask 4

Summary The display is set up in a way that the following values of the engine and
the main steering can be read at the same time. When pressing the star
key – ‘selection of objects’ – return key, the display-menu will list all of
the values:

42 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
Description in Ger- Description in Eng- Parameter-description Value range Normal values
man lish
Hydrauliköltemp. Hydr. Oil. temp. Hydraulic oil temperature -40 °C - +140 °C -20 - +80 °C
Handgas Hand throttle Hand acceleration / Pedal 0 – 100% 0 – 100 %
position
Drehmoment im AP Eng. Torque WP Eng. Torque WP 0 – 125 % 8 – 30 %
Drehmoment Soll Eng. Torque requ. Eng. Torque requ. 0 – 125 % 0 – 100 %
Drehmoment Ist Eng. Torque active Eng. Torque active 0 – 125 % 0 – 100 %
Motordrehzahl Engine speed Engine rev 0 – 2500 UpM 0 – 2500 UpM
Dieselbetrieb engine hours Diesel engine working hours >0h >0h
Kühlmitteltemp. coolant temp.. coolant temperature 0 - +140 °C 0 – 106 °C
Motoröldruck oil pressure Oil pressure 0 – 10 bar 0 – 10 bar
Kühlmittelstand cooling level Cooling level 0 – 100 % 0 – 100 %
Geschwindigkeit vehicle speed Vehicle speed 0 – 250 km/h 0 – 100 km/h
Kraftstoff/Zeit fuel rate/time Fuel rate/time 0 – 3212 L/h 0 – 204 L/h
Umgebungsdruck barometric press Barometric pressure 0 – 1,25 bar 0 – 1,25 bar
Ladeluftdruck boost pressure Boost pressure 0 – 5 bar 0 – 5 bar
Ladelufttemp. manifold temp. Manifold temperature 40 – 125 °C 40 – 95 °C
Batteriespannung battery voltage Batteries voltage 0 – 3212 V 10 – 30 V
CAN1 Fehler CAN1 Failure no connection possible to all 0/1 0/1
connections at Bus CAN1
CAN1 A12 Fehler CAN1 A12 Failure no connection to CAN-IO- 0/1 0/1
Module A12
CAN1 A13 Fehler CAN1 A13 Failure no connection to CAN-IO- 0/1 0/1
Module A13
CAN1 A14 Fehler CAN1 A14 Failure no connection to CAN-IO- 0/1 0/1
Module A14 (only applicable
if IO-Module A14 integrated
in machine)
A12 VBBo Fehler A12 VBBo Failure no VBBo-voltage on Can- 0/1 0/1
Module A12
A13VBBo Fehler A13 VBBo Failure no VBBo-Voltage on Can- 0/1 0/1
Module A13
A14 VBBo Fehler A14 VBBo Failure no VBBo-Voltage on Can- 0/1 0/1
Module A14 (only applicable
if IO-Module A14 in ma-
chine integrated)
HydTempS Kurzsch. Hyd. Temp S shorted Short circuit on hydraulic oil 0/1 0/1
sensor
HydTempS Leiterbr Hyd. Temp S un- Hydraulic oil temperature 0/1 0/1
plugged sensor unplugged
Gesamtbetrieb Total hours Total working hours (Diesel- >0h >0h
and electrical drive)
Elektrobetrieb E-Mode hours Electric drive hours >0h >0h
Hammerbetrieb Rock breaker hours Rock breaker working hours >0h >0h
Tank Füllstand fuel level Tank full stand 0 – 100 % 20 – 100 %

Model ITC 120N / 0479 43

5 Tunnel Heading Machine description

5.3.2.2 Warning and error messages during Diesel drive

CAN-Transmission error In case of transmission error via the CAN-bus, the display shows 3 hori-
zontal lines instead of the numeric values. in case of error this signal will
flash to indicate to the driver that this parameter cannot be transmitted
any more via the CAN-Bus.
Does this occur with all the J1939 parameters it is possible that the entire
CAN-communication is disturbed?

Engine warnings and errors All warning and error messages concerning the engine steering which
are transmitted in the J1939 format have to be confirmed by the user with
the return key. They are shown in a pop-up window on the display.
Part of the error message is two codes: SPN and FMI. They indicate the
actual error and permit an immediate correction. A list with the codes and
corresponding error descriptions and solutions should either be placed in
the machine cabin or can be obtained as an annex to the user manual. It
is issued directly by the engine manufacturer.
Illustration 5.5 shows active errors. This indicates that the error arose
recently and is still active. Illustration 5.6 shows a message of an inactive
error which has occurred however has been resolved in the meantime.

Illustration 0-5: Popup-window "Active CAN-error"

Illustration 0-6 : Popup-window "Inactive CAN-error"

44 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
For the following errors additional information can be obtained (alternatively in English):
SPN FMI Description
91 2 Hand throttle, problem with signal transmission
91 3 Hand throttle, signal value higher prescription value
91 4 Hand throttle, signal value lower prescription value
91 11 Hand throttle, unknown error source
94 2 Low pressure fuel, problem with signal transmission
94 3 Low pressure fuel, signal too high or ‘’plus’’ circuit breaker
94 4 Low pressure fuel, signal too low or masse circuit breaker
97 3 Sensor for „water in fuel“ / water separator, Signal too high or ‘’plus’’ circuit breaker
97 4 Sensor for „water in fuel“ / water separator, Signal too low or masse circuit breaker
97 12 Sensor for „water in fuel“ / water separator, Sensor defect
100 0 Engine oil pressure too high
100 1 Motor oil pressure, too low
100 2 Motor oil pressure, signal error
100 3 Engine oil pressure too high or ‘’plus’’ circuit breaker
100 4 Engine oil pressure too low or masse circuit breaker
102 2 Load pressure sensor, problem with signal transmission
102 3 Load pressure sensor, signal transmission too high or ‘’plus’’ circuit breaker
102 4 Load pressure sensor, signal transmission too low or masse circuit breaker
102 11 Load pressure sensor, unknown error source
105 0 Loading air temperature too high
105 2 Loading air temperature, problem signal transmission
105 3 Loading air temperature, signal too high or ‘’plus’’ circuit breaker
105 4 Loading air temperature, signal too low or masse circuit breaker
107 0 Air filter dirty
110 0 Cooling agent temperature too high
110 2 Cooling agent temperature, problem signal transmission
110 3 Cooling agent temperature, signal too high or ‘’plus’’ circuit breaker
110 4 Cooling agent temperature, signal too low or masse circuit breaker
111 1 Coolant level too low
157 0 Rail pressure too high
157 1 Rail pressure too low
157 3 Rail pressure signal too big or ‘’plus’’ circuit breaker
157 4 Rail pressure signal too low or masse circuit breaker
168 0 Battery voltage too high
168 1 Battery voltage too low
168 2 Battery voltage incorrect
190 0 Rev-number

Model ITC 120N / 0479 45

5 Tunnel Heading Machine description

190 2 Crank shaft on cam shaft out of phase

190 8 Rev-signals on crank shaft and cam shaft incorrect
190 12 Number of rev-signals on crank shaft incorrect
630 12 Motor-ECU 1, EPROM incorrect
1323 12 Cylinder 1 incorrect combustion
1324 12 Cylinder 2 incorrect combustion
1325 12 Cylinder 3 incorrect combustion
1326 12 Cylinder 4 incorrect combustion
1327 12 Cylinder 5 incorrect combustion (do not apply)
1328 12 Cylinder 6 incorrect combustion (do not apply)
2634 3 Main relay, Voltage too high or ‘’plus’’ circuit breaker
2634 4 Main relay, Voltage too low or masse circuit breaker
Motor-ECU 1 not stopped correctly (Possibly because of pressing the battery discon-
2634 12 necting switch too early)

Table 5-2: J1939 – Warning and Error messages

(1) – ECU: Engine Control Unit (Motor distribution bzw. Motorsteuergerät).

46 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
In case of engine error the user is informed by the warning and/or error
message system and in addition by a red flashing error LED at the lower
right edge of display (frequency of cycles per second).In case of engine
failure the control turns engine after a few seconds off.

Checking of values The Engine meter can indicate up to four parameters (engine data, sen-
sor values or condition of the system). Does the indicated value not cor-
respond to the desired values (between minimal and maximal value), the
pop-up window on the display will indicate the error message (see Illus-
tration 5-7).

Illustration 0-7: Excess in range of values

The following parameters are being check on the ITC 312:

Parameter Minimal Maximal value Unit
value
Hydraulic oil tem- -19 80 °C
perature
Coolant level 80 100 %
CAN1 A12 error 0 (no error) 1 (error)
CAN1 A13 error 0 (no error) 1 (error)

Table 0-1: System parameters supervised by the display

Model ITC 120N / 0479 47

5 Tunnel Heading Machine description

5.3.2.3 Additional error messages during Diesel usage

Hydraulic oil temperature sensor
In case of short circuit of the hydraulic oil temperature sensor, the value
will be fixed on –999 °C (see illustration 5-8). In case the temperature
was beforehand higher than the min. value (see table 5-3), an additional
pop-up window appears. The same procedure applies for a line breakage
the value field on –888°C (see ill. 5-9).

Illustration 5-8 : Short circuit hydraulic oil temperature sensor

Illustration 5-9 : Hydraulic oil temperature oil line breakage

CAN 1 communication error In case the communication between the main control and the IO module
A12/13 on the Bus CAN1 fails, the parameters “CAN1A12 error” and
“CAN1 A13 error” are fixed on the value “1”.
The values are corrected automatically to ‚0’ as soon as the communica-
tion has been restored.

Illustration 0-10 : Pop-Up-window “CAN1 A12 error”

Illustration 0-11 : Pop-Up-window “CAN1 A13 error”

48 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
Depending upon combination of the announced errors "CAN1 A12 error"
and "CAN1 A13 error" conclusions on the cause of the error message
can be closed.
Depending upon combination of the announced errors ‘CAN1 A12 error’
and CAN1 A13 error’ conclusion on the cause of the error message can
be drawn.
Example 1: only ‚CAN1 A12 error’ is indicated, the problem is caused by
the IO-module A12 or is cables (problem module, interruption of power
supply or problem with CAN-connection).
Example 2: both error message are indicated - the problem could be
caused by the CAN-connection of both of the IO-modules to the control-
ler.

5.3.3 Electric configuration of the Displays

5.3.3.1 Indicated values during electric drive

During electric drive the display indicates the chosen control and sensor
values via two masks.
In the following chapters 7.2.1 – 7.2.2 page 130 the two masks are de-
scribed in detail: the indicated parameter value, its position on the display
and the max-and normal value range.

PS: The indicated values on the following illustrations have been estab-
lished with simulation at the PC and may contain machine atypical val-
ues.

Mask 1 Display numeric.

Position Description Value range
Lower left Electrical working hours >0 h
side
Lower right Hydraulic oil temperature -999, -888, -40 - +140 °C
side

Illustration 0-12 : Electric drive mask 1

Model ITC 120N / 0479 49

5 Tunnel Heading Machine description

Mask 2 Display numeric.

Position Description Value range
Lower left Total of working hours >0 h
side
Lower right Working hours of >0 h
side hammer

Illustration 0-13: Electric drive Mask 2

5.3.3.2 Warning and error messages during electrical drive

All detected warning and error message of the machine control are indi-
cated on the display by the means of a symbol. To draw the attention of
the driver to look at the display in case of problem messages, a triangle
warning symbol appears on the upper left side on the display. As soon as
error has been solved the symbol disappears automatically.

Phase relay
In case of problem with the phase-relay the following symbol appears:

Illustration 0-14: Error-symbol "Phase-relay"

Overcharge relay In case of problem with the overcharge relay the following symbol ap-
pears:

Illustration 0-15: error-symbol «Overload relay»

50 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
Winding up of the cable drum If more than two layers in the cable drum are rolled up, the following sym-
bol appears:

Illustration 0-16: Error-symbol "Wind-up cable drum"

If the hydraulic oil temperature exceeds a value of 80C or a short circuit

and/or a breakage of the ‘’line breakage’’ of the sensor is present, the
following symbol appears:

Illustration 0-17: Error symbol "Hydraulic oil temperature"

Model ITC 120N / 0479 51

5 Tunnel Heading Machine description

CAN1 Communication error

If no communication between the control A11 and the IO-modules A12
and A13 via the Can-Bus CAN1 is possible the following symbol appears:

Illustration 0-18: Error symbol " CAN1 Error"

If no communication between the control A11 and the IO-module A12 via
the Can-Bus CAN1 is possible the following symbol appears:

Illustration 0-19: Error symbol" CAN1 A12 Error"

If no communication between the control A11 and the IO-module A13 via
the Can-Bus CAN 1 is possible, the following symbol appears:

Illustration 0-20: Error symbol " CAN1 A13 error"

Depending upon the indicated symbol conclusions on the cause of the

error message is possible. Example 1: Error message ‚CAN1 A12 error’
(not CAN1 error) the source of the problem has to be the IO-module A12
or its cables (module incorrect, interruption of the power supply or prob-
lems with CAN-connection).
Example 2: Error message ‚CAN1 error’ - the problem could be the CAN-
connection of the two IO-modules of the control.

52 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
5.3.4 Customized changes of the display configuration
It is possible to adapt the configuration on the display after delivery of the
machine according to customer wishes. To enable this, the machine has
to be put in diesel drive mode, as the changes concern only the diesel
configuration display (see chapter 5.3.4 page 53).

5.3.4.1 Language
The language on the display can either be in German or English
To change the language (can be stopped at any time with the asterisk):
1) Press Asterisk to obtain selection menu

2) Choose settings with arrows

3) Press return
4) Choose language with arrows

5) Press return
6) Choose language with arrows

7) Press return to activate language

Model ITC 120N / 0479 53

5 Tunnel Heading Machine description

5.3.4.2 Units
The units of the indicated values can alternatively appear as metric (°C,
km, liter...) or as US (F, miles, gal...) units.
To change units (can be stopped at any time with asterisk):
1) Press asterisk to obtain selection menu

2) Choose settings with arrows

3) Press return
4) Choose units with arrows

5) Press return
6) Choose unit with arrows

7) Press return to activate unit

54 Model ITC 120N / 0479

 Tunnel Heading Machine description 5
5.3.5 Resetting of Display configuration
In case of unwanted changes or problems with the display, it is possible
to reset the display in the original condition, as long as diesel drive is
active. The indications of the service intervals remain unchanged. The
resetting can be done as follows (can be stopped at any moment with the
asterisk) :
1) Press Asterisk to choose selection menu

2) Choose settings with arrows

3) Press return
4) Choose default settings with arrows

5) press return
6) choose answer with the arrows

7) press return to confirm chosen answer

Model ITC 120N / 0479 55

5 Tunnel Heading Machine description

5.3.6 Display for camera system

Fig 5.1 Color LCD for two cameras

- See documentation of manufacturer in folder 6

5.4 Extinguisher system

□ 1 Extinguisher BATEC
□ 2 Extinguishing switch rear left
□ 3 Extinguishing switch rear right
□ 4 Extinguishing switch in cab
□ 5 Light signal and acoustic signal

4
2 3

- See documentation of manufacturer in folder 6

56 Model ITC 120N / 0479

 Maintenance and Upkeep 6
6 Maintenance
Note
Strictly observe all safety notes.
See chapter 3.18 "Change of work attachments, maintenance
and repair" page 21.

6.1 General
The good operating condition and life expectancy of tunnel heading ma-
chines 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 lubri-
cating tasks.

6.2 Care and cleaning

Cleaning the machine
• For cleaning park the machine on a suitable base with oil separator.
• Neither a steam-jet nor a high-pressure cleaner must be used for clean-
ing during the first two months after the machine has been used for the
first time, or when newly painted, to ensure that the paint can cure suffi-
ciently.
• Do not use aggressive detergents to clean the machine. We recom-
mend using commercially available cleaning agents for passenger cars.
• Do not exceed a hot water jet temperature of 176.00°F/80°C and a jet
pressure of 1015 psi/70 bar.
• Linings (insulating materials, etc.) should not be exposed directly to
water, steam or high-pressure jets.
• When cleaning with water or steam jets, take care not to direct the jet
into exhaust/diesel particle filter and air filter openings.
• When cleaning the engine with water or steam jet, do not expose sensi-
tive engine parts, such as generator, wiring, oil pressure switches, etc.
directly to the jet.
• After wet cleaning lubricate the machine as specified in the lubrication
plan and check all clearances, support and travel functions.
• Allow the radiators to dry after cleaning.

Model ITC 120N / 0479 57

6 Maintenance and Upkeep

6.3 Inspection intervals

The machine is equipped with a DEUTZ diesel engine.
The inspection intervals of TEREX and DEUTZ SERVICE are different
and are therefore listed below.

TEREX DEUTZ service

1.Inspection 100 O.H 50 O.H
2.Inspection 300 O.H 125 O.H
3.Inspection 600 O.H 250 O.H
4.Inspection 900 O.H 375 O.H
5.Inspection 1200 O 500 O.H
H
Then every 300 O.H 125 O.H
O.H = Operating hours

Note
The diesel engine needs much more maintenance than
the Electric motor!

During operation of the machine there can be a higher dust accumula-

tion. According to this you have to count with a higher maintenance work.
The imperatively required service intervals have to be checked and ac-
cording to the real dust accumulation eventually abbreviated.

Machine
Note
The reading of the operating hour meter on the operating
display is decisive for the inspection intervals of the ma-
chine. See chapter 5.3.2 "Display" page 40 and chapter
5.2.2. “Display and operating elements” page 32.

58 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Machine

Interval Description See page…

Initial inspection Once before first outing into opera-

tion

Daily tasks Every 10 O.H or every work shift 1)

Weekly tasks Weekly or after 50 O.H 1)

100 O.H Once after first putting into operation

2)

300 O.H Always after 300 O.H

600 O.H Always after 600 O.H

1200 O.H Always after 1200 O.H

1)
Whichever comes first
2)
Also applicable if new or overhauled engines are put into operation

Diesel engine The machine is equipped with a DEUTZ diesel engine.

The inspection intervals of TEREX and DEUTZ SERVICE are different
and are therefore listed below.
Note
The reading of the operating hour meter on the operating display
is decisive for the inspection intervals of the machine. See chap-
ter 5.3.2 "Display" page 40 and chapter 5.2.2 “Display and oper-
ating elements” page 32.

Interval Description See page…

Initial inspec- Once before first putting into opera-

tion tion

Daily tasks Every 10 O.H or every work shift 1)

Weekly tasks Weekly or after 50 O.H 1)

50 O.H Once after first putting into operation

2)

125 O.H Always after 125 O.H

250 O.H Always after 250 O.H

375 O.H Always after 375 O.H

500 O.H Always after 500 O.H

1000 O.H Always after 1000 O.H

1)
Whichever comes first
2)
Also applicable if new or overhauled diesel engines are put into opera-
tion

Model ITC 120N / 0479 59

6 Maintenance and Upkeep

6.3.1 Regular Oil Analyses

Oil analysis are not intended as a substitute for the stipulated oil change
intervals but – apart from a possible reduction of maintenance costs and
as a form of preventive maintenance – they take into account the increas-
ing environmental awareness.

Benefits of Oil Analysis • Extends the oil change intervals under normal or mild operating condi-
tions.
• Minimizes the high-quality component wear if the lubricant is used opti-
mally.
• Periodic laboratory analysis enables an early detection of imminent
damage.
• Repairs undertaken before they become absolutely necessary help
prevent serious and unexpected damage.
• Resulting damage will also be prevented.

Oil analysis intervals Regular oil analysis will indicate any developing trends regarding the
state of the oil and the machine. The oils should be analyzed at the fol-
lowing intervals:
Oil Operating hours
Hydraulic oil 1000 O.H
Gearbox oil 500 O.H
Engine oil 100 O.H

Based on the first results, the laboratory recommends the interval for the
next sampling.

Note
The oil analysis according to the defined intervals is absolutely
mandatory.
The results of the oil analysis shall be provided to TEREX Ser-
vice.
Failure to do so may adversely affect our warranty coverage.

6.3.2 Warranty
During the warranty period thorough inspections are stipulated for the
machine which are obligatory and must be carried out by trained special-
ist dealer personnel.
The engine inspections specified by the manufacturer must also be per-
formed.
Note
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.
Failure to do so may adversely affect our warranty coverage.

60 Model ITC 120N / 0479

 Maintenance and Upkeep 6
6.4 Inspection Means

6.4.1 Service Parts

Spare Parts Fi
Pos. DEUTZ
Number g
Hydraulic oil – filter insert return filter . 5 380 660 840
Breather filter ...................................... 5 003 657 020
Engine oil filter cartridge ..................... 5 501 316 450
Fuel filter cartridge .............................. 5 411 656 493
Fuel pre-filter....................................... 5 411 665 011
Fuel pre-filter cartridge........................ 5 411 665 001
Air filter – main cartridge ..................... 5 501 660 922
Air filter – safety cartridge ................... 5 501 660 924
Cover seal valve ................................. 5 411 656 337
V-belt – Ventilator ............................... 5 411 656 409
V-belt – generator ............................... 5 411 656 408
Various
TEREX oil, mineral.............................. 4 312 005 050
TEREX Hydraulic oil, biologically For more detailed information, contact
degradable .......................................... your TEREX dealer
Transmission oil (SAE 85 W 90 LS) ... 4 314 005 775
Engine oil ( SAE 15 W 40) .................. 4 312 905 759
Cooler liquid with anti-corrosive and 4 440 305 025
anti-freeze for engine cooler

Note
Service parts for inspections should be ordered well in advance!
Observe our offer on service packages for the inspections. Contact
your dealer!

Model ITC 120N / 0479 61

6 Maintenance and Upkeep

6.4.2 Fuels, lubricants and coolants

Property damage
Machine damage caused by
non-mixable bio oils.
Do not mix bio-degradable oils
from different manufacturers.

Property damage.
Machine damage caused by wrong
proportion of cooling solvent.
Follow the indications of the cooling
system in the operation manual of the
engine manufacturer.

Note
When changing from mineral to bio-degradable hydraulic oils, the tank
and hydraulic system must be completely drained, cleaned and
flushed.
Before changing ask your TEREX dealer for further details.

Fuel specification

It is required to use a qualitative high class fuel for achieving the stated
engine performance.
Recommended fuel specifica- • N590 Diesel engine – AUTO/C0/C1/C2/C3/C4
tion • BS2869 category A2
• ASTM D975-91 category 2-2DA, US DF1, US DF2, US DFA
• JIS K2204 (1992) category 1, 2, 3 and special category 3
Note
By using sulfur-free it needs grease additives

Note
The following fuel specifications are sufficient but can reduce
the life time of the fuel injection device.

Adequate fuel specification • ASTM D975-91 Classes 1-1DA

• JP7, MIL T38216 XF63
• NATO F63

62 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Fuel with low sulfur content Use only commercial trade diesel fuel with sulfur content below 0,5%.
Sulfur content in fuel in % Oil change interval
< 0,5 normal
0,5 to 1,0 0,75 from normal
> 1,0 0,50 from normal

Tab. 6-4 Change interval with higher sulfur content fuel

Stipulated consumables for use in central Europe

Code des- Specifica-
Applica- ignation tions, Stan-
Name Remarks
tion according dards, Qual-
1)
to Bi ity
DIN EN 590
Before using RME-fuels
ASTM D975 1-D /
Engine -- Diesel fuel ask your Terex dealer for
2-D
further details
JIS K2204 G1/G2
SAE 10W-40
See also engine manufac-
Engine Engine oil ACEA E4-99/E- turer’s operating manual.
04
Antifreeze based
Cooling for See also engine manufac-
SP-C Coolant on ethylene
engine turer’s operating manual.
glycol
The following viscosity limit
values must be observed
HVLP D 46 (according to ASTM 445):
Hydraulic oil or
Hydraulic
HYD 1040 multi-grade Or At 100°C min 12mm²/sec
system
engine oil (cSt)
SAE 10W-40
At -10°C approx.
1500mm²/sec. (cSt)
Filling according
Bio-degradable
BIO-E- to customers The same viscosity values
hydraulic oil
specifications. apply as for mineral hydrau-
HYD-HEES based on syn-
Brand label on lic oils.
thetic ester
machine
SAE 80W-90LS Alternate recommendations
Crawler gear GO 90 LS Gearbox oil
API-GL 5 SAE 80-90LS
Multipurpose , K2K-30
Lubrication
MPG-A lithium-soaps
points. DIN 51825
based grease

Ring gear Semi-fluid GOOM-30

swing bearing grease DIN 51502
1)
In conformity with the regulation lubricants of the Main Association of the German Building Indus-
try e.V.

Model ITC 120N / 0479 63

6 Maintenance and Upkeep

Alternate Recommendations for Other Temperature Ranges

Engine oil According to API CG 4 or CF 4 and

According to ACEA E3 or E2

Hydraulic Oil According to DIN 51524.T3 HVLP

Filling capacity Medium

Filling location
140.0 ltr. Diesel fuel
Fuel tank:...................................
Engine oil (initial fill-
Engine oil with filter: .................. 10.0 ltr.
ing)
Hydraulic oil, tank and system: . 400 ltr. Hydraulic oil
Hydraulic oil (change
Hydraulic oil tank:...................... 300 ltr.
quantity)
Travel-drive gear unit: ............... 2,5 ltr. Gearbox oil
Water with anti-
Cooler liquid for Diesel engine 18 ltr. corrosive agent and
antifreeze

Note
All values stated are approximate. The level marking is always
the decisive factor. See chapter 5.3.2 "Display" page 40 and
chapter 5.2.2 “Display and operating elements” page 32.

64 Model ITC 120N / 0479

 Maintenance and Upkeep 6
6.5 Lubrication

Property damage
Damaged grease nipples can
cause machine damage.
Check grease nipples for grease
passing through.
Replace damage grease nipple
immediatly.

Note
The intervals stated apply for single-shift operation.
In case of special operating conditions, e.g. working on sandy
soil, the lubrication intervals should be shortened, in order to
achieve self-cleaning of bearing points.

Lubricants The machine’s life expectancy and operating condition largely depend on
the use of the specified lubricants and compliance with the service inter-
vals.
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.
Note
Lubricate all lubrication points with multi-purpose grease.
Grease specification: See chapter 6.4.2 "Fuels, lubricants, and
coolants" page 62.

6.5.1 Central lubrication system

The machine is equipped with a central lubrication system automatically
supplying a large portion of the bearing points with lubricating grease.

Self-check • A function check of the drive motor of the central lubrication system and
of the control light of the ‘’Auxiliary lubrication’’ switch is performed
whenever the ignition is switched on.
• The control light lights for 2 seconds. The control light extinguishes if no
malfunction is detected.
• A malfunction of the lubrication system is indicated by a blinking control
light.
• The control light is defective if it does not light.
• If the control light blinks during operation, please refer to the operating
instructions of the central lubrication system to study the meaning of the
blinking signals.

Model ITC 120N / 0479 65

6 Maintenance and Upkeep

Filling the grease containers

X

Note
(Option)
The grease must be free of contaminations and may not
change its consistency over time. No grease additives such as
Molybdenum disulfide may be added.

Note
Let the pump run during filling. The lines are automatically
vented toward the lubricating point.

2 1

• Fill the container through the filling nipple (2) up to the “Max” mark.
Greases up to the consistency class NLGI 2 can be used.
• Auxiliary lubrications may need to be initiated after filling to achieve
complete venting.

Lubrication with defective

lubricating pump

• In the event of a defective lubricating pump, supply the grease nipples

(1) manually with grease.

You can initiate an additional lubrication process at any time.

Initiating auxiliary lubrication
• Turn the switch “Auxiliary lubrication” on the control console to the right
for approx. 3 seconds.
The control light lights during the lubrication process.

66 Model ITC 120N / 0479

 Maintenance and Upkeep 6
6.5.2 Rock breaker lubrication system
Lubricating the rock breaker vehicle the lubricating pump is defec-
tive (emergency lubrication)

1 Emergency lubrication
2 Auxiliary circuit – rock breaker lubricating system
3 Auxiliary circuit – return line
4 Auxiliary circuit – rock breaker pressure line

• If the rock breaker lubricating system fails, disconnect the lubrication

hose at the “Rock breaks lubricating system” connection (2).
• Perform the lubrication via the “Emergency lubrication” (1) connection
using the manual grease gun.

6.5.3 Lubrication plan

X

Note
The machine is equipped with a central lubricating system
automatically supplying the major part of the lubricating points.
The following lubricating points must be manually lubri-
cated!

Note
In the case of special operating conditions, e.g. working on
sandy ground, the lubrication intervals should be shortened, in
order to achieve self cleaning of the bearing points.

Lubricating point overview - Pos. Description Q Interval

Machine 1 Bearing king post 3 Daily/ Each Shift
(Figure 27) cylinder
2 Bearing king post 3 Daily/ Each Shift
3 Bearing king post 3 Daily/ Each Shift
cylinder
4 Bearing king post 3 Daily/ Each Shift
5 Bearing conveyor 4 Weekly
6 Bearing conveyor 3 Daily/ Each Shift
cylinder
7 Bearing conveyor 3 Daily/ Each Shift
cylinder
8 Conveyor 2 Daily/ Each Shift

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6 Maintenance and Upkeep

Lubrication point in Crawler Pos Description Q Interval

track
1 1 Grease nipple 2 Daily/ Each Shift
(Figure 27.1)

Figure 27 Base Machine

Hydraulic Cylinders (rams)
• There is a lubrication nipple located on the ground side bearing eye
and on the piston rod bearing eye on each cylinder.

Base Machine - Daily/Each Shift

• Swivel cylinder pin support in chassis front and back (one lubrication
nipple above cylinder eyes and 1 lubrication nipple in cover above
and below. (27/2)
• A central of greasing to the rear right of the machine (27/3)
• A ramp of greasing below the conveyor, at rear of machine. (27/4)
• Crawler carrier rack roller and idler wheat nave forte fine greasing
(27.1/1).

Figure 27.1 Crawler track tensioning

68 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Chain conveyor (Figure 28) • Bearing of the running shaft, on both sides (cover lubrication)
• Right and left side wings(28/5): 2 bearing seating each
• Side wing adjustment cylinders: 1 bearing seating in wing and in con-
veyor belt.
• Conveyor belt bearing in chassis: the lubrication points with lubrica-
tion line are located on the outside of the conveyor belt through be-
tween the apron and the crawler.
• Conveyor belt lifting cylinder: lubrication point in conveyor belt
• Conveyor belt drive motors: each 1x. (28/9) The lubrication point is
located on the housing, accessible from the back side of the con-
veyor belt.
• This grease fitting avoids five duct to enter the sealing element of the
hydraulic motor

Figure 28 Chain conveyor

Boom equipment – Dai-

ly/Each Shift
X

Note
The jib elements change depending on the boom equipment.
This creates changes in the layout, but the lubrication points are
always the same in principle

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6 Maintenance and Upkeep

King Post • Slewing rim: 4 lubrication fitting (from down) (29/1)

• Swivel cylinder: 1 bolt with 1 lubrication nipple in both covers. (29/2)
• Jib bearing in the king post: on the king post. (29/4)
• Jib cylinder bearing in the king post: 1 lubrication nipple on each of
both covers and one lubrication nipple between both cylinders. (29/3)
2 3

Figure 29 King Post

Jib F3 • Jib in king post: 1 lubrication nipple on each of both covers and 1 lu-
brication nipple on Jib. (30/1).
• Jib cylinder in king post: 1 lubrication nipple on each of both covers
and one lubrication nipple between both cylinders (30/2).
• Jib cylinder in Jib: 1 lubrication nipple on each of both covers and one
lubrication nipple between both cylinders (30/3).
• Swivel console on dipper stick: 1 lubrication nipple on each of both
covers and 1 lubrication nipple on dipper stick (30/4).
• Dipper stick cylinder in swivel console: 1 lubrication nipple on each of
both covers and one lubrication nipple between both cylinders (30/5).
• Swivel console cylinder on swivel console: je 1 lubrication nipple on
each of both covers and one lubrication nipple between both cylinders
(30/6).
• Swivel console ram in jib: 1 lubrication nipple on each of both covers
and one lubrication nipple between both cylinders (30/7).
4

5
6
2

7
1

Figure 30 Jib and Swivel console

70 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Intermediate jib F8 • Jib in Intermediate jib: 1 lubrication nipple on each of both covers and
1 lubrication nipple on intermediate jib. (31/1).
• Intermediate jib cylinder in Jib: 1 lubrication nipple on each of both
covers and one lubrication nipple between both cylinders (31/2).
• Intermediate jib cylinder in intermediate jib: 1 lubrication nipple on
each of both covers and one lubrication nipple between both cylinder
(31/3).
• Dipper stick cylinder in intermediate jib: 1 lubrication nipple on each of
both covers and one lubrication nipple between both cylinders(31/4).
• Intermediate jib in dipper stick: 1 lubrication nipple on each of both
covers and one lubrication nipple on dipper stick (31/5).

Figure 31 Intermediate jib F8

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6 Maintenance and Upkeep

Dipper stick F3 4

2
7

8
Figure 33 Dipper Stick

Pos Grease nipple Nbr. Daily

1 Dipper stick – Swivel console 3 X
2 Bucket ram – Dipper stick 3 X
3 Bucket ram – Tipping lever – Bucket rod 3 X
4 Bucket rod - Bucket 3 X
5 Bucket – Dipper stick 3 X
6 Dipper stick – Tipping lever 3 X
7 Dipper stick ram – Dipper stick 3 X
8 Dipper stick ram – Swivel console 3 X

72 Model ITC 120N / 0479

 Maintenance and Upkeep 6

6.6 Initial Inspection (Transfer Inspection)

The inspection plan lists all work activities that needs to be carried out on
the tunnel heading Machine eat regular intervals.

6.6.1 Initial inspection

Work to be completed by Trained Dealer Service Personnel
Chapter
1 Check whether Operating Manual for the machine is at the machine --
The Operating Manual must be gone over page for page and explained in detail with
practical exercises on the machine.
Determine and explain maintenance intervals and points on the machine according to the
maintenance and inspection schedule
Deliver the diesel engine Operating Manual, pointing out the instructions for running in
diesel motors
Explain warranty provisions
2 Check hydraulic oil level 6.7.8
1)
3 Check engine oil level
4 Cooler agent level 6.7.1
5 Check fuel level 6.7.4
6 Check transmission oil levels 6.7.7
7 Check chain tension 6.7.6
8 Check battery fluid level and charge status 6.7.10
9 Check functionality of diesel/electric drive selector switch, including indicator --
10 Check electrical control and warning elements as well as lighting for functionality --
11 Check functionality of cable reel 6.7.11
12 Lubricate machine (all lubrication points) 6.5
Discuss lubrication intervals and lubrication points according to lubrication point overview
on the machine
13 Test run, hydraulic function check and test work --
14 Visual inspection for good seals in all lines, hoses, cylinders, etc. --
15 Completely fill out warranty transfer card according to instructions and send back to --
TEREX
1) See DEUTZ operating manual Type 2012 for maintenance description for diesel engine

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6 Maintenance and Upkeep

6.6.2 Daily and Weekly Work

Inspection and Maintenance Work to be completed by Operating
Personnel
Chapter
Inspection and maintenance work to be completed daily or in every shift by the operat- --
ing personnel (fill, clean, repair, replace as necessary)
1. Checks in the Operator’s Cab
1.1 Instruments
• Coolant temperature
• Hydraulic oil temperature
1.2 Check diesel / Electric selector switch
1.3 Check horn
1.4 Check light switch
1.5 Check operation
• Joystick L/H and R/H
• Conveyor micro switch in right joystick
• Hammer/cutter micro switch in left joystick
• Conveyor belt lever
• Apron lever
• Right crawler pedal/lever
• Hammer pedal
• Swivel console pedal
• Tilt console pedal
• Left crawler pedal/lever
1.6 Check canopy
1.7 Check Emergency Off switch
1.8 Check yellow warning light
1.9 Check armrest switch

74 Model ITC 120N / 0479

 Maintenance and Upkeep 6
2. Checks on the Machine
2.1 Check crawler chain tension, L/H + R/H
2.2 Check chain links and base plates, L/H + R/H
2.3 Check machine for oil leaks

When retightening hose or line connections, lock pipe fittings

against twisting.
2.4 Check V-belt tension
2.5 Check engine for oil and fuel level + leakages

In order to prevent condensation from forming before the next start-

up, fill up fuel tank completely after daily use. Seal tank closure after
refilling.
2.6 Check air filter cartridge
2.7 Check coolant lever
2.8 Check fuel pre-filter if accumulation of water, if necessary drain
2.9 Check Emergency Off switches, rear left and right
2.10 Check fire extinguisher
2.11 Check coolers and ventilators

Clean cooler fins accordingly in case of visible build up

of dust or cementation between them.
2.12 Check hydraulic oil level
2.13 Check tank breathing filter
2.14 Check tank filling
2.15 Check oil cooler and axial fan

Clean cooling fins accordingly in case of visible build up of dust or

cementation between them.
2.16 Check electrical motor for clean cooler grille and cooling fins

Clean cooling fins accordingly in case of visible build up of dust or

cementation between them.
2.17 Check fastening bolts of electrical motor
2.18 Check terminal box and cable entry points
2.19 Check electrical cabinet doors and hinges
2.20 Check tension of conveyor chain
2.21 Check chain covering screws
2.22 Check conveyor hydraulic hoses
2.23 Check teeth of chain sprocket
2.24 Check flights and links
2.25 Check front conveyor belt return shaft
2.26 Check conveyor belt sliding plats

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6 Maintenance and Upkeep

2.27 Check rubber cleats on dumper stop

2.28 Check mirrors: left, middle, right
3. Boom Equipment Inspection
3.0 Visual inspection for possible cracks
3.1 Check hoses for leakage

When retightening hose or line connections, lock pipe fittings

against twisting.
3.2 Check hoses for wear or scouring
3.3 Check cylinders for wear and leakage
3.4 Check bushings for wear or play
3.5 Check apron cutting edge for wear
3.6 Check bolts and cover
3.7 Check hammer connecting rod and wearing plates
3.8 Check hammer fastening bolts / cutter fastening bolts
3.9 Check teeth and retaining elements
3.10 Check nut locking on bucket tilt levers
4 Start-Up Inspection
4.1 Activate horn
4.2 Start engine
4.3 Check forward and reverse crawler movement
4.4 Check all excavator movements
4.5 Check all conveyor belt movements
4.6 Check all spotlights
5 Diesel engine
See operating manual of diesel motor manufacturer.
6 Particles Filter (Option)

See operating manual of particle filter manufacturer.

7 Hammer (Option)
7.1 Check chisel bushing wear
7.2 Check chisel wear
See operating manual of the manufacturer.
8 Cable reel

76 Model ITC 120N / 0479

 Maintenance and Upkeep 6

Work which can be accomplished weekly.

1 Clean cooling fins of the hydraulic oil radiator

Clean these in the case of visible dusty condition and/or cementing

between the cooling fins
2 Clean cooling fins water of the radiator

Clean these in the case of visible dusty condition and/or cementing

between the cooling fins
3 Clean dust discharge valve at the air cleaner
4
Examine flanged connection of the crawler carrier.
5
Examine crawler carrier oil level in the two transmissions
6
Examine lubricating of the roller bearings at the conveyor chain idle shaft
7
Examine lubricating labyrinth seal system at the conveyor drive shaft
8 Examine guiding plate for wear
9
Examine mechanical notices for the hydraulic cylinders for up settings
10’ Lubricate machine lubrication fitting overview
11 Examine safety devices for function, condition and completeness

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6 Maintenance and Upkeep

6.6.3 Inspection Schedule Diesel engine

X

Note
Perform all inspection work on the diesel engine at operating
temperature

Work to be completed by Trained Dealer Service Personnel

O = Check, Maintenance Operating Hours
min
X = Replace
1x

Carry out work while machine is warm after every every every every an- Chap-
nually
50 125 250 500 1000 ter

1 Check whether operating manual for diesel engine is O O --

at the machine
5)
2 Change engine oil X X 2)4) X
5)
3 Change engine oil filter X X X
5)
4 Clean cooling system O O
5)
5 Check V-belt tension O O
6 Engine speed activation; check upper and lower idle O O --
speed
5)
7 Check valve play on engine and adjust if necessary O
8 Dewater fuel tank O O 6.7.4
5)
9 Change fuel filter X X
10 Change fuel pre-screeners X
11 Check air inlet O O 6.7.3
12 Air filter – replace main cartridge According to service X 6.7.3
indicator
13 Air filter – replace safety cartridge As required 6.7.3
14 Check acid level and connections of the battery O 6.7.10
15 Freeze protection of the cooling agent examine O
16 Change cooling agents As required
17 Cooling fins of the water cooler clean O O
With intensified dusty condition the
cleaning intervals are to be shortened
1) At least every 2 years
2) In the case of fuels with a sulphur content of >0.5 to 1%, the oil change times must be halved
In the case of fuels with a sulphur content of greater than 1%, inquire at your service agency
4) Extension of oil change intervals according to TEREX oil analysis and lab report
See Chapter 6.3 “Inspection interval” page 58, for more information
5) See DEUTZ operating manual Type 2012 for maintenance description for diesel engine

78 Model ITC 120N / 0479

 Maintenance and Upkeep 6
6.6.4 Inspection plan machine
Note
Perform all inspection work on the machine at operating tem-
perature.

O = Check, Maintenance Operating Hours

min min
X = Replace
2x 1x

Carry out work while machine is warm after every every every an- an- Chap-
nually nually
100 300 600 1200 ter

1 Check whether machine operating manual is at the O O --

machine
2 Check electrical control and warning elements and O O 6.7.10
the lighting system
3 Check operating elements for mobility and adjust if O O --
necessary
4 Check locks, hinges, gas compression springs, etc. O O --
for proper functionality and replace if necessary
5 Check diesel engine mounting and pump fastening O O --
6 Check electrical motor mounting and pump fasten- O O --
ing
7 Check apron condition and functionality O O --
8 Check safety equipment for functionality, condition O O --
and completeness
9 Check condition and fastening of base plates on the O O 6.7.6
crawler chain.
After changing base plates, check bolts after
the first, third and fifth work day (or shift).
Tightening torque: 385±20 Nm
10 Chain drive – sprocket wheel, transmissions and O O --
hydro motor for fixed seating
11 Check slip plate and rock rollers for mobility and O O 6.7.6
wear
12 Transmission oil check or change X O X X 6.7.7
13 Check functionality of parking brake O O --
14 Check bearing bushings, bolts, flexible bearings and O O 6.7.12
stops of boom equipment and replace if necessary
15 Check fixing bolts of king post for fastening 6.7.12
16 Clean cooling fins of hydraulic oil cooler O O O 6.7.8
In case of increased dust build-up, the
cleaning intervals must be shortened

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6 Maintenance and Upkeep

O = Check, Maintenance Operating Hours

min min
X = Replace
2x 1x

Carry out work while machine is warm after every every every an- an- Chap-
nually nually
100 300 600 1200 ter

17 Seal check of all lines, hoses, control valves, hy- O O --

draulic pumps, cylinders, etc.
When retightening hose or line connections,
lock pipe fittings against twisting.
18 Hydraulic oil check or change O O X 2) --
19 Hydraulic oil - replace pressure filter insert X According to X --
service indicator
20 Change ventilation filter X X --
21 Hydraulic function check with pressure check of O O --
functions
22 Check transfer belt conveyor drive motor fastening O O --
23 Check transfer belt conveyor chain tension O O --
24 Check transfer belt conveyor condition, such as O O --
deformation of flights
25 Check chain sprocket condition and functionality O O --
26 Check guide plates for firm seat and wear O O --
27 Check cable reel condition and functionality O O --
28 Lubricate machine according to lubrication overview O O --
29 Test run and test work O O --
3)
30 Sign inspection card and send back to TEREX O O --

1) Within warranty period.

2) Extension of oil change intervals according to TEREX oil analysis and lab report:
See chapter 6.3.1 ‘’Regular Oil Analyses’’ page 60, for more information”

80 Model ITC 120N / 0479

 Maintenance and Upkeep 6
6.7 Maintenance and inspection work

Personal injury
Eye injuries caused by parts
flying around.
Wear protective goggles during
work.

Environmentally hazardous
substances
Environmental damage caused by
environmental hazardous
substance.
Do not allow oil to seep into the
ground.
Always place a receptacle for the
collection of waste oil under the
working area when draining oil or
removing the filter insert.
Collect waste oil and dispose of
according to regulations.

Note
All maintenance and inspection work must be performed acc. to
the inspection plan.
See chapter 6.7 "Maintenance and Inspection work" page 81.

Note
Perform all service and inspection work on the diesel engine
according to the DEUTZ Operating Manual.
See chapter 6.6.3 "Inspection plan Diesel engine" page 78.

Model ITC 120N / 0479 81

6 Maintenance and Upkeep

6.7.1 Diesel engine

Checking the engine oil

Property damage.
Machine damage caused by too
much oil.
Do not fill in the engine oil tank over the
permitted fill level. Excessive oil can
enter into the crankcase ventilation and
causing breakdowns of the engine
speed control.

All maintenance and inspection work on the diesel motor must be carried
out according to the DEUTZ motor operating manual.
See also chapter 6.7.1 "Diesel Engine" page 82.

Checking oil level

• To be daily controlled the oil level is with horizontally standing ma-
chine before the start,.
• The notches of the engine oil dipstick (56/2) indicate the minimum and
maximum oil level
• If necessary, refill engine oil. Cap (56/1) unscrew and with clean con-
tainer oil supplement

2
HR32-041

Figure 56 Engine oil

82 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Changing engine oil

Danger of burning
Danger of scalding by hot oil.
Be carful when draining hot oil.
Wear suitable protective clothing
and safety goggles.

• Run hot engine oil temperature approx. 80°C.

• Ensure that the machine is on level surface.
• Switch off engine. Wait 5 minutes and check the oil level.
• Place an oil tray beneath the engine.
• Unscrew drain plug (57/1). Drain oil.

When discharging hot engine oil danger

of scalding exists!

• Remove oil drain hose and protective cap onto valve (57/1) screw.
• Changing the engine oil filter.
• Engine oil to "MAX" marking at the engine oil dipstick fill in.
• Engine start and in the idling operation approx. 2 minutes operate.
• Turn off driving motor.
• Control oil level, refill if necessary.

HR32-042

Figure 57 Changing engine oil

Model ITC 120N / 0479 83

6 Maintenance and Upkeep

With each oil change also the engine oil filter is to be changed:
Engine oil filter
• Place an oil tray beneath the oil filter.
• Clean outside of oil filter
• Filter cartridge (58/1) with commercial tools loosen and unscrew, ex-
amine whether attachment connecting piece sits firmly in the filter
head.
• Clean filter cartridge correctly.
• Clean any dirt from the filter head sealing surface.
• Lightly oil the rubber gasket of the new lube oil filter cartridge.
• Manually screw in the new cartridge until the gasket is flush. Tighten
the lube oil filter cartridge with another half-turn.
After test run engine examine oil filter cartridge for tightness.

1
HR32-043

Figure 58 Engine oil filter

84 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Pipe and hose assemblies Checking the pipe and hose assemblies for leak tightness.
• Unscrew the back pressure lines from the diesel particle filter.
• Place a suitable rubber hose on the unscrewed end of the line.
• Blow into the line with an air pump and then close the pushed-on rubber
hose with a clamp to keep the pressure created in the line.
The back pressure value should reach approx. 200 mbar.
• Read the back pressure value on the back pressure display (data log-
ger display).
If the back pressure drops or only a low back pressure is indicated,
there is a leak in the back pressure line or in the condensate separator.
• Immediately replace the leaking component.
If no back pressure is indicated when blowing into the unit, the line is
clogged or the condensate separated overfilled with condensate or the
filter in the condensate separator is clogged.
• Check the condensate separation.
• Clean the back pressure line.

Cleaning the back pressure

line

Property damage
Machine damage due to back
pressure lines that not been
pulled off.
Pull off back pressure lines from
the components descibed below
cleaning with compressed air.

• Pull off the back pressure lines on the data logger and on the conden-
sate separator (intake and outlet line).
• Blow through all segments of the back pressure line with uncoiled com-
pressed air.

Note
Alternatively, you can also block with a compressed air gun into
the back pressure line. In doing so, you must first reduce the
compressed air to max.
0.5 bar since the electronic back pressure control will otherwise
be destroyed.

Model ITC 120N / 0479 85

6 Maintenance and Upkeep

Condensate separator Checking the condensate separator

• Check the filling level of the condensate container.
If the sight glass (1) is filled more than half with condensate, it must be
drained.
• Pull of the pressure lines.
• Close the outlet side of the condensate separator with the thumb.
• Blow with your mouth into the intake side of the condensate separator.
The condensate separator must be replaced if the air escapes.
• Check the filter element in the sight glass of the condensate separator
for dirt contamination.
The filter element must be replaced if it is heavily contaminated.

Draining condensate
• Unscrew the sight glass (1) from the condensate separator.
• Empty the sight glass.
• Screw the sight glass back onto the condensate separator.

Replacing the filter element of the condensate separator

• Unscrew the sight glass (1) from the condensate separator.
• Empty the sight glass.
• Replace the filter element.
• Screw the sight glass back onto the condensate separator.

86 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Electronic back pressure Checking the electronic back pressure control
control
• Unscrew the back pressure lines from the diesel particle filter.
• Place a suitable rubber hose on the unscrewed end of the line.
• Blow into the line with an air pump and then close the pushed-on rubber
hose with a clamp to keep the pressure created in the line.
• Observe the back pressure value on the back pressure display (data
logger display).
When the back pressure value is 150 mbar for more than 30 seconds,
the green warning light must light, the red warning light must blink and an
acoustic signal must automatically sound.

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6 Maintenance and Upkeep

6.7.2 Engine cooling system

Danger of burning.
Danger of scalding by hot oil.
Only open the radiator cap when the
engine is cold.
Wear suitable protective clothing and
safety goggles.

Refilling coolant
• Turn the cap (1) until the pressure relief valve responds.
• Only open the cap completely after venting.
• Take off the cap.
• If necessary top up the coolant with a 50/50% mixture of water and anti-
freeze. See chapter 6.4.2 "Fluid capacities" page 62.

Checking Antifreeze
• Check the antifreeze setting before the beginning of the cold season.
• At the factory, the antifreeze protection is set to approx. 25°C. Adjust
the antifreeze properties for lower temperatures, if required.

HR32-044

Fig 28 Cap of coolant tank

88 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Cleaning Cooling fans

Property damage.
Machine damage caused by
overheating of engine and/or
hydraulic oil.
Clean the radiator carefully.

Property damage.
Machine damage caused by high
dust accumulation.
Clean the cooling fins in time for
avoiding an overheat of the engine
and/or the hydraulic oil.

• Clean the radiator by blowing it out with compressed air from the air
discharge side (inside).
• If necessary, e. g. in case of oil contaminated radiator, clean the radia-
tor with cold cleansing agent or steam cleaning equipment. For this
work park the machine on a washing area equipped with an oil separa-
tor.
• After cleaning, run the engine until it reaches operating temperature to
dry the cooler.

HR32-045

Fig 29 Cooling fan

Model ITC 120N / 0479 89

6 Maintenance and Upkeep

Changing coolant

Burn hazard.
Bodily parts can be burnt with hot
coolent solvent.
Open the radiator cap only chilled
engine.
Wear adequate protective clothing
and safety glasses.

• Park the machine on level ground.

• Turn off the engine and allow the cooling system to cool.
• Remove the radiator cap (59/1).
• Unscrew the water drain plug (61/1) from the cylinder block and drain
coolant.
• Remove the drain plug of the water radiator and drain coolant.
• If necessary, flush the cooling system with clean water.
• Re-fit the drain plug to the engine and the water radiator.
• Fill the cooling system with coolant and close the cap.
• Start the engine and bring to operating temperature; turn off the en-
gine and allow cooling.
• Check the coolant level and top up (several times, if necessary).

HR32-046

Figure 61 Engine block

90 Model ITC 120N / 0479

 Maintenance and Upkeep 6

6.7.3 Air intake system

Property damage
Machine damage due to back
pressure lines that have not
been pulled off.
Pull off back pressure lines from
the components descibed below
cleaning with compressed air.

Checking the air intake

Fig 26 Dust ejection valve

Dust ejection valves (1) are almost maintenance-free.

• Remove possible dust deposits by pressing the valve together.

Cleaning the dust ejection • Clean the air intake space in front of the air filter from any dirt (foliage,
valve etc.).
• Check the air filter fastening for damage.
• Check the air channel after the air filter for leaks.
• Check the rubber parts for damage.
• Replace damaged parts immediately.

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6 Maintenance and Upkeep

Cartridge maintenance inter- Replacing the main air filter cartridge

vals
• Replace the main air filter cartridge if the control light for filter mainte-
nance in the control console lights up during operation.
X

Note
A brief delay in maintenance does not result in lower filter effi-
ciency.

Replacing the air filter safety cartridge

• Replace the air filter safety cartridge:
• After the fifth maintenance of the main cartridge
• At the latest after 2 years of operation.
• If the service indicator comes on again after the main cartridge has
just been serviced
• If the main cartridge is damaged
• If the safety cartridge is defective

Changing the main cartridge

X

Note
Remove the safety cartridge only in the case of necessary
maintenance work. Open the seal (5) of the safety cartridge
only for replacement.

Fig 27 Main cartridge

• Unlock the wire fasteners (1) and remove the bottom of the housing (4).
• Pull out the main cartridge (2) while slightly rotating it back and forth.
• Check whether the safety cartridge 3) must be replaced.
• Mark the maintenance in the corresponding marking fields on the safety
cartridge.
• Carefully insert the new or cleaned main cartridge with the open side
first into the filter housing.
• Ensure that the main cartridge is properly seated.
• Position the bottom part of the housing; observe the position of the dust
ejection valve.
• Insert the wire fasteners in the groove of the flange and tension them.

92 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Changing the safety cartridge

Property damage.
Machine damage caused by
damaged safety cartridge.
Note that the safety cartridge can not
be cleaned and re-used after
dismounting.

Fig 27 Main cartridge

• Dismantle the main filter cartridge (2). See chapter "Changing the main
cartridge".
• Penetrate the seal (5) of the safety cartridge (3) from the inside out us-
ing a suitable tool (screw driver).
• Pull up both tabs (6).
• Grasp the safety cartridge on the two tabs and pull it out while slightly
rotating it back and forth.
• Dispose of the safety cartridge.
• Insert the new safety cartridge and observe correct seating.
• Install the main cartridge.

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6 Maintenance and Upkeep

Cleaning the main cartridge

Property damage.
Machine damage caused by
damaged main cartridge.
Never clean the main cartridge through
washing out or brushing.
Be care when blowing out not to put
dust on the inner side of the main
cartridge.
Never re-use damaged main cartridges.
In case of doubt use a new one.

Fig 27 Main cartridge

• For cleaning, attach a tube to the compressed air gun where the end is
bent at 90°. It must be sufficiently long to reach the floor of the car-
tridge.
• Blow out the main cartridge from the inside to the outside with dry com-
pressed air (max. 5 bar) by moving the tube up and down in the car-
tridge and continue until no more dust escapes. Make sure that no dust
ends up on the inside of the main cartridge when blowing out.
• Inspect the cleaned main cartridge for damages to the paper bellows
and rubber seals. Tears and perforations in the paper bellows can be
determined using a torch.
• Mark the maintenance in the corresponding marking fields on the main
cartridge.

94 Model ITC 120N / 0479

 Maintenance and Upkeep 6
6.7.4 Fuel System

Property damage.
Machine damage due to over-
pressure in the fuel tank.
When fuelling with the electrical
refuelling pump, the fuel tank lid must
be opened to avoid excessive pressure
in the fuel tank!

Refueling
• Check the fuel level based on the gauge on the operating display.
(31/P1)
To prevent condensation from forming before the machine is next put
into operation, top off fuel every day after use.
• Climb on the machine using the foothold.
• Open the fuel tank lid (32/1).
• Refuel through the filler opening (32/1).
• When fuelling with the electrical refueling pump (optional), the fuel tank
lid must be opened to avoid excessive pressure in the fuel tank!

Fig 31 Fuel level

Fig 32 Fuel Tank

Model ITC 120N / 0479 95

6 Maintenance and Upkeep

Cleaning and replacing the fuel filter

Property damage.
Machine damage caused by
air in the filter.
Before starting the engine you need to
activate the fuel transfert pump for
one minute for emptying the air out
of the filter.

• Clean the two fuel filters (1) on the outside.

• Place a collecting vessel under the two fuel filters.
• Unscrew the filter cartridges (1).
• Catch running out fuel and dispose of environmentally.
• Dispose of the filter cartridges properly.
• Clean the filter heads and inspect their condition.
• Lightly moisten the two sealing rings of the filter cartridge with fuel.
• Screw the cartridges hand-tight until the seal is in place.
• Tighten the filter cartridges with an additional half turn.
• Bleed the fuel system (see DEUTZ Operating Manual in folder 5).
• Perform a test run and check the fuel system for leaks.

HR32-048

Fig 33 Diesel Filter

96 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Drain water from the fuel tank
• Drain water from the fuel tank via the drain plug (34/1).
• Clean the filling screens (34/2) and check it for damage.

Fig 34 Fuel Tank

Fig 35 Diesel pre-filter

Model ITC 120N / 0479 97

6 Maintenance and Upkeep

Replacing Filter Insert of Fuel Pre-filter

• Clean the outside of the fuel filter.
• Drain fuel through the drain plug (65/1).

Collect fuel!

• Unscrew the centre screw and remove the cap.

• Extract the filter insert by turning.
• Flush the filter housing using clean fuel.
• Fit the new or cleaned filter insert.
Cleaning Filter Insert of Fuel Pre-filter

When cleaning, take care to ensure

that dust does not land on the inside
(clean side) of the insert.
• Immerse the screen insert of the fuel pre-filter in clean fuel. Mean-
while, blow out from the inside and brush off using a medium-hard
cleaning brush.

Only use brushes with synthetic or

natural bristles.
Do not use wire brushes!
• After brushing, immerse the insert in clean fuel and blow out from the
inside at the same time.
• Remove the filter insert from the bath and blow out hard from the in-
side until there is no more fuel foam on the surface of the insert.
• Check that the filter insert is undamaged and that there is no dirt on
the inside.
• The insert is ready to be re-installed.

Fig 36 Diesel pre-filter

98 Model ITC 120N / 0479

 Maintenance and Upkeep 6
6.7.5 V-belt

Danger of crushing
Body parts may be crushed by
moving parts.
Check or tension V-belts only when the
engine is turned off.

Checking V-belt Tension

We recommend the use of a tension measuring device in order to check
the V-belt tension.
• Perform the test procedure following the corresponding manufac-
turer's operating instructions.

Checking Tension without Using a Tension Measuring Instrument

• To check the tension, press the V-belt with your thumb in the middle
of the greatest free length, and measure the sag.
• Using medium thumb pressure of approx. 45 N, the V-belt sag should
equal approx. 10 mm.

Tensioning V-belts – Coolant/Fuel Pump

• Slacken the fastening screws (38/1, x2) on the control handle.
• Swing the fuel pump (38/2) until the tension is correct.
• Re-tighten the fastening screws (38/1) of the control handle.

Check the tension again.

Tensioning V-belts – Generator
• Slacken the fastening screws (38/3, x3) of the generator (38/5).
• Adjust the generator using the screw (38/4) until the V-belt tension is
correct.
• Re-tighten the fastening screws (38/3).

1
2
1

Fig 38 Tensioning the V-belt

Model ITC 120N / 0479 99

6 Maintenance and Upkeep

Changing the V-belt

Note
The V-belt is to be replaced if distance (AB) is smaller than 3
mm.

Fig 39 Changing the V-belt

Note
When new V-belts are mounted, their tension has to be
checked after the first 15 min. of operation, and adjusted if nec-
essary.

100 Model ITC 120N / 0479

 Maintenance and Upkeep 6
6.7.6 Crawler Travel gear
Checking the crawler track tension
• Park the machine on level ground to check.
• Check the sag within the measuring distance between the support roll-
ers. The sag (43/1) of the crawler should be approx. 10-15 mm.
• Check the second track in the same way.

Figure 43 Chain Tension

Tensioning the crawler track

Property damage
Excessively tensioned track cause
higher wear.
Do not tension the track too much. The
specified sagging must always be
maintained.

• Unscrew the cover to the right and left of the roller carrier.
• Connect the manual grease gun to the grease nipple by means of a
sliding coupling (27.1/1).
• Press in grease, until the correct track tension is reached.
• Move the track and check the track tension again.

Figure 27.1 Crawler track tensioning

Model ITC 120N / 0479 101

6 Maintenance and Upkeep

Relieving the crawler track tension

Property damage
Danger of injury caused by grease
emergency under pressure.
Wear suitable protective clothing and
safety goggles.
Relieve the track slowly and carefully.

• Unscrew the cover to the right and left of the roller carrier.
• Slowly loosen the grease nipple (27.1/1) to relieve the tension.
• Allow grease to emerge, until the correct track tension is reached.
• Retighten the grease nipple
• Wipe off all grease and dispose of environmentally.
• Move the track and check the track tension again.

Figure 27.1 Crawler track tension, un-tensioning

102 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Replacing track shoes

Property damage
Machine damage caused by
damaged track shoes.
Damaged track shoes must be replaced
without delay.

• Remove the four hexagon screws (44/2).

• Remove the square nut (44/1) from the groove of the chain link.
• Remove the track shoe (44/3).
• Insert the new track shoe. Observe the installation position!
• Fasten the new track shoe with new bolts and nuts. Fastening torque:
650 Nm.

Figure 44 Base plates

Model ITC 120N / 0479 103

6 Maintenance and Upkeep

Replacing the crawler

Danger of injury
Material chipping off hardened end
pins represents significants
hazards for the installer.
Exercise care when mounting without
press.

• When positioning the crawler, make absolutely sure that the installation
is done on the correct side. The protrusion of the track shoe must point
in the direction of the drive sprocket in the lower part of the crawler. The
ends of the crawler are connected with crawler end pins.
• When performing the assembly without press, drive the end pin home
with a sledge hammer, mandrel and guide tube.
• To prevent damage to the bearing of the idler and the drive wheel, apply
counter support when driving home the end pin.

Inspecting track rollers and support rollers

The track rollers and support rollers are maintenance-free.
• Perform daily visual inspection for possible leaks in the area of the slid-
ing ring seals, especially after longer uninterrupted trips.
• Check the tightening torque of the mounting screws (45/1) after 100
operating hours using a torque wrench. The required torque MA = 295
Nm.
• Subsequently, perform regular visual checks for possible loosening of
the screws as part of the general equipment maintenance.

Figure 45 Rack Roller

104 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Checking the idler unit

Property damage
Drive unit damage by failling below
the specified tensioning pressure.
With elastomer tensioning cylinders,
the tensioning pressure may not drop
below 80% of the specified tensioning
pressure.
The elastomer cylinder must be
replaced immediately when the
tensioning drop below 80%.

The idler unit is maintenance-free.

It consists of the idler with sliders, the crossbar and the elastomeric ten-
sioning cylinder.
• Perform a daily visual inspection for possible leaks of the sliding ring
seals in the idler.
The task of the elastomeric tensioning cylinder is to bring the crawler into
its operation position. The feed is created through grease filling (with
manual grease gun).
• The crawler has the proper tension when it has a gap of approx. 20-30
mm on both sides of the crawler support. Pay attention that only the
feed of the idler or the tensioning of the crawler is initiated with the elas-
tomeric tensioning cylinder.
• When the crawler must be dismantled, relieve the elastomeric tension-
ing cylinder by carefully unscrewing the filling valve. The pressurized
grease escapes then via groove in the filling valve.

Model ITC 120N / 0479 105

6 Maintenance and Upkeep

Wear Limits of the crawler parts

New Replace
1 Chain link 96 87.50
2 Chain bolt 684.40 702.20
3 Chain bushing 50.62 46.10
4 Triple grouser shoe 25 6
5 Track roller 155 142
6 Guide wheel 21.50 27.5

1
Ersetzen Neu
replace new

Neu
new
Ersetzen
replace

Ersetzen
replace
Neu
new

4 Ersetzen
replace

Neu
new

5
Ersetzen
replace

new
Neu

Neu
6 new
Ersetzen
replace

312-45

Figure 45 Chain Drive Wear Values

106 Model ITC 120N / 0479

 Maintenance and Upkeep 6
6.7.7 Travel-drive gear unit
Checking the oil level in the crawler gear unit
• Rotate the crawler gear unit to inspection position (46/1).
• Remove the level control plug (46/3), if required fill in oil, until it reaches
the bottom edge of the bore.

Changing the crawler gear oil

• Run the engine warm.
• Park the machine in horizontal position.
• Rotate the crawler gear unit to drain position (46/2).
• Place suitable oil collecting vessels under the drain opening.
• Remove the level inspection plug (46/3) from the gear unit.
• Unscrew the oil drain plug (46/4) and catch running out oil.
• Clean the gear unit with flushing oil.
• Rotate the crawler gear unit to inspection position (46/1).
• Fill up gear oil through the drain bore (46/4), until it starts to run out from
the level inspection bore (46/3).

Figure 46 Transmission

Model ITC 120N / 0479 107

6 Maintenance and Upkeep

6.7.8 Hydraulic System

X

Note
Check hydraulic oil level The excavating equipment must be stretched out on the
ground.

• The hydraulic oil level is monitored automatically.

• With too low hydraulic oil level, with the ignition appear in the display
screen, “hydraulic oil level”.
• Check the hydraulic oil level daily in level machine
• Fill to compensate to a low hydraulic oil level.
• The oil level should be in the top third of the sight glass.

Fig 48 Hydraulic oil tank

Hydraulic oil refill • Set the machine horizontally.

• Hydraulic oil level sight glass (one read) and top back on the air hydrau-
lic oil filter (48/2).
• The oil level should be in the top third of the sight glass (48/1).

• Set the machine horizontally.

• Hydraulic oil level sight glass (48/1 read) and if necessary Hydraulic oil
over the aeration filter (top up 48/2).
• The oil level should be in the top third of the sight glass (48/1).

108 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Changing hydraulic oil

Danger of burning
Danger of scalding by hot oil.
Be careful when draining hot oil.
Wear suitable protective clothing
and safety goggles.

Environmentally hazardous
substances.
Environmental damage caused
by environmentally hazardous
substances.
Do not allow oil seep into the ground
Collect waste oil and dispose of
according to regulations!

• Run the engine warm.

• Retract all hydraulic cylinders.
• Shut down the engine.
• Unscrew the breathing filter (48/2).
• Place suitable oil collecting vessels under the drain opening.
• Connect the oil drain hose with the oil change valve.
• Clean and flush the hydraulic tank as needed (remove cleaning cap
(48/3) for this purpose).
• Remove the oil drain hose and screw the protective cap on the oil
change valve.
• Fill the hydraulic oil through the breather (48/2) or with the pushbutton
“Hydraulic oil fuelling pump” (5) until the right level has been reached
on the sight glass (48/1).
• Screw in the breathing filter.
• Check the filter and drain plug for leaks.

Fig 48 Hydraulic oil tank

Model ITC 120N / 0479 109

6 Maintenance and Upkeep

Hydraulic Oil – change the

breather filter

Property damage.
Machine damage caused by
dirt falling into the open hydraulic
oil tank.
Before beginning clean all parts laying
on the tank.

Note
The excavating equipment must be stretched out on the
ground.

• Remove the breathing filter (48/2).

• Replace it with a new one and tighten it hand-tight.

Figure 48 Hydraulic oil tank

110 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Hydraulic oil return filter

Property damage.
Machine damage caused by dirt
falling into the open hydraulic oil
tank.
Before beginning clean all parts laying
on the tank.

Note
After major repairs the filter cartridge of the return filter must be
replaced after the test run.

Changing the filter insert

• Shut down the engine.
• Loosen the breather filter (47/2) on the hydraulic oil tank.
• Loosen the return filter cap (47/3) on the hydraulic oil tank.
• Remove the compression spring.
• Remove the filter element (48/3) by rotating and pulling it at the same
time.
• Inspect the O-rings (48/5) (48/6) and replace the damaged parts.
• Insert a new filter element (48/3) and the compression spring.
• Apply some oil to the cap seal (47/2) and firmly tighten the cap.
• Screw the breathing filter tight.
• Check the filter for leaks.

Cartridge maintenance inter-

vals • Replace the filter cartridge if the control light for filter maintenance in the
control console lights up during operation.

Figure 47 Hydraulic Oil Tank Figure 48 Return Filter

X

Note
When the hydraulic oil is cold, the hydraulic oil filter clogging
indicator may light up briefly. It will go out once the operating
temperature is reached.

Model ITC 120N / 0479 111

6 Maintenance and Upkeep

Hydraulic Oil Pressure Filter Change the Filter Insert

(OPTION)
• Shut down the engine.
• Depressurize the system.
• Place a suitable collecting container underneath.
• Unscrew the filter housing (49/5).
• Remove the filter element (49/1) by turning and pulling it at the same
time from the filter bowl and dispose of it properly.
• Clean the filter housing.
• Check the condition of the sealing components (49/2, 3, 4,) and replace
damaged parts.
• Insert a new filter element in the filter bowl.
• Screw the filter housing tight.
• Check the filter for leaks.

Cartridge maintenance inter- • Replace the filter cartridge if the control light for filter maintenance in the
vals control console lights up during operation.

3
4

1
5

R41L43

Figure 49 Pressure Filter

112 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Hydraulic Oil Cooler Cleaning the hydraulic oil cooler

Property damage.
Machine damage caused by over-
heating of engine.
Clean the radiator carefully.

• Clean the hydraulic oil cooler with compressed air from the air dis-
charge side (inside).
• If necessary, e.g. in case of oil contaminated hydraulic oil cooler, clean
the radiator with cold cleansing agent or steam cleaning equipment.
• For this work park the machine on a washing area equipped with an oil
separator.
• After cleaning, run the engine until it reaches operating temperature to
dry the hydraulic oil cooler.

Figure 51 Hydraulic oil cooler

Model ITC 120N / 0479 113

6 Maintenance and Upkeep

6.7.9 Additional control circuit (Option)

Note
Rock breaker
Maintenance of the hydraulic rock breaker must be performed
according to the instructions of the hydraulic rock breaker manu-
facturer.

We would like to inform that the operation of the transverse cutting unit is
Cutting unit
only possible in connection with the dismounted hammer adapter plate
(S29 + holder + guider + cylinder)!

The machine can not lift anymore the transverse cutting unit with the
hammer kinematic, without dismounted hammer, on the tilting console
cylinder. Also the durability and stability of the machine are not given like
this.

Note
Maintenance of the cutting unit must be performed according to
the instructions of the cutting unit manufacturer!

114 Model ITC 120N / 0479

 Maintenance and Upkeep 6
6.7.10 Electrical Equipment

Battery
Danger of explosion
Death, bums or blindness
through explosive gasses or
contact with caustic acids.
Arc, sparks, open fire and glowing
tabacco products must be kept
away.
Wear protection gear.

Note
Follow the instructions of the battery manufacturer when taking
a battery into service for the first time.

The battery is located behind the operator's stand, below the bottom plate
(1) on the left-hand side.

Checking the battery

X

Hinweis
Bei wartungsfreier Batterie entfällt die Kontrolle.

• Shut down the engine.

• The acid level should be approximately 10 mm above the plate edges. If
necessary, top up with distilled water.
For maintenance-free batteries, this check is not necessary.

Model ITC 120N / 0479 115

6 Maintenance and Upkeep

Removing batteries
• Disconnect the circuit with the main battery switch (6) before installing
or removing the batteries.

Person and property damage.

Risk of accident caused by wrong
operation.
Never activate the circuit breaker
when engine running.
After stopping the engine you need
to wait 2 minutes before activating
the circuit breaker because the
engine control unti is saving errors
durring this time. In case of non-
observance there can be damages
on the control engine unit.

• Disconnect the ground cable (51/2) first, the plus cable (51/3) after.
• Remove the connecting cable (51/4).
• Loosen the clamping angle (51/1).
• Lift out both batteries.

Figure 52 Batteries

116 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Installing batteries

Property damage
Machine damage caused by
reversing the terminals.
Connect the minus terminal with the
minus pole and the plus terminal with
the plus pole.

• Place the batteries into the machine and fasten it with the clamping
angles (51/1).
• Attach the connecting cables (51/4) accordingly to: Positive pole of bat-
tery 1 with negative pole of battery 2.
• Connect the plus cable (51/3) first and the ground cable (51/2) last.
Ensure that the negative terminal is connected to the negative pole (–)
and the positive terminal to the positive pole (+).
• Close the bottom plate.
• Pay attention to a good charge condition of the battery, especially in
winter.

Lighting and warning equip- Checking the lighting and warning equipment
ment • Check the function of the lighting equipment.
• Check the function of the warning lights.
• Check the function of the warning equipment.

Figure 52 Batteries

Model ITC 120N / 0479 117

6 Maintenance and Upkeep

6.7.11 Cable reel

Check the cable reel

• Check unwinding functionality when traveling forward.
• Check condition of cable.
• Check automatic winding of cable when traveling backward.
• Carry out all other inspection and maintenance work according to "Ca-
ble Reel" operating manual in folder 6.

118 Model ITC 120N / 0479

 Maintenance and Upkeep 6
6.7.12 Boom equipment
General The possibility of trapped air cannot be completely ruled out during repair
work on hydraulic lines or replacement of hydraulic cylinders. Therefore,
the following items must be observed.

Systematically De-aerate Sys- • After installation of a cylinder, fill the cylinder through the connections
tem and then move it only slowly at first; loosen connections slightly if nec-
essary and do not retighten until hydraulic oil escapes without bubbles.
• Gently move the hydraulic cylinders to both stop positions several times
in order to clear any possible trapped air as much as possible.
• Slowly increase hydraulic pressure and work speed to the normal val-
ues.

Danger of explosion !
Machine damage caused by
sealing components.
In an extrem case, an explosive heat
build-up (diesel effect) can result
through compression of the trapped
air bubbles, resulting in damage to
the sealing components and interior
space of the cylinder.

The theoretical stroke of several hydraulic cylinders cannot be 100%

Stroke Stops utilized because kinematics of the structural steel components is limited
by corresponding mechanical stops.
These stops become "crushed" over time, whereby the stroke reserves of
the cylinders are needed.
X

Note
Crushed stops must be re-welded or replaced. A schedule of
limited cylinders must be requested from Service.

Model ITC 120N / 0479 119

6 Maintenance and Upkeep

6.7.13 Transfer Belt Conveyor

Roller Chain: Maintenance The chains tend to briquette under the heavy underground application
and Upkeep conditions, as the dust from the environment packs into the chain links
and make them stiff. The chain is forced to make a jointed movement
when running into the chain wheel. If the link is stiff, bolt, sleeve or plate
breakage may occur or the chain may stop.

Link Corrosion with Addi- If the conveyor is not operated for a longer period of time, link corrosion
tional Briquetting occurs. This causes the links to become absolutely stiff and breakages
occur once more.

Required Procedures • Move chains regularly.

• If a certain period of standstill cannot be avoided, the chains must first
be brushed with a low viscosity oil (or also diesel fuel or oil from an oil
change in exceptional cases) on the high plate edges. Then run the
chain for about ¼ hour so that the joint movement causes the oil to pe-
netrate the chain links.
Check Chain Tension • If the chains are already stiff, they must be placed in a bath with ESSO
Rust Ban (or an equivalent product) for the duration of approx. 12
hours. It may also be necessary to restore mobility by hand afterward.
In place of ESSO Rust, petroleum or diesel fuel may also be substi-
tuted.

Danger of crushing
Body parts be crushing by moving
parts.
Do not touch the running conveyor
chain.

Note
Only check chain tension while in cleaned condition

• Move flight between last folding plate from the return channel and the
drive shaft
312-54

• Shut machine down (engine)

Figure 54 Roller Chain
• Move flight up by hand. Path must be at least 15 mm up to a max. of
approx. 50 mm.
• Counter-check: conveyor chain must likewise have a visible sag in this
range while chain conveyor is running.

120 Model ITC 120N / 0479

 Maintenance and Upkeep 6
Tensioning Roller Chain:

Property damage.
Chain break caused by mal-
funtion of spring wahser.
Never pullback nuts against the
tension device screws during
operation.

• The forward nuts on the adjustment spindles are solely there so that the
drive shaft can be pulled forward in case of repair (slacken chain)
• Pullback nuts never against the tension device screws during operation.
The spring washers can no longer work and chain breakage can occur.

Check Roller Chain for Wear

Transfer belt conveyor chain: two sections consists of 8 links (2")
Wear limit
New Replace
406,40mm 416,50mm

Disassembly of Roller Chain

• Channel and apron must be thoroughly cleaned before disassembling
the roller chain if possible with steam jet.
• Then find (while chain is running) the zero flight (marked with a cross)
and position on the openings.
• Loosen screws and remove cover
• Loosen nut
• Knock out flight stud together with external plate
• Remove chain covering, if installed
• Remove flight
• The chain can now be removed with any lifting tool or with the hydraulic
motors in that the studs and plates are inserted on the other side of the
chain
• Turn chain until the marked flight is above the chain drive wheel.
• Remove stud and let chain fall to the ground.
Installation of the Roller
Chain
• There are several options available; one of them is the following:
• Hang chain on a cable, lead cable through the return opening of the
chain conveyor to the apron.
• Attach the other end of the cable to the bucket and pull chain up to the
running shaft.
• Pull the chain around the running shaft with the bucket.
• Push the flights on the belt with a beam up to the chain drive wheel.
• Link the chain in the reverse sequence as the disassembly,
• Check chain tension.

Model ITC 120N / 0479 121

6 Maintenance and Upkeep

Sprocket • Inspect wear and damage to teeth of chain star wheel.

• Fastening of upper left folding plates
• Fastening of upper right folding plates
• Check glide bracket fastening
• Retighten and secure screws if necessary.

Wear inspection In general: replace drive shaft when the chain belt has worked its way
more than 5mm in the tooth.
• Replace chain drive shafts with every chain replacement.

Running shaft Running shaft inspection

• Check the chain return channel in the running shaft area. ‘’Spacer chis-
els’’ that cut the conveyor channel area free can be welded onto 2
flights.
• Always keep this area very clean! Otherwise, there is the danger that
the chain will rise and jam on the thread base plate.

Wear inspection As a principle rule: If the guide ring is worn down so that the external
latches on the chain touch the shaft, is it necessary to replace the run-
ning shaft completely.

Wear plate and Slip plate Replacing wear plate and slip plate
• Remove chain as described.
• Remove chain covering if installed.
• Remove wearing plates.
• Remove folding plates if necessary
• Seal new wearing and folding plates in the conveyor trough (only tack).

Wear control Wear limit

New Replace
10mm Wear height 4mm Remain height

Replacing the flight

Flight
• Turn chain until the marked flight is above the chain exchange area.
• Replacing with the new flight in the same area.

Flight limit
Flight control
New Replace
50mm Flight height 40mm Remain height

122 Model ITC 120N / 0479

 Maintenance and Upkeep 6

6.8 Immobilization

6.8.1 Preservation (temporary immobilization)

Property damage
Machine damage caused by bearing
defect (e.g. corrosion damage)
during shutdown periods over three
months.
Preserve the machine.

Preserving the machine

• We recommend keeping the machine in a dry, dust-free room during the
storage period.
• Thoroughly clean the inside and outside of the machine, including the
engine.
• Lubricate the machine by following the lubrication plan. See chapter 6.5
"Lubrication plan" page 65.
• Check and top up all oil levels in components like engine, gearbox, etc.
• Check and top up the hydraulic oil level.
• Repair paint damage.
• Fill the diesel fuel tank completely to avoid wall corrosion.
• Check the antifreeze properties of the coolant and adapt these, if nec-
essary.
• Apply all preservation measures as specified in the operating instruc-
tions for the engine.
• Check the crawler tension for the required value.
• Treat bare piston rods with a commercially available corrosion protec-
tion agent.
• Remove the battery, clean it and store it properly in a dry and, over
winter, in a frost-free room. Cover the poles with pole grease.
• Close the air intake openings of the air filter system and the exhaust
outlet on the exhaust pipe.

Model ITC 120N / 0479 123

6 Maintenance and Upkeep

6.8.2 While being taken out of service

Running the movements
• Beforehand the anti-corrosion coat must be removed from the piston
rods, and the openings of the air filter system and the exhaust pipe
freed.
• When the machine is out of use for 6 months, after this time all assem-
blies must be brought to operating temperature and maneuvered for
approx. 15 minutes.
• Renew the preservation after the movement test.

6.8.3 After the machine had been taken out of service

Before putting the machine into operation once more, the following meas-
ures must be carried out:
Taking the machine back into service
• Clean the piston rods from the corrosion protection coating.
• Clear the air intake of the air filter and the exhaust opening.
• Check the condition of main air filter element and safety cartridge, re-
place if necessary.
• Wash the machine with a neutral cleansing agent.
• Check the battery, recharge if necessary and install it.
• Carry out all measures for putting the diesel engine back into operation
listed in the Engine Operating Manual.
• If the machine has been out of use for more than 6 months, the oil in the
assemblies such as engine, gearbox, etc. must be changed.
• After a downtime of six month or more replace the hydraulic filters
(pressure, return flow, and breathing filter, if applicable).
• Lubricate the machine by following the lubrication plan. See chapter 6.5
"Lubrication plan" page 65.

6.8.4 To remove waste

Person and property damage.

Risk of accident and environmental
damage caused by trashing the
machine unprofessionally at the
end of its durability.
Scrap the machine only from a
professional waste management
company.
Terex recommends the return to a
Terex dealer.

124 Model ITC 120N / 0479

 Operation 7
7 Operation X

Note
Strictly observe all safety notes.
See chapter 7.2.8 "Operation" page 141.

7.1 Before operation

Damage to persons and

prperty.
Danger of accident caused by
wrong actuation and uncontrolled
machine movements.
Becom familiar with all display and
control elements before starting
excavating. See chapter 5.3.2
''Operating controls'' page 26.

Note
Initial inspection must be carried out before commissioning.
See chapter 6.7 "Maintenance and Inspection work" page 81.

The chapter "Operation" describes all functions for operating the tunnel
loading machine.
• Familiarize yourself with the control levers and pedals. See chapter
7.2.8 "Operating the excavator equipment" page 141.
• Thoroughly inspect the tunnel heading machine visually before each
start-up. Watch out for damage, loose or missing screws, oil deposits
and oil or fuel leaks.
• Any faults must be immediately rectified.
• If the operational safety of the tunnel loading machine is at risk, you
may only start operation after the faults have been eliminated.

Model ITC 120N / 0479 125

7 Operation

7.1.1 Settings
Adjusting the driver’s seat
• Operate the horizontal adjustment (2) to move the seat to the position
most convenient for you.
• Operate the angle and the horizontal adjustment (1) of the seat to the
position most convenient for you.
• Adjust the weight settings (3) for your weight.
• Adjust the settings of the lumbar support (4) for the position most com-
fortable for you.
• Adjust the armrest with the inclination (5) most convenient for you.
• Adjust the backrest (6) to the position most comfortable for you.

Fig. 9 Operator’s seat

Fig. 54 Armrest console

126 Model ITC 120N / 0479

 Operation 7
7.2 Running

Danger to life
Physical injury caused by
machine movements.

Before starting the engine, make

sure that no one in the immediate
vicinity ot the tunnel heading
machine or in th danger zone.

Damage to personne and

property.
Danger of accident caused by
wrong actuation and uncontrolled
machine movements.
Start at low engine speed when
familiarizing your self with the controls.

Note
When the left control panel is raised, all hydraulic functions are
interrupted and the parking brake is activated. See chapter 7.2.5
‘’Parking’’ page 139.

Model ITC 120N / 0479 127

7 Operation

Control The standard equipment of the tunnel heading machine includes an “ISO-
control" serving as basis for the following description. The tunnel heading
machine can be equipped with a switch able control system for the work
equipment, if requested by the customer.
• Check therefore on your tunnel heading machine if there is built in a
special control.

Engine
This tunnel heading machine is fitted with 2 drive systems:
• Electro drive, for an emission-free working on-site.
• Diesel drive, basically for operating. You can also operate on-site under
consideration of the needed ventilation.

Note
You can only operate one drive at time! Both drives are hydrauli-
cally equal.

128 Model ITC 120N / 0479

 Operation 7
7.2.1 Starting and stopping the engine
Starting the Diesel engine

Property damage.
Engine damage caused by improper
operation.
Do not drive the engine at full throttle
straight away.
Drive with restraint until the operating
temperature of the engine has been
reached.

• Set all control levers to neutral position.

• Insert the ignition key into the preheating/start switch.
• Turn the ignition key clockwise to position "1".
The control light “Charge indicator” lights up.
The control lamp on the operating display blinks for approx. 5 seconds.
The message light ‘’Start release’’ lights up, the control light in the op-
erating display extinguishes.
• Turn the ignition key to position "2".
• Preheat the engine for approx. 1 minute (longer, if it is cold).
Check the control light ‘’Preheating’’ during this process.
• Turn the ignition key to position "3".
• Release the ignition key as soon as the engine is running smoothly.
Figure 10 Dash board
The engine runs, the control light ‘’Charge indicator’’ must extinguish.
• If the engine does not start after max. 15 seconds, return the ignition
key to position "1" or "0". Repeat the starting procedure at the earliest
after 1 minute.

Shutting down the engine

X

Note
Do not shut down the engine all of a sudden from full load, but
let it idle without load for a while.

• Turn the ignition key (1) to position "0".

The engine stops automatically.

General hint
X

Note
In case of excessive oil consumption, please report to the
manufacturer (Terex).
Avoid low load. Ensure that the engine is operating at least at
20% of its power!

Model ITC 120N / 0479 129

7 Operation

7.2.2 Electric motor operation start and stop

Electric motor start

• Put all gearshift levers in the neutral position.
• Set main switch in position ’’1’’.
• Set selector switch to electrical mode ’’1’’ or ‘’E’’.
• Start electrical motor with pressure switch on ’’I’’.
The electric motor started.

Electric motor stops

• Stop electrical motor with pressure switch on ’’0’’.
The electrical motor stopped.
• Set selector switch to electrical mode ’’0’’.
• Set main switch in position ’’0’’.

Figure 10 Dash board

130 Model ITC 120N / 0479

 Operation 7
7.2.3 Driving and steering

Danger to life
Personal injury caused by
wrong operation.
The multifunction circuit breaker
can only be activated by standstill
of the machine and when both
driving direction pre-selector are in
central position. If the driving
direction pre-selector are opposite
the machine will stop.
During road driving the joystick for
the work equipment above the multi-
function circuit breaker has to be
switched off. Herewith is also the
driving direction pre-selector in the
joystick out of operation.

Danger to life
Personal injury caused by
wrong operation.
Be carreful by driving downhill,
drive slowly. Don't pass through
the throttle to the edge.
Before changing the hydraulic fast
gear ''rabbit'' into the hydraulic
slow gear the drive speed has to
be reduced.

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7 Operation

Fig 56 Operator’s seat

Posit. / Actuated Effect

Pedal for right hand track (4)
Right-hand track moves for-
Front
ward
Right-hand track moves
Rear
backward

Posit. / Actuated Effect

Pedal for left hand track (3)
Left-hand track moves for-
Front
ward
Left-hand track moves back-
Rear
ward

Switch fast driving Posit. / Actuated Effect

On (slanted pos.) Driving fast
Off (straight pos.) Driving slow

132 Model ITC 120N / 0479

 Operation 7

Figure 10 Dash board

Adjusting the travel speed

• Operate the switch "Travel slow/fast" on the control panel, to set the
desired travel speed.

Driving forward or reverse

• Press the right (6) and left (5) pedals uniformly toward the front or back.

Cornering
• Reduce the speed of the track on the inside of the curve to match the
speed to the curve.

Turning on the spot

• Operate the right (6) and left (5) pedals in opposite directions.

Turning over one crawler track

• Operate only the right (6) or left (5) pedal.

Model ITC 120N / 0479 133

7 Operation

7.2.4 Monitoring during operation

Property damage.
Severe engine damage.
All malfunctions must be eliminated
before restarting the engine and the
tunnel excavator.

Warning lights – Operating The tunnel heading machine is equipped with safety features triggering a
console warning signal or shutting down the engine if one of the following mal-
functions occurs:
• Insufficient power supply.
• Max permitted hydraulic oil temperature exceeded.
• Min. hydraulic oil level is too low.
• Emergency-stop actuated.
• Air filter soiled.
• Return filter soiled.
• Air filter soiled.

In case of a fault the corresponding warning lights in the control console

will light up. See chapter 5.2.2 "Display and operating elements" page 32.

134 Model ITC 120N / 0479

 Operation 7
Activities when the control light indicates insufficient power supply

• Shut down the machine immediately and turn off the engine.
• Perform trouble shooting, call out service personnel, if necessary.

Activities when the control light indicates insufficient power supply

• Interrupt the work and open the hood.

• Continue to let the machine idle to cool down.
• Perform trouble shooting, call out service personnel, if necessary.

Activities when the control light indicates minimum hydraulic level

• Shut down the machine immediately and turn off the engine.
• Replenish hydraulic oil and determine the cause if possible.
See chapter "Checking the hydraulic oil level".

Activities when the control light indicates Emergency-stop shut-

down

• The emergency-stop button has been actuated; the engine has been
shut down.
• Determine the cause for the emergency-stop and weather persons are
in danger.
• Unlock the emergency-stop button and turn on the machine.

Activities when the control light indicates air filter contamination

• Service the air filter and determine the cause for the contamination, if
applicable.
• See chapter 6.7.3 "Air intake system" page 91.

Model ITC 120N / 0479 135

7 Operation

Activities when the warning lamp lights up Hydraulic oil filter con-
tamination (return flow filter and pressure filter)

Property damage.
Serious damage in the hydraulic
system.
The dirt contamination display of the
hydraulic oil filter must always be
observed.

Note
When the hydraulic oil is cold, the hydraulic oil filter clogging
indicator may light up briefly. It will go out once the operating
temperature is reached.

• Service the filter element, if necessary determines the cause for the
contamination.
See chapter "Hydraulic oil return filter".
See chapter "Hydraulic oil pressure filter" (Option).

136 Model ITC 120N / 0479

 Operation 7
Activities when the error messages “Fuel Containers Water’’ lights
up.
• Stop work.
• Drain water from the fuel pre-filter.
See chapter "Draining Fuel Pre-filter".

Activities when the error message “Oil level too low’’ lights up
• Shut down the machine immediately and turn off the engine.
• Replenish engine oil and determine the cause if possible.
See chapter "Checking the engine oil level".

Activities when the error message “Oil pressure faulty’’ lights up

• Shut down the machine immediately and turn off the engine.
• Perform trouble shooting, call out service personnel, if necessary.

Activities when the error message “Charge pressure too low’’ lights
up
• Shut down the machine immediately and turn off the engine.
• Perform trouble shooting, call out service personnel, if necessary.

Activities when the error message “Charge air temperature too

high’’ lights up
• Interrupt the work and open the hood.
• Continue to let the machine idle to cool down.
• Perform trouble shooting, call out service personnel, if necessary.

Activities when the error message “Coolant level too low’’ lights up.
• Shut down the machine immediately and turn off the engine.
• Replenish coolant and determine the cause if possible.
See chapter "Refilling coolant".

Activities when the error message “Coolant temperature too high’’

lights up
• Interrupt the work and open the hood.
• Continue to let the machine idle to cool down.
• Perform trouble shooting, call out service personnel, if necessary.

Model ITC 120N / 0479 137

7 Operation

7.2.5 Parking
Parking the tunnel heading machine

• If possible park the on solid and level ground.

• Place the work equipment on the ground.
• Shut down the engine and pull out the ignition key.
• Put the exit barrier (13) in upright position.
• Interrupt the machine circuit on the main battery switch (22) for ex-
tended standstill periods or at the end of a shift.

Note
Interrupt the machine circuit with the main battery switch only
after approx. 15-20 seconds following the engine stop since the
diesel engine control is automatically deactivated!
If not observed, an error message appears in the operating
display when restarting the diesel engine.
X

Note
When the exit barrier is raised, all hydraulic functions are inter-
rupted and the parking brake is activated.

Figure 10 Dash board

138 Model ITC 120N / 0479

 Operation 7
7.2.6 Shut-down in case of emergency (emergency-stop)

The machine is equipped with 3 emergency-stop buttons:

Rear left Rear right Dash board

Stop machine in case of emergency

• Push the emergency-stop button.

The drive is shut off.

7.2.7 Start up after emergency (emergency-stop)

Tunnel heading machine starting after emergency-stop

• Unlock the emergency-stop button by turning it.

The machine is ready to start.

Model ITC 120N / 0479 139

7 Operation

7.2.8 Operating the excavator equipment

Danger to life
Physical injury caused by
incorrect operation of control
system.
Check which type of control the
machine is furnished with.
Become familiar with control.

Damage to persons and

property.
Danger of accident caused by
uncontrolled movements of the
machine.
The holding brake must be operated
with special work activities.

140 Model ITC 120N / 0479

 Operation 7
Operation of excavator equipment

Posit./actuate Effect
Joystick Excavator equip-
ment (1) Front (a) Raise dipper stick
Rear (b) Lower dipper stick
Left (c) Swivel boom equipment to the left
Swivel boom equipment to the
Right (d)
right
Left switch (e) Hammer
Right switch (f) TCU

Joystick Excavator equip-

ment (2) Posit./actuate Effect
Front (a) Lower jib
Rear (b) Raiser jib
Left (c) Close bucket
Right (d) Open bucket
Left switch (e) Transfer belt conveyor backward
Right switch (f) Transfer belt conveyor forward
Switch (g) Quick hitch

Crawler forward – backward

Posit./actuate Effect
(3-4)
Front Crawlers forward
rear Crawlers backward

Model ITC 120N / 0479 141

7 Operation

Posit./actuate Effect
Up and down the conveyor Front Conveyor up
(5)
rear Conveyor down

Posit./actuate Effect
Raise and lower apron left (6) Front Raise apron
rear Lower apron

Posit./actuate Effect
Raise and lower apron right Front Raise apron
(7)
rear Lower apron

Effect
Manual throttle diesel engine
Throttle lever D-engine (8) Armrest blocking hydraulic when
Armrest blocking (9) lifted

Switch Hammer (10) Switch Hammer (Option)

Switch TCU (11) Switch TCU (Option)

Switch quick hitch (12) Switch quick hitch (Option)

142 Model ITC 120N / 0479

 Operation 7
Operating the rock breaker

Property damage.
Severe property damage to rock
breaker, mounting and machine
through improper use.
Exert the pressure force axially to the
rock breaker and vertically to the
material surface.
The pressure force of the rock breaker
may not be generated via the vehicle!

• Turn the switch ‘’Rock breaker pre selection’’ on the operating console
to the right.
The control light in the switch “Rock breaker pre selection” blinks.
A warning sound for the rock breaker operation sounds, the rotating
beacon lights.
• Operate the rock breaker with button after warning sound extinguishes
(after approx. 5 seconds).
• Switch off the "Rock breaker" function after completing work by turning
the switch "Rock breaker pre selection" clockwise again.

Figure 10 Dash board

Model ITC 120N / 0479 143

7 Operation

Operating the cutting unit

Property damage.
Severe property damage to cutting
unit, mounting and machine
through improper use.
Exert the pressure force axially to the
cutting unit and vertically to the
material surface.
The pressure force of the cutting unit
may not be generated via the vehicle!

• Turn the switch ‘’cutting unit pre selection’’ on the operating console to
the right.
The control light in the switch “Cutting unit pre selection” blinks.
A warning sound for the cutting unit operation sounds, the rotating
beacon lights.
• Operate the cutting unit with button after warning sound extinguishes
(after approx. 5 seconds).
• Switch off the "Cutting unit" function after completing work by turning
the switch "Cutting unit pre selection" clockwise again.

Figure 10 Dash board

144 Model ITC 120N / 0479

 Operation 7
7.2.9 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.
An auxiliary control circuit must be available to connect a rock breaker or
cutting unit.

Damage to persons and

property.
Danger unused working
attachments tilting and over-
turning.
Secure unused working attachments
with wedges or similar.

Damage to persons and

property.
Risk of injury caused by con-
nections under pressure.
The system must be relieved of
pressure before hydraulic connections
are disconnected.
X

Note
The bearings on the quick-mount hitch and work attachment, or
on the dipper stick, bucket rod and work attachment must be free
of dirt.

Change process with Quick Mounting and changing working attachments

mount feature • Place the working attachment on the ground so that it cannot tip or turn
over.
Addition information on operation, see Operating Instructions for quick-
mount device.

Change process without • Place the working attachment on the ground so that it cannot tip or turn
Quick mount feature over.
• Remove the pins connecting the work attachment to the dipper stick
and the bucket rod.
• Mount the other work attachment.
• Grease the pins if required.
• Insert the pin once more and ensure a secure seat.

Model ITC 120N / 0479 145

7 Operation

Attaching the hydraulic rock breaker

Property damage.
Machine damage due to improper
use.
The mounting, operating and service
instruction of the hydraulic rock breaker
manufacturer must be observed.
Only use rock breaker approved by
TEREX.
The hydraulic circuit of the rock breaker
must be protected according to the
instruction of the hydraulic rock breaker
manufacturer. Standard protection:
180 bar.
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 connection is made with the lines of the auxiliary
control circuits “Return line” and “Rock breaker pressure line”.
• Connect the hydraulic rock breaker to a rock breaker lubrication system
with fitting.

Attaching the cutting unit

• Mechanical installation is similar to the attachment of a bucket with or
without quick-attach system.
• The hydraulic pressure connection is made with the lines of the auxiliary
control circuits “Leakage oil cutting unit”, “Return line” and “Cutting unit
pressure line”.
• Store the dust caps of the connections with the machine tool kit when
the cutting unit is detached.
• Mount the dust caps securely again on the connections after the cutting
unit has been dismantled.

146 Model ITC 120N / 0479

 Operation 7
7.2.10 Notes for winter operation
The following points and the relevant notes in the engine instruction man-
ual should be observed during winter operation.

• If the machine has not been used for longer periods of time at tempera-
Hydraulic oil
tures around and below freezing, warm up the engine by running at
medium revs for approx. 3-5 min

Engine oil The oil viscosity (SAE class) should be selected according to the ambient
temperature at the machine’s place of operation.

Condition of the battery A good cold start performance requires a well-charged battery.
• Warm up the battery to approx. + 68.00°F (remove the battery after
shutting down the engine and store it in a warm room). This can help to
lower the start limit temperatures by 4-5°C.
• Ensure good contact of the terminal connections when installing the
battery.
• Only tighten terminal screws hand-thigh, to prevent deformation of the
terminal cones!

Coolant • Check the antifreeze setting before the beginning of the cold season.
• Match the antifreeze to the ambient temperature, as required. At the
factory, the antifreeze protection is set to approx. -25 °C.

Model ITC 120N / 0479 147

7 Operation

Fuel

Danger of explosion
Serious physical injury through
explosives.
No gasoline may be added to
the diesel fuel !

• The Operating Instructions of the manufacturer must absolutely be ob-

served when installing a particle filter system.
• Use only commercial diesel fuel brands according to DIN EN 590 with a
sulfur content below 350 ppm.
• Use only winter diesel fuel in winter to prevent line connections becom-
ing blocked through paraffin deposits. At very low temperatures, trou-
blesome deposits may also occur when winter diesel is used.
• If only summer diesel is available, or if winter diesel must be used at
very low temperatures, we recommend the addition up to 30% of petro-
leum or additives.

1 Summer diesel fuel

2 Winter diesel fuel
3 Super diesel fuel
4 Additive percentage Petroleum
5 External temperature

Note
These mixtures should only be used temporarily, never for longer
periods.

• Mix only inside the tank!

• First fill the required quantity of petroleum and then add the diesel fuel.

Note
Flow improvement agents are to be selected according to the
specifications of your fuel supplier.

148 Model ITC 120N / 0479

 Operation 7
Quick hitch operation To release the quick hitch, press the buttons (1) and (2) simultaneously.
(Option) To lock the quick hitch, simply release the buttons (1) and (2).

1 2

Note
To operate correctly the quick hitch, please read carefully the operating
instruction of the Quick Hitch manufacturer (in folder 6).

Fire extinguishing system Powder extinguisher system

(Option)
4

Photo: 64

1. Extinguishing system
2. Manometer
3. Pilot hoses.
4. Extinguishing system hoses.

Photo: 65 Photo: 66 Photo: 67

Extinguisher switch Extinguisher switch Extinguisher switch

In rear left in rear right in cab

Model ITC 120N / 0479 149

7 Operation

Photo: 68

Safety light and acoustic signal in cab

Buses for the extinguishing

system

Above the electric motor

Above the diesel engine, to the radiator

Above the diesel engine, to the pump

150 Model ITC 120N / 0479

 Transport 8
8 Transport X

Note
Strictly observe all safety notes.
See chapter 3.19 "Recovery, Loading and Transporting".

8.1 Salvaging the Machine

Danger to life
Personal injury caused by
inadvertent rolling of the
machine.
During all service or reparation
works secure the machine with
wheel chocks and discharge the
hydraulic system.

Property damage.
Machine damage caused by
towing.
Tow the machine only in walking place.
Tow the machine maximum 50m.

Property damage.
Machine damage caused by
polution of the hydraulic system.
During works on the hydraulic system
keep highest cleanness.

Model ITC 120N / 0479 151

8 Transport

Procedures for Towing a • Remove the cover plates over the travel motors on the back side of the
Broken-Down Machine: machine.
• Connect the towing rope to the towing ring on the back side of the vehi-
cle with a clevis. (Attention: provide a sufficiently dimensioned motor
tractor at the other end of the rope: wheel-loader / skip truck)
• Remove the two fastening bolts of each travel motor.
• Pull both travel motors out of the gearboxes. (Protect exposed travel
motor shaft ends from dust and dirt)
• Build up hydraulic pressure in the brake lines with the hand pump at-
tached on site. (The hydraulic pressure releases a spring pre-loaded
holding brake in the interior of the travel gearbox)
• The machine is ready for towing.
• After the machine has been towed to the desired site, the brake control
circuit is relieved again with the hand wheel on the hand hydraulic
pump. The brakes tighten automatically.
• Remove towing rope and clevis.
• Replace both travel motors in the gearboxes. Look out for any clogging
of the shaft and the hubs in the gearboxes.
• Retighten the travel motor fastening bolts (tightening torque: 560 Nm)
• Replace and screw down cover plates.

Procedures for Towing Other • Connect the towing rope to the towing ring on the back side of the vehi-
Machines cle with a clevis. If the machine to be towed cannot brake, be sure to
use a tow-bar.
• Set the travelling gear of the ITC 120N into the working gear (do not tow
in the fast gear).
• The maximum allowable traction force is 150 kN. The traction force
required to tow another machine must be determined from the mass,
angle of inclination of the roadway and the rolling resistance and may
not exceed the allowable traction force.

152 Model ITC 120N / 0479

 Transport 8

8.2 Lifting the Machine with a Crane

Danger to life
Danger to life when exceeding
the maximum weight-lifting
capacity.
Use a crane with adequate lifting
capacity

Note
Only use the original TEREX crane lifting harness.

The following actions must be taken to load the excavator by crane:

Secure Tunnel heading machine
• Empty and clean apron with the shovel
• Empty and close the bucket.
• Let the chain conveyor idle.
• Put tilt-swivel console in centre position.
• Retract dipper stick.
• Disengage drive motor.
• Exit machine

Lifting tunnel heading machine

• Suspend machine correctly with lifting gear at the indicated point (Figure 21)
• Raise carefully the tunnel loading machine.

Figure 21 Crane Loading

Model ITC 120N / 0479 153

8 Transport

8.3 Transporting the Machine

Danger to life
Danger to life due to disregar-
ding the total transport height.
It is essential to observe the
clearance heights of tunnels,
bridges, etc.....

When transporting by flatbed truck, train, etc…, the machine must be correctly
secured:

Secure tunnel heading machine

• The apron and boom equipment must be set down on the floor.
• Secured the machine with wedge blocks.
• The tunnel heading machine must be fastened down with retaining straps.

Figure 21.1 Marked points

154 Model ITC 120N / 0479

 Technical data 9
9 Technical Data
9.1 Views

9.1.1 Front, top, left and right side views with F8 boom geometry

Model ITC 120N / 0479 155

9 Technical Data

9.2 Technical data

9.2.1 Operating data.

Minimal cross section ca. 10 m²
Machine width 1’900 mm
Machine height on cab 2’400 – 2’750 mm
Transport height 2’400 mm
Length (depend of conveyor) ~10’000 mm
Loading apron width 1’900 – 2’900 mm
Height of conveyor internal 620 mm
Conveyor gutter width, inside 620 mm
Conveyor capacity, up to ca. 150 m³/h
Loading performance with a loading boom
ca. 2.5 m³/min
equipment
Conveyor discharge height 1’800 – 2’500 mm
Operating weight approx. 22 t

9.2.2 Diesel Drive

Diesel engine is for operating underground and above ground. All work
movements can be carried out.
• Air cooled diesel engine with exhaust turbo supercharger and engine
adjustment.
• Optional: Soot particles filter. Catalyser.

Engine model DEUTZ TCD 2012 L04 2V

Diesel engine complies with emission EEC Euro 3 / COM 3
standard
Cylinders 4
Cubic capacity 4’038 cm³
Power 74 kW
Speed 2’000 min-1
Batteries 2 x 12V 66 Ah
Spec. fuel consumption 245 g / kWh
Engine oil capacity 15,5 L
Fuel tank capacity 420 L
Starter 24 V / 4 kW
Three-phase alternator 28 V / 55 A

156 Model ITC 120N / 0479

 Technical Data 9
9.2.3 Electrical Drive
Electrical drive for emission free work on site.
Quadripole, air cooled electric motor with direct start.

Rated power 400V / 50Hz .... 55 kW

Speed ................................... 1480 min-1
Rated torque ........................ 355 Nm
Rated current ....................... 104 A
Protection class.................... IP 55
Insulation class B

Electric system • Electrical voltage 400 V / 50 Hz.

• Phase sequence relay, thermal protection, control current in 110 V,
connection: designed with main switch on rear (right), installed capacity
kVA 60, transformer with rectifier for lighting. Emergency cut off switch
and warning lamp. Batteries charger.
• Safety installation with deactivation of the electrical motor if threshold
values are exceeded.

Additional equipment
Cable reel with hydraulic drive and reverse command (push button).
• Loading capacity approx. 75 m.
• Cable cross-section 3 x 50 + 3 x 10 mm² (not supplied)

9.2.4 Brake

Brake
Service brake Hydrostatic drive.
Parking brake The parking brake is activated from the control
valve. The brake is hydraulically released by the
high pressure and is closed by springs.
Braking valve The braking valve has the task to hold the exca-
vator down the hill at constant speed. If the exca-
vator became faster, that means that at the for-
ward pressure side, the pressure drops, than over
a spring with piston, the backwards pressure side
is throttled until the pressure is equilibrated on
both sides.

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9 Technical Data

9.2.5 Hydraulic System

Hydraulic System, Electrical LS axial piston pump, with load sense control, with double gear pump.
Motor:
Oil flow: max. 1 x 190 l/min + 1 x 75 l/min + 1 x 21 l/min
Pressure: max. 350/250/250 bar
Hydraulic System, Diesel En- LS axial piston pump, with load sense control, with double gear pump.
gine: Oil flow: max. 1 x 190 l/min + 1 x 85 l/min + 1 x 20 l/min
Pressure: max. 350/250/250 bar

Hydraulic Oil Filter: Full current return flow filter and coolant oil pressure filter with electrical
clogging indicator
Working control: Excavator work movements: Hydraulic pilot control via ISO joystick.
Oil tank: With level and temperature indicators
Hydraulic oil cooler:: Oil air-cooling system with thermostatically controlled, hydrostatically
driven ventilators.
Additional hydr. control circuit For rock breaker and hammer stroke, rail wheel set (pony truck), cutters.
Hydraulic cylinder: Double acting actuators, partially with end position absorption.

9.2.6 Travel gear

• Traction drive acting directly on the chain drive wheels via hydro motor
with reduction gear units and with hydro parking break.
• Brake valves for sharp inclines integrated in the traction motors.
• Maintenance-free crawler travel gear type B4-HD.
• Hydraulic chain tensioning.
• Steering: Independent individual control of crawler, counter rotated by
LS hydraulics.
• Travelling speed: quick / slow
• Forward – reverse, infinitely variable
• Optional: Pony Truck for railway transport.

Travel gear
Crawler carrier type B4-HD
Triple grouser shoe wide 400 mm

Electric / Diesel engine (slow) 0 – 1,6 km/h

Electric / Diesel engine (quick) 0 – 3,5 km/h
Tractive effort 162 kN

158 Model ITC 120N / 0479

 Technical Data 9
9.2.7 Conveyor
• Chain conveyor consisting of loading apron, hydraulically height-
adjustable, with hydr. adjustable side-wings and integrated rubber
plated conveyor (optional).
• Conveyors made of wear resistant, 2 lateral running roller chain with
flights
• Chain belt drive via 2 hydr. radial piston motors.
• The conveyance capacity depends in particular on the type, lumpi-
ness and water content of the debris.
• Optional: Rubber plate chain for abrasive debris.
• Optional: Conveyor with 2 speed motor and a pump regulator.

Conveyor
Conveyor discharge height 1’900 – 2.900 mm
Height of conveyor, internal 650 mm

Conveyor chain speed (with 2 speed): Low Quick

Electric motor 0,7 m/s 1,4 m/s
Diesel engine 0,7 m/s 1,4 m/s
Conveyor extension:
Extension 1/1 (2x) 1’625 mm
Extension ½ (1x) 812 mm
Curve extension 14° (Option) 1’220 mm

9.2.8 Lighting system

Power supply with electrical drive through transformer 400V/24V; with
diesel drive, directly through vehicle battery:
• 2 XENON spotlights in front on cab for working area.
• 1 double beam spotlight in front of chassis for working area.
• 1 XENON spotlight in rear on cab for loading area.
• 1 double beam spotlight in rear on chassis for loading area.
• 1 revolving yellow light during reverses movement.
• 1 cab light.
• 2 position red light in rear on chassis.

Model ITC 120N / 0479 159

9 Technical Data

9.2.9 Operating
In operator’s cab:
• Emergency stop switch
• Horn switch
• Flood light switch
• Drive selector switch diesel / electrical
• Electric motor start / Stop switch
• Control lights
• Diesel engine ignition key
• Cooler liquid and hydraulic temperature control
• Operating hour counter for diesel engine and electric motor
• Hydraulic oil filter and diesel engine air filter control
• Yellow revolving lamp for backwards

On right and left side of the machine:

• Electric main switch
• Emergency stop switch

9.2.10 Boom equipment

Boom equipment F8 composed of:
• King post (50° right and left)
• F3 - Jib 56°
• F3 - Swivel console 2x 45°
• F8 - Intermediate Jib 74°
• F3 - Dipper stick 88°
• Loading bucket 146° and 700 mm wide with 4 teeth
• Tear-out force over dipper stick: 56 kN
• Lifting power (without tool): 57 kN
• Piston force: 30 kN
• Excavation and mucking bucket in option, width 350 – 900mm.

Optional:
• Quick Hitch Winkelbauer
• Q.H. loading bucket 400mm with 2 teeth
• Q.H. hammer Montabert M700 with adapter plate

160 Model ITC 120N / 0479

 Technical Data 9
9.3 Pressure measurement table

PRESSURE MEASUREMENT TABLE

..........................................................................................................................................
Date . Machine Type ITC 120N
Ambient Temperature °C Year of Manufacture 2012
Oil Temperature °C Serial Number 120N #0479
Operating Hours, Electric hr
Operating Hours, Diesel hr
Operating Hours, Hammer hr

Group A (5606.660.444) [ bar ]

Main Pressure Control Valve 380 ---- ---- ----
Dipper stick up 380 ---- ---- ----
down 380 ---- ---- ----
Bucket up 380 ---- ---- ----
down 380 ---- ---- ----
Hammer On 140 ---- ---- ----
Option (free) On 200 ---- ---- ----
Jib up 380 ---- ---- ----
down 270 ---- ---- ----
Travel drive left for. 280 ---- ---- ----
Rev. 280 ---- ---- ----
Travel drive right for. 280 ---- ---- ----
Rev. 280 ---- ---- ----

Group B (5606.660.446)
King post for. 380 ---- ---- ----
rev. 270 ---- ---- ----
Option (free) for. 250 ---- ---- ----
rev. 250 ---- ---- ----
Swivel console left 250 ---- ---- ----
right 250 ---- ---- ----
Intermediate Jib On 380 ---- ---- ----
Off 270 ---- ---- ----

Group C (5606.660.448)
Main Pressure Control Valve 230 ---- ---- ----
Pony truck up. 250 ---- ---- ----
down 250 ---- ---- ----
Cable reel On 200 ---- ---- ----
Off 200 ---- ---- ----
Apron right On 250 ---- ---- ----
Off 250 ---- ---- ----
Apron left On 250 ---- ---- ----
Off 250 ---- ---- ----
Conveyor up/down for. 250 ---- ---- ----
Rev. 250 ---- ---- ----
Conveyor drive up 250 ---- ---- ----
down 250 ---- ---- ----
Option (Hammer stroke) for 150 ---- ---- ----
Rev. 75 ---- ---- ----
Control Pressure 35 ---- ---- ----

*) Pressure setting on the motor

**) Observe hammer or cutter operating manual
***) activated with pilot pressure

Model ITC 120N / 0479 161

10 Trouble shooting and fault rectification

10 Trouble shooting and

fault rectification
Malfunctions are frequently caused by:
• Incorrect handling of the machine.
• Use of unsuitable fuels and lubricants.
• Irregular maintenance.

10.1 Who is allowed to rectify malfunctions

• During the warranty period, malfunctions must be dealt with by your
responsible Service Agent or a specialist workshop.
• If a problem can only be eliminated through repair, then your re-
sponsible Service Agent must be called in.

Engine faults • All defects and faults in the diesel engine must be examined as de-
scribed in the separate engine instruction book.
• During the warranty period, malfunctions must be dealt with by the
responsible SERVICE Agent or a specialist workshop.

10.2 Before trouble shooting and fault rectification

• Park the tunnel heading machine on a solid and level base.

• The tunnel heading machine is only to be parked in places where it
does not obstruct e. g. the public traffic or the construction site traffic.
• Lower the work equipment to the ground by supporting it on the bucket.
• Lower the dozer blade.
• Shut down the engine and pull out the ignition key.
• Put the exit barrier in upright position.
• Interrupt the machine circuit on the main battery switch at the left below
the driver's seat.
• Close or lock doors and panels.
• Secure the tunnel heading machine through warning equipment, e.g.
triangles, warning cordons, flashing or hazard lights.

162 Model ITC 120N / 0479

 Trouble shooting and fault rectification 10

Malfunction: Machine fails to 10.3 Trouble shooting and fault rectification

drive
Cause:
• Exit barrier lifted or switch defective
• Insufficient engine power
• Hydraulic oil level is too low
• Hydraulic pump has failed
• Main relief valves have failed
• Pilot pressure too low

Remedy:
• Check, repair or replace exit barrier if necessary.
• Check the engine.
• Top off the hydraulic oil to the mark.
• Have pump checked by specialist and replace if necessary.
• Check main relief valves and replace, if necessary.
• Check pilot pressure.
Malfunction: Poor travel per-
formance
Cause:
• Insufficient engine power
• Crawler chains tensioned too tightly
• Hydraulic pump has insufficient output

Remedy:
• Check the engine.
• Check crawler track tension and reduce if required.
• Check and replace the hydraulic pump if required.
Malfunction: Excavator
equipment not working
Cause:
• Exit barrier on operator’s seat raised
• Switch on the exit barrier defective
• Oil supply to hydraulic pump interrupted
• Hydraulic pump has failed
• Engine compartment access panel, left rear open or switch defec-
tive.
Remedy:

• Lower exit barrier

• Repair or replace switch on the exit barrier
• Check lines to hydraulic pump.
• Have hydraulic pump checked by specialist and replace if necessary.
• Check main relief valves and replace, if necessary.
• Close engine compartment access panel.
• Repair or replace switch at the engine compartment access panel.

Model ITC 120N / 0479 163

10 Trouble shooting and fault rectification

Malfunction: Drop in ma-

chine’s performance
Cause: • Insufficient engine power.
• Hydraulic oil levels is too low.
• Pump is sucking in air.
• Insufficient operating pressure.

Remedy: • Check the engine.

• Top up hydraulic oil to the recommended mark.
• Retighten hose connections.
• Replace O-Ring or seals.
• Re-adjust main relief valves (pressure cut-off) or replace if required.

Malfunction: Machine work-

ing too slowly and hydraulic
oil is becoming too hot
Cause: • Main relief valves (pressure cut off) set too low or valves are dam-
aged.
• Unacceptable wear of hydraulic pump
• Insufficient oil levels
• Air in hydraulic system
• Oil cooler dirty or damaged
• Thermo switch defective

Remedy: • Readjust main relief valve (pressure cut-off) or replace if required.

• Replace hydraulic pump.
• Quality of hydraulic oil must conform to our recommendation. See chap-
ter 6.4.2 ‘’Fuels, lubricants and coolant’’.
• Top up oil to mark on sight glass.
• Tighten connections with engine off and system relieved of pressure.
• Replace thermo switch.

164 Model ITC 120N / 0479

 Trouble shooting and fault rectification 10

Malfunction: Faults in the

electrical system
Cause:
• Outside and / or internal lighting without function.
• Horn not responding.
• Warning / Indicating elements are imprecise.
• Starting system not working.

Remedy:
• Check cable, connections, bulbs and fuses.
• Check cable, connections and fuses. Replace horn completely.
• Determine source of defect or fault and remedy, call Service if neces-
sary.
• Unlock emergency-stop button.
Conveyor:
Malfunction: Conveyor chain
stopped
Cause: • Chain tension.
• Pressure on main pressure control valve
• Wear plate are used.
• Chain drive wheel or/and running shaft are used.
• Return channel are dirty.
• The flight is twisted.
• Briquetted chain links.

Remedy: • Check chain tension, pressure on main pressure control valve.

• Check wearing plates for wear.
• Check chain drive wheel for wear and running shaft condition.
• Clean return channel.
• Check whether flights are twisted and getting caught in return channel.
• Briquetted chain links due to long period of standstill.
In the no-load operation: Mo-
tor noise idling
Cause:
• Bearing is used.

Remedy:
• Check bearing and replace if necessary.

Model ITC 120N / 0479 165

10 Trouble shooting and fault rectification

Malfunction: Vibrations
Cause: • Loose fastenings or pipelines.

Remedy: • Tighten with target torque.

Malfunction: Engine noise

during load: Rattling
Cause: • Feed pressure to low.

Remedy: • Check adjustment and condition of back-pressure valve.

Malfunction: Cavitations;
strong leakage
Cause: • Condition of cylinder block and distributor.

Remedy: • Check condition of cylinder block and distributor.

Malfunction: The motor does

not run.
Cause: • The motor is not being fed.
• The pressure in the circuit is not increasing.
• Strong leakage.

Remedy: • Check pump drive and supply.

• Check condition of secondary pressure control valve.
• Check condition cylinder block and distributor.

Malfunction: The motor does

not rotate at normal speed
while under load.
Cause:
• The pump flow rate is insufficient.
• Strong leakage.
• The operational pressure is too low.

Remedy: • Check speed of drive shaft and condition of pump.

• Check condition of cylinder block and distributor.
• Secondary pressure control valve adjustment.

166 Model ITC 120N / 0479

 Trouble shooting and fault rectification 10

Malfunction: The motor runs

irregularly

Cause: • Irregular transported volume.

• Strong leakage.

Remedy: • Check flow rate of pump.

• Check condition of cylinder block and distributor.
Malfunction: External oil lea-
kage
Cause:
• Housing pressure too high.
• Seal damaged by pressure surges.
• Operational temperature too high.
• Fluid in use that is unsuitable for the seals or is contaminated.
• Improper assembly.

Remedy:
• Check overflow oil circuit and filter.

Model ITC 120N / 0479 167

11 Service and spare parts information

11 Service and spare

parts information
11.1 Spare parts
Insist that only original TEREX spare parts are used in the event of any
repair work. In this way, you will have a product of lasting high quality,
thereby ensuring that your tunnel heading machine maintains its original
condition.

Purchasing spare parts

To Ms. Manuela Cadouot
ITC SA
Fusion 122,
CH – 1920 Martigny
Switzerland

Phone: +41 277 222 191

Fax: +41 277 222 185
E-mail: info@itcsa.com

Note
Instructions for ordering spare parts - always state the type of
machine, the vehicle identification number ("machine plate"),
parts designation, complete spare part number, number of piec-
es, delivery address, etc…

How to order spare parts !

HOW TO PROCEED

For all requests, please indicate the complete following information:

1. Your order number

2. Machine- Type and serial number

3. Figure and position in the catalogue

4. Reference Nr. and description of the spare part

5. Quantity required.

6. The way to deliver the spare parts (airfreight, post parcel, railway,
courier, Night Service, DHL, sea freight, etc…)

7. Precise delivery address and invoice address if different.

8. If in Europe, indicate your VAT Nr.

9. If outside of Europe, name of forwarder for custom clearing in des-

tination country.

10. Type of requested packing.

11. Marking on the packing

168 Model ITC 120N / 0479

 Service and spare parts information 11
In this way, the delivery is highly facilitated and the risk of unnecessary
delay reduced.
X

Note
Availability and delivery time is given only for indication,
without commitment neither from our side nor Terex's side.
Sales in the meantime reserved.

Emergency orders are possible, against supplement. For a delivery within

the day, if the part is available, the written order with all required informa-
tion must be in our possession before 11:00 a.m. (CET).

The spare parts are delivered from TEREX in Rothenburg o.d. Tauber in
Germany.

11.2 Service
Customer service
To Ms. Manuela Cadouot
ITC SA
Fusion 122,
CH – 1920 Martigny
Switzerland

Phone: +41 277 222 191

Fax: +41 277 222 185
E-mail: info@itcsa.com

Model ITC 120N / 0479 169

12 Standards and regulations

12 Standards and regu-

lations
12.1 Applicable standards and regulations
The tunnel heading machine was designed in according with the follow-
ing regulations:

Directives and laws

• Machine directive 2006/42/EC
• EMC- directive 89/336/EEC
• EMVG
• Low voltage directives 73/23/EWG
• Personal protection gear 89/686/EWG
• See regulations book ‘’Demolition work’’ (BGI 665) published by the
German Tiefbau- Berfsgenossenschaft (Civil Engineering Employer’s
Liability Insurance Association)
• Accident prevention regulations (UVV)
• Construction works (BGV C22)
• Safety rules for construction work underground (BGR 160)

Norms
• DIN EN 292, Safety of machines, equipment and plants
• DIN EN 60 204-1, Electrical equipment for industrial machines
• Tunneling machine (DIN EN 12111)
• DIN EN 474-1, Earth construction equipment, safety, general require-
ments
• DIN EN 474-5, Earth construction equipment, safety, general require-
ments for hydraulic excavators

12.2 Acquisition of standards and regulations

This section contains a summary of links to the search data base in the
internet.
Information is available there on published national and international
standards and specifications, such as: DIN ad ISO standards, VG stan-
dards, VDI guidelines; DVS-M/R; ASTM, ASME BPVC, IEEE, SAE stan-
dards (US); JIS standards (JPN).

www.din.de
www.beuth.de
www.vde-verlag.de
www.ce-richtlinien.de

170 Model ITC 120N / 0479

 Index 13
13 Index

A E
Additional control circuit ........................................... 114 Electric motor start................................................. 130
Air intake system ........................................................ 91 Electric motor stop ................................................. 130
Announcement ........................................................... 30 Electrical Drive ......................................................... 157
Auxiliary lubrication ................................................. 66 Electrical Equipment................................................. 115
Electronic back pressure control ............................ 87
B Emergency-stop ................................................. 29, 139
Engine cooling system................................................ 88
Battery ..................................................................... 115 Engine oil .................................................................. 64
Battery main switch .................................................... 39 Engine oil level ......................................................... 82
Before operation....................................................... 125 Explosion danger ....................................................... 7
Benefits of Oil Analysis ........................................... 60 Extinguisher................................................................ 56
Boom equipment ...................................... 69, 119, 160
Breather filter .......................................................... 110
F
Briquetting .............................................................. 120
Face protection........................................................... 10
C Failure of hydraulic system ......................................... 24
Falling objects ............................................................ 18
Cable reel .......................................................... 17, 118 Fire extinguisher ........................................................... 8
Camera system .......................................................... 56 Fire protection ............................................................ 24
Care and cleaning ...................................................... 57 First assistance box...................................................... 8
Cartridge maintenance intervals ..................... 92, 111 Flight ....................................................................... 122
Caution ........................................................................ 6 Flight control .......................................................... 122
Central lubrication system .......................................... 65 Foreword ...................................................................... 1
Chain conveyor ........................................................ 69 Fuel .................................................................... 62, 148
Chain tension ......................................................... 120 Fuel System ............................................................... 95
Change of work attachments...................................... 21 Fuse ........................................................................... 34
Changing engine oil.................................................... 83
Changing hydraulic oil .......................................... 109 G
Check hydraulic oil level ....................................... 108
Checking the air intake ............................................ 91 General safety notes .................................................. 12
Checking the battery .............................................. 115 Grease containers .................................................... 66
Checking the idler unit .......................................... 105 Guides ........................................................................ 18
Cleaning the dust ejection valve ............................. 91
Closed spaces............................................................ 20 H
Condensate separator ............................................. 86
Handing ...................................................................... 26
Control .................................................................... 128
Hazard classification..................................................... 6
Control elements ........................................................ 30
Hazardous dusts ........................................................ 7
Conveyor.................................................................. 159
Hazardous electric voltage ........................................ 7
Coolants ..................................................................... 62
Hazardous spot ............................................................ 7
Crawler Travel gear.................................................. 101
Hearing protection ...................................................... 10
Crushing danger ........................................................ 7
Hydraulic Oil ............................................................... 64
Customer service ................................................... 169
Hydraulic Oil Cooler ............................................... 113
Cutting unit ............................................................... 17
Hydraulic oil return filter ........................................ 111
Hydraulic System.............................................. 108, 158
D
Daily and Weekly Work .............................................. 74 I
Danger ......................................................................... 6
Identification plate....................................................... 39
Danger of burning ...................................................... 7
Immobilization .......................................................... 123
Danger zone............................................................... 14
Inclination ................................................................. 15
Dash board................................................................. 32
Initial familiarization .................................................... 26
Deactivation ............................................................... 11
Initial Inspection.......................................................... 73
Declaration of Conformity............................................. 5
Initial installation ......................................................... 26
Description ................................................................. 27
Inspection intervals..................................................... 58
Diesel Drive.............................................................. 156
Inspection Means ....................................................... 61
Diesel engine ....................................................... 78, 82
Inspection plan machine............................................. 79
Directives and laws .................................................. 170
Inspections ................................................................. 23
Disassembly of roller chain................................... 121
Installation of the roller chain ............................... 121
Display ................................................................. 32, 40
Installing batteries .................................................. 117
Driver’s Seat............................................................... 38
Instruction the operator............................................... 26
Driver’s Station........................................................... 30
Intended use................................................................. 4
Driving and steering ................................................. 131

Model ITC 120N / 0479 171

13 Index

L Respiratory protection ................................................ 10

Rock breaker employment.......................................... 17
Lifting the Machine ................................................... 153 Rock breaker lubrication............................................. 67
Lighting and warning equipment.......................... 117 Roller chain ..................................................... 120, 121
Lighting system ........................................................ 159 Running .................................................................... 127
Loading ...................................................................... 23 Running shaft ......................................................... 122
Lubricants............................................................. 62, 65
Lubricating point ...................................................... 67
S
Lubricating pump ..................................................... 66
Lubrication.................................................................. 65 Safe distance ............................................................ 19
Lubrication plan .......................................................... 67 Safety cartridge ........................................................ 93
Lubrication point in Crawler track .......................... 68 safety notes ............................................................ 3, 6
Safety signs.................................................................. 8
M Safety symbol ............................................................... 6
Salvaging the Machine ............................................. 151
Machine deployment .................................................. 16
Self-check ................................................................. 65
Main cartridge........................................................... 94 Service ..................................................................... 169
Main switch ................................................................ 29 Service and spare parts information ......................... 168
Maintenance......................................................... 21, 57 Service Parts .............................................................. 61
Maintenance and inspection work .............................. 81 Settings .............................................................. 26, 126
Monitoring .................................................................. 23
Shutting down the engine ..................................... 129
Monitoring during operation...................................... 134
Spare parts............................................................... 168
Spare parts list ......................................................... 26
N Sprocket .................................................................. 122
Norms....................................................................... 170 Stability....................................................................... 14
Starting the Diesel engine ..................................... 129
O Suspended load .......................................................... 7

Oil analysis intervals................................................... 60 T

Operating ................................................................. 160
Operating Elements.................................................... 32 Taken out of service ................................................. 124
Operating instructions ............................................ 1, 26 Technical data .......................................................... 156
Operating the excavator equipment ......................... 140 Technical Data ......................................................... 155
Operation ..................................................... 13, 15, 125 Temperature Ranges ................................................ 64
Overhead power lines ................................................ 19 Tensioning roller chain .......................................... 121
Overviews .................................................................. 27 Transfer belt conveyor.............................................. 120
Transport .................................................................. 151
P Transport persons ...................................................... 14
Transporting ............................................................... 23
Parking ..................................................................... 138 Transporting the Machine......................................... 154
Personal protection equipment................................... 10 Travel gear ............................................................... 158
Personal safety .......................................................... 10 Travel-drive gear unit................................................ 107
Pictograms ................................................................... 9 Trouble shooting and fault rectification ..................... 162
Pipe and hose assemblies....................................... 85
Pollution ...................................................................... 7 U
Pressure measurement table ................................... 161
Protective clothing ...................................................... 10 Unintended use ............................................................ 4
Protective glasses ...................................................... 10
Protective gloves........................................................ 10 V
Purchasing spare parts ......................................... 168
V-belt .......................................................................... 99
Vicinity of underground............................................... 18
Q Views........................................................................ 155
Quick hitch ............................................................... 149
W
R Warning ................................................................... 6, 7
Re-activation .............................................................. 11 Warranty........................................................... 4, 26, 60
Recovery .................................................................... 23 Wear inspection ...................................................... 122
Regular Oil Analyses.................................................. 60 Wear Limits of the crawler parts ........................... 106
Removing batteries ................................................ 116 Winter operation ....................................................... 147
Repair......................................................................... 21 Work attachments .................................................... 145
Replacing the crawler ............................................ 104 Work practices............................................................ 11
Replacing track shoes ........................................... 103 Work stoppages ......................................................... 20
Residual dangers ....................................................... 24 Work zone safety........................................................ 11

172 Model ITC 120N / 0479