Official Workshop Suite: Terex 820, 860/880 SX & ELITE, 970/980 ELITE, TX760B, TX860B, TX970B, TX980B (2008)

Terex 820, 860, 880, 970, 980 Series Service Manual - 2008

This technical volume establishes the authoritative service framework and calibration benchmarks for the Terex backhoe loader range. A critical factor for maintaining operational integrity involves the hydraulic filtration and fluid specification: maintaining the hydraulic system with ISO VG46 or VG68 oil is mandatory, as incorrect viscosity grades under high-pressure conditions (up to 225 bar) can lead to internal spool bypass exceeding 11cc/min, resulting in a significant degradation of precision control and lifting force. All diagnostic protocols are aligned with factory-certified engineering tolerances to maximize machine uptime.

Technical Applicability & Configuration Matrices

The following models are categorized by chassis architecture and steering system logic as defined in the master technical index:

Two-Wheel Steer (2WS) / Sideshift & Centremount Configurations

• Terex 820 (Standard Platform)
• Terex 860 SX / 860 ELITE
• Terex 880 SX / 880 ELITE
• Terex TX760B
• Terex TX860B

Four-Wheel Steer (4WS) / Heavy-Duty Configurations

• Terex 970 ELITE
• Terex 980 ELITE
• Terex TX970B
• Terex TX980B

Axle & Drivetrain Sub-Systems

• Front Axle Assemblies: 26.18LP, 26.28LP
• Rear Axle Assemblies: 28.43M, 26.43LP

Strategic Operational Parameters

• Maintenance intervals are structured in 10, 250, 500, and 1000-hour increments to ensure powertrain longevity and structural stability.
• Hydraulic pump flow benchmarks (80 l/min) and relief valve settings (225 bar) provide the baseline for secondary circuit performance validation.
• Safety-critical systems, including ROPS/FOPS structural integrity and hose burst valve logic, are detailed to ensure full site compliance.

Document Metadata

• Print Number: 6111283M2
• Page Count: 1579 Pages
• File Format: PDF Digital Resource

Technical Depth & Factory Benchmarks

Technical engineers utilize the following calibration data for precision system alignment:

• Engine Parameters: Perkins 1104C-44T turbocharged builds with a 16.5:1 compression ratio and 1.0 bar wastegate operating pressure.
• Hydraulic Benchmarks: Relief valve settings at 225 bar (Pump 1) and 207 bar (Pump 2) with a compensator pressure of 20 bar at 1800 rpm.
• Transmission Stall Speeds: Maximum engine no-load speed is benchmarked at 2350 +/- 25 RPM across all 800/900 series variants.

Visual Navigation Aids

• System Logic: Detailed cross-sectional diagrams for synchro-shuttle (Turner) and powershift (Dana/Carraro) transmissions.
• Circuit Schematics: Full-page wiring diagrams covering power supply, engine control, and 4WS steering mode logic.
• Component Breakdowns: Exploded views of hydraulic cylinders, axle beams, and steering orbitrols for rapid assembly reference.

Table of Contents

• Section 0: General Information & Safety
• Section A01: Accessories & Quick Attach Systems
• Section B02: Loader & Backhoe Buckets
• Section D04: Digger Boom & Dipperstick Assemblies
• Section E05: Digger Swing & Stabilizer Systems
• Section F06: Main Hydraulics & Pressure Testing
• Section G07: Loader Beam & Control Logic
• Section H08: Operator Environment & HVAC
• Section J09: Electrical Systems & Wiring Diagrams
• Section L11: Front Axle & Steering Groups (2WD/4WD/4WS)
• Section N13: Drivetrain, Braking, & Transmission Variants
• Section P14: Perkins 1100 Series Engine Integration

Operational Limits & Specifications

Detailed fastener and fluid standards include:

• Critical Fasteners: Extendable dipper top bolts require 920Nm +/- 120, while slew hydraulic cylinder pistons are set to 1075Nm.
• Fluid Capacities: Fuel tank (130L), Hydraulic system (143L total), and Engine oil (7.3L).
• Standardized Torque: Universal metric and inch tables for zinc-coated and waxed fasteners from M3 to M36.

Does this manual cover the specific technical configurations for both the 800 and 900 series chassis? Yes, the manual defines applicability for a wide range of models including the 820, 860 SX/ELITE, 880 SX/ELITE, and the 970/980 ELITE, as well as the TX760B through TX980B variants. It provides distinct procedures for different chassis architectures, such as the Four-Wheel Steer (4WS) systems found in Section L11 and various sideshift or centremount configurations.

What are the primary hydraulic pressure benchmarks for system diagnostics? The manual specifies that the main relief valve (PRV) settings should be calibrated to 225 bar for Pump 1 and 207 bar for Pump 2 at an engine speed of 1800 rpm. Additionally, it notes that a compensator pressure of 20 bar is required for the load-sensing system to function correctly under standard operating conditions.

Can I find detailed engine performance and cold-start specifications within this documentation? Detailed data for the Perkins 1104C-44T engine is located in Section P14, including a compression ratio of 16.5:1 and a specific wastegate operating pressure of 1.0 bar. For winter operations, it details the Beru glow plug system, which draws an initial current of 30A that reduces to 9A after 60 seconds of activation.

Does the manual provide specific torque sequences for high-stress structural components? Section D04 and other assembly chapters list critical torque values, such as the 1075 Nm requirement for the slew hydraulic cylinder piston-to-rod connection and the 920 Nm (+/- 120) torque for the extendable dipper top bolts. These exact specifications are vital for preventing structural failure during heavy-duty excavation tasks.

How does the digital format enhance the utility of the integrated electrical schematics? The digital PDF format allows for instant navigation to Section J09, where full-page wiring diagrams for power supply and engine control are located. Users can zoom into high-resolution circuit traces for the 4WS steering mode logic or print specific pages for use in the field, ensuring that complex electrical troubleshooting is performed with factory-level accuracy.