Terex 820, 860/880 SX & ELITE, 970/980 ELITE, TX760B, TX860B, TX970B, TX980B 2008 Backhoe Loader 2008 Workshop Manual (P/N 6111283M2)

Terex workshop manual P/N 6111283M2, published January 2008, revision 02.00.00, covers the 820; 860/880 SX and ELITE; 970/980 ELITE; and TX760B, TX860B, TX970B, and TX980B backhoe loaders.

PDF Search, Diagram Detail and Page Count

Search and diagram navigation: Service text is searchable, although some connector and component-location illustrations do not have searchable labels. No embedded PDF bookmarks are provided. Small wiring labels require zooming for comfortable reading.

Supplied as one printable, English-language 1,579-page PDF, including the original cover, seven general contents pages and 147 blank pages.

Backhoe, Hydraulic and Drivetrain Repair

These selected repair topics show the manual’s main workshop coverage. Other subjects include wheel and tire removal and chassis-panel removal and installation.

• Loader and backhoe: Standard and multi-purpose buckets, loader and backhoe quick-attach units, boom and dipper removal, center-mount and side-shift stabilizers, and hydraulic-cylinder rebuilding.

• Hydraulics: Pressure diagnosis, contamination cleanup, pump and control-valve repair, plus steering-priority, ride-control, servo-control and changeover-valve service.

• Transmission repair: Dana and Carraro Powershift and Turner and Carraro Synchroshuttle diagnosis, pressure testing, step-by-step disassembly and assembly, clutch and shaft service, and control-valve work.

• Axles, steering and brakes: Hubs, epicyclic reductions, differentials, pinion setup, steering cylinders, toe-in and steering-angle adjustment, power and SAFIM brake systems, and brake bleeding.

• Electrical diagnosis: Starting, charging and battery tests; fuse, relay, connector and component-location information; system wiring diagrams; and transmission-controller diagnostics.

• Cab and HVAC: Cab removal, heater and evaporator service, hose replacement, and air-conditioning recovery and charging procedures.

The shop-level overhaul and adjustment procedures are suited to experienced technicians with the lifting equipment, hydraulic gauges, pullers and setting tools required for heavy drivetrain and axle work.

VIN Identification and Build Differences

The VIN tables distinguish Terex/TCE and Fermec identifiers, transmission and drive type, standard or extendable dipper, cab or ROPS, production year, engine output, and chassis configuration. These distinctions help match the machine to the appropriate repair information before selecting procedures.

Separate hydraulic-pump procedures cover the 2007 configuration. Orbitrol steering-motor removal is divided into “up to 2007” and “2007 onwards” procedures.

Perkins Engine Work and Coverage Limit

The Perkins 1104C-44T chapter covers engine removal and installation, radiator and fuel-tank work, air-cleaner and exhaust components, throttle adjustment, and cooling-system draining, filling and bleeding.

Internal engine overhaul requires the separate Perkins Engine Manual. This workshop manual provides engine specifications but does not include a full internal engine rebuilding chapter.

Transmission Calibration and Repair Details

Dana Powershift clutch-fill calibration is described using the T16000 Diagnostic Monitor or the controller’s stand-alone procedure. Carraro Powershift coverage adds TRAX controller startup checks and CTC blink-code tables with fault meanings, operating effects and diagnostic actions.

The Carraro Synchroshuttle section warns that pulling a bearing and gear together against the intervening snap ring can damage the transmission. Its four-wheel-drive-shaft procedures also explain how incorrect Teflon-seal installation or sizing can cause premature seal failure and subsequent transmission damage.

Synchronizer disassembly in that section is for inspection; individual internal synchronizer parts are not serviceable.

Fault-Isolation Diagrams and Workshop References

The main hydraulic circuit, Dana Powershift and Turner/Carraro Synchroshuttle schematics support tracing fluid paths and component relationships. Electrical examples include Powershift controller and test-socket wiring, the 4WS steer-mode and proximity-switch circuit, ride-control and hose-burst wiring, and separate quick-attach/changeover circuits for cab and ROPS machines.

Assembly data includes torque tables, approved fluids and capacities, pressure-test specifications, operational test times, shim ranges, shaft end float, clearances, inspection limits and electrical test values.

Referenced equipment includes hydraulic pressure-test kit 6108395M91, portable filter CAS-10162A with fitting kit CAS-10508, transmission lifting tool TG 1500-676, and Carraro axle tools CA119099 and CA715022.

Safety guidance addresses raised attachments, stored hydraulic pressure, electrical isolation and heavy-component lifting. The HVAC procedures require certified refrigerant-management equipment operated by a certified technician. Hose-burst valves are covered for operation and replacement; internal repair or adjustment is prohibited.

Examples of Extendable-Dipper Adjustment Data

The upper internal side wear-pad procedure specifies a total clearance of 0.5–1.0 mm and lists 1.0 mm and 2.0 mm adjusting shims. These dimensions accompany the pad-measurement and shim-selection instructions.