tpp450

Level ground cutter

tpp450

Operator's manual
Level ground cutter

Language version: EN

Edition: 2012-02

Order number: 5780211752

From tool ID no.: xxxxxxxx>


Terex Deutschland GmbH
Terex Deutschland GmbH
Geschftsbereich Compact
Geschftsbereich Compact
Kraftwerkstrasse
Kraftwerkstrasse 44
74564 Crailsheim
74564 Crailsheim
Deutschland
Germany
Tel.
Tel. +49(0)7951 9357-0
+49(0)7951/9357-0
Fax +49(0)7951 9357 671
E-Mail: info@terex-compact.com
www.terex.com
www.terexconstruction.com
E-Mail: info@terex.com

Please complete before commissioning the cutting unit:

Cutting unit model: .........................................................................................

Cutting unit ID no: .........................................................................................

Year of construction: ........................................................................................

Commissioned on: .........................................................................................

Dealer:

This operator's manual is protected by limited copyright. It may be reproduced for and used by the driver/
plant operator.
 Table of Contents

1 Table of Contents

1 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Concerning this operator's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Notes on using the operator's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Definition of target groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Proper use of the level ground cutter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Improper use of the level ground cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1.1 Safety symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1.2 Danger levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1.3 Descriptions of symbols and hazard symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1.4 Location of safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1.5 Maintenance and replacement of safety signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2.1 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Work zone safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3.1 General work zone regulations safe working practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3.2 Deactivation and protection against re-activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3.3 Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3.4 Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Adaptor bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Details on the adaptor bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3.1 Hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.4 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5 Before initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Starting the cutting work with a preset depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Carrying out the cutting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4 Ending the cutting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.5 Examples of using the level ground cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.5.1 Examples of using the level ground cutter on asphalt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.5.2 Examples of using the level ground cutter on walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.6 Selecting cutting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.6.1 Recommended picks for asphalt cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.6.2 Recommended picks for concrete and rock cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.7 Regulations concerning environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Maintenance and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.4 Replacing the picks on the cutting drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.4.1 Removing picks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.4.2 Installing picks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Table of Contents
6.5 Replacing the drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.5.1 Removing the drums. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.5.2 Installing the drums. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.3 Transport of the packed level ground cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.4 Transport of the unpackaged level ground cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.4.1 Transportation on an excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.4.2 Transport by crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.2 Picks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2/30 Chapter01_en_TOC.fm 29.2.12 Version 1.0 TPP 450

 Foreword 2

2 Foreword

2.1 Concerning this operator's 2.3 Definition of target groups

manual
This operator's manual is aimed at a diverse target
Please read this operator's manual carefully so that audience. The level of knowledge each target group
you are acquainted with the correct handling and must have is defined here.
operation. All target groups must have read and understood
The operator must also follow the enclosed this operator's manual.
operating instructions for components supplied
externally. Operating staff must
Observe the national legal and miscellaneous be of the minimum legal age.
regulations.
All target groups must have read and understood have been instructed in the use of the machine.
this operator's manual. be familiar with the country-specific accident
prevention regulations.
Should you have any questions concerning the
operator's manual, please contact our customer Maintenance personnel must
service:
be of the minimum legal age.
TEREX Deutschland GmbH know the machine's service schedule.
Postfach 12 64 D-91534 Rothenburg, Germany
Erlbacher Str. 115 D-91541 Rothenburg, Germany know the country-specific environmental
Tel.: + 49 (0) 9861/972-0 regulations for the disposal of lubricants.
Fax: +49 (0) 9861/972-460 See chapter 5.7, page 16.

Customer service personnel must

2.2 Notes on using the operator's be of the minimum legal age.
manual
have sound school education and vocational
training.
Structure of safety instructions
have been instructed by TEREX in the
1 2 performance of service jobs on the machine.

CAUTION have been trained in the rules and procedures

3 related to a case of malfunction.
KIND OF DANGER
Consequence 4
Measures
5

Fig. 1 Structure of safety instructions

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

"Caution" symbol

Caution
This symbol depicts information containing
important notes about the correct use
and/or how to proceed. Non-compliance
may lead to malfunction.

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2 Foreword
2.4 Proper use of the level ground
cutter
The TPP level ground cutter is an attachment for an
attachment carrier such as e.g. crawler excavators
and wheeled excavators, backhoe loaders, and skid
steer loaders.
It is used for cutting asphalt and concrete, and for
precise cutting of small areas.
Ensure that the maintenance schedule has been
adhered to before operating the machine.
The machine must only be used by fully trained
operating personnel with competent knowledge.
The machine must only be maintained and
repaired by fully trained maintenance personnel
with competent knowledge.
Operate the levers smoothly, without jerking. If
the cutting head stalls, back the cutter away from
the workface. Do not overload the picks as this
may cause damage to the cutting unit.
Always ensure that the cutting unit or any part of
the unit is correctly attached during any
maintenance work.
4/30 Chapter02_en_Foreword.fm 1.3.12 Version 1.0
2.5 Improper use of the level ground
cutter
Do not try to move the level ground cutter
sideways while it is on the ground! Before
moving the level ground cutter sideways please
ensure that it is raised and not in contact with the
ground.
Do not attempt to work on the level ground cutter
or the attachment carrier with the hydraulics
switched on. The hydraulic pressure must under
all circumstances be released before separating
any hoses or removing the cutter from the
attachment carrier.To do so, switch off the
engine and activate all control elements.
Do not handle the level ground cutter in the same
way as a backhoe dipper; it could be damaged if
it comes into contact with fixed items and could
also impair the stability of the attachment carrier.
TPP 450
 Safety 3

3 Safety

3.1 General safety 3.1.3 Descriptions of symbols and hazard

symbols

3.1.1 Safety symbol The symbols used in this manual and on the
machine identify the following hazards:
The safety symbol is used to
warn you of potential personal Symbol Meaning
injury. WARNING OF A
Observe all instructions HAZARDOUS SPOT
associated with this safety If the required precautionary
symbol in order to avoid measures are not taken, death,
potential injuries or death. personal injury, and substantial
property or equipment damage
may occur.
3.1.2 Danger levels
WARNING RELATED TO THE
The precautionary statements are divided into four CUTTING DRUM
categories: If the required precautionary
measures are not taken, the
Indicates an imminently transverse cutting unit may
GEFAHR
DANGER hazardous situation which, if cause personal injury and
the safety regulations are not substantial property or
observed, will result in death or equipment damage.
serious injury. WARNING OF
Indicates a potentially ENVIRONMENTALLY
WARNING
WARNUNG hazardous situation which, if HAZARDOUS SUBSTANCES
the safety regulations are not If the required precautionary
observed, may result in death measures are not taken, these
or serious injury. substances may cause serious
Indicates a potentially environmental damage.
CAUTION hazardous situation which, if WARNING OF CRUSHING
the safety regulations are not DANGER
observed, may result in If the required precautionary
property or equipment measures are not taken,
damage, or minor or moderate personal injury due to crushing
personal injury. may occur.
No safety symbol indicates a WARNING OF SUSPENDED
CAUTION
VORSICHT potentially hazardous situation LOAD
which, if the safety regulations If the required precautionary
are not observed, may result in measures are not taken, death,
property or equipment personal injury, and substantial
damage. property or equipment damage
may occur due to suspended or
falling loads.

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3 Safety
3.1.4 Location of safety signs 3.2 Personal Safety
The safety signs are located in the following places The operator's manual and the symbols described
on the machine: have to be read and understood by all persons
working on and with the machine.

3.2.1 Personal Protective Equipment

1
The mandatory signs used in this manual and on the
machine require the following safety measures:

Symbol Meaning
WORK WITH PROTECTIVE
CLOTHING
If the required protective
clothing is not worn during
work, personal injury may
result.
2
WORK WITH PROTECTIVE
Fig. 2 Location of safety signs GLOVES
1 Warning of hazardous location, in the case of the If the required protective gloves
engine of the attachment carrier not being are not worn during work, hand
switched off injuries may result.
2 Warning of crushing danger WORK WITH PROTECTIVE
GOGGLES
If the required protective
3.1.5 Maintenance and replacement of safety goggles are not worn during
signs
work, eye injuries or a total loss
of sight may result.
Operator safety always comes first. Replace any
safety signs which have been damaged or are no WORK WITH HEARING
longer visible. Use mild detergents and water to PROTECTION
clean the safety signs. Do not use detergents If the required hearing
containing solvents. protection is not worn during
work, hearing defects may
result.
Use the following additional personal safety
equipment while working on and with the machine:
Safety boots
Helmet
Avoid the following while working on and with the
machine:
Loose clothing
Uncovered or loose hair

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6/30 TPP 450
 Safety 3
3.3 Work zone safety 3.3.3 Vibration

CAUTION
3.3.1 General work zone regulations safe
working practices DANGER CAUSED BY
VIBRATION
In order to ensure functionality and the safe Vibration can damage health.
operation of the equipment, we recommend you Z Do not exceed the specified
handle it properly and regularly perform labor time per day.
maintenance and inspection tasks.
Improper handling will result not only in problems Exposure limits and provocation values acc. to
with the unit, but will also negatively affect operating directive 2002/44/EC
performance.
For vibration of the whole body
Obtain information on routine machine checks and
The daily exposure limit, standardized to a
consult the relevant authorities with regard to work
reference time of 8 hours, is fixed to 1.15 m/s2 or,
regulations.
if desired by a member state, to a vibration dose
value of 21 m/s1.75.
Ensure all the following safety instructions are read
prior to using or servicing the cutting unit, to avoid The daily provocation value, standardized to a
personal injury. reference time of 8 hours, is fixed to 0.55 m/s2 or,
Ensure the area is clear of personnel before and if desired by a member state, to a vibration dose
during operation of the cutting unit. As soon as value of 9.1 m/s1.75.
someone enters this zone, stop the cutting Milling operations generate vibrations which are
operation, and turn off the engine of the transferred to work equipment and the operator.
excavator. The intensity of these vibrations differs depending
If you leave the excavator and are controlling or on the material to be processed. The maximum time
servicing the cutter, place the level ground cutter the operator may be exposed to these vibrations is
on the ground and switch the engine off. specified in the following table.
Never touch the cutting unit while the cutting Intensity of Material Labor time in
drums are rotating. vibrations hours per day
Do not adjust hydraulic valves or any part of the Medium intensity e.g. asphalt 6
hydraulic system while the machine is running. High intensity e.g. rock, 4
Always change frayed, crushed or damaged concrete
hoses immediately.
Always use original TEREX spare parts and
change at once if damaged. 3.3.4 Noise protection

The operator must observe the noise protection

3.3.2 Deactivation and protection against re- guidelines when working and must carry out a noise
activation measurement where applicable. Appropriate
protective measures must be taken.
Set the travel drive of the attachment carrier to
neutral and the engine to idle speed.
Switch the level ground cutter off.
Place the level ground cutter down in such a way
that it is resting completely on the ground.
Apply the parking brake of the attachment
carrier. Slowly move the throttle of the
attachment carrier to the idle position, switch the
engine off, and remove the ignition key.
Relieve the hydraulic pressure by moving the
cylinder control lever in both directions.

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3 Safety

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 Installation 4

4 Installation

4.1 Adaptor bracket

The level ground cutter requires an adaptor bracket in order to fit onto the excavator. The adaptor bracket of
the level ground cutter uses the existing bearing points and pins of the excavator.

4 1

Fig. 3 Adaptor bracket

1 Dipperstick
2 Engine
3 Bucket rod
4 Adaptor bracket
5 Cutting unit

Attention
When cutting on the wall, the level ground
cutter must be rotated by 180 and attached
to the adaptor bracket, i.e., the ejection
opening (always on the threaded spindle
side) must point downwards so that
loosened material can be ejected from the
cutter housing.

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4 Installation
4.2 Details on the adaptor bracket

The following drawing contains all specifications for

the manufacture of an adaptor bracket:

280

353

400
39 56 56 39
10x14
10x14
10x17
10x17

76 95 95 76

410

Fig. 4 Adaptor bracket

The following drawing contains all specifications for

the manufacture of an adaptor bracket: Attention
The adaptor bracket must have a
X3
X1
thickness of 20 mm and be welded by
Y1 expert personnel.

X5

Y2

X2
X4

Y1= Bucket rod bolt diameter

Y2= Dipperstick bolt diameter
X1= Bucket rod width
X2= Dipperstick width
X3= Bucket rod bolt length (not including
length for retention)
X4= Dipperstick bolt length (not including additional
length for retention)
X5= Bolt spacing; bucket rod/dipperstick

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 Installation 4
4.3 Hydraulic connections 4.4 Hydraulic oil

Connect the level ground cutter as follows: Oil type HLP 46 or 68

HV mineral oils possessing improved
Connect the pressure line to the excavator. viscosity/temperature properties (DIN 50524,
Connect the return line to the excavator. Part 3).
Biodegradable oil
Attention
If there is no separate leak-oil line installed Attention
on the excavator arm, the leak-oil line may Please contact TEREX before using any
be integrated from the cutting unit into the other hydraulic oil.
return line, i.e. both lines may be Any other hydraulic oils must be approved
consolidated. in writing.

1
2
1

Fig. 5 Hydraulic connections

1 Return line
2 Pressure line

CAUTION
VORSICHT
MATERIAL DAMAGE TO THE
ENGINE AND LINES
Cavitation may occur from
leaving the cutting drum running.
Z The pressure lines must not be
obstructed when switching off
the additional control circuit.
Z Where necessary speak to
customer services or CMT at
TEREX.

4.3.1 Hydraulic hoses

Pressure and return line connection (Fig. 5)

Pressure and return line G 1"
External leak-oil line G 1/4"

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4 Installation
4.5 Before initial start-up

WARNING
WARNUNG
SERIOUS PERSONAL INJURY
Injury through non-compliance
with precautionary measures
Z Before starting any work with the
cutter, the procedure for
deactivating and protecting from
re-activation must be carried
out. See chapter 3.3.2, page 7.

Check the surface to be processed with the

cutter.
Once everything is ready, start the engine of the
attachment carrier and ensure that the cutting
drum is not touching the ground.
Switch the ground level cutter on and check the
rotation of the drum.
Increase the engine speed with the drum
rotating.

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5 Operation
5.1 Description
The cutter must be connected to the attachment
carrier fitted with the necessary hydraulic and
operating elements.
The boom arranged in the center ensures that the
forces of the attachment carrier work directly via the
cutting drum which increases stability and at the
same time reduces tension and bouncing when
cutting.
A sturdy frame with rollers reduces friction when
pulling. The unique design of the hood and of the
maintenance opening does not just help keep the
loosened material secure, it also above all enables
simple and safe access when replacing the cutting
pick, while the cutter is lying on the ground.
The level ground cutters can be used for repairing
asphalt surfaces, for precise profiling work, and for
upper surface removal - horizontally, vertically, at an
angle or overhead.
Asphalt and concrete can be cut using the standard
drum. Drums with more picks are available for more
delicate surfaces.
The TPP 450 level ground cutter is designed for
excavators/attachment carriers with an operating
weight between 8 t and 14 t. Your TEREX technical
team can advise you on the most appropriate
machine configuration and the ideal equipment for
your project.
TPP 450 Chapter05_en_Operation.fm 1.3.12 Version 1.0
Operation 5
5.2 Starting the cutting work with a
preset depth
Move the level ground cutter to the desired
starting position.
Start the drum rotation with the attachment
carrier engine at low speed.
Increase the speed to maximum and slowly
lower the cutter onto the surface to be processed
until the weight of the cutter is resting on the
cutter wheels.
Move the boom of the excavator further
downwards in order to guarantee sufficient
pressure for stable operation.
The maximum cutting depth is determined by the
type of material to be cut, the weight and the
hydraulic power of the attachment carrier as well
as the size of the cutter.
The general recommendation is to start with a
depth of 20 to 30 mm for concrete and 25 to
60 mm for asphalt.
This is just a guide and the actual values can be
increased where the weight and power of the
attachment carrier permit.
13/30
5 Operation
5.3 Carrying out the cutting work 5.4 Ending the cutting work

Move the cutter in the same direction as the Stop the level ground cutter advancing and raise
cutting pick is moving in the material being cut. it out of the material being cut.
If the cutting work is not to be continued, set the
engine of the attachment carrier to idle and
switch the cutter off.
3
The cutter must not be transported on the
1 excavator while it is switched on.

CAUTION
VORSICHT
DAMAGE TO PROPERTY
Hydraulic oil can overheat
depending on the ambient
2 temperature and the length of
time that the machine is switched
Fig. 6 Direction of drum and attachment carrier on.
1 Lowering the cutter Z When using level ground cutters
2 Cutting direction on loaders that are fitted with
high-flow systems, the engine-
3 Attachment carrier
oil temperature display must be
If the cutting drum comes to a stop, then you observed on a regular basis.
have moved the cutter into the cutting material Z If the display is flashing, switch
too quickly or too deeply. the cutter off and let the loader
Pull the device out of the material being cut until continue to run idle until the
the drum starts rotating again and then continue hydraulic temperature has
working. dropped below 80C.

If the cutter constantly moves out of the material

to be processed, apply the procedure described
in the above paragraph so that the cutter wheels
remain on the surface to be cut.
Avoid moving the cutter sideways whilst the
drum is in cutting operation. The drum will not cut
laterally.

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 Operation 5
5.5 Examples of using the level ground cutters

5.5.1 Examples of using the level ground cutter on asphalt

Fig. 7 Typical asphalt cutting

5.5.2 Examples of using the level ground cutter on walls

Fig. 8 Wall cutting

Attention
When cutting on the wall, the level ground
cutter must be rotated by 180 and attached
to the adaptor bracket, i.e., the ejection
opening (always on the threaded spindle
side) must point downwards so that
loosened material can be ejected from the
cutter housing.

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5 Operation
5.6 Selecting cutting tools 5.7 Regulations concerning
environmental protection
Different pick attachments can be selected. Always
consult your TEREX dealer. Applicable environmental requirements must be
For technical data on the picks see chapter 8.2, observed for all tasks performed on and with the
page 25. machine.
During installation, repair, and maintenance tasks,
particular care must be taken that substances that
5.6.1 Recommended picks for asphalt cutting would damage the environment such as:
Lubrication greases and oils
Hydraulic fluids
Fuels
Coolants
Or cleaning fluids containing solvents do not
seep into the ground or the sewerage system.
These substances must be collected, transported,
stored, and disposed of in suitable containers.
If any of the fluids mentioned above seep into the
earth, the leakage must be brought to a halt, and the
fluids have to be bound with suitable binding agents.
If necessary, the soil affected must be removed.
Binding agents and removed soil must be disposed
of properly. Applicable environmental requirements
must be observed.
Fig. 9 BSH 188 type

5.6.2 Recommended picks for concrete and

rock cutting

Fig. 10 BSH 200 type

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 Maintenance and Care 6

6 Maintenance and Care

6.1 Safety instructions

WARNUNG
WARNING
SERIOUS PERSONAL INJURY
Injury through non-compliance
with precautionary measures
Z Before cleaning, lubricating or
performing maintenance work
on the device, the procedure for
deactivating and protecting from
re-activation must be carried
out. See chapter 3.3.2, page 7.
Z Before starting any work on the
drum, the level ground cutter
must under all circumstances be
set to the maintenance position
and be placed securely on the
ground.

WARNING
WARNUNG
SERIOUS INJURY
Any liquid escaping under
pressure can cause serious
injury
Z Never check hydraulic hoses
and connections with bare
hands.

CAUTION
VORSICHT
DANGER DUE TO
ENVIRONMENTALLY
HAZARDOUS SUBSTANCES
Escaping oil may pollute the
environment.
Z Wear protective clothing when
handling oil.
Z Collect the waste oil and dispose
of according to regulations.

Attention
Information on the valves which control the
quantity of oil for the cutting unit can be
found in the attachment carrier manual.

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6 Maintenance and Care
6.2 Maintenance schedule
The maintenance intervals indicated are
recommended values and must be adhered to.
Local operating conditions may require shorter
maintenance intervals.
Maintenance interval for
single-shift operation
Daily before start-up
At least twice each day
Daily after work
Temporary shutdown
18/30
Attention
The maintenance intervals are based on
single-shift operation (8h/day,
20 days/month, 12 months/year). In
multiple-shift operation, the maintenance
intervals must be shortened accordingly.
Activity To be
performed by
Check the level ground cutter is correctly installed on the Operating
adaptor bracket and attachment carrier. personnel
Check for leaks and damage on the hoses.
Tighten or replace any loose hydraulic fittings.
Grease both sides of the cutter housing grease nipple.
See chapter 6.3, page 19.
Check all brackets to see if they need to be greased.
Remove any dust and dirt. Oil the surfaces where
required.
Tighten any loose parts with the wrench.
Check that all picks run freely and check for wear. Operating
Replace any picks that are not rotating freely or that personnel
are heavily worn. See chapter 6.4, page 19.
Clean the level ground cutter thoroughly. Operating
personnel
Check that all picks are moving freely.
Clean the level ground cutter thoroughly. Operating
personnel
Stored it in a dry place.
If necessary, dismount the picks due to danger of
corrosion.
Chapter06_en_Maintenance.fm 1.3.12 Version 1.0
TPP 450
 Maintenance and Care 6
6.3 Lubrication 6.4.1 Removing picks

Daily, before starting to work, the grease nipples (1) CAUTION

VORSICHT
on the end of the swivel carrier arm must be
greased, on both sides of the cutter housing. MATERIAL DAMAGE TO THE
LEVEL GROUND CUTTER
Standard commercial multi-purpose grease is Damage due to improper repairs
sufficient for this. Z Repairs can only be carried out
by trained customer support
personnel.

Clean the cutting unit and the working area

thoroughly.
Switch the level ground cutter off.
Rotate the threaded spindle (1) so that the
housing lowers and the cutting drum can rotate.

1 1 1
Fig. 11 Grease the
1 Grease nipples

6.4 Replacing the picks on the cutting

drums

In order to achieve maximum service life and

optimum performance for the picks, they need to be
replaced under the following circumstances: Fig. 12 Lower housing

They have broken off or are worn down. 1 Threaded spindle

They get stuck in the pick box and cannot rotate Switch off the engine of the attachment carrier.
freely.

WARNUNG
WARNING
Attention DANGER CAUSED BY PARTS
Replacing individual picks is permitted. FLYING AROUND.
Keep some picks that are partly worn down, Parts flying around during repair
in case damage is ever caused by work can cause severe eye injury
reinforced iron bars. or the loss of eyesight
Z Use goggles or another kind of
Please read the following instructions carefully. eye protection.
Failure to observe them may void the warranty. If Z Only use a lead or copper
you have queries, contact your dealer or TEREX. hammer to replace the picks.

Open the upper hinged cover:

Rotate the drum until the pick to be removed can
be comfortably reached.
Use a lead or copper hammer (3) and the drift
punch (1) to hit the pick shank from behind, so
that the pick collar lifts off the pick box.
Place the jaws of the wedge punch (2) under the
collar of the pick. By doing so, the tool handle
pulls away from the pick box.

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6 Maintenance and Care
Using a lead or copper hammer (3) hit the
striking surface of the wedge punch (2) until the
pick lifts completely out of the pick box.
1
2 pick is in full contact with the pick box.
6.4.2 Installing picks
Hold the tools for the pick installation in one hand
and place the new pick in the jaw of the tool so
that the striking surface of the tool is pointing in
the same direction as the end of the pick.
Position the pick shank in the hole of the pick
box.
Using a lead or copper hammer hit the striking
surface of the tool so as to insert the pick into the
pick box.
Strike the striking surface firmly to ensure that
the pick is inserted into the hole of the pick box.
The pick is correctly positioned if the body of the
Ensure that the picks can rotate freely.

Attention
If the pick does not have a groove, place the
3 pick shank into the hole of the pick box and
carefully hit the end of the pick using a lead
or rubber hammer until the pick is in the pick
Fig. 13 Removing
box.
1 Drift punch BZ43 1.862.000.093
2 Wedge punch BZ38 - 1.862.000.086
3 Lead or copper hammer

Attention
If the pick does not have a groove then use
the drift punch (punch tool) and a lead or
copper hammer to hit the pick from the rear,
out of the pick box.

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20/30 TPP 450
 Maintenance and Care 6
6.5 Replacing the drums

6.5.1 Removing the drums After the engine has been removed, pull the
engine and shaft (5) out of the bearings.
Check whether parts of the engine have been
removed and replace any damaged parts.
1

Tubular drums and separate axles

2
If your cutter is fitted with a tubular drum and
separate axle, remove the six screws that fasten
the drum to the axle. Screw two of these
capscrews into the thread holes of the drum until
the drum comes loose from the axle.
Fig. 14 Replacing the drums Lift the drum and remove it from the cutter.
Remove the pin for lower depth adjustment (1). If the drum has not been removed for some time,
Remove the depth indicator (2). it may be necessary to clean any dirt and/or
asphalt from the inside of the drum starting from
the opposite end to the side that is screwed
down.

3 4 6
5
6.5.2 Installing the drums

The drums are installed in reverse sequence.

7 When installing the engine, clean the shaft hole

and the motor shaft, and treat all the equipment
11
8 with anti-seize.
9
10

Fig. 15 Replacing the drums

Raise the level ground cutter high enough so that
the roller frame (7) is able to swivel in front of the
cutter; lower the cutter and at the same time
move the attachment carrier back so that the
roller frame (7) is pulled out towards the front.
Lower the cutter onto the ground.
Remove the three capscrews (3) which connect
the cutter's right carrier arm (11) to the rear
hinged plate of the carrier. Remove the
capscrew (10) in the center of the housing side
bracket (8) and place the carrier arm (11) to the
side.
Remove the four cylinder countersunk screws
(4) which fix the housing side bracket (8) to the
housing and the cylinder screws (9) to the cutting
drum central bearing. Use a hammer to knock
the housing side bracket (8) out of the guide
pins. Remove the bearing housing from the axle.
Put the housing side bracket (8) and the bearing
housing to one side.
To remove the drum, pull the engine (6) out of
the drum. Some engines can be difficult to
remove and may require pulling equipment.

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6 Maintenance and Care

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 Transporting 7

7 Transporting

7.1 Delivery 7.3 Transport of the packed level

ground cutter
Before shipment, the delivery is carefully checked
and packaged. However, it is not possible to rule out The packed level ground cutter is to be transported
damage caused during transportation. by forklift truck.
Check against the packing list for completeness.
Check the delivery for damage (visual WARNING
inspection).
DANGER DUE TO SUSPENDED
If the delivery was damaged in transport, LOADS
then contact the forwarding agent immediately. If the level ground cutter falls, it
may cause serious injury.
Z Ensure sufficient load bearing
7.2 Packing capacity of the forklift truck.
Weight of the level ground cutter:
The transport units are bolted to wooden pallets and 600 kg.
protected by plastic foil. The wooden pallets are Z The operator must be authorized
additionally provided with a wooden box. to drive the forklift truck.

If not specially agreed upon in the contract, the
packing corresponds with the packing regulations
issued by the German Federal Association for
wooden packing means, pallets, export packing
(Deutscher Bundesverband Holzmittel, Paletten,
Exportverpackung e.V.).
Securing the level ground cutter before packing
Place the level ground cutter on a pallet.
Lash the level ground cutter down (Fig. 16).
Fig. 16 Lashing the level ground cutter down
Drive with the forks between the longitudinal
beams (Fig. 17) of the pallet.
The center of gravity of the pallet is located in the
middle between these longitudinal beams,
unless stated otherwise.
If the centre of gravity is not in the middle, this is
clearly indicated in the transport documents and
on the transport unit, using the international
symbol acc. to ISO R/780 (International
Organization for Standardization) and
DIN 55 402 (German Institute for
Standardization).
For unloading and transport, the position of the
center of gravity must be determined by
technically instructed safety personnel.
Lift the box by a maximum of 10 cm and check
the stability.
Transport the box slowly and carefully to the
installation place.
Lower the box carefully and evenly.

Fig. 17 Packaged level ground cutter

1 Longitudinal beams

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TPP 450 23/30
7 Transporting
7.4 Transport of the unpackaged level
ground cutter

7.4.1 Transportation on an excavator

WARNUNG
WARNING
SERIOUS PERSONAL INJURY
Injury through non-compliance
with precautionary measures
Z The level ground cutter must be
switched off before
transportation. See chapter 5.4,
page 14.

7.4.2 Transport by crane

WARNUNG
WARNING
DANGER DUE TO SUSPENDED
LOADS
If the level ground cutter falls, it
may cause serious injury.
Z Use adequate lifting gear; weight
of the level ground cutter:
600 kg.
Z The crane operator must be
authorized to operate the lifting
gear. See chapter 2.3, page 3.
Z Observe the accident prevention
regulations.

Attach the lifting gear.

Carefully lift the level ground cutter.
Transport the level ground cutter carefully and
slowly.
Switch the level ground cutter off slowly.

Chapter07_en_Transport.fm 1.3.12 Version 1.0

24/30 TPP 450
 Technical data 8
8 Technical data

For the TPP 450 level ground cutter from TEREX , there is a selection of hydraulic motors that fit the relevant
carrier attachment. (If different picks are required, contact your responsible TEREX dealer).

8.1 Specifications

Corresponding excavator size 8 - 14 t

Cutting width 450 mm
Cutting depth 0 - 145 mm
Cutting distance from the curb 50 mm
Upper boom angle 66
Min. hydraulic input power 40 kW
Oil capacity 100 - 125 l/min
Recommended operating pressure 180 - 210 bar
Cutting drum speed 110 - 175 rpm
Recommended quantity of oil/drum speed 110 l/min = 140 rpm
Number of picks 58
Operating weight (without connected pick box) 600 kg

8.2 Picks

1 2

Fig. 18 Types of pick

1 Asphalt picks
2 Concrete and rock picks

Cutting material Type Art. no.:

Asphalt BSH 188 5.429.020.046
Concrete and rock BSH 200 5.429.020.049

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8 Technical data

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9 Troubleshooting
Malfunction Action
Cutting performance
deteriorates
Cutting performance
deteriorates
Cutting drums stop
turning
Cutting drums do not turn
Hydraulic oil is leaking
from the area of the
hydraulic motor
Damage/wear on the pick
boxes
TPP 450
Troubleshooting 9
To be performed
by
Check all picks and pick boxes for completeness, damage, Operating
and wear. personnel
Check the hydraulic motor (see "Maintenance" chapter:
Checking the condition of the hydraulic motor).
Ensure that the excavator's hydraulic circuit is working Customer service
correctly (pressure and quantity). personnel
Check the correct connection of quick couplings. Operating
personnel
Check if anything is trapped around the cutting drums and
is blocking them.
With the excavator switched off, disconnect the hydraulic
hoses, and see if the cutting drums will turn by hand.
Ensure that the excavator's hydraulic circuit is working Customer service
correctly (pressure and quantity). personnel
If the cutting drums will not turn, remove the hydraulic
motor (see Service Manual, Removing the hydraulic
motor). If the cutting drums now turn, then the hydraulic
motor is damaged and should be replaced.
If the cutting drums still do not turn, once the hydraulic
motor has been removed, remove the cutting drums (see
Service Manual, Removing the cutting drums) to see if
anything is trapped inside the drums.
Check if the hose fittings are tight. Operating
personnel
Check if the screws and seals on the hydraulic motor are
securely fastened.
Wear on the pick box increases if worn picks are not Operating
replaced. You should therefore check the picks regularly. personnel
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9 Troubleshooting

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 Index 10

10 Index

A R
Adaptor bracket 9 Re-activation 7
Asphalt cutting 15 Recommended picks 16
Removing picks 19
C Removing the drums 21
Care 17 Replacing the drums 21
Carrying out the cutting work 14 Return line 11
Caution 3
Cavitation 11 S
Customer service personnel 3 Safety signs 6
Cutting on the wall 9 Safety symbol 5
Cutting tools 16 Separate axles 21
Specifications 25
D Starting the cutting work 13
Danger levels 5 Symbols and hazard symbols 5
Deactivation 7
Delivery 23 T
Target groups 3
E Technical data 25
Environmental protection 16 Transport by crane 24
Transporting 23, 24
G Troubleshooting 27
grease nipples 19 Tubular drums 21

H V
Hydraulic connections 11 Vibration 7
Hydraulic hoses 11
Hydraulic oil 11 W
Wall cutting 15
I Work zone regulations 7
Improper use 4
Initial start-up 12
Installation 9
Installing picks 20
Installing the drums 21

L
Leaving the cutting drum running 11
Lubrication 19

M
Maintenance 17
Maintenance intervals 18
Maintenance personnel 3
Maintenance schedule 18

N
Noise protection 7

O
Operating staff 3

P
Packing 23
Personal safety gear 6
Pressure line 11
Proper use 4

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10 Index

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