Document 6081546 is the factory shop manual Terex Atlas wrote for its 1504 LC and 1604 LC hydraulic excavators, reproduced here as the complete 456 page Terex Atlas 1504 LC, 1604 LC shop manual PDF. Hydraulic schematics trace the pilot circuit and variable displacement pump, while separate adjusting instruction tables for each machine take up roughly a third of the book. Circuit and location diagrams map the electrical system, and exploded views of the slewing gear pair with bolt pre-loadings and tightening torques. Set the pilot pump to 25 to 27 bar, and pre-tension the slewing ring bolts to 50 Nm when you run the swing angle method. An excavator parked over a bad adjustment burns crew hours by the day. Bookmarks and a full text layer put the right table in front of you fast, so the machine is digging again instead of waiting.
What's Inside This Terex Atlas 1504 LC, 1604 LC Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Data | 9-12 | Service Weight, Shovel Capacity, Engine Power, Hydraulic System, Slewing Speed, Dimensions |
| General Information on Hydraulics | 13-16 | Energy Conversion, Hydraulic Installations, Hydrostatics, Hydrodynamics, Hydraulic Components |
| Cab Serial 935 | 17-34 | Display and Controls |
| Hydraulics | 35-102 | Variable Displacement Pump, Slewing Motor |
| Adjusting Instructions and Tables for 1504 Lc | 103-178 | Engine Speeds for the 1504 LC with Minimum Idle and Maximum Checked at 1400 RPM, The Adjustment Chart and Its Tolerances, Hydraulic Pressure Settings Across the 25 to 460 Bar Range, And the Safety Notes for Handling Hydraulic Fluid |
| Adjusting Instructions and Tables for 1604 Lc | 179-254 | Engine Speeds for the 1604 LC with Minimum Idle and Maximum Checked at 1400 RPM, The Adjustment Chart and Its Tolerances, Hydraulic Pressure Settings Across the 25 to 460 Bar Range, And the Safety Notes for Handling Hydraulic Fluid |
| Electric | 255-302 | Circuit and Location Diagrams |
| Engine | 303-306 | Valve Setting, Adjusting Instruction, Valve Free-Play Scheme |
| Ball Rotation Connection | 307-312 | Transport, Storage, Installation, Lubrication, Maintenance, Swing Angle Method |
| Slewing Gear | 313-340 | Exploded View, Bolt Pre-Loadings, Tightening Torques, Maintenance, Brake Discs, Brake Assembly |
| Gear Box | 341-380 | Name Plate, Installation, Lubrication, Maintenance, Disassembling, Reassembly |
| Cylinder | 381-390 | General View, Assembly, Spherical Bearing, Piston Rod, Cylinder Nut, Piston |
| Air Condition System | 391-422 | Components, Troubleshooting |
| Maintenance | 423-440 | Safety Instructions for Maintenance |
| Miscellaneous | 441-456 | Repair Instruction for Welded Assemblies |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Primary valve - Pump | 50-60 bar | p. 109 |
| Fuel admission pressure | 5 bar to 5.5 bar | p. 118 |
| Pre-tension moment for swing angle method | 50 Nm | p. 312 |
| Lubrication interval for conveying system | 100 operating hours | p. 311 |
| Lubrication interval for roller bearings | 50 operating hours | p. 311 |
| Safety screws (M 8) | 22 Nm | p. 389 |
| Max. hydraulic pressure | 340 bar | p. 10 |
| Inlet valve free-play | 0.3 mm | p. 304 |
| 1504 LC | ||
| Service weight | 17.7 t | p. 10 |
| Engine power | 88 kW | p. 10 |
| 1604 LC | ||
| Service weight | 22 t | p. 10 |
| Engine power | 121 kW | p. 10 |
Terex Atlas 1504 LC, 1604 LC Common Problems This Manual Covers
Terex Atlas 1604 LC swing bearing play and grinding noise when slewing under load
Grease the roller bearings every 50 operating hours and the conveying system every 100 hours per the intervals on page 311. Check ring bolt pre-tension using the swing angle method on page 312 with a 50 Nm pre-tension moment. Replace the slewing ring if play or noise persists after lubrication.
Manual Section: Ball Rotation Connection p. 311Hydraulic pump whines, all functions slow, boom and travel weak at full throttle
Connect a gauge at the measuring unions and test against the adjusting tables starting on page 103 for the 1504 LC or page 179 for the 1604 LC. Verify the primary valve pump setting holds 50-60 bar; maximum system pressure is 340 bar. Bleed the system after any pump work, then retest before condemning the pump.
Manual Section: Hydraulics p. 35Boom drops under load overnight, bucket cylinder weeps oil past the rod seal
Remove the cylinder and disassemble it following the sequence starting on page 381. Replace the piston and rod seals and inspect the rod for scoring. On reassembly, torque the piston to 1000 Nm and the M8 safety screws to 22 Nm per page 389, then torque 100 mm and 105 mm cylinder nuts to 60 Nm from page 390.
Manual Section: Cylinder p. 381Upper structure creeps on slopes, swing brake drags, chatters, or fails to hold
Inspect the brake discs following the slewing gear maintenance procedures starting on page 313. Renew worn discs or the complete brake assembly, torquing the brake assembly bolts to 49 Nm as specified on page 325. Check the transmission stages while the unit is open and pull remaining fastener values from the torque table on page 316.
Manual Section: Slewing Gear p. 325Diesel runs rough at idle, lacks power, valve train clatters when hot
Set valve free-play with the engine cold using the adjusting instruction and free-play scheme on page 304. Gap inlet valves to 0.3 mm and outlet valves to 0.5 mm. Rotate the crank to each cylinder's compression stroke before adjusting, then run the engine and listen for remaining clatter before chasing fuel delivery problems.
Manual Section: Engine p. 304Frequently Asked Questions
What are the torque specifications for the slewing gear socket head screws?
The socket head screws for the slewing gear must be tightened to a torque of 49 Nm. p. 325
What is the required tightening torque for the gearbox installation screws?
When installing the gearbox to the machine or the sprocket, the M20 screws must be tightened to a torque of 41.5 daNm. p. 347
What is the procedure for bleeding the hydraulic fluid tank?
To bleed the hydraulic fluid tank, connect a pressure gauge to the compressed air union, pressurize the tank (do not exceed 0.5 bar), open the valve, and slacken the bleed screw until the fluid is free of air bubbles. p. 114
What are the valve free-play settings for the BFM 2012 engine?
For the BFM 2012 engine, the inlet valve free-play is 0.3 mm and the outlet valve free-play is 0.5 mm. After initial assembly or cylinder-head gasket replacement, these values are 0.4 mm and 0.6 mm respectively. p. 304
What is the maintenance interval for the hydraulic fluid filter element?
The hydraulic fluid filter element should be renewed for the first time after 50 hours of operation, and then every 500 hours of operation. p. 428
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