Terberg Rosroca TGV-2 Operating and installation instructions

M A N U A L B I N L I T S Y S T E M
37701
TGV-2
Baronieweg 23, 3403 NL Jsselstein
The Netherlands
Telephone: [phone]
Telefax: ([phone]
Homepage: www.terbergmachines.nl
E-mail: [e-mail]
Translation of the original instruction
ssue date 01-2017
The original Dutch version (article code 37700) can be obtained
from Terberg. Please send a mail to: [e-mail]

2EN
EN
Contents
37701
01-2017
ãTerberg Machines B.V., IJsselstein, The Netherlands
All rights reserved. No part of this book may be reproduced, stored in database or retrieval system, or published, in any form or in any
way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher.
Pa e Pa e
FOREWORD
•General 3
•Guarantee 3
•Operator requirements 3
•Description of sections 3
•Symbols used 3
1. NTRODUCT ON
1.1 Description of the bin lift system 4
1.2 Technical specifications 5
Bin and bin lift information 5
2. SAFETY
2.1 General safety instructions 6
2.2 Safety instructions
During use of the bin lift system 7
During maintenance and repair 7
2.3 Warning signs 8
3. B N L FT OPERAT ON
3.1 mportant components 10
3.2 Warnings and tips 11
3.3 Daily checks 11
3.4 Loading using D N pick-up arms 12
3.5 Loading using Pocket pick-up arms 13
3.6 Travel height and footboards 14
4. MA NTENANCE AND CLEAN NG
4.1 General and daily maintenance 16
4.2 Weekly maintenance 16
4.3 Six-weekly maintenance 17
4.4 Annual maintenance 17
4.5 Maintenance schedule 19
4.6 Troubleshooting 18
5. D MENS ONS
5.1 Bin lift dimensions and required
dimensions of the compaction body
(also for an TGV2 with comb sled) 20
6. NSTALLAT ON
6.1 Tools, support, lifting, mounting
and connections 21
7. HYDRAUL CS
7.1 Hydraulic connections and
components 22
8. DECOMM SS ON NG (disposing) 24
PARTS BOOK 101

EN 3
EN
37701
01-2017
Foreword
ãTerberg Machines B.V., IJsselstein, The Netherlands
All rights reserved. No part of this book may be reproduced, stored in database or retrieval system, or published, in any form or in any
way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher.
Foreword
This user manual provides information about the
operation and maintenance of the TGV-2 bin lift sys-
tem.
In order to work safely and efficiently with this man-
ual bin lift system, it is essential that you read this
manual carefully before putting the bin lift into use.
Make the user manual available to everyone con-
cerned with the operation and/or the maintenance
of the bin lift.
Where necessary, refer to the user manual of the
refuse collection vehicle and the refuse handling
body.
When all the operating and maintenance instructions
have been met the bin lift can be safely used.
Should you nonetheless have any further questions,
please get in touch with your distributor.
Guarantee
or more information about the conditions of guar-
antee, please contact your distributor.
Operator requirements
- The bin lift system may only be operated by per-
sons who are familiar with the operation of the bin
lift.
- Repairs may only be carried out by qualified per-
sonnel.
The user manual has the following sections:
ntroduction
A description of the function, conditions of use and
the operating principle of the machine.
Safety
Description of the safety provisions and the mea-
sures that need to be taken into account in order to
work safely with the machine. As well as an explana-
tion of the symbols on the machine.
Operation
A clear description of the most important compo-
nents and instructions for emptying different types of
bin.
Maintenance and cleaning
Covers all the periodic procedures needed for the
proper functioning of the machine.
Technical data
Hydraulic connections and components, trou-
bleshooting and parts.
Symbols used
Note:
Additional information.
Warning:
If these instructions are not followed, there
is a risk of damage to the equipment
and/or personal injury.
Stop:
If these instructions are not followed cor-
rectly, there is a risk of personal injury
and/or risk of serious damage to the equip-
ment.

02
01
09
08
04
08 03
04
05
07
06
10
11
4EN
EN
1. ntroduction
37701
01-2017
1.1 Description of the bin lift system
The TGV-2 is a manually-operated bin lift system that
can be very widely used and is particularly well suit-
ed to collecting industrial waste.
The TGV-2 is fitted with DIN pick-up arms for emp-
tying 4-wheel bins that conform to the EN 840-2 and
EN 840-3 standards.
It is also fitted with Pocket pick-up arms for emptying
4-wheel large object refuse bins with capacities of
2,5m3and 4,5m3.
The maximum lifting force of the bin lift system is
20,000 N (2000 kg).
The manual controls are on the right of the bin lift
system.
ãTerberg Machines B.V., IJsselstein, The Netherlands
All rights reserved. No part of this book may be reproduced, stored in database or retrieval system, or published, in any form or in any
way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher.
01 = Operating lifting / lowering (lift / lower lever)
02 = Catcherbar operation (catcherbar lever)
03 = Catcherbar, 2 positions
04 = Guide track
(opens lid of the 2500-4500 litre containers)
05 = Tilt frame
06 = D N pick-up arms
07 = Pocket pick-up arms
08 = Handle bars
09 = Footboards (option)
10 = Sensor lift / lower lever
(sends signal to the PTO for increasing revs)
11 = Locking for the Pocket pick-up arms

4-wheel
flat-topped containers
4-wheel
roll-topped containers
4-wheel container
with Pocket arm pick-up
Capacity (litres) 500 - 770
1000 - 1280 770 - 1100 2500 - 4500
According to standard EN 840-2 EN 840-3 EN 12574-1
Pocket lifting bin type 3
Lifting capacity 7500 N (750 kg) 20,000 N (2000 kg)
Cycle time ±16 seconds
Pick-up arms Pocket no no yes
Pick-up arms D N yes yes no
Catcherbar
not applicable yes not applicable
May be folded inwards
or outwards. olded out. olded in.
EN 5
EN
37701
01-2017
1. ntroduction
1.2 Technical specifications
ãTerberg Machines B.V., IJsselstein, The Netherlands
All rights reserved. No part of this book may be reproduced, stored in database or retrieval system, or published, in any form or in any
way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher.
Bin and bin lift information
Directives and Standards 2006/42/EG, EN 1501-1 & EN 1501-5: 2011
Weight 885 kg (not including footboards)
Sound pressure 65 dB(A)
Vibration 2,5 m/s2
Operating voltage 24 Volts DC
Current 10 Ampère / 24V DC
Oil flow 40-60 litre/minute
Operating pressure PTO Min. 180 bar / Max. 200 bar
The Pocket pick-up arms must be closed
when there are bins loaded on the DIN pick-
up arms.
The emptyin of bin types other than those
indicated above, is not permitted with this bin
lift system. If in doubt, please contact your
distributor.

•Technical faults should be reported immediately to
the person responsible for supervising the loading.
The bin lift must be taken out of operation until
the fault (if this could present a danger) is reme-
died.
•Never use the pick-up arms or any other part of
the bin lift system as a seat.
This is life-threateningly dangerous!
•The controls may under no circumstances be
altered.
•None of the installed safety features may be
removed or altered.
•If the safety features are damaged, they must be
immediately repaired or replaced by original parts.
•The movement speeds and lifting forces set by the
manufacturer may on no condition be altered.
•Operating and safety stickers should be present
and clearly legible.
•Actions that override the safety provisions are
expressly forbidden!
•It is forbidden to stand on the footboards while
the refuse collection vehicle is reversing.
•Take care that during reversing you are visible to
the driver of the refuse collection vehicle.
•The bin lift may never be used as a hoisting instru-
ment.
•No vehicle may be towed with the towing cable
attached to the bin lift system.
•The refuse collection vehicle may never be raised
on the lifting points of the bin lift system.
•The pick-up arms should be folded in while the
vehicle is in motion.
•When riding on the vehicle you must absolutely
not sit or stand on parts of the machine other
than the special footboards for this purpose, this
really is extremely dangerous!
•In extremely bad weather (storms, thunder-
storms, etc.) it is not advisable to use the bin lift
system.
6EN
EN
2. Safety
37701
01-2017
2.1 General safety instructions
ãTerberg Machines B.V., IJsselstein, The Netherlands
All rights reserved. No part of this book may be reproduced, stored in database or retrieval system, or published, in any form or in any
way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher.
Terms of conformity
This bin lift conforms to the current standards at the
time of production. It has been tested and checked,
on a rig, in normal conditions with an increase of
25% weight in static and 10% weight in dynamic
operation.
It is the end user’s responsibility to maintain the
equipment in accordance with the manufacturer’s
recommendations, also if there is a risk of damages
or injury the bin lift must be taken out of service
immediately.
General
•The bin lift system may never be operated when
the refuse collection vehicle is travelling along and
also not with reverse gear engaged.
•The bin lift system may only be operated by per-
sons who have received operator training and are
fully familiar with its operation.
•irst read the operating instructions before you
start using the bin lift.
•Read through the operating instructions for the
compaction body carefully.
•In your daily work as bin lift operative you are work-
ing in traffic, do not put it or yourself in danger.
•Before starting the collection round, discuss with
your colleagues how to act in certain situations
such as stopping, driving off, etc.
•When you are working with the bin lift, you
should not wear any loose clothing and jewellery.
•While working always wear work clothing, safety
footwear and work gloves that comply with the
standards indicated in the table below.
•Make sure that an unattended bin lift can never be
put into operation by unauthorised persons
(remove the ignition key).
•Do not use the bin lift system in spaces or installa-
tions where the presence of gasses and/or flam-
mable materials creates a danger of fire or explo-
sion.
•The bin lift system may under no circumstances
be used if the oil feed rate is higher than 60 litres
per minute.
Personal protection
equipment: According to standard:
Work clothingNEN-EN-ISO 20471:2013
Safety footwear NEN-EN-ISO 20345:2011
Work gloves NEN-EN 420:2003+A1:2009

EN 7
EN
37701
01-2017
2. Safety
2.2 Safety instructions applicable during operation, maintenance and repair
ãTerberg Machines B.V., IJsselstein, The Netherlands
All rights reserved. No part of this book may be reproduced, stored in database or retrieval system, or published, in any form or in any
way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher.
During the operation of the bin lift system
•Ensure that no-one is in the immediate vicinity of
the bin lift system during the loading cycle.
•If the bin lift system is in operation, you may under
no circumstances reach into the lifting system
(danger of injury).
•Check that there are no foreign objects in or
between the bin lift system that can hinder its
operation.
•Loose refuse may not be loaded above the edge
of the hopper.
•The compactor may not be used while objects are
protruding from the throw-in hole.
•Never use the bin lift system when the view of the
load is obstructed.
•Never use the bin lift system on a very uneven
surface.
•The bin lift system may not be driven up against a
bin or a pile of refuse.
•Take account of the heating of the hydraulic oil.
This can become 40°C warmer than the environ-
ment. As a result, the pipes and hoses can cause
light burns at high ambient temperatures.
•It is not permitted to use bin types not listed in the
manual.
•Nothing should protrude from the bin and only
bins whose lids are fully closed should be emptied.
•Do not empty any damaged bins. These can cause
problems.
•Overweight bins should be removed from the
bin lift system.
max. lifting force DIN arm pick-up:
7500 N (750 kg)
max. lifting capacity of Pocket-arm pick-up:
20,000 N (2000 kg)
•Check that the bin is located correctly on the DIN
/ Pocket pick-up arms before you empty it.
•Let go of the bin as soon as it is picked up by the
bin lift system.
•It is expressly forbidden to manually ‘help’ the lift-
ing system.
•Only remove the bin when the bin lift system has
come to rest and the bin is back on the ground.
•Place empty bins where they do not pose a dan-
ger to other road users.
•It is forbidden to empty bins that contain danger-
ous and/or radioactive substances.
•It is not permitted to empty bins that contain
burning or smouldering materials.
•Do not walk backwards towards the bin lift sys-
tem.
•A bin may only be offered to the bin lift system
when held by the handle bars.
During maintenance and repair
•Maintenance and repairs may only be carried out
by authorised technical personnel.
•Any faults detected should be corrected before
the bin lift system is used.
•or maintenance and repairs switch the bin lift sys-
tem off (switch off the engine of the refuse col-
lection vehicle and turn off the main power
switch).
•While working, accidental activation should be
prevented by removing the key from the ignition
switch (keep on your person).
•You may not go under the tilt frame for repair or
cleaning unless the tilt frame is supported.
•Before cleaning can begin, you should switch off
the drive gear of the refuse collection vehicle.
•The grease between the pivots may get washed
away if you use a high pressure hose. Think about
the safety of your eyes and use safety glasses.
•The bin lift system should only be raised by its lift-
ing points.
•When working on the hydraulic system, you
should bear in mind that this is filled with hydraulic
fluid under pressure. Always use personal protec-
tive equipment to avoid contact with skin and
eyes. Use absorbents to avoid environmental pol-
lution.
•You must comply with the maintenance interval
specified by the manufacturer.
•On disassembly, disconnect the plugs and cou-
plings from the vehicle.
•ollowing a collision involving the bin lift system
Terberg will need to assess whether it is still safe
to use or first needs to be repaired.
•Original or specified parts should always be used
for repair or maintenance.
•Do not stand under the bin lift or the bin!
Keep a minimum distance of 5 meter
between the bin lift and objects which are
located behind the bin lift system. This is to
avoid a dan erous situation in case that a bin
comes loose.

Warning signs
All safety and instruction stickers affixed must be
replaced if damaged.
The pictogram stickers have the following meanings:
Do not stand under the tilt frame!
Do not stand behind a working bin lift!
Do not reach into the bin lift, danger of
injury!
8EN
EN
2. Safety
37701
01-2017
2.2 Safety instructions (continued)
ãTerberg Machines B.V., IJsselstein, The Netherlands
All rights reserved. No part of this book may be reproduced, stored in database or retrieval system, or published, in any form or in any
way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher.
2.3 Warning signs
Repairs may only be carried out by qualified
personnel, never rectify faults yourself, this
may cause dan er for you and dama e to the
bin lift system!

EN 9
EN
37701
01-2017
ãTerberg Machines B.V., IJsselstein, The Netherlands
All rights reserved. No part of this book may be reproduced, stored in database or retrieval system, or published, in any form or in any
way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher.
TH S PAGE NTENT ONALLY LEFT BLANK

10 EN
EN
3. Bin lift operation
37701
01-2017
ãTerberg Machines B.V., IJsselstein, The Netherlands
All rights reserved. No part of this book may be reproduced, stored in database or retrieval system, or published, in any form or in any
way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher.
3.1 mportant components
02
01
09
08
04
08 03
04
05
07
06
10
11
01 = Operating lifting / lowering (lift/lower lever)
02 = Catcherbar operation (catcherbar lever)
03 = Catcherbar, 2 positions
04 = Guide track
(opens lid of the 2500-4500 litre bins)
05 = Tilt frame
06 = D N pick-up arms
07 = Pocket pick-up arms
08 = Handle bars
09 = Footboards (option)
10 = Sensor lift / lower lever
(sends signal to the PTO for increasing revs)
11 = Locking for the Pocket pick-up arms

EN 11
EN
37701
01-2017
3. Bin lift operation
3.2 Warnings and tips 3.3 Daily checks
ãTerberg Machines B.V., IJsselstein, The Netherlands
All rights reserved. No part of this book may be reproduced, stored in database or retrieval system, or published, in any form or in any
way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher.
•It is expressly prohibited to help the bin lift system
‘manually’ with lifting.
•Lifting capacity of the DIN pick-up arms:
max. 750 kg.
•Lifting capacity via the Pocket pick-up arms:
max. 2000 kg.
•Excessively heavy bins must not be lifted.
•Do not remove the bin before the bin lift has
come to a standstill.
•Always approach the bin lift forwards with out-
stretched arms, even when removing the bins.
•When you are working you are in traffic; do not
put it and yourself in danger. Place empty bins
where they do not cause any danger to other road
users.
•When you are working with the bin lift system, do
not wear loose clothing and jewellery.
•Loading is teamwork. Before starting the collec-
tion round, discuss with your colleagues how to
act in certain situations such as stopping, driving
off, etc.
•Never use the bin lift system as a seat.
This is life-
threateningly dangerous.
•When the bin lift system is in operation, you may
not reach into the lifting system, this may cause a
danger of injury.
•It is forbidden to stand on the footboards while
the refuse collection vehicle is reversing.
•Take care that during reversing you are visible to
the driver of the refuse collection vehicle.
Before you start work, you must check the bin lift
system for the following points:
•Check that no oil loss has occurred.
•Look to see if there are any foreign objects
(branches, twigs, plastic bags, etc) in the bin lift sys-
tem that could hinder its operation.
•Operation of the controls
Check the operation of all the controls by per-
forming all the possible actions with empty bins
(for information on catcherbar position / bin type
see Section 1):
- Catcherbar adjustment; fold the catcherbar
inwards and outwards.
- Lift / lower lever (the lever should also return to
the mid position by itself after use).
•Working footboards (option)
Check the operation and mounting of the foot-
boards.
Before startin to use the bin lift system, first
read the operatin instructions.

12 EN
EN
3. Bin lift operation
37701
01-2017
3.4 Loading with D N pick-up arms
ãTerberg Machines B.V., IJsselstein, The Netherlands
All rights reserved. No part of this book may be reproduced, stored in database or retrieval system, or published, in any form or in any
way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher.
4-wheel bins
with a ROUND lid;
contents 770-1100 litres
with a FLAT lid;
contents 500 to 1280 litres
1) Engage the PTO of the refuse collection
vehicle.
2) Fold down both footboards (09).
3) Fold out both D N pick-up arms (06).
4) Fold the catcherbar OUTWARDS:
If the catcherbar (03) has not yet been folded
OUTWARDS (this is the working position), put
the catcherbar lever (02) in the forward position
(see illustration below) and fold the catcherbar
OUTWARDS by pushing the lift / lower lever
(01) slightly forwards.
Caution: The first path [2a] of the lift / lower
lever brings the catcherbar outwards; the second
path [2b] (next movement) raises the bin.
(The catcherbar can, if necessary, also be folded
outwards by moving the lift / lower lever back-
wards).
5) Roll the bin between the two pick-up arms.
6) Raise the lifting heads to the right height:
Using the lift / lower lever (01) raise both pick-up
arms until level with the lifting lugs of the bin.
7) Emptying the bin:
Use the lift / lower lever (01) to raise the bin fur-
ther until it reaches the tilt position. The bin is
emptied.
8) Removing the bin:
Then use the lift / lower lever (01) to return the
bin to the ground. Make sure the lifting lugs of the
bin are released from the pick-up heads of the
DIN arms (06).
Roll the bin out of the bin lift system.
n this case, do the following:
•Raise the bin using the lift / lower lever (01) slight-
ly until the wheels are free of the ground.
•Pull the bin backwards so that the lifting lugs of the
bin are in the lower position of the lifting heads.
•Then let the bin descend.
The Pocket pick-up arms must be closed
when there are bins loaded on the DIN pick-
up arms.
Take reat care that the bin’s liftin lu s insert
firmly into both liftin heads of the DIN arms.
On an uneven road surface the liftin lu s of
the bin may et stuck in the top position of the
liftin heads.
Never pull hard on the operatin levers. This
can cause dama e and has no effect on the
operation of the bin lift system.
Ensure that your fin ers do not become
trapped when foldin in the pick-up arms.

EN 13
EN
37701
01-2017
3. Bin lift operation
3.5 Loading with Pocket pick-up arms
ãTerberg Machines B.V., IJsselstein, The Netherlands
All rights reserved. No part of this book may be reproduced, stored in database or retrieval system, or published, in any form or in any
way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher.
(The catcherbar can if necessary also be folded
inwards by moving the lift / lower lever back-
wards).
5) Roll the bin in front of the pick-up arms.
6) Raise the pick-up arms to the right height:
Using the lift / lower lever (01), raise both pick-up
arms until they can be inserted into the lifting
flanges (pockets).
7) Roll the bin over the pick-up arms.
8) Emptying the bin:
Use the lift / lower lever (01) to raise the bin fur-
ther until it reaches the tilt position. The two
guide tracks (04) above, on either side of the bin
lift system, have meanwhile opened the lid. The
bin is emptied.
9) Removing the bin:
Then use the lift / lower lever (01) to return the
bin to the ground.
Roll the bin out of the pick-up arms and out of
the bin lift.
1) Engage the PTO of the refuse collection
vehicle.
2) Fold down both footboards (09).
3) Fold out both Pocket pick-up arms.
Press the pick-up arm locking (11) downwards
and fold both Pocket pick-up arms (07) outwards.
4) Fold the catcherbar NWARDS:
If the catcherbar (03) has not yet been folded
INWARDS (stowed position), put the catcherbar
lever (02) in the rear position and fold the
catcherbar INWARDS by pushing the lift / lower
lever (01) slightly forwards.
Caution: The first path [2a] of the lift / lower
lever brings the catcherbar inwards; the second
path [2b] (next movement) raises the bin.
1:10
1:10
4-wheel bins with Pocket-arm pick-up:
contents 2,500 - 4,500 litres
11
Never pull hard on the operatin levers. This
can cause dama e and has no effect on the
operation of the bin lift system.
Ensure that your fin ers do not become
trapped when foldin in the pick-up arms.

Throwing waste in manually
Throw large heavy objects across the width of the
compacter space to prevent damage to the bin lift
system.
Obstacles or uneven surfaces
When driving over large obstacles or uneven terrain,
it is important to place the footboards in the trans-
port position and tilt the bin lift up for adequate
ground clearance.
14 EN
EN
3. Bin lift operation
37701
01-2017
ãTerberg Machines B.V., IJsselstein, The Netherlands
All rights reserved. No part of this book may be reproduced, stored in database or retrieval system, or published, in any form or in any
way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher.
3.6 Travel height and footboards
Footboards and handle bars
The bin lift system is fitted with footboards and han-
dle bars. The handle bars - two brackets on either
side - are fixed.
These are used in three situations. In each of these
situations, the footboards must be in the correct
position.
1) Transport
ootboards folded up.
2) Loading
ootboards folded down.
3) Riding
ootboards folded down.
f someone is standing on the footboard:
•Reversing is not permitted.
•The refuse collection vehicle may not be driven at
more than 30 kilometres per hour (19 mph).
•The compactor should not run in full automatic
mode.
Transport
Hand-
positions
B
A
Loading Riding
The bin lift may never be operated when the
refuse collection vehicle is travellin alon and
also not when reverse ear is en a ed.
Never stand on other parts of the bin lift and
also never use them as a seat,
this is
extremely dangerous!