Terex PT100 Operation And Maintenance Manual

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Service & repair manual (93 pages)

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Page 1 8/17/2016 Language: English Geographic Region: Serial Number Range: SN TTD03910-Current PT100 Operation and Maintenance Manual This manual is complements of TrackLoaderParts.com The world's best source for Terex parts. Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 (800)616-8156...
Page 2 CONTENTS Introduction ..........2 Safety ............5 Technical Data..........31 Machine Description / Controls..... 37 Operation ............. 45 Transportation ..........55 Maintenance ..........61 Service Log ..........82...
Page 3: Introduction
PIN when making inquiries in regards to parts, service, or warranty. 1.2 Introduction Thank you for purchasing a Terex Rubber Track Loader. We are confident that the machine you have chosen will provide excellent performance and efficient operation. The information contained in this manual is intended to provide the operator with all necessary information for the proper use of the machine.
Page 4 1.6 Warranty Your Terex PT-100 is warranted under the Terex Rubber Track Loader and Utility Vehicle Standard Limited New Product Warranty (“Warranty”). A copy of the Warranty certificate is included with this manual and is also available from your...
Page 6 2 SAFETY 2.1 Safety Alert Symbol ........ 7 2.2 Pictograms..........8 2.3 Safety Symbols ........11 2.4 Safety Signs ........... 14 2.5 General Notes ........16 2.6 Personal Protection Equipment....17 2.7 Danger Zone .......... 17 2.8 Operation ..........18 2.9 Stability..........
Page 8: Safety Alert Symbol
2 SAFETY 2.1 Safety Alert Symbol This symbol means: Attention! Be alert! Your safety is involved! The safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Page 9: Pictograms
2 SAFETY 2.2 Pictograms Symbol Description Engine Start Engine Stop Engine Pre-heat Battery Engine Speed: Fast Transmission Range: High Wiper Speed: High Engine Speed: Slow Transmission Range: Low Wiper Speed: Low Unlock Lock Windshield Washer Windshield Wiper...
Page 10 2 SAFETY Symbol Description Beacon Light Tie Down Auxiliary Hydraulics Auxiliary Hydraulics (high flow) Power Quick Attach (unlock) Power Quick Attach (lock) Air Conditioning Oil Pressure Engine Oil Temperature Hydraulic Oil Temperature...
Page 11 2 SAFETY Symbol Description Work Lights Parking Brake Bucket Positioning...
Page 12: Safety Symbols
2 SAFETY 2.3 Safety Symbols Hazard Avoidance Description Hazard: Injection Avoidance: Use a piece of card- board or paper to search for leaks. Do not use your hand. Fluid injectied into the skin must be surgically removedwithin a few hours by a doctor familiar with this type of injury or gangrene will result.
Page 13 2 SAFETY Hazard Avoidance Description Hazard: Falling Avoidance: Use three points of contact when entering or exiting the machine. Hazard: Falling (no riders) Avoidance: Do not allow riders in or on the machine at any time. Hazard: Burn Avoidance: Allow surfaces to cool before servicing.
Page 14 2 SAFETY Hazard Avoidance Description Hazard: Falling (from bucket or attachment) Avoidance: Keep away. Do not use the bucket or attachment as a work platform. Hazard: Run Over / Crush Avoidance: Keep away from the machine while it is in operation. Hazard: Loader Crush Avoidance: Keep out from under unsupported lift arms.
Page 15: Safety Signs
2 SAFETY 2.4 Safety Signs The safety signs are located in/on the machine as indicated. (Descriptions of the symbols are provided in section 2.3) 2030-565 2030-553 2030-427 2030-418 2030-425 2030-415 2030-417 2030-416 Falling hazard Skin (oil) injection hazard Crushing hazard (lift arms) Fire hazard (read manual) (inside cab) Pressurized fluid/gas hazard (engine area) Run over hazard...
Page 16 2 SAFETY Note: If any of the safety signs shown in this section are missing or damaged, contact your dealer to obtain a replacement. 2030-553 2030-417 2030-551 2030-415 2030-426 2030-416 2030-420 Key (continued) 10. Skin (oil) injection hazard 11. Crushing Hazard (Lift arms) 12.
Page 17 2 SAFETY 2.5 General Safety Notes • Read and understand all safety signs and operator’s manuals prior to opera- tion. • Never jump off of the machine. Instead use the hand holds and step designed for entering and exiting the machine. Face the machine and use three points of contact to ensure your safety.
Page 18: Personal Protection Equipment
2 SAFETY 2.6 Personal Protection Equipment The machine is designed to accommodate and protect an operator during opera- tion from foreseeable injury when used as intended and when equipped prop- erly for the task(s) being performed. Operators should not wear rings, scarves, open jackets, and should ensure that all clothing is tightly secured.
Page 19: Operation
2 SAFETY 2.8 Operation Earth moving machines are only to be operated and serviced by individuals who • are physically and mentally able to operate and / or service the machine in a safe manner. • have been instructed in the proper operation or maintenance of the machine and have demonstrated competence in these areas.
Page 20: Stability
2 SAFETY 2.9 Stability The machine must always be operated with caution in order to maximize machine stability and guard against the possibility of a rollover. • Travel only at speeds appropriate for the local conditions. • Do not exceed the operating capacity of the machine. •...
Page 21: Fire Prevention
2 SAFETY 2.11 Fire Prevention Rubber track loaders have components that operate at high temperatures. It is important to observe all inspection, operation and maintenance guidelines to min- imize the possibility of fire. • Turn the engine off when refueling. •...
Page 22 2 SAFETY 2.12 Crush and Burn Avoidance • Do not work under the lift arms unless they are resting safely on the ground or supported by the lift arm brace. • Do not use any restraining devices such as cables or chains that are damaged or do not have sufficient carrying capacity.
Page 23: Placing Into Operation
2 SAFETY 2.13 Placing into Operation • Every time before placing the machine into operation, perform a thorough walk-around inspection of the machine. • Check the machine for loose pins, cracks, tears, wear, leaks and deliberate damage. • Never place a damaged machine into operation. •...
Page 24: Jobsite Safety
2 SAFETY 2.15 Jobsite Safety • Before beginning work, become acquainted with any special features or requirements of the work site. These may include, for example, obstructions in the work area, the carrying capacity of the ground and requirements to close the work site off from public traffic.
Page 25: Parking The Machine
2 SAFETY 2.16 Parking the Machine • If possible, turn the machine off only on an even and solid surface. • Lower the lift arms to the frame stop and rest the bucket on the ground. • Turn off the engine as described in the operating instructions. •...
Page 26: Transporting
2 SAFETY 2.18 Transporting the Machine • Use only suitable transport and lifting equipment with sufficient carrying capacity. • Load the machine on firm and level ground. • Before driving onto the ramps, clean them and the machine tracks of any materials that may cause slippage (snow, ice, sludge, etc.).
Page 27: Maintenance
Do not work on or under any machine that is supported only by a hydraulic jack or hoist. Always use mechanical supports to ensure that the machine will not fall. Terex jack stands work well to support the machine while per forming maintenance or repair work.
Page 28 Do not use flammable liquids to clean the machine. • Perform tasks on the machine that involve welding or grinding only if approved by Terex. Clean the machine and the work area of dust and any combustible materials before welding or grinding to avoid fire or explosion. •...
Page 29: Battery
2 SAFETY • Do not attempt to lift heavy parts. Use work aids with sufficient carrying capacity designed for that purpose. Fasten and secure individual parts and large assemblies carefully on lifting equipment to minimize the possibility of objects falling. Use only suitable lifting equipment with no technical defects. Do not work under suspended loads.
Page 30 2 SAFETY 2.21 Hydraulic Hoses/Lines • Repairs to hydraulic hoses and hydraulic hose lines are forbidden! These repairs must be performed by trained personnel. • All hoses, hose lines and screw connections must be checked regularly, at least once a year, for leaks and externally visible damage! Replace any damaged parts immediately! Oil spraying out can cause injuries and burns.
Page 32: Technical Data
3 TECHNICAL DATA 3.1 General Structure ........33 3.2 Views ............. 34 3.3 Engine............ 34 3.4 Electrical System........34 3.5 Undercarriage ........34 3.6 Transmission .......... 35 3.7 Auxiliary Hydraulics ........ 35 3.8 Ground Pressure ........35 3.9 Operating Specifications......35 3.10 Service / Refill Capacities.....
Page 34 3 TECHNICAL DATA 3.1 General Structure Bucket Lift Arm Operator Enclosure (R.O.P.S./F.O.P.S. approved) Hydraulic Oil (fill location) Diesel Fuel (fill location) Hood (engine cover) Engine Drive Motor and Sprocket Undercarriage 10. Quick Attach 11. Product PIN Plate (beside operator seat, inside enclosure)
Page 35 3 TECHNICAL DATA 3.2 Views 125 in. 3175 mm 80 in. 2023 mm 14 in. / 356 mm 72.5 in. 1842 mm 18 in. 117.5 in. 457mm 2985 mm 69 in. 148 in. 1753mm 3760 mm 3.3 Engine Make Perkins 1104C-44T Type Design...
Page 36 3 TECHNICAL DATA 3.6 Transmission Rexroth Make Type A22VG Variable displacement / axial piston pump Design Discplacement 45 cc/revolution 37,920 kPa Relief Pressure 3.7 Auxiliary Hydraulics Make Rexroth Type A10V060 Design Axial-Piston Displacement 63 cc/revolution Relief pressure 22,750 kPa Flow 144 lpm @ 2,300 RPM 3.8 Ground pressure 26.7 kPa...
Page 37 3 TECHNICAL DATA 3.11 Fluid Specifications Specifications Specification/standard Designation Fuel Diesel Fuel EN590 or ASTM D975 1-D / 2-D Engine Oil Engine Oil SAE 10W-30 (API CH-4) Engine Coolant Coolant Antifreeze/Water w/SCA additive Hydraulic Oil Hydraulic Oil Chevron-Rykon MV or equivalent Lubricating Points MP Grease Multi-purpose lithium grease...
Page 38: Machine Description / Controls
4 MACHINE DESCRIPTION / CONTROLS 4.1 Display Elements........39 4.2 Controls..........40 4.3 Throttle........... 41 4.4 Two Speed ..........41 4.5 Bucket Positioning........41 4.6 Auxiliary Hydraulics ........ 42 4.7 Electric Attachment Control ....43...
Page 40 4 MACHINE DESCRIPTION / CONTROLS 4.1 Display Elements Learn the location and function of these items prior to operation. Switch Panels 1 - Work lights 2 - Heater fan (optional) 3 - Front wiper (optional) 4 - Beacon light (optional) 9 - Low Flow Auxiliary hydraulics 10 - Bucket positioning (optional) 11 - Power Q/A (optional)
Page 41 4 MACHINE DESCRIPTION / CONTROLS 4.2 Controls The PT-100 has two hydraulic pilot joystick controls. The joysticks are used to control machine speed and direction as well as lift arm and bucket functions. 4.2.1 Lift Arm Control The lift arm joystick is used to control the lift arms, bucket, and to engage the float function.
Page 42 4 MACHINE DESCRIPTION / CONTROLS 4.3 Throttle The throttle (hand lever) is located to the right of the operator’s right leg when seated in the machine. The throttle controls engine rpm. • Move the lever forward to increase engine RPM. •...
Page 43 4 MACHINE DESCRIPTION / CONTROLS 4.6-1 4.6-2 4.6 Auxiliary Hydraulics The PT-100 models come equipped with an auxiliary hydraulic system designed to power approved hydraulic attachments. To operate, connect the attachment to the quick couplers (fig. 4.6-1). To release resid- ual pressure in the system, press the button 4.6-3 labeled 1 (fig.
Page 44 4 MACHINE DESCRIPTION / CONTROLS 4.7-1 4.7-2 4.7 Electric Attachment Control Attachments for the PT-100 are controlled by pressing various buttons on the machines joysticks. Most attachments are controlled hydraulically, but some require both hydraulic and electrical inputs. The 4 buttons on the left joystick (4.7-1) send electrical current to the receptacle on the lift arms (4.7-2).
Page 46: Operation
5 OPERATION 5.1 General Information........ 47 5.2 Pre-Operation Safety Checklist....47 5.3 Starting Procedure ......... 48 5.4 Surface Preservation ......49 5.5 Filling the Bucket ........49 5.6 Grading ..........50 5.7 Leveling ..........50 5.8 Loading ..........51 5.9 Fastening Attachments ......51 5.10 Unfastening Attachments......
Page 48 5 OPERATION 5.1 General Information Operating a Terex Rubber Track Loader is intended to be as safe and simple as possible. This section expands on the machine controls portion of the manual and also covers safe operation procedures to follow while operating.
Page 49 5 OPERATION 5.3-1 5.3-2 5.3 Starting Procedure Before starting the engine, perform the pre-operation safety checklist. Once com- plete, you may proceed by following this procedure: Enter machine with lift arms all the way down. Maintain three points of contact with the machine (fig. 5.3-1). Sit down into the operator’s seat, fasten seat belt, then lower lap bar into position.
Page 50 5 OPERATION 5.4 Surface Preservation Terex rubber track loaders are 5.4-1 designed to produce minimal ground disturbance while operat- ing on finished surfaces like turf, however, care should be taken while operating on these surfaces to prevent blemishes from occur- ring.
Page 51 5 OPERATION 5.6 Grading Steps: (see illustration) Lower the lift arms until they rest on the frame. Tilt the bucket slowly forward until the cutting edge engages the ground. Drive the machine forward making slight bucket angle adjustments to vary cut depth as necessary.
Page 52 5 OPERATION 5.8 Loading Steps: (see illustration) Engage the bucket positioning function (if equipped), then raise the lift arms upward until the bottom of the bucket clears the side of the truck bed or trailer. Once clear, drive the machine forward until the pivot point of the bucket clears the bed side.
Page 53 5 OPERATION 5.10 Unfastening Attachments (optional) (see section 5.11) Lower the lift arms so that the attachment is just barely off of the ground. Pull the locking levers on the quick attach mechanism upwards and toward the outside of the machine to unlock the attachment. 5.10-1 Lay the attachment gently onto the ground by moving the lift arm control joystick slowly...
Page 54 5 OPERATION 5.12 Operation on Inclines By design, Rubber Track Loaders are very stable on inclines. Machine weight is distributed evenly throughout the chassis and the suspended undercarriage track system provides excellent traction and floatation on nearly all surfaces. Even with these capabilities, caution should always be exercised while operating the machine on an incline.
Page 55 5 OPERATION 5.14 Lift Arm Brace When the lift arms must be left in the raised position, the lift arm brace must be engaged. To install: Lower the lift arms, remove any attachments and park the 5.14-1 machine on firm and level ground.
Page 56: Transportation
6 TRANSPORTATION 6.1 Transporting ........... 57 6.2 Towing / Retrieving......... 57 6.3 Loading / Unloading Procedure ..... 58 6.4 Lifting Procedure........59...
Page 58 6 TRANSPORTATION 6.1 Transporting At times, you will most likely need to transport the machine to distant locations with a transport vehicle. To do this safely, there are some precautions that must be observed. When transporting: Always make sure the transport vehicle (trailer or truck) being used to haul the machine is capable of bearing the weight and size of the machine over the distance and terrain that will be covered.
Page 59 6 TRANSPORTATION 6.3 Transport Loading / Unloading procedure Load the machine only on firm and level ground. Before driving onto the ramps, clean them and the machine tracks of any materials that may cause slippage (snow, ice, sludge, etc.). Properly align the machine with the loading ramp. Have a guide give the machine operator any necessary signs to maximize safety during loading.
Page 60 Once in place, jack/lift the machine upward making sure it remains stable until it has reached sufficient height to install a Terex approved jack stand beneath the machine. (fig. 6.4-1) Slide the jack stand into place making sure it is centered under the machine...
Page 62: Maintenance
7 MAINTENANCE 7.1 General ..........63 7.2 Care and Cleaning........63 7.3 Maintenance Intervals ......64 7.4 Lubrication Points........65 7.5 Engine Oil Check ........66 7.6 Engine Oil Change........67 7.7 Hydraulic Oil Change ......68 7.8 Hydraulic Filter Change ......69 7.9 Accessory Belt........
Page 64 7 MAINTENANCE 7.1 General The operating condition and life expectancy of a machine is largely influenced by care and maintenance. For this reason, it is in every machine owner’s interest to perform the specified maintenance work and comply with the service intervals. This chapter describes periodic maintenance, inspection and lubricating tasks.
Page 65 7 MAINTENANCE 7.3 Maintenance Intervals 7.3-1 Daily Maintenance Tasks Daily Page Check hydraulic oil level (figure 7.7-3, p-68) Check engine oil level Check fuel level (gauge on instrument panel) Check fan belt tension / condition Check track tension / condition Check for proper control operation Check for proper switch and lighting operation Check / clean air cleaner elements...
Page 66 7 MAINTENANCE 7.4 Lubrication Points The illustration below shows the location of grease points found on the left side of the machine. Identical points also exist on the opposite side of the machine. Lubricate all points daily, prior to operation.
Page 67 7 MAINTENANCE 7.5 Engine Oil Check Park the machine on level ground, lower the lift arms, stop the engine and remove the key. Open the hood to gain access to the engine compartment. Locate and remove the engine oil dipstick (1) from its tube. (fig. 7.5-1) 7.5-1 Wipe the dipstick with a clean shop cloth and reinsert it into the tube...
Page 68 7.6-2 7.6 Engine Oil Change Regular oil changes are necessary to maintain a strong running engine. Terex rec- ommends a normal oil change interval of 250 hours or every six months. Allow the machine to cool prior to service. Wear safety glasses, safety gloves and any other items necessary to ensure your safety while performing maintenance or service.
Page 69 7 MAINTENANCE 7.7 Hydraulic Oil Change 7.7-1 7.7-2 The hydraulic oil should be changed 7.7-3 every 500 service hours. Before begin- ning the procedure, make sure the machine is in a clean working environ- ment. Take any necessary measures to prevent dirt or debris from entering the hydraulic system.
Page 70 7 MAINTENANCE 7.8 Hydraulic Filter Change The hydraulic filters should be changed every 250 hours. Hydrostatic components require extremely clean oil in order to have a long service life. Use caution when changing the hydraulic filters. Before beginning the procedure, make sure the machine is in a clean working environment.
Page 71 7 MAINTENANCE 7.10 Water Separator The water separator (fig. 7.10-1), located on the left side of the engine) removes water from the fuel supply as the engine runs. Drain the water separator daily to maintain proper function. 7.10-1 To drain the water separator: With the engine off and cool, and key removed from the ignition, open the hood at the rear of the machine to access the water separator.
Page 72 The undercarriage assemblies typically operate in harsh working conditions. They work in mud, gravel, debris and various other abrasive materials during operation. Terex recommends a daily inspection of the undercarriage assemblies and clean- ing if necessary. Materials that are particularly sticky or abrasive like clay, mud, or gravel should be cleaned from the undercarriages often to minimize component wear.
Page 73 7 MAINTENANCE 7.13-2 7.13-1 7.14 Track Tension Adjust The front of the drive table is secured by two bolts (1). Note: If the bolts (1) are at the rear of their mounting slots they can be used to tighten the track in their current positions. If they 7.14-1 are at the front of their slots, they need to be relocated.
Page 74 Visually inspect rollers every 50 hours and replace any that show signs of crack- ing or wear-through. Drive sprocket removal and roller / pin replacement should be performed by your local Terex dealer.
Page 75 7 MAINTENANCE 7.16 Air Cleaner Removal / Inspection The air cleaner is one of the most important maintenance items on the machine. Regular inspection and replacement is necessary to ensure proper performance and to prolong engine life. Inspect the air cleaner elements daily. If damaged or heavily soiled, clean or replace the elements.
Page 76 7 MAINTENANCE 7.17 Air Cleaner Cleaning procedure Remove loose dirt from the element with compressed air or water hose. • Compressed air: 690 kPa max. .32cm diameter nozzle at least 5cm away from the filter element. • Water: 276 kPa max. without nozzle. Soak the filter element in a non sudsing detergent solution for at least 15 minutes moving it gently through the solution to further clean the element.
Page 77 7 MAINTENANCE 7.18 Radiator / Oil Cooler Cleaning Procedure The radiator and oil cooler must be clean to ensure proper operation. Engine and hydraulic system over- heating, damage and even failure can result if the radiator/oil cooler is 7.18-1 not kept clean. A pressure washer or compressed air nozzle work well to blow debris clear of the fins in the oil cooler and radiator.
Page 78 7 MAINTENANCE 7.20 Chassis Cleaning Procedure Periodic cleaning of the chassis area beneath the cab and engine com- partment is also necessary to main- tain safe operation. Clean as neces- sary. (fig. 7.20-1) 7.20-1 To clean the chassis/engine: With the engine off and cool and the key removed from the ignition, remove the belly pans on the underside of the machine.
Page 79 7 MAINTENANCE 7.21 Electrical System ELECTRICAL PANEL PT100 AUX LDR 1 AUX LDR 2 AUX LDR 3 AUX LDR 4 40 A. 40 A. 40 A. 40 A. RELAY RELAY RELAY RELAY #87417B #87417B #87417B #87417B MAIN PWR A L. AUX HYD R.
Page 80 7 MAINTENANCE 7.22 Storage It may be necessary to store your Terex Rubber Track Loader for an extended period of time. Perform the following tasks to prepare the machine for storage. 7.22.1 Storage Preparation • Thoroughly clean the machine (inside and out) including the engine compart- ment and underbody.
Page 81 7 MAINTENANCE 7.22.2 Removal From Storage Perform the following tasks to remove the Terex Rubber Track Loader from stor- age and return to operating condition. Return to Operating Condition: • Remove protective lubricant from cylinder rods. • Lubricate all chassis, loader and undercarriage points.
Page 82 7 MAINTENANCE 7.23-1 7.23-2 7.23 Cab Tilt Procedure The ROPS/FOPS approved cab (1) tilts up to allow easy access to components while performing maintenance or service. It is equipped with a gas spring assist and a brace mechanism to hold it in place while tilted. To tilt the cab: Remove any attachments that may be fastened to the machine.
Page 83: Service Log
SERVICE LOG Hours Service Performed Notes...
Page 84 SERVICE LOG Hours Service Performed Notes...
Page 85 SERVICE LOG Hours Service Performed Notes...
Page 86 SERVICE LOG Hours Service Performed Notes...
Page 87 Purchasing spare parts Terex I Ersatzteile GmbH Postfach 12 64 • D-91534 Rothenburg Erlbacher Str. 115 • D-91541 Rothenburg Phone + 49 (0) 9861/972-0 Fax + 49 (0) 9861/972-410 Customer Service Terex Construction Motherwell Scotland ML1 5RY Phone +44 (0) 16 98 50 30 77...

Terex PT100 Operation And Maintenance Manual

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