Related Manuals for Terex R190T
Summary of Contents for Terex R190T
- Page 1 C o m p a c t Tr a c k L o a d e r Operation and Maintenance Manual Version: EN Edition: 2014-06 Part Number: 0404-490 (US) Valid From Serial No: 00101 Original Instructions R160T / R190T...
- Page 2 Please fill in before commissioning the machine: Model: _________________________ Vehicle Serial Number: _________________________ Year of Manufacture: _________________________ Commissioned on: _________________________ Dealer:...
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Page 3: Table Of Contents
CONTENTS The operator must read and understand all the instructions in this manual before operating the R160T / R190T. Page Introduction ..........2 Safety ............5 Technical Data..........29 Machine Description / Controls..... 35 Operation ............. 45 Transportation ..........55 Maintenance .......... -
Page 4: Introduction
PIN when making inquiries in regards to parts, service, or warranty. 1.2 Introduction Thank you for purchasing your R160T / R190T Compact Track Loader. We are confident that the machine you have chosen will provide excellent performance and efficient operation. - Page 5 This manual is copyrighted. It shall not, either in whole or in part, be reproduced, transmitted, or used for the purpose of competition without our prior written consent. R160T / R190T US O&M 0404-490 2014-06...
- Page 6 Authorized Terex Distributor. 1.9 Tier 4f Compliance Information The US R160T / R190T is equipped with an engine that is legally Tier 4 final com- pliant. However, in this configuration, no special operation or maintenance consid- erations exist specifically relating to tier 4 compliance.
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Page 7: Safety
2.14 Jobsite Safety ........21 2.15 Parking the Machine ......22 2.16 Towing / Retrieving....... 22 2.17 Transporting ......... 23 2.18 Maintenance ........24 2.19 Battery ..........26 2.20 Hydraulic Lines / Hoses......27 R160T / R190T US O&M 0404-490 2014-06... - Page 8 This Page Intentionally Left Blank R160T / R190T US O&M 0404-490 2014-06...
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Page 9: Safety Alert System
CAUTION, used with the safety alert symbol, indicates a hazardous situ- ation which, if not avoided, could result in minor or moderate injury. R160T / R190T US O&M 0404-490 2014-06... -
Page 10: Graphical Symbols
Hazard: Corrosive Avoidance: Read and understand the operator’s manual. Hazard: Entanglement Avoidance: Stop machine and remove key before servicing. Hazard: Burn/Scald Avoidance: Allow to cool before opening. R160T / R190T US O&M 0404-490 2014-06... - Page 11 Hazard: Fall Avoidance: Use the provided access system when entering or exiting the machine. Hazard: Fall Avoidance: No Riders. Hazard: Burn Avoidance: Do not touch hot surfaces. Hazard: Crush Avoidance: Fasten seat belt. R160T / R190T US O&M 0404-490 2014-06...
- Page 12 Hazard: Fall Avoidance: Do not use the bucket or attachment as a work platform. Hazard: Crush Avoidance: Stay clear of moving machine. Hazard: Crush Avoidance: Keep clear of lift arms and attachments. R160T / R190T US O&M 0404-490 2014-06...
- Page 13 Obey all safe- ty messages that follow this sym- bol to avoid possible injury or death. Avoidance: Read and understand the operator’s manual. Hazard: Fire Avoidance: Read and understand the operator’s manual. R160T / R190T US O&M 0404-490 2014-06...
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Page 14: Safety Signs (Ansi)
Skin (oil) injection hazard Fire hazard (read manual) Burn hazard Explosion / burn hazard (read operator’s manual) Tie down location Clean undercarriages notice Crush hazard (run over) 10. Crush hazard (lift arm brace) R160T / R190T US O&M 0404-490 2014-06... - Page 15 14. Crush Hazard (Lift arms) 15. Fall hazard / rollover Hazard / read operator’s manual 16. Crush / fall hazards 17. Crush (run over) hazard 18. Clean undercarriages notice 19. Tie down location 20. Burn hazard R160T / R190T US O&M 0404-490 2014-06...
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Page 16: General Notes
• Any persons in close proximity to the machine during operation should familiarize themselves with the safety precautions described in this manual prior to operation. R160T / R190T US O&M 0404-490 2014-06... -
Page 17: Personal Protection Equipment
If conditions are such that the machine operator’s view of the driving and working zone is restricted, he must be guided or the driving and working zone must be secured by means of a solid barricade. R160T / R190T US O&M 0404-490 2014-06... -
Page 18: Operation
If done, the machine will stop abruptly. To stop all machine movement in case of emergency: • Turn the ignition key to the off position (item 15, section 4.1). R160T / R190T US O&M 0404-490 2014-06... -
Page 19: Stability
Decrease work speeds, limit load size and make any other necessary adjustments to maximize your safety and that of others in the work area. 2.9 Transporting Persons • The machine must not be used to transport persons. R160T / R190T US O&M 0404-490 2014-06... -
Page 20: Fire Prevention
• Never use fuel for cleaning purposes. • Always use the correct fuel grade for the operating season. R160T / R190T US O&M 0404-490 2014-06... -
Page 21: Crush / Burn Avoidance
• Exhaust components are hot when at or near operating temperature. Allow the machine to cool thoroughly prior to touching or performing service work on exhaust components to avoid the possibility of burns. R160T / R190T US O&M 0404-490 2014-06... -
Page 22: Placing Into Operation
• Move the machine carefully to open ground and then check the functionality of the lift arm and drive controls as well as the signal and lighting equipment. R160T / R190T US O&M 0404-490 2014-06... -
Page 23: Jobsite Safety
Stay seated with the seat belt fastened while working. • Report any operating faults immediately. Make sure any necessary repairs are performed prior to resuming operation. • Never leave the machine unattended with the engine running. R160T / R190T US O&M 0404-490 2014-06... -
Page 24: Parking The Machine
• Pull the rope taut slowly and carefully. A sudden jerk can cause a sagging rope or cable to tear or snap. R160T / R190T US O&M 0404-490 2014-06... -
Page 25: Transporting
When lifting attachments or components, use caution. Attach straps or chains securely and in such a way that they evenly distribute the weight of the item to be lifted, ensuring a balanced load. Stay clear of expected travel path. R160T / R190T US O&M 0404-490 2014-06... -
Page 26: Maintenance
• When replacing parts or fasteners, use parts of equivalent quality, grade and/or size. Use original Terex components to ensure the proper form, fit, and function of replacement parts. • When performing maintenance work, always wear appropriate safety clothing for the task to be performed. - Page 27 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. •...
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Page 28: Battery
DO NOT smoke or allow open flame or sparks near the battery. Explosion could result. • When disconnecting the battery, disconnect the negative terminal first. • When connecting the battery, connect the negative terminal last. R160T / R190T US O&M 0404-490 2014-06... -
Page 29: Hydraulic Lines / Hoses
• When replacing hoses and hose lines, use only original spare parts. Install hoses and hose lines properly. Do not confuse connections. R160T / R190T US O&M 0404-490 2014-06... - Page 30 This Page Intentionally Left Blank R160T / R190T US O&M 0404-490 2014-06...
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Page 31: Technical Data
3.6 Transmission .......... 33 3.7 Auxiliary Hydraulics ........ 33 3.8 Ground Pressure ........33 3.9 Operating Specifications......33 3.10 Service / Refill Capacities..... 33 3.11 Fluid Specifications ......34 3.12 Dimensions and Weights ...... 34 R160T / R190T US O&M 0404-490 2014-06... - Page 32 This Page Intentionally Left Blank R160T / R190T US O&M 0404-490 2014-06...
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Page 33: General Structure
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) R160T / R190T US O&M 0404-490 2014-06... -
Page 34: Views
6 / 11 mph (10 / 17.7 kph) Max. Speed (Low / High) Power Transmission variable disp. / axial piston variable disp. / axial piston 59 in. (149.9 cm) 59 in. (149.9 cm) Track length, on ground R160T / R190T US O&M 0404-490 2014-06... -
Page 35: Transmission
Operating capacity 35% 1600 lb (725 kg) 1900 lb (861 kg) Note: The Maximum Gross Vehicle Weight of the R160T/R190T is not to exceed 8500 lb. (3856 kg). This excludes an operator, but does include accessories, attachments and material being carried. -
Page 36: Fluid Specifications
77 in. (1956 mm) Ground Clearance 12 in. (305 mm) 12 in. (305 mm) Weight (operating) 6200 lb (2812 kg) 6350 lb (2880 kg) Weight (ship / no bucket) 5500 lb (2495 kg) 5600 lb(2540 kg) R160T / R190T US O&M 0404-490 2014-06... -
Page 37: Machine Description / Controls
4.3 Controls..........40 4.4 Throttle........... 41 4.5 Two Speed ..........41 4.6 Bucket Positioning........41 4.7 Auxiliary Hydraulics ........ 42 4.8 Electric Attachment Control ....43 4.9 Emergency Exits........43 4.10 Attachment Compatibility...... 44 R160T / R190T US O&M 0404-490 2014-06... - Page 38 This Page Intentionally Left Blank R160T / R190T US O&M 0404-490 2014-06...
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Page 39: Display Elements
Diagnose the problem and make any necessary repairs before resum- ing operation. The glow plug operation light (17) will illuminate only when the key switch is turned to engine pre-heat, showing normal operation. R160T / R190T US O&M 0404-490 2014-06... -
Page 40: Symbols
4.2 Symbols Symbol Description Engine Pre-heat Battery Engine Speed: Fast Transmission Range: High Engine Speed: Slow Transmission Range: Low Windshield Wiper Beacon Light Oil Pressure Engine Coolant Temperature Hydraulic Oil Temperature Air Conditioning R160T / R190T US O&M 0404-490 2014-06... - Page 41 4 MACHINE DESCRIPTION / CONTROLS Symbol Description Work Lights Bucket Positioning R160T / R190T US O&M 0404-490 2014-06...
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Page 42: Controls
4 MACHINE DESCRIPTION / CONTROLS 4.3 Controls The R160T / R190T machines have two hydraulic pilot joystick controls. The joy- sticks are used to control machine speed and direction as well as lift arm and bucket functions. 4.3.1 Lift Arm Control The lift arm joystick is used to control the lift arms, bucket, and to engage the float function. -
Page 43: Throttle
Select a higher rpm for faster travel speed or when more power or flow is required for a task. 4.5 Two Speed The R190T is equipped with a two-speed drive system. Low range is best suited to performing strenuous work or operating attachments. High range is intended mainly for transporting. -
Page 44: Auxiliary Hydraulics
4 MACHINE DESCRIPTION / CONTROLS 4.7-1 4.7-2 4.7 Auxiliary Hydraulics The R160T / R190T models come equipped with an auxiliary hydraulic system designed to power compatible hydraulic attachments. To operate, connect the attachment to the appropriate quick couplers (fig. 4.7-1). -
Page 45: Electric Attachment Control
4.8-2 4.8 Electric Attachment Control Attachments for the R160T / R190T 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 (4.8-1) send electrical current to the receptacle on the lift arms (4.8-2). -
Page 46: Attachment Compatibility
A compatible attachment must: • Be designed for use with the Terex CTL quick attach system. It must mate and attach securely to the machine using the supplied quick attach and locking pins (see sections 5.9-5.11). -
Page 47: Operation
5.8 Loading ..........51 5.9 Fastening Attachments ......51 5.10 Unfastening Attachments...... 52 5.11 Power Quick Attach ......52 5.12 Operation on Inclines......53 5.13 Shut-Down Procedure ......53 5.14 Lift Arm Brace ........54 R160T / R190T US O&M 0404-490 2014-06... - Page 48 This Page Intentionally Left Blank R160T / R190T US O&M 0404-490 2014-06...
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Page 49: General Information
5 OPERATION 5.1 General Information Operating a Terex Compact 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 50: Starting Procedure
Entering or exiting the vehicle under raised lift arms could result in injury or death. Never allow anyone beneath raised, unsecured lift arms (fig. 5.3-2). R160T / R190T US O&M 0404-490 2014-06... -
Page 51: Surface Preservation
Curl the bucket and raise the lift arms simultaneously to break the load free from the pile. Maneuver the machine clear of the pile and then lower the lift arms, keeping the bucket curled upward, to approximately 10-12 in. (25-30 cm) above the ground for transporting. R160T / R190T US O&M 0404-490 2014-06... -
Page 52: Grading
Lower the lift arms until the cutting edge rests on the ground. Engage the float function and back the machine over the material varying bucket angle slightly as necessary to maintain grade. R160T / R190T US O&M 0404-490 2014-06... -
Page 53: Loading
Note: When fastening an attachment, always visually verify that the attachment is locked in place prior to operation. (fig. 5.10-2, 5.10-3) To physically verify that the attachment is properly locked in place, apply light pressure to the attachment while rotating it against the ground. R160T / R190T US O&M 0404-490 2014-06... -
Page 54: Unfastening Attachments
To lock the quick attach: • Press the switch (item 1) into the lock position. To unlock the quick attach: • Press the switch (item 1) into the unlock position R160T / R190T US O&M 0404-490 2014-06... -
Page 55: Operation On Inclines
Turn the ignition key counterclockwise to stop the engine, remove key. Remove the seat belt and raise the lap bar. Open the door (if equipped) and exit the machine using 3 points of contact as described in the starting procedure in this section. R160T / R190T US O&M 0404-490 2014-06... -
Page 56: Lift Arm Brace
Position the lift arm brace over the fender brackets as found and install the retaining pins to secure it there. Do not go beneath unsecured lift arms. Always install the lift arm brace prior to going beneath the lift arms while raised. R160T / R190T US O&M 0404-490 2014-06... -
Page 57: Transportation
6 TRANSPORTATION Page 6.1 Transporting ........... 57 6.2 Towing / Retrieving......... 58 6.3 Loading / Unloading Procedure ..... 59 R160T / R190T US O&M 0404-490 2014-06... - Page 58 This Page Intentionally Left Blank R160T / R190T US O&M 0404-490 2014-06...
- Page 59 (Items A, see photo). Tighten as needed to eliminate possible load shift during transport. Note: Close and latch doors and windows, secure any loose items prior to trans- porting. R160T / R190T US O&M 0404-490 2014-06...
- Page 60 Use only chains that are rated for pulling a machine of this size and weight. Attach these chains to at least two of the D-rings in the front or rear of the machine. R160T / R190T US O&M 0404-490 2014-06...
- Page 61 Remove all cables or chains. Start the engine as described in the operating instructions. Carefully drive down the ramp from the transport vehicle using a guide if necessary to direct movement. R160T / R190T US O&M 0404-490 2014-06...
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Page 63: Maintenance
7.17 Air Cleaner Cleaning ......75 7.18 Radiator Oil Cooler Cleaning....76 7.19 Engine Coolant Change ......76 7.20 Chassis Cleaning........77 7.21 Electrical System........78 7.22 Storage ..........79 7.23 Lifting Procedure........81 R160T / R190T US O&M 0404-490 2014-06... - Page 64 This Page Intentionally Left Blank R160T / R190T US O&M 0404-490 2014-06...
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Page 65: General
The maintenance interval charts list all work to be performed on the machine at regular intervals. Note: Always use genuine Terex replacement parts when performing maintenance or service to maintain the highest possible level of quality. The supplemental engine operation and maintenance manual provided with every machine contains information specific to the proper operation, inspection and maintenance of the engine and its internal components. -
Page 66: Maintenance Intervals
Replace engine oil & filter Replace hydraulic filter(s) Every 500 operating hours Page Replace fuel filter element Every 1000 operating hours Page Replace hydraulic oil Replace engine coolant (use SCA additive, see engine manual) R160T / R190T US O&M 0404-490 2014-06... -
Page 67: 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. R160T / R190T US O&M 0404-490 2014-06... -
Page 68: Engine Oil Check
If the level is low, add the proper grade and viscosity engine oil and re-check as necessary until the proper level has been achieved. Then re-install the dipstick and filler cap and close and latch the hood to complete the procedure. R160T / R190T US O&M 0404-490 2014-06... -
Page 69: Engine Oil Change
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 70: Hydraulic Oil Change
Once full, start the engine according to the proper starting procedure and operate all hydraulic circuits to work any trapped air out of the system. Then, check the oil level. If low, add oil as necessary until full. R160T / R190T US O&M 0404-490 2014-06... -
Page 71: Hydraulic Filter Change
The engine uses a belt to drive accessories like the alternator, water pump, and cooling fan. Belts typically stretch and wear during their service life. As a result, the accessory belt on the R160T / R190T should be visually inspected daily for tension, condition, and presence prior to operating your machine. -
Page 72: Water Separator
Remove bolt (2) on the top of the filter assembly, then remove filter. (fig. 7.11-1) Note: Drain fluids into a suitable catch container. Dispose according to mandates. Reverse step 3 to install the new fuel filter into the machine. R160T / R190T US O&M 0404-490 2014-06... -
Page 73: General Undercarriage
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 74: Track Tension Adjustment
Once proper tension is achieved, retighten the jam nut on the tensioner. Note: If the track tensioner is stiff, it may be helpful to apply a penetrating lubri- cant onto the threads prior to adjusting tension. R160T / R190T US O&M 0404-490 2014-06... -
Page 75: Drive Sprocket Rollers
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. R160T / R190T US O&M 0404-490 2014-06... -
Page 76: Air Cleaner Removal / Inspection
Remove the secondary element (2). The secondary element is not serviceable or washable. The secondary element should be replaced every three cleanings of the primary element. R160T / R190T US O&M 0404-490 2014-06... -
Page 77: Air Cleaner Cleaning
Do not use any heat source other than warm air at less than 160° F (71° C) to dry the filter. NOTICE During the engine warranty period, do not clean the filter elements. Instead, replace the filter elements when soiled or damaged to comply with engine warranty requirements. R160T / R190T US O&M 0404-490 2014-06... -
Page 78: Radiator Oil Cooler Cleaning
Check the coolant level, and top off (repeat steps 4 and 5 until all air has been purged and the level is full when cold). R160T / R190T US O&M 0404-490 2014-06... -
Page 79: Chassis Cleaning
They can be reap- plied according to the location illustration in section 2.3 of this manual. When using pressurized air or water for cleaning purposes, always wear appropriate personal protection equipment to ensure your safety. R160T / R190T US O&M 0404-490 2014-06... -
Page 80: Electrical System
# 12177234 MAIN The electrical systems in Terex Compact Track Loaders are equipped with fuses that help to protect the electrical components from damage. They are found in the fuse panel enclosure which is located on the left side of the engine compartment. -
Page 81: Storage
7 MAINTENANCE 7.22 Storage It may be necessary to store your Terex Compact 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 82 7 MAINTENANCE 7.22.2 Removal From Storage Perform the following tasks to remove the Terex Compact 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.
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Page 83: Lifting Procedure
7 MAINTENANCE 7.23 Lifting Procedure Lifting your Terex R160T-R190T should only be done from beneath the machine with a jack of the proper capacity. To safely lift the machine: Remove any attachments that may be fastened to the machine and raise the lift arms. -
Page 84: California Proposition 65
California (U.S.A.) state law stipulates that manufacturers of machines operated within its borders must provide a clear warning to customers regarding exposure to substances commonly associated with the machine that are recognized by the state as harmful. Terex complies with this requirement by providing the following information. CALIFORNIA...