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Summary of Contents for Terex DTM 00101 (standard)
- 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: 2011-10 Part Number: 2076-200 Valid From Serial No: DTM 00101 (standard) DTN 00101 (forestry) RWS 00101 (standard) RWF 00101 (forestry) Original Instructions PT-100G/PT-100G F...
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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 machine. Page Introduction............2 Safety ..............5 Technical Data..........33 Machine Description / Controls....39 Operation............59 Transportation..........69 Maintenance ............. 75 California Proposition 65......96 Service Log ............ -
Page 4: Introduction
PIN when making inquiries in regards to parts, service, or warranty. 1.2 Introduction Thank you for purchasing a Terex Compact Track Loader. We are confident that the machine you have chosen will provide excellent performance and effi- cient 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 5 Debris should be cleaned frequently from these areas. Although these mulching type heads work extremely well on Terex machines with high flow hydraulics, educate yourself on the increased maintenance and operat- ing costs before using this type of attachment.
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Page 7: Safety
2 SAFETY Page 2.1 Safety Alert System ......... 7 2.2 Safety Pictorials ........8 2.3 Graphical Symbols........10 2.4 Safety Signs (ANSI) ........14 2.4.1 Safety Signs (ISO)........16 2.5 General Notes..........18 2.6 Personal Protection Equipment ..19 2.7 Hazard Zone..........19 2.8 Operation............ -
Page 9: Safety Alert System
2 SAFETY 2.1 Safety Alert System 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 10: Safety Pictorials
2 SAFETY 2.2 Safety Pictorials Symbol Description Diesel Fuel Battery Engine Speed: Fast Transmission Range: High Engine Speed: Slow Transmission Range: Low Windshield Wiper Engine Pre-Heat Oil Pressure Engine Coolant Temperature Hydraulic Oil Temperature Air Inlet Temperature... - Page 11 2 SAFETY Symbol Description Engine RPM Work Lights Bucket Positioning Power Quick Attach Parking Brake High flow Auxiliary Low Flow Auxiliary High Flow Auxiliary (reverse flow) Low Flow Auxiliary (reverse flow)
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Page 12: Graphical Symbols
2 SAFETY 2.3 Graphical Symbols Hazard Avoidance Pictorial Pictorial Description Hazard: Skin/Oil Injection Avoidance: • Relieve internal pressure before disconnecting any line or fitting. • Keep away from leaks or pin- holes. • Use cardboard to check for leaks. Fluid injected into skin must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene will... - Page 13 2 SAFETY Hazard Avoidance Pictorial Pictorial Description Hazard: Explosion/Burn Avoidance: • Keep all flames/sparks away! • No Smoking! • Read and understand all manuals. Hazard: Fall Avoidance: Use the provided access system when entering or exiting the machine. Hazard: Fall Avoidance: No Riders.
- Page 14 2 SAFETY Hazard Avoidance Pictorial Pictorial Description Hazard: Entanglement Avoidance: Stop machine and remove key before servicing. Hazard: Rollover / Ejection Avoidance: Carry loads low, keep heaviest end of machine uphill at all times while operating on inclines. Hazard: Fall Avoidance: Do not use the bucket or attachment as a work platform.
- Page 15 2 SAFETY Hazard Avoidance Pictorial Pictorial Description Hazard: Crush Avoidance: Install lift arm brace 2030-417 before servicing. Hazard: The safety alert symbol is used to alert you to potential per- sonal injury hazards. Obey all safe- ty messages that follow this sym- bol to avoid possible injury or death.
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Page 16: Safety Signs (Ansi)
2 SAFETY 2.4 (ANSI) Safety Signs The safety signs are located in/on the machine as indicated. (Descriptions of the symbols are provided in section 2.3) WARNING WARNING Improper operation or maintenance can result in serious injury or death. • Relieve internal pressure before disconnecting any line or fitting. - Page 17 2 SAFETY Note: If any of the safety signs shown in this section are missing or damaged, contact your dealer to obtain a replacement. WARNING Crush Hazard Rollover can crush and result in serious injury or death. WARNING Fasten Seat Belt WARNING Explosion/Burn Hazard Will cause death, burns or...
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Page 18: Safety Signs (Iso)
2 SAFETY 2.4.1 (ISO) Safety Signs The safety signs are located in/on the machine as indicated. (Descriptions of the symbols are provided in section 2.3) 2030-553 2030-551 2046-146 2030-425 2030-416 2030-415 2030-417 Fall hazard Read operator’s manual / fall hazard / fire hazard (inside cab enclosure) Skin (oil) injection hazard Entanglement hazard (engine compartment) Tie down location (found beneath loader in front locations) - Page 19 2 SAFETY Note: If any of the safety signs shown in this section are missing or damaged, contact your dealer to obtain a replacement. 2030-418 2030-565 2046-147 2076-387 2030-553 2030-415 2030-416 2030-417 Key (continued) Tie down location 10. Flying Debris (100G Forestry only) 11.
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Page 20: General Notes
2 SAFETY 2.5 General Safety Notes • Read and understand all safety signs and operator’s manuals prior to opera- tion. • If safety signs are obstructed by dirt or debris, clean them using mild soap and water prior to operation. •... -
Page 21: 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 22: 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 23: 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 24: Fire Prevention
2 SAFETY 2.11 Fire Prevention Compact 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 25: Crush / Burn Avoidance
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 26: 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 27: 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 28: Parking The Machine
2 SAFETY 2.16 Parking the Machine • Stop the machine only on an even and solid surface. • Lower the lift arms to the frame stop and rest the bucket on the ground. • Shut the machine down as described in section 5.13. •... -
Page 29: 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, water, mud, sludge, oil, etc.). -
Page 30: 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 31 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 32: 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 33: Hydraulic Lines / Hoses
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 35: Technical Data
3 TECHNICAL DATA Page 3.1 General Structure........35 3.2 Views............. 36 3.3 Engine ............36 3.4 Electrical System ........36 3.5 Undercarriage ........... 36 3.6 Transmission ..........37 3.7 Auxiliary Hydraulics......... 37 3.8 Ground Pressure........37 3.9 Operating Specifications....... 37 3.10 Service / Refill Capacities.... -
Page 37: General Structure
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, right side of machine) Hood (engine cover) Engine Drive Motor and Sprocket Undercarriage 10. Quick Attach 11. Product PIN Plate (on front of operator enclosure) -
Page 38: Views
3 TECHNICAL DATA 3.2 Views 14.75 in (375 mm) 71 in (1803 mm) 18 in (457 mm) 34 in 117.5 in (2985 mm) (864 mm) 149 in (3785 mm) 70 in (1778 mm) 3.3 Engine PT-100G PT-100G F Make Perkins Perkins 1104D-44T 1104D-44T... -
Page 39: Transmission
3 TECHNICAL DATA 3.6 Transmission PT-100G PT-100G F Make Rexroth Rexroth Type A10VG63 A10VG63 Design Axial piston Axial piston Displacement 3.84 in.³ (63 cc) / rev. 3.84 in.³ (63 cc) / rev. Relief Pressure 5500 psi (37,920 kPa) 5500 psi (37,920 kPa) 3.7 Auxiliary Hydraulics PT-100G PT-100G F... -
Page 40: Fluid Specifications
3 TECHNICAL DATA 3.11 Fluid Specifications (applies to both machines) Specifications Designation Specification/standard 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 Mobil DTE 10 Excel Series 46 Hydraulic Oil Hydraulic Oil Chevron-Rykon MV or equivalent... -
Page 41: Machine Description / Controls
4 MACHINE DESCRIPTION / CONTROLS Page 4.1 Display Elements........41 4.2 Controls ............42 4.3 Throttle ............43 4.4 Operator Seat ..........43 4.5 Two Speed ..........43 4.6 Auxiliary Hydraulics......... 44 4.7 Bucket Positioning........45 4.8 Electric Attachment Control ....45 4.9 Auto Idle............ -
Page 43: Display Elements
4 MACHINE DESCRIPTION / CONTROLS 4.1 Display Elements / Switches Learn the location and function of these items prior to operation. Item: 1. Ignition Switch 2. Operator Interface 3. Rear View Mirror NOTICE 4. Beacon Switch (optional) 5. Switch Panel Should an alarm message be displayed 6. -
Page 44: Controls
4 MACHINE DESCRIPTION / CONTROLS 4.2 Controls RIGHT LEFT Mode Mode LEFT RIGHT LEFT RIGHT LEFT RIGHT The PT-100G is equipped with joystick style controls. The joysticks are used to control machine speed and direction as well as lift arm and bucket functions. The operator can select between two propel modes (accessed through the operator interface) to suit operator preference, ISO (standard) and H mode. -
Page 45: Throttle
4 MACHINE DESCRIPTION / CONTROLS 4.3 Throttle The throttle (foot pedal) is located beneath the operator’s right foot when seated in the machine. The throttle controls engine rpm. • Press the front of the pedal down to increase engine RPM. •... -
Page 46: Auxiliary Hydraulics
4 MACHINE DESCRIPTION / CONTROLS 4.6-1 4.6-2 4.6 Auxiliary Hydraulics The PT-100G 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 connect couplers: 4.6-3 1. -
Page 47: Bucket Positioning
4 MACHINE DESCRIPTION / CONTROLS 4.7 Bucket Positioning (optional) The PT-100G machines are equipped with feature commonly referred to as “bucket positioning”. The bucket positioning system does not automatically level your attachment. Instead, it will maintain the current angle of the quick attach (relative to level) throughout the upward cycle of the lift arms. -
Page 48: Operator Interface
4 MACHINE DESCRIPTION / CONTROLS 4.10 Operator Interface The operator interface allows the operator to monitor machine systems and configure the machine as needed to adapt to operator experience and conditions. Note: to view the selection bar (if available) at the bottom of each screen, press any of the four buttons beneath the screen. - Page 49 4 MACHINE DESCRIPTION / CONTROLS Gauge Screen 2 2 45° F 149° F Air Inlet Coolant 41° F Eng. Oil Hyd. Oil This screen displays engine air inlet temperature, engine coolant temperature, engine oil pressure, and hydraulic oil temperature. These readings are critical to machine function and if abnormal, all can cause the engine to derate (or shut down in the event of high coolant temperature or low oil pressure) in an effort to protect the engine and hydraulic systems.
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Page 50: Status Menu
4 MACHINE DESCRIPTION / CONTROLS 4.10-1 Status Menu Status Menu Config Status Machine Status Active Faults Seat Status Software Status This screen allows you to monitor the status of various systems and features. If the selection bar is not visible, press one of the buttons beneath the screen to bring up the selection bar, then use the buttons beneath the up and down arrows to select a sub-menu. - Page 51 4 MACHINE DESCRIPTION / CONTROLS Machine Status Screen Machine Status Engine Hours: Miles: This screen allows you to view the engine hours and miles that have accumulated on the machine since new. Active Faults Active Faults fault ( 1 ) o f ( 2 ) 2-Speed Fault - Solenoid open or shorted This screen will display any faults detected by the operator interface.
- Page 52 4 MACHINE DESCRIPTION / CONTROLS Seat Status Seat Status Cab Seat Occupied Attachment Seat Un-Occupied Lap Bar Lowered This screen displays the current status of the seat, attachment seat (if equipped), and lap bar. Software Status Software Version Main Controller 1.00 Display 1.00...
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Page 53: Config Menu
4 MACHINE DESCRIPTION / CONTROLS 4.10-2 Config Menu Config Menu Propel Mode Max Speed Lift Arm Speed Auto Idle High Flow Display Units Fan Control This screen allows you to access editable parameters of the machines control systems. Use the buttons beneath the up and down arrows to select a sub-menu, then press the button beneath the check mark to select. - Page 54 4 MACHINE DESCRIPTION / CONTROLS Max Speed Max Speed 100% Adjust This screen allows you to change the maximum travel speed for the machine. To change the speed, press the button beneath the check mark. Then use the buttons beneath the arrows to raise or lower the value until your desired speed is displayed, then confirm your selection by pressing the button beneath the check mark again.
- Page 55 4 MACHINE DESCRIPTION / CONTROLS Auto Idle Auto Idle Enable Adjust This screen allows you to enable or disable the Auto Idle feature. To enable or disable this feature, press the button beneath the check mark. Then use the buttons beneath the arrows to toggle between the settings until your desired setting is displayed, then confirm your selection by pressing the button beneath the check mark again.
- Page 56 4 MACHINE DESCRIPTION / CONTROLS Display Units Display Units English Adjust This screen allows you to change the units used when displaying the various feedback provided by machine systems. To change the units, press the button beneath the check mark. Then use the but- tons beneath the arrows to toggle between the options until your desired format is displayed, then confirm your selection by pressing the button beneath the check mark again.
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Page 57: Splash Screens
4 MACHINE DESCRIPTION / CONTROLS 4.10-3 Splash Screens Splash Screens display when the operator needs to be notified of issues quickly. Some display momentarily and then disappear. Others indicate a problem that must be acknowledged or resolved before operation can resume. Startup Screen Propel Mode ISO Mode... - Page 58 4 MACHINE DESCRIPTION / CONTROLS Door Open Door Open This screen indicates the door switch is not making contact (door is not com- pletely closed). The joysticks and auxiliary hydraulic controls will not operate if the door is not properly closed. Close door to clear screen and resume operation. High Flow 45 GPM This screen indicates the current high flow volume over time setting in gallons...
- Page 59 4 MACHINE DESCRIPTION / CONTROLS Low Fuel Alarm Fuel Level Low This screen is displayed when the fuel level reaches approximately 10% of capacity. Alarm Alarm Check Engine Soon This screen indicates that a system fault has occurred. It must be acknowledged by pressing the button beneath the arrow key.
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Page 60: Emergency Exits
4 MACHINE DESCRIPTION / CONTROLS 4.11 Emergency Exits 4.11-1 2076-213 4.11-2 2076-212 Familiarize yourself with the emergency exits and associated features located in the cab enclosure prior to operation. These features allow an operator to escape from the cab in an emergency. Standard Operator Escape (door and rear window exit) Firmly grasp the triangular tag attached to the 4.11-3... -
Page 61: Operation
5 OPERATION Page 5.1 General Information........ 61 5.2 Pre-Operation Safety Checklist... 61 5.3 Starting Procedure ........62 5.4 Surface Preservation....... 63 5.5 Filling the Bucket ........63 5.6 Grading............64 5.7 Leveling ............64 5.8 Loading............65 5.9 Fastening Attachments......65 5.10 Unfastening Attachments .... -
Page 63: 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 64: Starting Procedure
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 (defined as: one foot and two hands, or one hand and two feet) with the machine (fig. -
Page 65: Surface Preservation
5 OPERATION 5.4 Surface Preservation Terex Compact 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 66: Grading
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 67: Loading
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 68: Unfastening Attachments
5 OPERATION 5.10 Unfastening Attachments (see also section 5.11) Lower the lift arms so that the attachment is just slightly 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. -
Page 69: Operation On Inclines
5 OPERATION 5.12 Operation on Inclines By design, Compact 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, extreme caution should always be exercised while operating the machine on an incline. -
Page 70: Lift Arm Brace
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, stop and remove any attachments and 5.14-1 park the machine on firm and level ground. -
Page 71: Transportation
6 TRANSPORTATION Page 6.1 Transporting..........71 6.2 Towing / Retrieving ......... 72 6.3 Loading / Unloading Procedure ..73 6.4 Lifting Procedure ........74... -
Page 73: Transporting
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 74: Towing / Retrieving
6 TRANSPORTATION 6.2 Towing / Retrieving In the event that the PT-100G needs to be towed or retrieved, it will not roll freely. You must perform the following procedure in order to pull it to safety. Locate the drive motors in the undercarriages and thoroughly clean them to prevent dirt or debris from entering the planetary drive. -
Page 75: Loading / Unloading Procedure
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, water, mud, sludge, oil, etc.). Properly align the machine with the loading ramp. -
Page 76: Lifting Procedure
6 TRANSPORTATION 6.4 Lifting Procedure Lifting the machine should only be done from beneath the machine with a jack of the proper capacity. To safely lift your machine: Remove any attachments that may be fastened to the machine and raise the lift arms. -
Page 77: Maintenance
7 MAINTENANCE Page 7.1 General ............77 7.2 Care and Cleaning ........77 7.3 Maintenance Intervals......78 7.4 Lubrication Points........79 7.5 Engine Oil Check ........80 7.6 Engine Oil Change........81 7.7 Hydraulic Oil Change......82 7.8 Hydraulic Filter Change ......83 7.9 Accessory Belt ........... -
Page 79: General
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 80: Maintenance Intervals
7 MAINTENANCE 7.3 Maintenance Intervals 7.3-1 Daily Maintenance Tasks Daily Page Check hydraulic oil level (figure 7.7-3, p-82) 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 81: Lubrication Points
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. A. -
Page 82: Engine Oil Check
7 MAINTENANCE 7.5 Engine Oil Check Shut the machine down according to the procedure in section 5.13. Open the hood to gain access to the engine compartment. Locate and remove the engine oil 7.5-1 dipstick (1) from its tube. (fig. 7.5-1) Wipe the dipstick with a clean shop cloth and reinsert it into the tube until it comes to rest in its seated... -
Page 83: 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 84: Hydraulic Oil Change
7 MAINTENANCE 7.7 Hydraulic Oil Change 7.7-1 7.7-2 The hydraulic oil should be changed every 1000 service hours. Before Full beginning the procedure, make sure the machine is in a clean working environment. Take any necessary measures to prevent dirt or debris from entering the hydraulic system. -
Page 85: Hydraulic Filter Change
7 MAINTENANCE 7.8 Hydraulic Filter Change The hydraulic filter 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 filter. Before beginning the procedure, make sure the machine is in a clean working environment. -
Page 86: Water Separator
7 MAINTENANCE 7.10 Water Separator The water separator (item 1) removes water from the fuel supply as the engine runs. (fig. 7.10-1) It is located on the right side of the radia- tor shroud. Drain the water separator daily to maintain proper function. 7.10-1 To drain the water separator: Shut the machine down... -
Page 87: 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 88: Track Tension Adjustment
7 MAINTENANCE 7.13-2 7.13-1 7.14 Track Tension Adjustment Shut the machine down as described in section 5.13, locate jam nut on track tension device and clean the threads thoroughly before proceeding. (fig. 7.14-1). Using a wrench, loosen the jam 7.14-1 nut (item 1) on the track tension device. -
Page 89: Drive Sprocket Rollers
At 50 hour intervals, shut the machine down as described in section 5.13 and visually inspect rollers. Replace any that show signs of cracking or wear-through. Drive sprocket removal and roller / pin replacement should be performed by your local Terex dealer. -
Page 90: Air Cleaner Removal / Inspection
7 MAINTENANCE 7.17 Air Cleaner Removal / Inspection 7.17-1 7.17-2 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. -
Page 91: Air Cleaner Cleaning
7 MAINTENANCE 7.18 Air Cleaner Cleaning Remove the primary air cleaner element as described in section 7.17. Remove loose dirt from the element with compressed air or water hose. • Compressed air: 100 psi (690 kPa) max. 1/8 in. (.32 cm) diameter nozzle at least 2 in. -
Page 92: Radiator Oil Cooler Cleaning
7 MAINTENANCE 7.19 Radiator / Oil Cooler Cleaning 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 7.19-1 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 93: Chassis Cleaning
7 MAINTENANCE Coolant and machine components can be HOT! Allow the machine to cool thoroughly prior to performing maintenance or service to avoid the possibility of burns. 7.20-1 7.20-2 7.21 Chassis/Engine Cleaning Periodic cleaning of the chassis area beneath the cab and engine com- partment is also necessary to main- tain safe operation. -
Page 94: Electrical System
7 MAINTENANCE 7.22 Electrical System ELECTRICAL PANEL 2075-840 GLOW ECU START AUX LDR C OVERRIDE PLUG B LOADER B AUX LDR G AUX LDR D 40 A. RELAY 40 A. RELAY 40 A. RELAY 40 A. RELAY 40 A. RELAY 40 A. -
Page 95: Storage
7 MAINTENANCE 7.23 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. 7.23.1 Storage Preparation • Thoroughly clean the machine (inside and out) including the engine compart- ment and underbody. - Page 96 7 MAINTENANCE 7.23.2 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, lift arm and undercarriage points.
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Page 97: Cab Tilt
7 MAINTENANCE 7.24-1 7.24-2 7.24 Cab Tilt 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. -
Page 98: 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/ASV complies with this requirement by providing the following information. CALIFORNIA... -
Page 99: Service Log
SERVICE LOG Hours Service Performed Notes... - Page 100 SERVICE LOG Hours Service Performed Notes...
- Page 101 SERVICE LOG Hours Service Performed Notes...
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