Terex PT100G Forestry Service Manual Download

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Repair

Disconnect the battery and discharge any capaci-

tor before beginning work on a machine. Attach a

Do Not Operate

tag in the cab to alert any opera-

tor that service is in progress.

If possible, make all repairs with the machine

parked on a level, hard surface. Use blocks to pre-

vent the machine from rolling while working on or

under the machine.

Do not work on or under any machine that is sup-

ported only by a hydraulic jack or hoist. Always

use some sort of mechanical support to ensure

that the machine will not fall. Terex jack stands

work well to support the machine while performing

maintenance or repair work.

Make sure the work area around the machine is

safe and make yourself aware of any hazardous

conditions that may exist. If the engine needs to

be started inside an enclosure, make sure that the

engine’s exhaust is properly vented.

Be sure all protective devices including guards and

shields are properly installed and functioning cor-

rectly before beginning any service task. If a guard

or shield must be removed to perform the repair

work, use extra caution.

Always use the appropriate tools for the work to be

performed. Tools should be in good condition and

you should understand how to use them properly

before performing any service work.

When replacing fasteners, use parts of equivalent

grade and size. Do not use a lesser quality fasten-

er if replacements are necessary.

Be prepared to stop an engine if it has been re-

cently overhauled or the fuel system has been

recently serviced. If the engine has not been

assembled correctly, or if the fuel settings are not

correct, the engine can possibly overspeed and

cause bodily injury, death or property damage. Be

prepared to shut off the fuel and air supply to the

engine in order to stop the engine.

Be careful when removing cover plates. Gradually

back off the last two bolts or nuts located on oppo-

site sides of the cover. Then, pry the cover loose

to relieve any spring or other pressure before

removing the last two nuts or bolts completely.

10.

Repairs requiring welding should be performed

only by personnel adequately trained and knowl-

edgeable in welding procedures and with the guid-

ance of appropriate reference information.

Determine the type of metal being welded and

select the correct welding procedure and filler

material to provide a weld that is as strong or

stronger than the original weld.

11.

Take precautions to avoid damaging wiring during

removal and installation operations. Carefully route

wires so that they will not contact sharp corners,

objects or hot surfaces during operation.

12.

When performing service that requires the lift arms

to be in the raised position, always utilize the lift

arm brace located on the rear of the loader tower.

13.

Relieve hydraulic system pressure by relaxing all

hydraulic actuators prior to attempting any

hydraulic maintenance or repair.

14.

Always tighten connections to the correct torque

specification. Make sure that all shields, clamps

and guards are installed correctly to avoid exces-

sive heat, vibration or unwanted contact between

parts during operation. Shields that protect

exhaust components from oil spray in event of a

line, tube or seal failure must be correctly installed.

15.

Do not operate a machine if any rotating part is

damaged or contacts other parts during operation.

Any high speed rotating component that has been

damaged or altered should be checked for balance

before reusing. Make sure all protective devices,

including guards and shields, are properly installed

and functioning correctly before starting the engine

or operating the machine.

1-3

Compact Track Loader

1. Product Safety

Accidental machine starting can cause injury
or even death to personnel working on a
Compact Track Loader.

As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to per-
forming any service work on a Compact Track Loader.

Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is
being serviced.

Prior to welding, disconnect the following to pre-
vent component damage:

•

Negative battery cable

•

J1/P1 connectors from the ECM (engine)

•

Main controller (machine)

•

Output module (machine)

•

Display (machine)

A proper ground is essential to protect the
machine from damage when welding. Improper
grounding can cause damage to mechanical,
hydraulic and electrical components.

As a precaution, connect the welding ground
clamp as close as possible to the weld area.

NOTICE