Track Loader Parts Terex PT30CE, Operation And Maintenance Manual

Page 1: ...SN ETA00101 Current English Not USA Language Geographic Region Serial Number Range This manual is complements of TrackLoaderParts com The world s best source for Terex parts Track Loader Parts 6543 C...

Page 2: ...CONTENTS Introduction 2 Safety 5 Technical Data 31 Machine Description Controls 37 Operation 45 Transportation 55 Maintenance 61 Service Log 81 1...

Page 3: ...is imperative that this manual be provided to the end user at the time of purchase prior to operation and kept with the machine at all times If lost or damaged contact your dealer immediately to obtai...

Page 4: ...the equipment can be used for corresponding applications The operator must follow the enclosed operating instructions for any externally supplied components or attachments Any use varying from that de...

Page 5: ...isions of the following European directives and amendments and the regulations transposing it into national law Machinery Safety Directive 98 37 EC Noise in the Environment Directive 2000 14 EC Measur...

Page 6: ...7 Danger Zone 17 2 8 Operation 18 2 9 Stability 19 2 10 Transport of Persons 19 2 11 Fire Prevention 20 2 12 Crush Burn Avoidance 21 2 13 Placing Into Operation 22 2 14 Starting the Machine 22 2 15 Jo...

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Page 8: ...roughout this manual as well as on decals and labels fixed to the machinery to assist in potential hazard recognition and prevention Property or equipment damage warnings in this publication are iden...

Page 9: ...ption 2 SAFETY 8 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 Windsh...

Page 10: ...on 2 SAFETY 9 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...

Page 11: ...2 SAFETY 10 Symbol Description High Beam Lights Low Beam Lights Work Lights Left Turn Signal Right Turn Signal Hazard Indicator Lights Fan Parking Brake Road Mode Bucket Positioning P...

Page 12: ...derstand the operator s manual before using or maintaining the machine Hazard Entanglement Avoidance Stop the engine before servicing the machine Hazard Explosion Pressurized Air Fluid Avoidance Allow...

Page 13: ...Burn Avoidance Allow surfaces to cool before servicing Hazard Ejection Roll Over Avoidance Fasten safety belt Hazard Rotating Parts can cause personal injury Avoidance Stop the engine before servicing...

Page 14: ...azard Loader Crush Avoidance Keep out from under unsupported lift arms Install lift arm brace prior to going beneath the lift arms Hazard Fire Overheat Avoidance Read and understand the operator s man...

Page 15: ...2 Skin oil injection hazard 3 Crushing hazard lift arms 4 Fire hazard read manual inside cab 5 Pressurized fluid gas hazard engine area 6 Battery acid explosion hazard engine area 7 Tie down location...

Page 16: ...fan entanglement hazard engine area 12 Skin oil injection hazard 13 Crushing Hazard Lift arms 14 Read operator s manual Falling hazards inside cab 15 Rollover Ejection hazard inside cab 16 Crushing ru...

Page 17: ...properly equipped for the task to be performed and when properly inspected and main tained to ensure safe operation The manufacturer s instructions regarding operation inspection maintenance repair an...

Page 18: ...ar safety shoes and any other equipment necessary to ensure your safety and the safety of others around you as you work 2 7 Danger Zone The danger zone encompasses the area around the machine in which...

Page 19: ...operation read and understand the instructions in this manual prior to operation and to follow them during operation familiarize him herself with the local worksite conditions and immediately remedy...

Page 20: ...ys carry loads low to maximize machine stability Always keep the heaviest end of the machine facing uphill when travelling on an incline When turning on an incline back down the hill while slowly turn...

Page 21: ...n these areas and can lead to fire Check the electrical system regularly Have any faults such as loose connections burnt fuses glow lamps and damaged wiring repaired by professional personnel immediat...

Page 22: ...ting temperature Avoid touching parts that carry coolant to avoid the possibility of burns Allow the machine to cool thoroughly prior to touching or removing the cooling system cap Once cool loosen th...

Page 23: ...ill be placed into operation Prior to placing the machine into operation adjust the driver s seat mirrors and ventilation system settings if equipped so you can work in comfort and safety 2 14 Startin...

Page 24: ...ep the machine at an adequate distance from overhead elec trical lines When working in the vicinity of overhead electrical lines do not come close to the lines with the machine Injury or death may res...

Page 25: ...e Always observe the correct procedure as described in the oper ating instructions The machine should be towed only in exceptional cases for example to bring the machine away from an endangered place...

Page 26: ...gnition key Secure the door windows and hood on the machine Secure the machine and any other items against slipping with chains ropes of the proper capacity Before departure investigate the route to b...

Page 27: ...y 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 s...

Page 28: ...welding or grinding to avoid fire or explosion Before cleaning the machine with water or steam jets high pressure cleaner or other cleaning agents cover or seal over all openings in which water steam...

Page 29: ...uirements for assembly tasks above body height Do not use machine parts as climbing aids if they were not designed for that purpose If working at significant height use a safety harness of the proper...

Page 30: ...d may reduce the duration of the usage period for example high temperatures multi shift operation Hoses and hose lines must be replaced if any of the following criteria are encountered during inspecti...

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Page 32: ...stem 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 Sound Vibration 35 3 11 Service Refill Capacities 36 3 12 Fluid...

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Page 34: ...P S F O P S approved 4 Hydraulic Oil fill location 5 Diesel Fuel fill location 6 Hood engine cover 7 Engine 8 Drive Motor and Sprocket 9 Undercarriage 10 Quick Attach 11 Product PIN Plate beside oper...

Page 35: ...Admissible inclined Positions 10 17 grade DO NOT EXCEED Cooling Water antifreeze for all year operation Operating Voltage 12 V Battery 12V 910 CCA 0 C Alternator 12V 65A Starter 1 4 kW Starting Aid G...

Page 36: ...on Relief Pressure 26 200 kPa Make Rexroth Type 9510290004 Design Gear Displacement 14 3 cc revolution Relief pressure 20 684 kPa Flow 30 7 lpm 2 200 RPM At operating weight 19 2 kPa At shipping weigh...

Page 37: ...A additive Hydraulic Oil Hydraulic Oil Chevron Rykon MV or equivalent Lubricating Points MP Grease Multi purpose lithium grease 30 22 20 4 10 14 0 32 10 50 20 68 30 86 40 104 50 C 122 F 0W 5W 20 10W 3...

Page 38: ...4 1 Display Elements 39 4 2 Controls 40 4 3 Throttle 41 4 4 Operator Seat 41 4 5 Auxiliary Hydraulics 42 4 6 Road Mode 43 4 7 Remote Lift Arm Valve 44 4 MACHINE DESCRIPTION CONTROLS 37...

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Page 40: ...aulic oil temperature light 22 Engine temperature light If the battery voltage light 20 illuminates drive the machine to a suitable location and shut the engine off Diagnose the problem and make any n...

Page 41: ...the relation ship between joystick movement and resulting lift arm action Note To activate the float function move the joystick fully forward in a quick motion The joystick will then be held in deten...

Page 42: ...more power or flow is required for a task 4 4 Operator Seat Seat Adjustment The seat in the PT 30 is a suspension style seat adjustable for both operator weight spring pre load and operator height va...

Page 43: ...the hydraulic flow intermittently activate the toggle type switch on the top of the right joystick fig 4 5 2 To engage the hydraulic flow continuously activate the 3 position switch on the dash panel...

Page 44: ...immobilize it for on road travel 6 Install the cutting edge guard onto the bucket and secure 7 Press the road mode switch item 4 on the dash panel to disable unnecessary items and enable road mode onl...

Page 45: ...s off and all moving components have stopped 3 Open the hood at the rear of the machine 4 Insert the proper size hex allen type wrench into the bleed screw on the remote lift arm valve RLV mounted to...

Page 46: ...ing 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 52 5 11 Operation on Incl...

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Page 48: ...operly tensioned 6 Hydraulic hoses and fittings are in good condition no visible signs of wear 7 Battery cables are in good condition and properly fastened 8 Joysticks auxiliary hydraulic switch are i...

Page 49: ...d the rabbit icon 4 Turn the ignition key to the left for 6 seconds to pre heat the engine While pre heating the glow plug operation light will illu minate 5 Turn the ignition key to the right to star...

Page 50: ...ng on turf make gradual turns see item A If space is limited turn gradually by moving back and forth until facing the desired direction see item B 5 5 Filling The Bucket Steps see illustration 1 Lower...

Page 51: ...lustration 1 Moving forward raise the lift arms as you tilt the bucket slowly forward to evenly spread the material out over the ground 2 Once the load is released tilt the bucket forward to an angle...

Page 52: ...Attachments 1 Make sure the locking levers on the quick attach mechanism are in their respective unlocked positions fig 5 9 1 2 Drive the machine to the attachment and hook the top edge of the quick a...

Page 53: ...ut side of the machine to unlock the attachment 3 Lay the attachment gently onto the ground by moving the lift arm control joy stick slowly to the right 4 Once the attachment is in con tact with the g...

Page 54: ...ame stops 4 Reduce engine RPM to a low idle 5 Turn the ignition key to the off position to stop the engine 6 Remove the safety belt and raise the lap bar if equipped 7 Open the door if equipped and ex...

Page 55: ...13 1 4 Raise the lift arms until the brace contacts the cylinder rod fig 5 13 2 5 Slowly lower lift arms until the lift arms come to rest stop on the brace 6 Shut the engine off and exit the machine...

Page 56: ...6 1 Transporting 57 6 2 Towing Retrieving 58 6 3 Loading Unloading Procedure 59 6 4 Lifting Procedure 60 6 TRANSPORTATION 55...

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Page 58: ...over the distance and terrain that will be covered 2 Secure the machine to the transport vehicle bed facing the direction of travel with heavy chains rated for use with a machine of this nature size...

Page 59: ...ining nut 2 Using two wrenches remove the retaining nuts A from the upper four bolts within the drive sprocket that support the drive teeth in contact with or close to the rubber track fig 6 2 1 2 3 U...

Page 60: ...auxiliary hydraulic switch are in their neutral positions Remove the ignition key 8 Secure the door windows and hood on the machine 9 Secure the machine and any other items to the transport vehicle wi...

Page 61: ...ting device centered over the machine use spreader bars if necessary This will help to balance the machine as well as distrib ute the weight evenly while being lifted Lift the machine straight up in a...

Page 62: ...ccessory Belt 69 7 10 Water Separator 70 7 11 Fuel Filter Change 70 7 12 General Undercarriage 71 7 13 Track Tension Check 71 7 14 Track Tension Adjustment 72 7 15 Drive Sprocket Rollers 73 7 16 Air C...

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Page 64: ...l and take any necessary precautions to ensure his her safe ty Wear appropriate personal protection equipment for all tasks 7 2 Care and cleaning Cleaning the machine Do not use aggressive detergents...

Page 65: ...k for cracks damage completeness 22 47 10 Check for leaks in hoses tubes valves pumps cylinders etc 20 29 47 11 Drain water separator 70 12 Lubricate all grease points 65 13 Inspect clean the radiator...

Page 66: ...he illustration below shows the location of grease points found on the left side of the machine Identical points also exist on the oppo site side of the machine Lubricate all points daily prior to ope...

Page 67: ...ve the dipstick once again and inspect the end for oil on the level indicator 6 Oil should be present on the dipstick up to but not over the upper full level indicator notch If the level is correct re...

Page 68: ...into a suitable catch container 5 Remove engine oil filter Upon removal make sure the filter gasket item 2 fig 7 6 1 is still present on the filter If not remove it from the filter port on the engine...

Page 69: ...anual 3 Locate and remove the hydraulic fluid drain plug item 1 through the drain hole in the belly pan fig 7 7 1 4 Drain the used oil into a suitable catch container 5 Dispose of the oil according to...

Page 70: ...hree bolts secur ing the cover and remove it 5 Remove the old filter from the housing and replace it with a new element Dispose of the used filter according to local man dates 6 Reinstall the cover an...

Page 71: ...ll of the water has been drained from the catch bowl and close the hood to complete the procedure 7 11 Fuel Filter Change The fuel filter should be changed every 500 service hours or as needed A plugg...

Page 72: ...ng premature wear and damage Operation on sand turf or other finished surfaces may require less frequent cleaning but daily inspection is still advised 7 13 Track Tension Check Proper track tension is...

Page 73: ...ension device 3 Once the jam nut is loose turn the tensioner until the track tension is within speci fication figure 7 14 2 4 Turn the tensioner the opposite direction to loosen the track 5 Once prope...

Page 74: ...eeded The rollers 1 rotate on steel pins 2 limiting wear to the inside of the rollers As they wear the rollers become thinner but will contin ue to function and perform as long as they are rotating Vi...

Page 75: ...the elements 1 With the engine off and cool and the key removed from the ignition open the hood release the latches on either side of the air cleaner then remove the cover 2 Remove the primary elemen...

Page 76: ...he solution to fur ther clean the element Never soak for more than 24 hours 3 Rinse the filter thoroughly with a gentle stream of water to remove all dirt and remaining detergent 4 Allow the filter to...

Page 77: ...e spray is directed straight through the cooler or the cooling fins may be damaged bent over which will decrease cooling performance Note If hydraulic oil or engine coolant temperature lights illumina...

Page 78: ...ns on the underside of the machine 2 Raise the hood at the rear of the machine 3 Pressure wash any debris from the engine compartment and chassis area out through the lower opening 4 Re install the be...

Page 79: ...working prop erly and inspect it If it appears damaged in any way replace it 7 MAINTENANCE 78 40 40 50 20 20 60 50 5 5 10 10 5 10 10 15 10 10 10 5 25 10 20 A RELAY 12077866 35 A RELAY 12177234 35 A RE...

Page 80: ...dry place that provides protection from the elements Drain and refill the cooling system with 50 50 pre mixed antifreeze water Replace engine oil and filter ch 7 Replace hydraulic oil and filters ch...

Page 81: ...Install fully charged battery Remove exhaust outlet cover Perform pre start checklist in chapter 5 of this manual Perform starting procedure chapter 5 Let engine run while observing engine monitoring...

Page 82: ...Hours Service Performed Notes SERVICE LOG 81...

Page 83: ...Hours Service Performed Notes SERVICE LOG 82...

Page 84: ...Hours Service Performed Notes SERVICE LOG 83...

Page 85: ...le 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 UK ML1 5RY Phone 44 0...