Terex Rubber Track Loader Pt70 80 Service Manual

Full download: [Link]

Service Manual
Rubber Track Loader

Brought to you by:

[Link]
5060 Fulton Industrial Blvd
Atlanta, GA 30336
PT-70/80
Part Number: 2046-310
877-857-7209
Printed (3-09)

This is the cut pages sample. Download all 141 page(s) at: [Link]
 Table of Contents

1. Product Safety 3. Circuit Diagrams

Chapter Overview . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter Overview . . . . . . . . . . . . . . . . . . . . . 3-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . 1-1 Hydraulic Charge Circuit . . . . . . . . . . . . . . . . 3-1
Information Messages . . . . . . . . . . . . . . . . . 1-1 Hydraulic Auxiliary Circuit . . . . . . . . . . . . . . . 3-2
Basic Precautions . . . . . . . . . . . . . . . . . . . . . 1-1 Hydraulic Drive Circuit . . . . . . . . . . . . . . . . . 3-3
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . 1-1 Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 3-4
Protective Equipment . . . . . . . . . . . . . . . . 1-1 Hydraulic Pilot Generation Solenoid Block . . 3-5
Entering and Exiting . . . . . . . . . . . . . . . . . 1-2 Electrical Attachment Outlet . . . . . . . . . . . . . 3-6
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Drive Control (line routing) . . . . . . . . . . . . . . 3-7
Hot Fluids and Components . . . . . . . . . . . 1-2 Lift Arm Control (line routing) . . . . . . . . . . . . 3-8
Corrosion Inhibitor . . . . . . . . . . . . . . . . . . . 1-2
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 4. Maintenance
Pressurized Items . . . . . . . . . . . . . . . . . . . 1-2 Chapter Overview . . . . . . . . . . . . . . . . . . . . . 4-1
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 4-1
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Lift-Arm Brace . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Asbestos Information . . . . . . . . . . . . . . . . . . 1-4 Tilt-up Cab . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Machine Labels and Decals . . . . . . . . . . . . . 1-4 Jacking Procedure . . . . . . . . . . . . . . . . . . . . 4-2
Product Identification Number . . . . . . . . . . 1-4 Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . 4-3
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . 1-4 Undercarriages . . . . . . . . . . . . . . . . . . . . . . . 4-3
Track Tension . . . . . . . . . . . . . . . . . . . . . . . . 4-4
2. Technical Specifications Drive Sprocket Rollers . . . . . . . . . . . . . . . . . 4-5
Specifications (PT-70) . . . . . . . . . . . . . . . . . . 2-1 Track Removal . . . . . . . . . . . . . . . . . . . . . . . 4-6
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Track Installation . . . . . . . . . . . . . . . . . . . . . . 4-8
Transmission . . . . . . . . . . . . . . . . . . . . . . . 2-1 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Drive Pumps . . . . . . . . . . . . . . . . . . . . . . 2-1 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Charge Pump . . . . . . . . . . . . . . . . . . . . . 2-1 Water Separator . . . . . . . . . . . . . . . . . . . . . . 4-11
Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Accessory Belt Tension . . . . . . . . . . . . . . . . 4-12
Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Fan Belt Removal/Installation . . . . . . . . . . . . 4-13
Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . 2-1 A/C Belt Removal/Installation . . . . . . . . . . . . 4-13
Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 2-1 Engine Oil/FIlter Change . . . . . . . . . . . . . . . 4-14
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Engine Oil Specifications . . . . . . . . . . . . . . . 4-15
Critical Torque Specifications . . . . . . . . . . . . 2-1 Oil Level Check . . . . . . . . . . . . . . . . . . . . . . 4-15
Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Hydraulic Fluid/Filter Change . . . . . . . . . . . . 4-16
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Radiator/Oil Cooler (cleaning) . . . . . . . . . . . 4-17
Specifications (PT-80) . . . . . . . . . . . . . . . . . . 2-2 Engine (cleaning) . . . . . . . . . . . . . . . . . . . . . 4-17
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Case Drain Filter . . . . . . . . . . . . . . . . . . . . . . 4-18
Transmission . . . . . . . . . . . . . . . . . . . . . . . 2-2 Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Drive Pumps . . . . . . . . . . . . . . . . . . . . . . 2-2 Maintenance Schedule . . . . . . . . . . . . . . . . . 4-19
Charge Pump . . . . . . . . . . . . . . . . . . . . . 2-2
Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 5. Machine Controls and Instrumentation
Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Chapter Overview . . . . . . . . . . . . . . . . . . . . . 5-1
Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . 2-2 Machine Controls . . . . . . . . . . . . . . . . . . . . . 5-1
Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 2-2 Lift Arm Control . . . . . . . . . . . . . . . . . . . . . . . 5-1
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Drive Control . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Critical Torque Specifications . . . . . . . . . . . . 2-2 Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . 5-1
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

I
Rubber Track Loader
Table of Contents

6. Operator Enclosure 9. Hydraulic Reservoir

Chapter Overview . . . . . . . . . . . . . . . . . . . . . 6-1 Chapter Overview . . . . . . . . . . . . . . . . . . . . . 9-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 6-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 9-1
Machine Preparation . . . . . . . . . . . . . . . . . . . 6-1 Machine Preparation . . . . . . . . . . . . . . . . . . . 9-1
Removal & Installation . . . . . . . . . . . . . . . . . 6-1 Removal & Installation . . . . . . . . . . . . . . . . . 9-1
Door Gas Spring . . . . . . . . . . . . . . . . . . . . 6-1 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . 9-1
Removal Procedure . . . . . . . . . . . . . . . . 6-1 Removal Procedure . . . . . . . . . . . . . . . . 9-1
Installation Procedure . . . . . . . . . . . . . . 6-1 Installation Procedure . . . . . . . . . . . . . . 9-7
Pillar Switch Panels . . . . . . . . . . . . . . . . . . 6-2 Suction Screen . . . . . . . . . . . . . . . . . . . . . 9-8
Removal Procedure . . . . . . . . . . . . . . . . 6-2 Removal Procedure . . . . . . . . . . . . . . . . 9-8
Installation Procedure . . . . . . . . . . . . . . 6-2 Installation Procedure . . . . . . . . . . . . . . 9-8
Side Panels/Gauges . . . . . . . . . . . . . . . . . 6-3
Removal Procedure . . . . . . . . . . . . . . . . 6-3 10. Lift Arm/Drive Controls
Installation Procedure . . . . . . . . . . . . . . 6-3 Chapter Overview . . . . . . . . . . . . . . . . . . . . .10-1
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Personal Safety . . . . . . . . . . . . . . . . . . . . . .10-1
Removal Procedure . . . . . . . . . . . . . . . . 6-4 Machine Preparation . . . . . . . . . . . . . . . . . . .10-1
Installation Procedure . . . . . . . . . . . . . . 6-4 Removal & Installation . . . . . . . . . . . . . . . . .10-1
Interior Panel, Rear . . . . . . . . . . . . . . . . . . 6-4 Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
Removal Procedure . . . . . . . . . . . . . . . . 6-4 Removal Procedure . . . . . . . . . . . . . . . .10-1
Installation Procedure . . . . . . . . . . . . . . 6-4 Installation Procedure . . . . . . . . . . . . . .10-3
Lift Arm Float Magnet . . . . . . . . . . . . . . . .10-3
7. Chassis and Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . .10-3
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 7-1 Installation . . . . . . . . . . . . . . . . . . . . . . .10-3
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 7-1 Lift Arm Control Valve . . . . . . . . . . . . . . . .10-4
Machine Preparation . . . . . . . . . . . . . . . . . . . 7-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . .10-4
Removal & Installation . . . . . . . . . . . . . . . . . 7-1 Installation . . . . . . . . . . . . . . . . . . . . . . .10-4
Fuel Sending Unit . . . . . . . . . . . . . . . . . . . 7-1
Removal Procedure . . . . . . . . . . . . . . . . 7-1 11. Hydraulic Pumps/Motors
Installation Procedure . . . . . . . . . . . . . . 7-2 Chapter Overview . . . . . . . . . . . . . . . . . . . . . 11-1
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 11-1
Removal Procedure . . . . . . . . . . . . . . . . 7-2 Machine Preparation . . . . . . . . . . . . . . . . . . . 11-1
Installation Procedure . . . . . . . . . . . . . . 7-3 Removal & Installation . . . . . . . . . . . . . . . . . 11-1
Footwell . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Removal Procedure . . . . . . . . . . . . . . . . 7-4 Removal Procedure . . . . . . . . . . . . . . . . . . 11-1
Installation Procedure . . . . . . . . . . . . . . 7-4 Installation Procedure . . . . . . . . . . . . . . . . 11-2
Foot Throttle Assembly . . . . . . . . . . . . . . . 7-5 Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . 11-3
Removal Procedure . . . . . . . . . . . . . . . . 7-5 Removal Procedure . . . . . . . . . . . . . . . . . . 11-3
Installation Procedure . . . . . . . . . . . . . . 7-5 Installation Procedure . . . . . . . . . . . . . . . . 11-4
Hood Assembly . . . . . . . . . . . . . . . . . . . . . 7-5 Tandem Drive Pump . . . . . . . . . . . . . . . . . . . 11-4
Removal Procedure . . . . . . . . . . . . . . . . 7-5 Removal Procedure . . . . . . . . . . . . . . . . . . 11-4
Installation Procedure . . . . . . . . . . . . . . 7-6 Installation Procedure . . . . . . . . . . . . . . . . 11-5
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
8. Radiator and Oil Cooler Removal Procedure . . . . . . . . . . . . . . . . . . 11-6
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 8-1 Installation Procedure . . . . . . . . . . . . . . . . 11-8
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 8-1
Machine Preparation . . . . . . . . . . . . . . . . . . . 8-1
Removal & Installation . . . . . . . . . . . . . . . . . 8-1
Fan Guard . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Removal Procedure . . . . . . . . . . . . . . . . 8-1
Installation Procedure . . . . . . . . . . . . . . 8-2
Fan & Shroud . . . . . . . . . . . . . . . . . . . . . . 8-2
Removal Procedure . . . . . . . . . . . . . . . . 8-2
Installation Procedure . . . . . . . . . . . . . . 8-3
Radiator/Oil Cooler . . . . . . . . . . . . . . . . . . 8-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Installation . . . . . . . . . . . . . . . . . . . . . . . 8-4

II
 Rubber Track Loader
Table of Contents

12. Engine 16. Hydraulic Component Service

Chapter Overview . . . . . . . . . . . . . . . . . . . . . 12-1 Chapter Overview . . . . . . . . . . . . . . . . . . . . . 16-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 12-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 16-1
Removal & Installation . . . . . . . . . . . . . . . . . 12-1 Disassembly & Assembly . . . . . . . . . . . . . . . 16-1
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . 16-1
Removal Procedure . . . . . . . . . . . . . . . . 12-1 Disassembly Procedure . . . . . . . . . . . . . 16-1
Installation Procedure . . . . . . . . . . . . . . 12-2 Assembly Procedure . . . . . . . . . . . . . . . 16-3
Exhaust System . . . . . . . . . . . . . . . . . . . . 12-2 Lift Arm Control Valve . . . . . . . . . . . . . . . . 16-4
Removal Procedure . . . . . . . . . . . . . . . . 12-2 Disassembly Procedure . . . . . . . . . . . . . 16-4
Installation Procedure . . . . . . . . . . . . . . 12-4 Assembly Procedure . . . . . . . . . . . . . . . 16-6
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Drive Motor (brake portion) . . . . . . . . . . . . 16-6
Removal Procedure . . . . . . . . . . . . . . . . 12-4 Disassembly Procedure . . . . . . . . . . . . . 16-6
Installation Procedure . . . . . . . . . . . . . . 12-5 Assembly Procedure . . . . . . . . . . . . . . . 16-7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 Drive Motor (motor portion) . . . . . . . . . . . . 16-8
Removal Procedure . . . . . . . . . . . . . . . . 12-5 Disassembly Procedure . . . . . . . . . . . . . 16-8
Installation Procedure . . . . . . . . . . . . . . 12-7 Assembly Procedure . . . . . . . . . . . . . . . 16-9
Drive Pump (Drive Relief Valves) . . . . . . . 16-9
13. Undercarriage Disassembly & Adjustment . . . . . . . . . . 16-9
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 13-1 Posi-Power Relief Valve . . . . . . . . . . . . . 16-10
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 13-1 Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . 16-10
Machine Preparation . . . . . . . . . . . . . . . . . . . 13-1 Disassembly Procedure . . . . . . . . . . . . . 16-10
Removal & Installation . . . . . . . . . . . . . . . . . 13-1 Assembly Procedure . . . . . . . . . . . . . . . 16-12
15” Idler Wheel (PT-80) . . . . . . . . . . . . . . . 13-1 Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . 16-14
Removal Procedure . . . . . . . . . . . . . . . . 13-1 Disassembly Procedure . . . . . . . . . . . . . 16-14
Installation Procedure . . . . . . . . . . . . . . 13-2 Assembly Procedure . . . . . . . . . . . . . . . 16-15
10’’ & 15” Wheel (PT-70) . . . . . . . . . . . . . . 13-3
Removal & Installation Procedure . . . . . 13-3 17. Hydraulic Pressure & Flow
10” Bogie Wheel & Hub (PT-80) . . . . . . . 13-4 Chapter Overview . . . . . . . . . . . . . . . . . . . . . 17-1
Removal & Service Procedure . . . . . . . . 13-4 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 17-1
Idler Hub . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8 Contamination Inspection . . . . . . . . . . . . . . . 17-1
Removal & Service Procedure . . . . . . . . 13-8 Pressure/Flow Test and Troubleshooting . . . 17-1
Charge Pressure Check & Adjust . . . . . . . 17-1
14. Lift Arm Components Auxiliary Pressure Check & Adjust . . . . . . 17-3
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 14-1 Lift Arm Pressure Check . . . . . . . . . . . . . . 17-4
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 14-1 Drive Pressure Check . . . . . . . . . . . . . . . . 17-4
Machine Preparation . . . . . . . . . . . . . . . . . . . 14-1 Troubleshooting . . . . . . . . . . . . . . . . . . . 17-5
Removal & Installation . . . . . . . . . . . . . . . . . 14-1 Posi-Power Pressure Check & Adjust . . . . 17-5
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 14-1 Auxiliary Flow Test . . . . . . . . . . . . . . . . . . . 17-6
Removal Procedure . . . . . . . . . . . . . . . . 14-1 Troubleshooting . . . . . . . . . . . . . . . . . . . 17-7
Installation Procedure . . . . . . . . . . . . . . 14-3
Bucket/Tilt Cylinder . . . . . . . . . . . . . . . . . . 14-3 18. Troubleshooting
Removal Procedure . . . . . . . . . . . . . . . . 14-3 Chapter Overview . . . . . . . . . . . . . . . . . . . . . 18-1
Installation Procedure . . . . . . . . . . . . . . 14-5 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 18-1
Q/C Block PRV . . . . . . . . . . . . . . . . . . . . . 14-5 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . 18-1
Removal Procedure . . . . . . . . . . . . . . . . 14-5 General Troubleshooting Scenarios . . . . . . . 18-1
Installation Procedure . . . . . . . . . . . . . . 14-5 Engine/Machine Troubleshooting . . . . . . . . . 18-3

15. Quick Attach 19. Lubricant and Fuel Specifications

Chapter Overview . . . . . . . . . . . . . . . . . . . . . 15-1 Chapter Overview . . . . . . . . . . . . . . . . . . . . . 19-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 15-1 Fluids & Fuel Specifications . . . . . . . . . . . . . 19-1
Machine Preparation . . . . . . . . . . . . . . . . . . . 15-1
Removal & Installation . . . . . . . . . . . . . . . . . 15-1
Locking Pin . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Removal Procedure . . . . . . . . . . . . . . . . 15-1
Installation Procedure . . . . . . . . . . . . . . 15-2
Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
Removal Procedure . . . . . . . . . . . . . . . . 15-3
Installation Procedure . . . . . . . . . . . . . . 15-3
III
 1. Product Safety

Chapter Overview The person(s) in charge of servicing a Rubber Track

This chapter contains product safety information for the Loader may be unfamiliar with many of the systems on
Terex PT-70/80 Rubber Track Loaders. Read and the machine. This makes it especially important to use
understand all product safety information before caution when performing service tasks. Familiarize
attempting to service any Rubber Track Loader. yourself with the affected system(s) and components
before attempting any type of maintenance or service.
Safety Alert Symbol
This symbol means: Attention! It is not possible to anticipate every potential haz-
Be alert! Your safety is ard. The safety messages included in this docu-
involved! ment and displayed on the machine are not all-
inclusive. They are intended to make you aware of
The safety alert symbol is used potential risks and encourage a safe approach to
to alert you to potential personal performing service work. If you use a tool, proce-
injury hazards. Obey all safety messages that follow dure, work method or operating technique that is
this symbol to avoid possible injury or death. not specifically recommended by Terex, you must
satisfy yourself that it is safe for you and others.
This symbol is used as an attention-getting device You must also ensure that the machine will not be
throughout this manual as well as on decals and labels damaged or be made unsafe by the operation,
fixed to the machinery to assist in potential hazard lubrication, maintenance or repair procedures that
recognition and prevention. you choose.
Property or equipment damage warnings in this publi-
cation are identified by the signal word "NOTICE". Basic Precautions
NOTICE Safety Labels
“NOTICE” Indicates a hazardous situation which, Safety labels have been included and are displayed in
if not avoided, could result in property or equip- various places throughout the machine to serve as
ment damage. warnings of potentially dangerous conditions. Read
and understand all "Safety" labels on any Rubber
The word “Note” is used throughout this manual to Track Loader before attempting to operate, maintain or
draw your attention to specific topics or to supplement repair it. Replace any damaged, illegible or missing
the information provided in that section. labels immediately, prior to service.

Improper or incomplete maintenance/repair of a

Rubber Track Loader can be dangerous and
Personal Protective Equipment
may result in machine damage, injury or death. Personal protection equipment is recommended when
performing maintenance or service on a machine.
Do not attempt to perform any type of repair or main-
Always wear appropriate protective equipment for
tenance on a Rubber Track Loader until you have read
and fully understood both this manual and the working conditions when working on or around the
machine specific operation and maintenance manual. machine. Loose clothing should not be worn and long
hair should be restrained. Wear hard hats, protective
Refer to the Operation and Maintenance manual for face/eyewear, safety shoes and any other equipment
instructions regarding proper machine operation and
necessary to ensure your safety and the safety of oth-
maintenance techniques before operating or servicing
any Rubber Track Loader. ers around you as you work.

1-1
Rubber Track Loader
1. Product Safety

Entering and Exiting Pressurized Items

Always use steps and handholds when entering or 1. Do not use hands or any other body part to check
exiting a Rubber Track Loader. Clean any mud or for fluid leaks in the hydraulic system. Always use
debris from steps or work platforms before using them. a solid material like wood or metal to check for this
Always face the machine when using steps and hand- type of leak. Leaking fluid under pressure can pen-
holds. When it is not possible to use the designed etrate body tissue. Fluid penetration can cause
entry/exit system, utilize ladders, scaffolds, or work serious injury and even death. If fluid is injected
platforms to safely gain access to the machine. into your skin, get treatment immediately. Seek
treatment from a doctor that is familiar with this
Lifting type of injury.
Use a hoist when lifting components that weigh 50 lb
(23 kg) or more, to avoid back injury. Make sure all 2. Relieve pressure from the hydraulic system before
chains, hooks, slings, etc., are in good condition and disconnecting or removing any lines, fittings or
are of the correct capacity. Be sure hooks are posi- related items. Do this by relaxing all hydraulic
tioned correctly and equipped with a spring latch. actuators. If the lift arms are raised, make sure
Lifting eyes are not to be side loaded during a lifting they are securely braced. Be alert for possible
operation. pressure release when disconnecting any device
from a pressurized system.
Hot Fluids and Components 3. Lower the lift arms before performing any work on
Stay clear of hot components and system fluids of the the machine. If this cannot be done, make sure
engine, exhaust, radiator/oil cooler and hydraulic they are securely braced to prevent them from
lines/tubes. Also, use caution when removing fill caps, dropping unexpectedly during service.
breathers and plugs on the machine. Hold a rag over
the cap or plug to prevent being sprayed or splashed 4. Loose or damaged fuel, oil, hydraulic, lines, tubes
by liquids under pressure. Be especially careful if the and hoses can cause fires. Do not bend or strike
machine has been operated recently, fluids may still be high pressure lines or install ones that have been
hot. To ensure your safety, allow the machine to cool bent or damaged. Check lines, tubes and hoses
before attempting any service procedure that involves carefully. See item 1 for precautions on checking
hot fluids or components. for fluid leaks.

Corrosion Inhibitor 5. Pressurized air or water can also cause injury.

Corrosion inhibitor contains alkali. Avoid contact with When pressurized air or water is used for clean-
eyes. Avoid prolonged or repeated contact with skin. ing, wear a protective face shield, protective cloth-
Do not take internally. In case of contact, wash skin ing, and protective shoes. The recommended max-
immediately with soap and water. For eyes, flush with imum air pressure for cleaning purposes is 30 psi
large amounts of water for at least 15 minutes. Call (205 kPa). When using a pressure washer, keep in
Physician. Keep out of reach of children. mind that nozzle pressures are typically very high.
Generally, pressures are well above 2000 psi
(13790 kPa). Follow all recommended practices
Batteries provided by the pressure washer manufacturer.
Do not smoke when inspecting the battery electrolyte
level. Never disconnect any charging unit circuit or bat-
tery circuit cable from the battery when the charging
unit is operating. A spark can cause an explosion from
the flammable vapor mixture of hydrogen and oxygen
that is released from the electrolyte through the battery
outlets. Do not let electrolyte solution make contact
with skin or eyes. Electrolyte solution is an acid. In
case of contact, immediately wash skin with soap and
water. For eyes, flush with large amounts of water for
at least 15 minutes. Call Physician. Keep out of reach
of children.

1-2
 Rubber Track Loader
1. Product Safety

Repair 8. Be prepared to stop an engine if it has been re-

cently overhauled or the fuel system has been
Accidental machine starting can cause injury recently serviced. If the engine has not been
or even death to personnel working on a assembled correctly, or if the fuel settings are not
Rubber Track Loader. correct, the engine can possibly overspeed and
As a precaution, disconnect the battery cables from cause bodily injury, death or property damage. Be
the battery terminals, tape the battery clamps and prepared to shut off the fuel and air supply to the
remove the key from the ignition switch prior to per- engine in order to stop the engine.
forming any service work on a Rubber Track Loader.
9. Be careful when removing cover plates. Gradually
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is back off the last two bolts or nuts located on oppo-
being serviced. 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.
1. Disconnect the battery and discharge any capaci-
tor before beginning work on a machine. Attach a 10. Repairs requiring welding should be performed
Do Not Operate tag in the cab to alert any opera- only by personnel adequately trained and knowl-
tor that service is in progress. edgeable in welding procedures and with the guid-
ance of appropriate reference information.
2. If possible, make all repairs with the machine Determine the type of metal being welded and
parked on a level, hard surface. Use blocks to pre- select the correct welding procedure and filler
vent the machine from rolling while working on or material to provide a weld that is as strong or
under the machine. stronger than the original weld.
3. Do not work on or under any machine that is sup- 11. Take precautions to avoid damaging wiring during
ported only by a hydraulic jack or hoist. Always removal and installation operations. Carefully route
use some sort of mechanical support to ensure wires so that they will not contact sharp corners,
that the machine will not fall. Terex jack stands objects or hot surfaces during operation.
work well to support the machine while performing
maintenance or repair work. 12. When performing service that requires the lift arms
to be in the raised position, always utilize the lift
4. Make sure the work area around the machine is arm brace located on the rear of the loader tower.
safe and make yourself aware of any hazardous
conditions that may exist. If the engine needs to 13. Relieve hydraulic system pressure by relaxing all
be started inside an enclosure, make sure that the hydraulic actuators prior to attempting any
engine’s exhaust is properly vented. hydraulic maintenance or repair.
5. Be sure all protective devices including guards and 14. Always tighten connections to the correct torque
shields are properly installed and functioning cor- specification. Make sure that all shields, clamps
rectly before beginning any service task. If a guard and guards are installed correctly to avoid exces-
or shield must be removed to perform the repair sive heat, vibration or unwanted contact between
work, use extra caution. parts during operation. Shields that protect
exhaust components from oil spray in event of a
6. Always use the appropriate tools for the work to be line, tube or seal failure must be correctly installed.
performed. Tools should be in good condition and
you should understand how to use them properly 15. Do not operate a machine if any rotating part is
before performing any service work. damaged or contacts other parts during operation.
Any high speed rotating component that has been
7. When replacing fasteners, use parts of equivalent damaged or altered should be checked for balance
grade and size. Do not use a lesser quality fasten- before reusing. Make sure all protective devices,
er if replacements are necessary. including guards and shields, are properly installed
and functioning correctly before starting the engine
or operating the machine.

1-3
Terex Rubber Track Loader Pt70 80 Service Manual
Full download:
Rubber[Link]
Track Loader
1. Product Safety

Attachments Safety Label Examples

Only use attachments that are recommended by Terex. Examples of the labels and decals displayed on the
machine are shown on this page.
Make sure that all necessary guards and protective
equipment are in place and functioning prior to operat- WARNING
ing any attachment.

Wear protective glasses and protective equipment as

required by conditions or as recommended in the Crush Hazard
Death or serious injury can result
Keep clear of lift arms and
attachment’s operation manual. from contact with moving lift arm or
attachment.
attachments.

When replacement parts are required for your

machine, use only genuine Terex replacement DANGER
parts or parts that meet or exceed original
specifications including, but not limited to physical
dimensions, type, strength and material.
Installing lesser components can lead to premature Crush Hazard
Serious injury or death can result Keep clear of moving machine.
failures, product damage, personal injury or death. from contact with moving machine.

Ensure that all personnel are far enough away from WARNING
the work area so they will not be struck by flying ob-
jects.

Stay clear of the cutting edges, pinching surfaces or Fall Hazard

Use the provided access system when
crushing surfaces of the attachment while performing Serious injury or death can result
from falling.
entering or exiting the machine.

any attachment maintenance, testing or adjustments.

WARNING
Machine Labels and Decals • Relieve internal pressure before
disconnecting any line or fitting.
Labels and decals placed on the machine provide • Keep away from leaks or pinholes.
• Use cardboard to check for leaks.
safety information and operating instructions. Injection Hazard
Fluid injected into skin must be surgi-
cally removed within a few hours by a
Escaping fluid under pressure can
Familiarize yourself with the location and significance penetrate skin, causing serious injury.
doctor familiar with this type of injury
or gangrene will result.

of these labels to ensure your safety.

WARNING
Product Identification Number
The Product Identification Number (PIN) is located on
the front of the cab enclosure (figure 1-1). Always pro-
vide the PIN when contacting the dealer about parts, Crush Hazard
Death or serious injury can result
service, warranty or accessories. No warranty claims from contact with moving lift arm or
attachment.
Install lift arm brace prior to servicing.

will be processed unless the PIN is provided.

WARNING

Keep away from fan and belt while the

Entanglement Hazard engine is running. Stop engine before
Rotating parts can cause personal injury. servicing.

WARNING
1-1

Burn Hazard Allow the machine to cool thoroughly

Hot fluid under pressure can scald. before opening.

1-4
This is the cut pages sample. Download all 141 page(s) at: [Link]