Terex PT-110 F User manual

PT-110/PT-110 F
Operation and Maintenance Manual
Compact Track Loader
Version: EN
Edition: 2013-02
Part Number: 2095-479 (US)
Valid From Serial No: 00101 (PT-110)
00101 (PT-110F)
Original Instructions

CONTENTS
Introduction...................................................... 2
Safety ................................................................. 5
Technical Data.................................................. 29
Machine Description / Controls................. 35
Operation........................................................... 59
Transportation.................................................. 69
Maintenance..................................................... 75
California Proposition 65.............................. 96
Service Log ........................................................ 97
1
Page
The operator must read and understand all the instructions in this
manual before operating the machine.
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1 INTRODUCTION
2
1.1 Product Identification (PIN)
The machine PIN is located on the identifi-
cation plate, on the front surface of the
operator enclosure.
Please state the model of the machine and
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.
It is imperative that this manual be provided to the end user at the time of pur-
chase, prior to operation and kept with the machine at all times. If lost or dam-
aged, contact your dealer immediately to obtain a replacement prior to resuming
operation.
It is very important that the operator read and understand the information in
this manual prior to operating the machine or performing maintenance or
service.
During operation, it is very important that the operator obey the instructions
in this manual to ensure safe and efficient operation.
Should you need clarification or further explanation of the topics in this manual,
please contact your dealer immediately for assistance.
Information describing special equipment or attachments and their operation are
not included in this manual.
This manual should be stored in the black plastic manual box located inside the
cab enclosure.
1.3 Safety Alert Symbol
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.
1.4 Intended Use
The machine with standard dirt bucket is intended to be used solely for work con-
sistent with its design. Such work includes loosening, collecting, transporting, and
distributing soil, rock, or similar materials as well as loading these materials onto
trucks, conveyors, or other methods of transport.
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1 INTRODUCTION
3
After installation of compatible (see section 4.13) special working attachments,
the equipment can be used for corresponding applications.
The operator must follow the enclosed operating instructions (manuals) for any
externally supplied components or attachments.
This machine can also be used for towing provided the specific operating
instructions found in the “towing” section of this manual are followed.
Any use varying from that described here or any lack of adherence to the operat-
ing instructions, maintenance procedures, or replacement intervals described in
this manual shall be regarded as unintended or improper use. The supplier cannot
be held responsible for any damage resulting from improper use. This risk is
borne solely by the user.
Note: Mulching type brush cutting attachments commonly used on this type of
machine may become unbalanced due to worn, damaged, or missing “teeth”,
causing vibration. If the attachment is operated in this condition, it can cause
metal fatigue and / or cracking in both the host machine and the attachment
itself. Vibration can also cause hydraulic component failure (ex: relief valves).
Mulching type brush cutters also generate more dust and flying debris than other
attachments. The increased particles can plug coolers, radiators, and air cleaners
much faster causing overheat or even engine failure if left unattended. The debris
can also be introduced into many high temperature areas and can become a fire
hazard. 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.
1.5 Bulletin Compliance
It is very important to comply with all safety related bulletins. Bulletins are tied to
the most current owner on record. Therefore, it is important that any new owner
contact their local dealer to register the machine in their name. This will ensure
that they will be notified in the event of a safety related bulletin affecting their
machine.
1.6 Contacting the Manufacturer
If you have questions relating to ownership including, but not limited to: accident
reporting, current owner updates, product applications and safety, standards and
regulations compliance, product modifications, transfer of ownership, please
consult your local dealer as the first point of contact.
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1.7 Copyright
This manual is intended for use by personnel responsible for operation, mainte-
nance, repair, and supervision activities involving the machine described within.
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 con-
sent.
1.8 Warranty
Your Terex PT-110 is warranted under the Terex Compact Track Loader and Utility
Vehicle Standard Limited New Product Warranty (“Warranty”). A copy of the
Warranty certificate is included with this manual and is also available from your
Authorized Terex Distributor.
1 INTRODUCTION
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2.1 Safety Alert System ................................. 7
2.2 Graphical Symbols................................... 8
2.3 Safety Signs (ANSI) .................................. 12
2.4 General Notes............................................ 14
2.5 Personal Protection Equipment ......... 15
2.6 Hazard Zone............................................... 15
2.7 Operation.................................................... 16
2.8 Stability........................................................ 17
2.9 Transport of Persons ............................... 17
2.10 Fire Prevention ....................................... 18
2.11 Crush / Burn Avoidance ...................... 19
2.12 Placing Into Operation ........................ 20
2.13 Starting the Machine ........................... 20
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
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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.
This symbol is used as an attention-getting device throughout this manual as well
as on decals and labels fixed to the machinery to assist in potential hazard recog-
nition and prevention.
NOTICE indicates a property damage
message.
Hazard Classification (applies only to ANSI safety signs)
The following signal words used with the safety alert symbol indicate a specific
level of severity of the potential hazard. Signal words used without the safety alert
symbol relate to property damage and protection only. Warnings in this publication
and on the product labels are identified by these symbols.
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DANGER indicates a hazardous situ-
ation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous sit-
uation which, if not avoided, could
result in death or serious injury.
CAUTION, used with the safety alert
symbol, indicates a hazardous situ-
ation which, if not avoided, could
result in minor or moderate injury.

2.2 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
result.
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.
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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.
Hazard: Burn
Avoidance: Do not touch hot
surfaces.
Hazard: Crush
Avoidance: Fasten seat belt.
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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.
Hazard: Crush
Avoidance: Keep clear of moving
machine.
Hazard: Crush
Avoidance: Keep clear of lift arms
and attachments.
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Hazard Avoidance
Pictorial Pictorial Description
Hazard: Crush
Avoidance: Install lift arm brace
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.
Avoidance: Read and understand
the operator’s manual.
Hazard: Fire
Avoidance: Read and understand
the operator’s manual.
Hazard: Flying Debris
Avoidance: Stay Clear of rear of
machine. Read and understand
the operator’s manual.
2030-41
7
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2.3 Safety Signs
The safety signs are located in/on the machine as indicated. (Descriptions of the
symbols are provided in section 2.2)
Key
1. Crush hazard (lift arms)
2. Fall hazard
3. Read operator’s manual / fall hazard (inside cab enclosure / fire notice)
4. Skin (oil) injection hazard
5. Entanglement hazard (engine compartment)
6. Clean undercarriages notice (one on each side of machine)
7. Tie down location (found beneath loader in front locations)
8. Crush hazard (run over)
9. Crush hazard (lift arm brace)
CRUSH HAZARD
Contact with moving machine can
result in death or serious injury.
Keep clear of moving machine.
2030-593
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment.
Keep clear of lift arms and
attachments. 2030-592
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment. Install lift arm brace prior to servicing.
2030-594
Fall Hazard
Serious injury or death can result
from falling.
Use the provided access system when
entering or exiting the machine.
2030-597
Injection Hazard
Escaping fluid under pressure can
penetrate skin, causing serious injury.
• Relieve internal pressure before
disconnecting any line or fitting.
• Keep away from leaks or pinholes.
• Use cardboard to check for leaks.
Fluid injected into skin must be surgi-
cally removed within a few hours by a
doctor familiar with this type of injury
or gangrene will result. 2030-602
Improper operation or maintenance
can result in serious injury or death.
Read and understand the opera-
tor’s manual and all safety signs
prior to operating or maintaining
the machine.
Fire Hazard
Flammable debris can collect near
hot components and lead to a fire.
Read Operator’s Manual
Keep the engine, exhaust and
chassis areas free of debris.
Do not use the bucket/attachment
as a work platform.
Fall Hazard
Falling can result in serious injury
or death.
2
4
1
3
7
9
8
Entanglement Hazard
Rotating parts can cause personal injury.
Keep away from fan and belt while the
engine is running. Stop engine before
servicing.
2030-600
5
12
2 SAFETY
Inspect undercarriages daily for
accumulation of debris. If debris
is present, clean thoroughly with
a pressure washer. If debris is
allowed to build up, it can cause
premature component wear and
decrease machine performance.
2085-253
NOTICE
6
WARNING
WARNING
A
R
WARNING
WARNING
WARNING
WARNING
WARNING
7
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Note:
Safety signs are designed and fitted to the product to warn of possible dangers,
and MUST be replaced immediately if they become unreadable or lost. If the
product is repaired and parts have been replaced on which safety signs were
fixed, be sure new safety signs are fitted before the product is put into
service.
Key (continued)
10. Burn hazard (engine compartment)
11. Burn hazard (engine compartment)
12. Explosion / burn hazard (read operator’s manual) (engine compartment)
13. Crush hazard / fall hazard / rollover/ejection hazard (inside cab)
14. Skin (oil) injection hazard
15. Crush hazard (lift arms)
16. Crush hazard (lift arm brace)
17. Crush hazard (run over)
18. Tie down location
19. Flying debris hazard
Burn Hazard
Hot fluid under pressure can scald.
Allow the machine to cool thoroughly
before opening.
2030-595
11 12
CRUSH HAZARD
Contact with moving machine can
result in death or serious injury.
Keep clear of moving machine.
2030-593
Crush Hazard
Rollover can crush and result in
serious injury or death.
Fasten Seat Belt
Fall Hazard
Falling from a machine can result
in serious injury or death
No Riders
Rollover/Ejection Hazard
Serious injury or death can result.
Carry loads low. Load unload and
turn on level ground. Travel on
inclines with heaviest end of
machine uphill. 2046-300
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment.
Keep clear of lift arms and
attachments. 2030-592
Injection Hazard
Escaping fluid under pressure can
penetrate skin, causing serious injury.
• Relieve internal pressure before
disconnecting any line or fitting.
• Keep away from leaks or pinholes.
• Use cardboard to check for leaks.
Fluid injected into skin must be surgi-
cally removed within a few hours by a
doctor familiar with this type of injury
or gangrene will result. 2030-602
14
15
13
17
18
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment. Install lift arm brace prior to servicing.
2030-594
16
13
2 SAFETY
2076-386
FLYING DEBRIS
Contact with flying debris can result in
death or serious injury.
Stay clear of rear of machine.
19
WARNING
WARNING WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
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Explosion/Burn Hazard
Will cause death, burns or
blindness due to ignition of
explosive gasses or contact
with corrosive acid.
• Keep all flames/sparks
away!
• No Smoking!
• Read and understand
all manuals prior to
operation. 2030-603
10
Burn Hazard
Contact with hot surfaces can
cause burns.
• Do not touch hot
components!
• Allow the machine to
cool thoroughly prior to
servicing. 2030-601
S

2.4 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. DO NOT use solvent based cleaners, as they
may damage the safety sign material.
• If safety signs are damaged or illegible, replace them immediately, prior to
operation.
• Never jump off of the machine. Instead use the hand holds and step
designed for entering and exiting the machine. Face the machine and use
three points of contact (defined as: one foot and two hands, or one hand
and two feet) to ensure your safety.
• Do not use any method of operation, inspection, or maintenance that may
impair safety.
• This machine is only to be used when properly equipped for the task to be
performed and when properly inspected and maintained to ensure safe
operation.
• The manufacturer’s instructions regarding operation, inspection, mainte-
nance, repair and transportation must be followed.
• Never place the machine into operation without having first performed a
thorough walk-around inspection and making any necessary repairs or
adjustments.
• Safety devices on the machine shall not be deactivated or removed.
• Do not make any changes, additions or conversions to the machine that
could have a negative effect on safety without the manufacturer’s written
approval.
• Any persons in close proximity to the machine during operation should
familiarize themselves with the safety precautions described in this manual
prior to operation.
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2.5 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. Long hair
should be restrained. Personal Protective Equipment (PPE) must be worn in the
absence of an enclosed cab. In this case PPE would include, but not be limited to,
safety glasses. The use of some attachments may require additional PPE, such as
hearing protection, hardhat, gloves, and steel-toed shoes. In some applications
high visibility/reflective jackets are required.
Personal protection equipment is also recommended when performing mainte-
nance or service on a machine. Always wear appropriate protective equipment for
working conditions when working on or around the machine. Loose clothing
should not be worn and long hair should be restrained. Wear hard hats, protective
face/eyewear, safety shoes and any other equipment necessary to ensure your
safety and the safety of others around you as you work.
2.6 Hazard Zone
The hazard zone encompasses the area around the machine in which persons
may be injured by movements of the machine, its attachments, or by falling loads,
during operation.
Do not position yourself or allow anyone else within this hazard zone during
machine operation. Keep a safe distance to ensure your safety while the machine
is in operation.
If someone enters the hazard zone, the operator must stop all work and give a
warning signal to the person who may be in danger to leave the hazard zone.
Work should not resume until all persons have vacated the hazard zone.
To minimize the possibility of a crushing hazard, a sufficient safety distance (min.
1.6 ft (0.5 m)) must be kept from solid objects, e. g. buildings, slopes, scaffolding,
other machines, etc. If that distance cannot be kept, fence off the area between
solid construction elements and the working elements of the machine.
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.
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2.7 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.
• can be trusted to perform their assigned duties in a safe and reliable
manner.
• are of the legal minimum age for performing such duties.
It is the responsibility of the operator to
• inspect the machine prior to operation and perform any necessary checks,
adjustments or repairs to ensure safe 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 any fault that may compromise safety.
• use the machine in accordance with the appropriate local job site
organization system to ensure safe coordination with other machines,
vehicles, and people on the job site.
Investigate any work site prior to operation to determine whether any special haz-
ards exist. Take necessary measures to eliminate or reduce any hazard.
Do not operate the machine in unsafe conditions including, but not limited
to: in inclement weather (example: electrical storm), near overhead electric lines,
in enclosed areas without proper ventilation, in contaminated areas without nec-
essary safety equipment and personnel.
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2.8 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.
• Exercise extreme caution while operating on inclines.
• Avoid operation on steep inclines.
• Do not make sudden changes in direction, move slowly, and always carry
loads low to maximize machine stability.
• Always keep the heaviest end of the machine facing uphill when working
on an incline.
• When operating on any surface other than firm and level ground, use extra
caution. 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.
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2.10 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.
• When refueling or charging the battery, do not smoke or allow open flame
near the machine.
• Always start the engine according to the procedure in the operating
instructions.
• Inspect and clean the radiator/oil cooler, engine compartment, exhaust
system and other areas where there may be hot or rotating parts daily. In
some work environments, flammable debris including but not limited to:
leaves, straw, wood particles (dust), and similar items can accumulate in
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 immediately.
• Regularly check all lines, hoses and threaded couplings for leaks and
damage. Repair leaks immediately and replace any defective parts. Oil leaks
can easily lead to a fire. NEVER use bare hands to check for hydraulic
leaks! Pressurized fluid (oil) can penetrate skin and cause gangrene. If
injection occurs, seek medical attention immediately!
• Do not use any starting aids containing ether to start diesel engines with
pre-heat systems! Use of starting aids of this nature can cause an
EXPLOSION!
• Familiarize yourself with the location of any fire extinguishers in/on the
machine and how to use them as well as local options for reporting and
fighting fires should one occur.
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2.11 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. Always wear safety
gloves when working with wire cables.
• Never align holes with your fingers when working on the machine. Instead
use a suitable mandrel.
• Keep yourself and all objects that could be drawn into the fan at a safe
distance while the engine is running. The fan may deflect these objects
away or destroy them and would likely be damaged by the objects.
• The entire cooling system is hot and under pressure when it is at or near
operating 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 the cover slowly to bleed off any
excess pressure.
• The engine and hydraulic oil are hot when at or near operating temperature.
Avoid skin contact with hot oil or parts carrying oil.
• Wear safety goggles and protective gloves when you are working with the
battery. keep sparks and open flames away from the work area.
• 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.
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