Terex PT100 Forestry Operating instructions

8/17/2016
Service Repair Manual
PT100 Forestry
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English
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i
Table of Contents
1. Product Safety
Chapter Overview ...................................................1-1
Basic Precautions ...................................................1-1
Safety Labels…. ................................................1-1
Personal Protective Equipment..........................1-1
Entering and Exiting...........................................1-2
Lifting.................................................................1-2
Hot Fluids and Components ..............................1-2
Corrosion Inhibitor .............................................1-2
Batteries ............................................................1-2
Pressurized Items..............................................1-2
Repair .....................................................................1-3
Attachments............................................................1-4
Machine Labels and Decals....................................1-4
Product ID Number..................................................1-4
Safety Label Examples......................................1-4
2. Technical Specifications
Specifications..........................................................2-1
Engine ...............................................................2-1
Transmission .....................................................2-1
Drive Motors ......................................................2-1
Control Handles.................................................2-1
Auxiliary Pump...................................................2-1
Loader Valve......................................................2-1
Cooler................................................................2-1
Critical Torque Specifications ............................2-1
3. Circuit Diagrams
Chapter Overview ...................................................3-1
Hydraulic Charge Circuit.........................................3-1
Hydraulic Auxiliary Circuit .......................................3-2
Hydraulic Drive Circuit.............................................3-3
Lift Arm Control Valve..............……………………...3-4
Hyd. Pilot Gen Block................……………………3-5
Electrical Attachment Outlet.........................................3-6
4. Machine Controls and Instrumentation
Chapter Overview ...................................................4-1
Machine Controls....................................................4-1
Loader Control...................................................4-1
Drive Control......................................................4-1
Throttle ..............................................................4-1
Instrumentation .......................................................4-1
Switches..................................................................4-2
5. Operator Enclosure Disassembly
and Assembly
Chapter Overview ...................................................5-1
Personal Safety.......................................................5-1
Machine Preparation...............................................5-1
Operator Enclosure Disassembly and Assembly
Procedures..............................................................5-1
Gauge Panel Removal and Installation...................5-1
Gauge Panel Removal.......................................5-1
Gauge Panel Installation....................................5-2
Ignition Switch Removal and Installation.................5-2
Ignition Switch Removal ....................................5-2
Ignition Switch Installation .................................5-3
Gauge Removal and Installation.............................5-4
Gauge Removal.................................................5-4
Gauge Installation..............................................5-4
Head light Removal and Installation........................5-5
Head Light Removal..........................................5-5
Head light Installation ........................................5-5
6. Fuel Tank Disassembly and Assembly
Chapter Overview...................................................6-1
Personal Safety.......................................................6-1
Machine Preparation...............................................6-1
Disassembly and Assembly Procedures................6-1
Fuel Sending Unit Removal & Installation...............6-1
Fuel Sending Unit Removal ...............................6-1
Fuel Sending unit Installation.............................6-2
Fuel Tank Removal.................................................6-2
Fuel Tank Installation..............................................6-3
7. Radiator/Oil Cooler Disassembly
and Assembly
Chapter Overview...................................................7-1
Personal Safety.......................................................7-1
Machine Preparation...............................................7-1
Radiator/Oil Cooler Disassembly and Assembly
Procedures..............................................................7-1
Fan Guard Removal and Installation.......................7-1
Fan Guard Removal ..........................................7-2
Fan Guard Installation…………………..……….7-2
Fan Removal .........................................................7-2
Fan Installation........................................................7-2
Radiator/Cooler Removal................................7-3
Radiator/Cooler Installation.....................................7-5
Reversible Fan Compressor and Control Box
Removal…..............................................................7-5
Reversible Fan Compressor and Control Box
Installation…...........................................................7-6
8. Loader/Transmission Controls Disassembly
and Assembly
Chapter Overview...................................................8-1
Personal Safety.......................................................8-1
Machine Preparation...............................................8-1
Loader/Transmission Controls Disassembly and
Assembly Procedures.............................................8-1
Joystick Removal and Installation...........................8-1
Joystick Removal...............................................8-1
Joystick Installation............................................8-2
Loader Float Magnet Removal and Installation .......8-3
Loader Float Magnet Removal ..........................8-3
Loader Float Magnet Installation...........................8-3

Rubber Track Loader
Table of Contents
ii
9. Hydrostatic & Aux. Pump Disassembly
and Assembly
Chapter Overview ...................................................9-1
Personal Safety.......................................................9-1
Machine Preparation...............................................9-1
Hydrostatic & Hydraulic Pump Disassembly
and Assembly Procedures ......................................9-1
Charge Pump Removal...........................................9-1
Auxiliary Pump Removal.........................................9-3
Auxiliary Pump Installation......................................9-4
Tandem Pump Removal..........................................9-4
Tandem Pump Installation.......................................9-5
Hydraulic Reservoir Clean out..................................... 9-5
10. Undercarriage Disassembly and Assembly
Chapter Overview .................................................10-1
Personal Safety.....................................................10-1
Machine Preparation.............................................10-1
Undercarriage Disassembly and Assembly
Procedures............................................................10-1
Sprocket Removal and installation........................10-1
Sprocket Removal............................................10-1
Sprocket Installation.........................................10-3
Drive Motor Removal.............................................10-3
Drive Motor Installation..........................................10-4
Wheel Replacement....................................................10-4
Wheel Installation….....................................................10-5
14" Wheel Keeper Plates......................................…..10-5
11. Maintenance
Chapter Overview .................................................11-1
Personal Safety.....................................................11-1
Air Cleaner............................................................11-1
Grease Fittings......................................................11-3
Undercarriages......................................................11-3
Track Tension........................................................11-3
Drive Sprocket Rollers...........................................11-4
Tilt-Up Canopy......................................................11-5
Jacking Procedure.................................................11-6
Lift Arm Brace ......................................................11-7
Track Removal......................................................11-8
Track Installation...................................................11-9
Engine Oil & Filter ...............................................11-11
Engine Oil Specifications ....................................11-13
Engine Oil Level Check.......................................11-13
Hydraulic Fluid & Filter .......................................11-14
Fuel Filter ............................................................11-15
Case Drain Filter .................................................11-15
Hydraulic Reservoir (Cleanout) ...........................11-15
Water Separator..................................................11-16
Fuse Panel..........................................................11-16
Drive Belt Tension Check....................................11-17
Drive Belt Tension Adjustment............................11-17
Drive Belt Removal ............................................11-18
Drive Belt Installation...........................................11-18
Radiator/Oil Cooler Cleaning...............................11-19
Chassis & Engine Cleaning.................................11-19
Extreme Conditions.............................................11-20
Cooler Air Flow Test ...........................................11-20
Cab Filtration.......................................................11-22
Fan Cleaning ......................................................11-22
Maintenance Schedule........................................11-23
12. Lubricant & Fuel Specifications
Specifications........................................................12-1
13. Troubleshooting
Chapter Overview.................................................13-1
Personal Safety.....................................................13-1
Machine Preparation.............................................13-1
Preliminary Checkout............................................13-1
Visual Inspection .............................................13-1
Troubleshooting Scenarios………………………...13-2
14. Hydraulic Pressure (Check & Adjustment)
Chapter Overview.................................................14-1
Personal Safety.....................................................14-1
Charge Pressure Check & Adjustment .................14-1
Auxiliary Pressure Check & Adjustment…..………14-3
High Flow Troubleshooting.…………....…………..14-4
Low Flow Troubleshooting....................................14-4
Lift Arm Pressure Check..……………..……………14-4
Drive Pressure Check & Troubleshooting……..….14-5
Posi-Power Pressure Check & Adjustment.….…..14-6
15. Hydraulic Cylinder & Loader Valve
Chapter Overview.................................................15-1
Personal Safety.....................................................15-1
Disassembly & Assembly......................................15-1
Hydraulic Cylinder Disassembly............................15-1
Hydraulic Cylinder Assembly ................................15-3
Loader Valve Disassembly....................................15-4
Loader Valve Assembly ........................................15-4

Chapter Overview
This chapter contains product safety information for the
Terex PT-100 Forestry Compact Track Loaders. Read
and understand all product safety information before
attempting to service any Compact Track Loader.
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
recognition and prevention.
Property or equipment damage warnings in this publi-
cation are identified by the signal word "NOTICE".
The word “Note” is used throughout this manual to
draw your attention to specific topics or to supplement
the information provided in that section.
The person(s) in charge of servicing a Compact Track
Loader may be unfamiliar with many of the systems on
the machine. This makes it especially important to use
caution when performing service tasks. Familiarize
yourself with the affected system(s) and components
before attempting any type of maintenance or service.
It is not possible to anticipate every potential haz-
ard. The safety messages included in this docu-
ment and displayed on the machine are not all-
inclusive. They are intended to make you aware of
potential risks and encourage a safe approach to
performing service work. If you use a tool, proce-
dure, work method or operating technique that is
not specifically recommended by Terex, you must
satisfy yourself that it is safe for you and others.
You must also ensure that the machine will not be
damaged or be made unsafe by the operation,
lubrication, maintenance or repair procedures that
you choose.
Basic Precautions
Safety Labels
Safety labels have been included and are displayed in
various places throughout the machine to serve as
warnings of potentially dangerous conditions. Read
and understand all "Safety" labels on any Compact
Track Loader before attempting to operate, maintain or
repair it. Replace any damaged, illegible or missing
labels immediately, prior to service.
Personal Protective Equipment
Personal protection equipment is recommended when
performing maintenance 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 oth-
ers around you as you work.
1. Product Safety
1-1
“NOTICE” Indicates a hazardous situation which,
if not avoided, could result in property or equip-
ment damage.
NOTICE
Improper or incomplete maintenance/repair of a
Compact Track Loader can be dangerous and
may result in machine damage, injury or death.
Do not attempt to perform any type of repair or main-
tenance on a Compact Track Loader until you have
read and fully understood both this manual and the
machine specific operation and maintenance manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation and
maintenance techniques before operating or servicing
any Compact Track Loader.

Entering and Exiting
Always use steps and handholds when entering or
exiting a Compact Track Loader. Clean any mud or
debris from steps or work platforms before using them.
Always face the machine when using steps and hand-
holds. When it is not possible to use the designed
entry/exit system, utilize ladders, scaffolds, or work
platforms to safely gain access to the machine.
Lifting
Use a hoist when lifting components that weigh 50 lb
(23 kg) or more, to avoid back injury. Make sure all
chains, hooks, slings, etc., are in good condition and
are of the correct capacity. Be sure hooks are posi-
tioned correctly and equipped with a spring latch.
Lifting eyes are not to be side loaded during a lifting
operation.
Hot Fluids and Components
Stay clear of hot components and system fluids of the
engine, exhaust, radiator/oil cooler and hydraulic
lines/tubes. Also, use caution when removing fill caps,
breathers and plugs on the machine. Hold a rag over
the cap or plug to prevent being sprayed or splashed
by liquids under pressure. Be especially careful if the
machine has been operated recently, fluids may still be
hot. To ensure your safety, allow the machine to cool
before attempting any service procedure that involves
hot fluids or components.
Corrosion Inhibitor
Corrosion inhibitor contains alkali. Avoid contact with
eyes. Avoid prolonged or repeated contact with skin.
Do not take internally. In case of contact, wash skin
immediately 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.
Batteries
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.
Pressurized Items
1. Do not use hands or any other body part to check
for fluid leaks in the hydraulic system. Always use
a solid material like wood or metal to check for this
type of leak. Leaking fluid under pressure can pen-
etrate body tissue. Fluid penetration can cause
serious injury and even death. If fluid is injected
into your skin, get treatment immediately. Seek
treatment from a doctor that is familiar with this
type of injury.
2. Relieve pressure from the hydraulic system before
disconnecting or removing any lines, fittings or
related items. Do this by relaxing all hydraulic
actuators. If the lift arms are raised, make sure
they are securely braced. Be alert for possible
pressure release when disconnecting any device
from a pressurized system.
3. Lower the lift arms before performing any work on
the machine. If this cannot be done, make sure
they are securely braced to prevent them from
dropping unexpectedly during service.
4. Loose or damaged fuel, oil, hydraulic, lines, tubes
and hoses can cause fires. Do not bend or strike
high pressure lines or install ones that have been
bent or damaged. Check lines, tubes and hoses
carefully. See item 1 for precautions on checking
for fluid leaks.
5. Pressurized air or water can also cause injury.
When pressurized air or water is used for clean-
ing, wear a protective face shield, protective cloth-
ing, and protective shoes. The recommended max-
imum air pressure for cleaning purposes is 30 psi
(205 kPA). When using a pressure washer, keep in
mind that nozzle pressures are typically very high.
Generally, pressures are well above 2000 psi
(13790 kPa). Follow all recommended practices
provided by the pressure washer manufacturer.
1-2
Compact Track Loader
1. Product Safety

Repair
1. 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.
2. 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.
3. 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.
4. 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.
5. 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.
6. 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.
7. When replacing fasteners, use parts of equivalent
grade and size. Do not use a lesser quality fasten-
er if replacements are necessary.
8. 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.
9. 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.

Attachments
Only use attachments that are recommended by Terex.
Make sure that all necessary guards and protective
equipment are in place and functioning prior to operat-
ing any attachment.
Wear protective glasses and protective equipment as
required by conditions or as recommended in the
attachment’s operation manual.
Ensure that all personnel are far enough away from
the work area so they will not be struck by flying ob-
jects.
Stay clear of the cutting edges, pinching surfaces or
crushing surfaces of the attachment while performing
any attachment maintenance, testing or adjustments.
Machine Labels and Decals
Labels and decals placed on the machine provide
safety information and operating instructions.
Familiarize yourself with the location and significance
of these labels to ensure your safety.
Product Identification Number
The Product Identification Number (PIN) is located on
the front of the left joystick tower (figure 1-1). Always
provide the PIN when contacting the dealer about
parts, service, warranty or accessories. No warranty
claims will be processed unless the PIN is provided.
Safety Label Examples
Examples of the labels and decals displayed on the
machine are shown on this page.
WARNING
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment.
Keep clear of lift arms and
attachments.
1-4
Compact Track Loader
1. Product Safety
1-1
When replacement parts are required for your
machine, use only genuine Terex replacement
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
failures, product damage, personal injury or death.
WARNING
CRUSH HAZARD
Contact with moving machine can
result in death or serious injury.
Keep clear of moving machine.
2030-593
WARNING
Fall Hazard
Serious injury or death can result
from falling.
Use the provided access system when
entering or exiting the machine.
WARNING
Entanglement Hazard
Rotating parts can cause personal injury.
Keep away from fan and belt while the
engine is running. Stop engine before
servicing.
WARNING
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment. Install lift arm brace prior to servicing.
NOTICE
Fire Hazard
Flammable debris can collect near hot
components and lead to a fire.
Read Operator’s manual
Keep engine, exhaust and chassis
areas free of debris.
WARNING
Burn Hazard
Hot fluid under pressure can scald.
Allow the machine to cool thoroughly
before opening.
2030-595
WARNING
WARNING
WARNING

1-5
Compact Track Loader
1. Product Safety
DANGER
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
WARNING
Fasten Seat Belt
Crush Hazard
Rollover can crush and result in serious injury or death.
Do not use the bucket/attachment as a work platform.
Fall Hazard
Falling can result in serious injury or death.
WARNING
WARNING
Read Operator’s Manual
Read and understand the operator’s manual
and all safety signs prior to operating or
maintaining the machine.
WARNING WARNING
Improper operation or maintenance can re-
sult in serious injury or death.
No Riders
Fall Hazard
Falling from a machine can result in serious
injury or death.
Carry loads low. Load unload and turn on
level ground. Travel on inclines with heaviest
end of machine uphill.
Rollover/Ejection Hazard
Serious injury or death can result.
WARNING
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.
WARNING
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
WARNING WARNING
WARNING WARNING WARNING
WARNING

2-1
2.Technical Specifications
PT-100 Forestry Specifications
Engine
−Model: Perkins 1104C-44T (Turbo)
−Displacement: 4.4 liter
−Gross horsepower: 99.9 hp (74.5 kW)
−Torque: 304 lb-ft. (412 Nm)
−Idle rpm: 1000 (low idle), 2300 (high idle)
−Average water /thermostat temperature:
190°F, 87.8°C
Transmission
−Model: A22VG tandem (Rexroth)
Drive pumps
−Displacement: 2.745 in3/rev (45 cc/rev)
−Relief pressure: 5500 psi, 380 bar
−Flow: 27.33 gpm (103.5 lpm) @ 2300 rpm
Charge pump
−Displacement: 1.587 in3/rev (26 cc/rev)
−Relief pressure: 400-450 psi (2758-3102 kPa)
650 to 700 psi (4481.6-4826.3 kPa) at filter
test port
Drive Motors
−Model: Rexroth MCR 5 (2-speed)
−Displacement Low 50 in3/rev (820 cc/rev)
−Displacement High 25 in3/rev (410 cc/rev)
Control Handles
−Model: 4TH6 (Rexroth)
Auxiliary Pump
−Make: Rexroth
−Type: Axial Piston, Variable Load Sense
−Displacement: 3.844 in3/rev (63 cc/rev)
−Max Flow: 38 gpm (143.8 lpm) @ 2300 rpm
−Relief pressure: 3300 psi (22,750 kPa)
−Marginal Pressure: 362 psi (2,495 kPa)
−Cooling/filtering: Oil is filtered and cooled at
all times. In auxiliary mode, the oil is filtered af-
ter the attachment to protect the machine if the
attachment motor fails or contaminants are in-
troduced from the quick couplers.
Loader Valve
−Make: Husco
−Type: Load Sense
Cooler
−Operating pressure: 150 psi (1034 kPa)
−Bypass relief pressure: 80 psi (689 kPa)
−Hot oil sending unit: 225°F (107.2°C)
Critical Torque Specs
−Transmission Mounting Bolts
o85 ft-lb. (230.5 Nm) w/Blue Loctite
−Drive Sprocket Drive Teeth Bolts
o85 ft-lb. (230.5 Nm) -Dry
−Bogie Wheel Retaining Nuts (10’’)
o37 ft-lb. (100.3 Nm) -Dry
−Bogie Wheel Retaining Nuts (14’’)
o37 ft-lb. (100.3 Nm) -Dry
−Drive Sprocket Lug Nuts
o177 ft-lb. (480 Nm) -Dry
−Drive Motor Mounting Bolts
o177ft-lbs. (480 Nm) -Dry