Terex TSV-70 User manual

TSV-70/80
Operation and Maintenance Manual
Skid Steer Loader
Version: EN
Edition: 2012-10
Part Number: 7005-995 (US/ROW)
Valid From Serial No: 00101 (TSV 70)
00101 (TSV 80)
Original Instructions

CONTENTS
Introduction...................................................... 2
Safety ................................................................. 5
Technical Data.................................................. 31
Machine Description / Controls................. 37
Operation........................................................... 47
Transportation.................................................. 57
Maintenance..................................................... 63
California Proposition 65.............................. 83
Service Log........................................................ 84
1
Page
The operator must read and understand all the instructions
in this manual before operating the machine.

1 INTRODUCTION
2
1.1 Product Identification (PIN)
The machine PIN is located on the identifi-
cation plate on the lower front portion of
the cab.
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 Skid Steer Loader. We are confident that the
machine you have chosen will provide excellent performance and efficient opera-
tion.
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.
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 INTRODUCTION
3
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 involves loosening, collecting, transporting, and
distributing soil, rock, or similar materials as well as loading these materials onto
trucks, conveyors, or other methods of transport.
After installation of additionally approved special working attachments, the equip-
ment 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 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.
1.5 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.
1.6 Warranty
Your Terex TSV is warranted under the Terex Skid Steer Loader 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.

4

2 SAFETY
5
2.1 Safety Alert System ................................ 7
2.2 Graphical Symbols ................................. 8
2.3 ANSI Safety Signs................................... 12
2.3.1 ISO Safety Signs.................................. 14
2.4 General Notes ........................................ 16
2.5 Personal Protection Equipment............... 17
2.6 Hazard Zone........................................... 17
2.7 Operation ............................................... 18
2.8 Stability.................................................. 19
2.9 Transport of Persons............................... 19
2.10 Fire Prevention ..................................... 20
2.11 Crush / Burn Avoidance........................ 21
2.12 Placing Into Operation .......................... 22
2.13 Starting the Machine............................ 22
2.14 Jobsite Safety ...................................... 23
2.15 Parking the Machine ............................ 24
2.16 Towing / Retrieving............................... 24
2.17 Transporting ......................................... 25
2.18 Maintenance ........................................ 26
2.19 Battery ................................................. 28
2.20 Hydraulic Lines / Hoses........................ 29
Page

6

2 SAFETY
7
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.
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 SAFETY
8
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.

2 SAFETY
9
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: Crush
Avoidance: Install lift arm brace
before servicing.
Hazard: Crush
Avoidance: Fasten seat belt.
2030

2 SAFETY
10
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: Stay clear of moving
machine.
Hazard: Crush
Avoidance: Keep clear of lift arms
and attachments.

2 SAFETY
11
Hazard Avoidance
Pictorial Pictorial Description
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: Burn
Avoidance: Do not touch hot
surfaces.
Hazard: Crush
Avoidance: Keep hands clear of
moving parts during equipment
operation.

2.3 ANSI 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. Fall hazard
2. Read operator’s manual / fall hazard (inside cab enclosure / fire notice)
3. Skin (oil) injection hazard
4. Crush hazard (pinch point)
5. Crush hazard (lift arm brace)
6. Crush hazard (run over)
7. Explosion / burn hazard (read operator’s manual) (on battery strap)
8. Crush hazard (lift arms)
9. Tie down locations, Front (on upper front corners of chassis)
2 SAFETY
12
WARNING
Crush Hazard
Contact with moving machine can
result in death or serious injury.
Stay clear of moving machine.
7005-813
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.
1
3
2
5
6
9
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
7
8
WARNING
Crush Hazard
Contact with moving parts can result
in serious injury.
Keep hands clear of moving parts
during equipment operation.
7005-812
4

Note:
If any of the safety signs shown in this section are missing or damaged, contact
your dealer to obtain a replacement.
Key (continued)
10. Entanglement hazard (engine compartment)
11. Burn hazard (engine compartment)
12. Crush hazard (pinch point)
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 locations, Rear (on rear bumper)
19. Burn Hazard (engine compartment)
2 SAFETY
13
Burn Hazard
Hot fluid under pressure can scald.
Allow the machine to cool thoroughly
before opening.
2030-595
11
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
10
WARNING
Crush Hazard
Contact with moving machine can
result in death or serious injury.
Stay clear of moving machine.
7005-813
WARNING
Crush Hazard
Machine rollover can result in
death or serious injury.
Always fasten Seat Belt
Fall Hazard
Falling from a machine can result
in death or serious injury.
No Riders
Rollover/Ejection Hazard
Death or serious injury can result.
Carry loads low. Load unload and
turn on level ground. Travel on
inclines with heaviest end of
machine uphill.
WARNING
WARNING
7005-825
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
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
19
WARNING
Crush Hazard
Contact with moving parts can result
in serious injury.
Keep hands clear of moving parts
during equipment operation.
7005-812
12

2.3.1 ISO 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. Fall hazard
2. Read operator’s manual / fall hazard (inside cab enclosure / fire notice)
3. Skin (oil) injection hazard
4. Crush hazard (pinch point)
5. Crush hazard (lift arm brace)
6. Crush hazard (run over)
7. Explosion / burn hazard (read operator’s manual) (on battery strap)
8. Crush hazard (lift arms)
9. Tie down locations, Front (on upper front corners of chassis)
7006-203
2030-415
2030-417
2030-425
2030-553
2046-146
1
3
2
5
6
9
2030-565
7
8
2 SAFETY
14
7006-204
4

2 SAFETY
15
Note:
If any of the safety signs shown in this section are missing or damaged, contact
your dealer to obtain a replacement.
Key (continued)
10. Entanglement hazard (engine compartment)
11. Burn hazard (engine compartment)
12. Crush hazard (pinch point)
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 locations, Rear (on rear bumper)
19. Burn Hazard (engine compartment)
2030-418
11
2030-551
10
7006-203
7006-202
2030-415
2030-553
14
15
13
17
18
2030-417
16
2030-552
19
7006-204
12

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.
• 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.
2 SAFETY
16

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.
2 SAFETY
17

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: near overhead electric lines, in enclosed areas without proper ventilation, in
contaminated areas without necessary safety equipment and personnel.
2 SAFETY
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