Terex DTM 00101 (standard) Operation And Maintenance Manual Download Page 77

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7 MAINTENANCE

7.1 General ........................................................ 77

7.2 Care and Cleaning ................................... 77

7.3 Maintenance Intervals............................ 78

7.4 Lubrication Points.................................... 79

7.5 Engine Oil Check ...................................... 80

7.6 Engine Oil Change................................... 81

7.7 Hydraulic Oil Change.............................. 82

7.8 Hydraulic Filter Change ......................... 83

7.9 Accessory Belt ........................................... 83

7.10 Water Separator ..................................... 84

7.11 Fuel Filter Change ................................. 84

7.12 General Undercarriage ....................... 85

7.13 Track Tension Check ............................. 85

7.14 Track Tension Adjustment .................. 86

7.15 Planetary Oil Change ........................... 86

7.16 Drive Sprocket Rollers.......................... 87

7.17 Air Cleaner Removal / Inspection.... 88

7.18 Air Cleaner Cleaning ........................... 89

7.19 Radiator Oil Cooler Cleaning............. 90

7.20 Engine Coolant Change ...................... 90

7.21 Chassis Cleaning .................................... 91

7.22 Electrical System.................................... 92

7.23 Storage ...................................................... 93

7.24 Cab Tilt....................................................... 95

Page

Summary of Contents for DTM 00101 (standard)

Page 1: ...n and Maintenance Manual C o m p a c t Tr a c k L o a d e r Version EN Edition 2011 10 Part Number 2076 200 Valid From Serial No DTM 00101 standard DTN 00101 forestry RWS 00101 standard RWF 00101 fore...

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Page 3: ...l Data 33 Machine Description Controls 39 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...

Page 4: ...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 an...

Page 5: ...atigue 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...

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Page 7: ...t 19 2 7 Hazard Zone 19 2 8 Operation 20 2 9 Stability 21 2 10 Transport of Persons 21 2 11 Fire Prevention 22 2 12 Crush Burn Avoidance 23 2 13 Placing Into Operation 24 2 14 Starting the Machine 24...

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Page 9: ...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 t...

Page 10: ...Transmission Range High Engine Speed Slow Transmission Range Low Windshield Wiper Engine Pre Heat Oil Pressure Engine Coolant Temperature Hydraulic Oil Temperature Air Inlet Temperature 8 2 SAFETY 2 2...

Page 11: ...RPM Work Lights Bucket Positioning Power Quick Attach Parking Brake High flow Auxiliary Low Flow Auxiliary High Flow Auxiliary reverse flow Low Flow Auxiliary reverse flow Fan 9 2 SAFETY Symbol Descr...

Page 12: ...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 Corrosiv...

Page 13: ...ll 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 A...

Page 14: ...rd 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...

Page 15: ...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 unders...

Page 16: ...connecting 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...

Page 17: ...ath 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 Haz...

Page 18: ...zard 2 Read operator s manual fall hazard fire hazard inside cab enclosure 3 Skin oil injection hazard 4 Entanglement hazard engine compartment 5 Tie down location found beneath loader in front locati...

Page 19: ...Forestry only 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 injectio...

Page 20: ...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...

Page 21: ...safety shoes and any other equipment necessary to ensure your safety and the safety of others around you as you work 2 7 Hazard Zone The hazard zone encompasses the area around the machine in which pe...

Page 22: ...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 a...

Page 23: ...ation 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 work...

Page 24: ...ulate 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 i...

Page 25: ...e 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...

Page 26: ...will be placed into operation Prior to placing the machine into operation adjust the driver s seat mirrors and ventilation system settings if equipped so you can work in comfort and safety 2 14 Starti...

Page 27: ...eep the machine at an adequate distance from overhead electrical lines When working in the vicinity of overhead electrical lines do not come close to the lines with the machine Injury or death may res...

Page 28: ...rve the correct procedure as described in the operating instructions The machine should be towed only in exceptional cases for example to bring the machine away from an endangered place for repair Che...

Page 29: ...e the ignition key Secure the door windows and hood on the machine Secure the machine and any other items against slipping with chains ropes of the proper capacity Before departure investigate the rou...

Page 30: ...e engine needs to be started inside an enclosure make sure that the engine s exhaust is properly vented Be sure all protective devices including guards and shields are properly installed and functioni...

Page 31: ...rials before welding or grinding to avoid fire or explosion Before cleaning the machine with water or steam jets high pressure cleaner or other cleaning agents cover or seal over all openings in which...

Page 32: ...limbing aids if they were not designed for that purpose If working at significant height use a safety harness of the proper style and capacity to prevent falls Keep all grips steps platforms ladders e...

Page 33: ...may reduce the duration of the usage period for example high temperatures multi shift operation Hoses and hose lines must be replaced if any of the following criteria are encountered during inspectio...

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Page 35: ...36 3 3 Engine 36 3 4 Electrical System 36 3 5 Undercarriage 36 3 6 Transmission 37 3 7 Auxiliary Hydraulics 37 3 8 Ground Pressure 37 3 9 Operating Specifications 37 3 10 Service Refill Capacities 37...

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Page 37: ...P S approved 4 Hydraulic Oil fill location 5 Diesel Fuel fill location right side of machine 6 Hood engine cover 7 Engine 8 Drive Motor and Sprocket 9 Undercarriage 10 Quick Attach 11 Product PIN Pla...

Page 38: ...9 hp 73 5 kW 99 9 hp 73 5 kW Admissible inclines 30 all directions engine 30 all directions engine Cooling Water antifreeze blend Water antifreeze blend Operating Voltage 12 V 12 V Battery 32 F 0 C 12...

Page 39: ...9 in 85 cc rev Relief press Low Flow 3300 psi 22 750 kPa 3300 psi 22 750 kPa Relief press High Flow 3800 psi 26 200 kPa 3800 psi 26 200 kPa Low Flow 2200 RPM 0 20 gpm 0 75 7 lpm 0 20 gpm 0 75 7 lpm Hi...

Page 40: ...Lubricating Points MP Grease Multi purpose lithium grease 30 22 20 4 10 14 0 32 10 50 20 68 30 86 40 104 50 C 122 F 0W 5W 20 10W 30 15W 40 20W 50 20W 30W 40W Recommended Viscosity Grades Ambient tempe...

Page 41: ...4 3 Throttle 43 4 4 Operator Seat 43 4 5 Two Speed 43 4 6 Auxiliary Hydraulics 44 4 7 Bucket Positioning 45 4 8 Electric Attachment Control 45 4 9 Auto Idle 45 4 10 Operator Interface 46 4 10 1 Status...

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Page 43: ...erse Note Items 15 16 17 19 20 have a delay feature to ensure the operator intends to activate the function To activate press the desired button until all three L E D lights illuminate at the top of t...

Page 44: ...control configuration 4 2 1 Right Joystick In ISO mode the right joystick is used to control the lift arms bucket and to engage the float function In H mode the right joystick controls bucket and righ...

Page 45: ...the knob clockwise for heavier operator or counter clockwise for lighter operator To adjust for height Pull outward on the height adjustment lever slide the seat forward or rearward as needed then rel...

Page 46: ...d intermittently or continuously depending on the requirements of the attachment being utilized To engage the low flow auxiliary circuit intermittently roll the switch on the top of the right joystick...

Page 47: ...joysticks or switches in the cab Most attachments are controlled hydraulically but some require both hydraulic and electrical inputs The upper 4 buttons on the left joystick 4 8 1 send electrical cur...

Page 48: ...y gauge screen 1 following two splash screens as pictured below This screen displays engine RPM fuel level and battery charge in volts The selection bar visible on this screen allows the operator to A...

Page 49: ...and hydraulic systems Gauge Screen 3 This screen displays speed engine hours and trip hours Units used in the display can be configured see 4 10 2 Config Menu Display Units To access these secondary g...

Page 50: ...orner above is present you may press the button beneath it to return to Gauge Screen 1 Config Status Screen This screen allows you to view the current Propel Mode ISO or H Max Speed adjustable to limi...

Page 51: ...ts detected by the operator interface The faults recorded here are typically ones that must be corrected in order to operate the machine If more than one fault is active press the buttons beneath the...

Page 52: ...ed and lap bar Software Status This screen displays the current version of software being utilized for the main controller and display 4 MACHINE DESCRIPTION CONTROLS 50 Seat Status CabSeat AttachmentS...

Page 53: ...ode is the standard mode identified in section 4 2 of this manual H mode are commonly refered to as Case type controls To switch between the modes press the button beneath the check mark Then use the...

Page 54: ...by pressing the button beneath the check mark again Lift Arm Speed This screen allows you to change the maximum lift arm speed for the machine To change the lift arm speed press the button beneath the...

Page 55: ...pressing the button beneath the check mark again High Flow This screen allows you to change the flow rate for the high flow auxiliary hydraulic circuit To change the flow in GPM press the button bene...

Page 56: ...rm your selection by pressing the button beneath the check mark again Fan Control if equipped This screen allows you to change the time interval between fan reversals on machines equipped with a rever...

Page 57: ...en disappear Others indicate a problem that must be acknowledged or resolved before operation can resume Startup Screen Propel Mode This screen indicates the current propel mode when the key is turned...

Page 58: ...ose door to clear screen and resume operation High Flow This screen indicates the current high flow volume over time setting in gallons per minute It is displayed for 2 seconds when auxiliary hydrauli...

Page 59: ...me alarm messages may report an event that will cause the engine to derate or shut down altogether If this occurs consult your dealer 4 MACHINE DESCRIPTION CONTROLS 57 Fuel Level Low Alarm Check Engin...

Page 60: ...kick the window out to escape fig 4 11 3 Forestry Operator Escape door exit Firmly grasp the red levers attached to the left side of the door opening Turn the upper lever clockwise and the lower lever...

Page 61: ...ng Procedure 62 5 4 Surface Preservation 63 5 5 Filling the Bucket 63 5 6 Grading 64 5 7 Leveling 64 5 8 Loading 65 5 9 Fastening Attachments 65 5 10 Unfastening Attachments 66 5 11 Power Quick Attach...

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Page 63: ...ocked 9 The R O P S F O P S approved operator enclosure is not damaged or distorted structurally in any way 10 The seat belt and lap bar restraint are in good working order 11 All safety signs are in...

Page 64: ...rd the rabbit icon 4 Turn the ignition key to the on position and hold for 6 seconds to pre heat the engine While pre heating the glow plug operation light will illuminate 5 Turn the ignition key to t...

Page 65: ...While working on turf make gradual turns see item A If space is limited turn gradually by moving back and forth until facing the desired direction see item B 5 5 Filling The Bucket Steps see illustrat...

Page 66: ...lift arms as you tilt the bucket slowly forward to evenly spread the material out over the ground 2 Once the load is released tilt the bucket forward to an angle 45 or less to the ground 3 Lower the l...

Page 67: ...e unlocked positions fig 5 10 1 2 With the lift arms fully lowered drive the machine to the attachment and hook the top edge of the quick attach under the upper lip of the attachment 3 Curl the quick...

Page 68: ...m control joystick gently to the right until the quick attach is clear of the attachment 5 Back the machine away from the attachment 5 11 Power Quick Attach optional Some machines may be equipped with...

Page 69: ...here it is protected from the elements and vandals 3 Lower the lift arms until they rest on the frame stops 4 Reduce engine RPM to a low idle 5 Turn the ignition key counterclockwise to stop the engin...

Page 70: ...n 4 Have the assistant place the lift arm brace onto the top side of the cylinder ram and install the retaining pin to secure it there 5 Slowly lower the lift arms until they come to rest on the brace...

Page 71: ...6 TRANSPORTATION 69 6 1 Transporting 71 6 2 Towing Retrieving 72 6 3 Loading Unloading Procedure 73 6 4 Lifting Procedure 74 Page...

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Page 73: ...size of the machine over the distance and terrain that will be covered 2 Secure the machine to the transport vehicle bed facing the direction of travel with heavy chains rated for use with a machine...

Page 74: ...e the center plug then using a suitable slide hammer and adapter remove the housing cover fig 6 2 2 6 2 3 5 Remove the o ring and planetary carrier from the housing fig 6 2 4 6 Repeat this procedure o...

Page 75: ...e operating levers and the auxiliary hydraulic switch are in their neutral positions Remove the ignition key 8 Secure the door windows and hood on the machine 9 Secure the machine and any other items...

Page 76: ...s or structural tubing along the bottom of the chassis only and spaced in such a manner that the machine will be stable when its weight rests solely on the supports 7 Once the supports are in place sl...

Page 77: ...Belt 83 7 10 Water Separator 84 7 11 Fuel Filter Change 84 7 12 General Undercarriage 85 7 13 Track Tension Check 85 7 14 Track Tension Adjustment 86 7 15 Planetary Oil Change 86 7 16 Drive Sprocket R...

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Page 79: ...es in this manual and take any necessary precautions to ensure his her safety Wear appropriate personal protec tion equipment for all tasks 7 2 Care and cleaning Cleaning the machine Do not use aggres...

Page 80: ...c 22 31 61 11 Drain water separator 84 12 Lubricate all grease points 79 13 Inspect clean the radiator cooler and engine compartment 90 91 14 Inspect clean undercarriages as needed 85 15 Inspect clean...

Page 81: ...machine Identical points also exist on the opposite side of the machine Lubricate all points daily prior to operation A Lower Bucket Cylinder Pivot B Upper Bucket Cylinder Pivot C Front Lift Cylinder...

Page 82: ...5 Remove the dipstick once again and inspect the end for oil on the level indicator 6 Oil should be present on the dipstick up to but not over the upper full level indicator notch If the level is corr...

Page 83: ...the right side of the pan 4 Drain the oil into a suitable catch container 5 Remove engine oil filter Upon removal make sure the filter gasket item 2 fig 7 6 1 is still present on the filter If not rem...

Page 84: ...ank drain Remove the hydraulic fluid drain plug item 1 as shown fig 7 7 1 4 Drain the used oil into a suitable catch container 5 Dispose of the oil according to local mandates 6 Reinstall the drain pl...

Page 85: ...chine is also equipped with a filter in the auxiliary circuit case drain line It protects the main hydraulic system in the event of catastrophic failure in an attachment This filter is designed to las...

Page 86: ...m the catch bowl and close the hood to complete the procedure 7 11 Fuel Filter Change The fuel filter should be changed every 500 service hours or as needed A plugged fuel filter can cause loss of eng...

Page 87: ...ing premature wear and damage Operation on sand turf or other finished surfaces may require less frequent cleaning but daily inspection is still advised 7 13 Track Tension Check Proper track tension i...

Page 88: ...bri cant onto the threads prior to adjusting tension 7 15 Planetary Oil Change see section 7 3 1 Place the machine on jackstands as described in section 6 4 orient the perimeter drain plug at the very...

Page 89: ...e rollers 1 rotate on steel pins 2 limiting wear to the inside of the rollers As they wear the rollers become thinner but will continue to function and perform as long as they are rotating At 50 hour...

Page 90: ...en the hood to uncover the air cleaner acess door on rear of the left loader tower 2 Open the access cover then pull the yellow slide lock 1 on the air cleaner housing outward as shown Next turn the c...

Page 91: ...solution for at least 15 minutes moving it gently through the solution to further clean the element Never soak for more than 24 hours 4 Rinse the filter thoroughly with a gentle stream of water to re...

Page 92: ...20 Engine Coolant Change 1 Shut the machine down as described in section 5 13 then remove the right rear belly pan 1 and open the hood fig 7 20 1 2 Open the valve 2 and drain the old coolant into a s...

Page 93: ...ough the lower opening Once complete close and latch the hood 4 Tilt the cab as described in section 7 24 5 Pressure wash any debris from the chassis area out through the lower opening Once complete l...

Page 94: ...30 20 60 80 10 10 5 20 30 5 30 20 30 5 MACHINE CONT MAIN A MAIN B MAIN C ENGINE ECU LIGHTS AUX LOADER MAIN PWR A MAIN PWR B MAIN C STARTER LIGHTS MACHINE ECU CONDENSOR WIPER HEATER VALVE STARTER HEAT...

Page 95: ...chine in a dry place that provides protection from the elements Drain and refill the cooling system with 50 50 pre mixed antifreeze water Replace engine oil and filter chapter 7 Replace hydraulic oil...

Page 96: ...chine to the ground Install fully charged battery Remove exhaust outlet cover Perform pre operation safety checklist in chapter 5 of this manual Perform starting procedure chapter 5 Let engine run whi...

Page 97: ...of the footwell inside the cab one in each of the front corners rear as well for forestry machines 5 Once the bolts have been removed tilt the cab slowly upwards The cab brace 3 should fall onto the s...

Page 98: ...cognized by the state as harmful Terex ASV complies with this requirement by providing the following information CALIFORNIA Proposition 65 Warning This product contains lead and lead compounds diesel...

Page 99: ...SERVICE LOG 97 Hours Service Performed Notes...

Page 100: ...SERVICE LOG 98 Hours Service Performed Notes...

Page 101: ...SERVICE LOG 99 Hours Service Performed Notes...

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