Professional Documents
Culture Documents
Terrex TSR 50-60 Service Manual PDF
Terrex TSR 50-60 Service Manual PDF
TSR-50/60
Part Number: 7000-756
Printed (12-10)
Table of Contents
I
Skid Steer Loader
Table of Contents
II
Skid Steer Loader
Table of Contents
III
1. Product Safety
1-1
Skid Steer Loader
1. Product Safety
1-2
Skid Steer Loader
1. Product Safety
1-3
Skid Steer Loader
1. Product Safety
any attachment maintenance, testing or adjustments. result in death or serious injury. 7005-813
WARNING
WARNING
Machine Labels and Decals
Labels and decals placed on the machine provide
safety information and operating instructions.
Fall Hazard
Familiarize yourself with the location and significance Serious injury or death can result
Use the provided access system when
entering or exiting the machine.
from falling.
of these labels to ensure your safety.
WARNING
WARNING
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or Install lift arm brace prior to servicing.
attachment.
1-1
WARNING
WARNING
WARNING
WARNING
1-4
Skid Steer Loader
1. Product Safety
WARNING
WARNING WARNING
WARNING DANGER
DANGER
WARNING
WARNING WARNING
WARNING • Keep all flames/sparks
away!
• No Smoking!
• Read and understand
all manuals prior to
Fall Hazard Fall Hazard operation. 2030-603
Falling can result in serious injury Falling from a machine can result
or death. in death or serious injury.
WARNING
WARNING
NOTICE
Rollover/Ejection Hazard
Fire Hazard Death or serious injury can result.
Flammable debris can collect near
hot components and lead to a fire.
1-5
2. Technical Specifications
& Service Tools
2-1
Skid Steer Loader
2. Technical Specifications
2-2
3. Circuit Diagrams
OIL COOLER
CHECK VALVE
(80 PSI / 552
kPa)
5 MICRON FILTER
TANK
INLET
FROM VALVE
CHARGE/AUXILIARY
PUMP
3-1
Skid Steer Loader
3. Circuit Diagrams
Hydraulic Control/Auxiliary
Circuit
Figure 3-2 TSR-50/60 Control Auxiliary Circuit
TO BUCKET CYL.
FROM ATTACHMENT
TO LIFT ARM CYL. CASE DRAIN Q/C
TO
TANK
TO POWER Q/A
TO
LIFT ARM VALVE TANK
CHARGE PRESSURE
TEST PORT
(450 / 3103 kPa)
AUXILIARY PUMP INLET
CHARGE/AUXILIARY
PUMP
3-2
Skid Steer Loader
3. Circuit Diagrams
DRIVE PUMP
DRIVE MOTOR
CASE DRAIN
(TO TANK)
DRIVE MOTOR
BRAKE
3-3
Skid Steer Loader
3. Circuit Diagrams
DRIVE PRESSURE
RELIEF VALVES (4)
(5500 PSI / 37920 kPa)
CHARGE PRESSURE
RELIEF (450 / 3103 kPa)
DRIVE PUMP
DRIVE MOTOR
BRAKE
DRIVE MOTOR
2-SPEED SHIFT
3-4
Skid Steer Loader
3. Circuit Diagrams
Shut-Off Plug
Assembly
Shut-Off Plug
Assemblies
3-5
Skid Steer Loader
3. Circuit Diagrams
3-6
Skid Steer Loader
3. Circuit Diagrams
3-7
Skid Steer Loader
3. Circuit Diagrams
3-8
Skid Steer Loader
3. Circuit Diagrams
3-9
4. Maintenance
4-2
4-1
Skid Steer Loader
4. Maintenance
4-4
4-3
4-2
Skid Steer Loader
4. Maintenance
Lubrication Points:
F
4-6
Grease Fittings
The TSR-50-60 are equipped with grease fittings at pivot points throughout the machine. The illustration above
shows the locations of all fittings on the left side of the machine. An identical fitting exists on the right side of the
machine for each one identified in the illustration. Lubricate all fittings DAILY or after every 10 hours of operation
to maximize component life and ensure proper machine function. (fig. 4-6)
4-3
Skid Steer Loader
4. Maintenance
Chain Tension Check 2. Remove the lug nuts securing the front
wheel to the pod, then remove the wheel
Proper chain tension should be maintained to minimize
(use a suitable hoist and lifting straps)(fig 4-9).
wear and prevent damage to the final drive system.
Chain tension should be checked every 500 hours and
adjusted as necessary.
B C
4-8
4-12 5 2
4-9
4-4
Skid Steer Loader
4. Maintenance
4-13
4-14
4-5
Skid Steer Loader
4. Maintenance
Air Cleaner
The TSR-50-60 are equipped with two air filter
elements to remove contaminants from the air used for
combustion. Regular inspection and replacement is
necessary to ensure proper performance and to
prolong engine life.
To remove and inspect your air cleaner elements:
1. Shut the machine down as described in section
5.13 of the operations manual.
4-16
2. Open the hood and rear door to gain access to the
engine compartment.
3. Locate the black air cleaner enclosure near the top A
left of the engine compartment (when viewed from
the rear as shown in fig. 4-16).
4. Open the upper and lower latches and remove the
housing cover (item A, figure 4-17) to expose the
primary element (item B, figure 4-18).
5. Remove the primary element and inspect it. If it
appears damaged in any way, replace it. If the
element is heavily soiled, replace it. If it appears to 4-17 Latch
be in good condition, clean if necessary and
re-install.
6. Once the primary element has been removed, the
secondary element (item C, figure 4-19) should be
visible. Remove and inspect it. If the element is
damaged or heavily soiled, replace it.
Note: The secondary element is not serviceable. It
should be replaced after every three cleanings of the
primary filter.
B
4-18
Note: The primary element may be cleaned and reused
up to five times if properly maintained, but should be
replaced at least once a year.
4-6
Skid Steer Loader
4. Maintenance
A 4-22
C
4-20
4-7
Skid Steer Loader
4. Maintenance
4-8
Skid Steer Loader
4. Maintenance
4-9
Skid Steer Loader
4. Maintenance
NOTICE
4-10
Skid Steer Loader
4. Maintenance
Engine Oil Specifications 7. If the level is low, add the proper grade and
Terex recommends using Terex 10W-30 Heavy Duty viscosity engine oil and re-check as necessary until
Engine Oil for most conditions. In the event of an the proper level has been achieved. Then
alternate working environment, the following chart may re-install the dipstick and filler cap and close and
be used as a guide to oil viscosity grades. latch the hood and rear door to complete the
procedure.
You may also use a quality engine oil substitute
meeting the following minimum specification:
• API CH-4 multigrade engine oil.
0W
5W-20
10W-30
15W-40
20W-50
20W
30W
40W
Ambient temperature
Low
Full
4-30a 4-30b
4-11
Skid Steer Loader
4. Maintenance
4-12
Skid Steer Loader
4. Maintenance
4-13
Skid Steer Loader
4. Maintenance
4-14
Skid Steer Loader
4. Maintenance
Maintenance Service
Interval Notes ServiceCapacity
Item Required
Greasefittings Lubricate Daily Greaseoften
Adjustlevelsas
Fluidlevels Check Daily
necessary
Adjusttensionas
Fantension Check Daily
necessary
Fancondition Inspect Daily Replaceifdamaged
4-15
5. Machine Controls and
Instrumentation
6 4
5
1
5-1
5-1
Skid Steer Loader
5. Machine Controls and Instrumentation
Switches
1 2 3 5 6
The various switches (Figure 5-3, 5-4) are
positioned to provide good access and
visibility. The standard and optional 7
switches are listed below.
5-2
6. Operator Enclosure
6-1
Skid Steer Loader
6. Operator Enclosure
Required Tools
Phillips Type Screwdriver
6-2
6-4
6-3
Installation
1. To reinstall the lap bar gas assist springs, reverse
the removal procedure. 6-5
Installation
1. To reinstall either cover, reverse the steps of the
removal procedure.
6-2
Skid Steer Loader
6. Operator Enclosure
Side Panels
Removal
Required Tools Power Outlet
6-9
Installation
1. To install the side panels, reverse the removal
6-6 procedure.
6-7
6-8
6-3
Skid Steer Loader
6. Operator Enclosure
Seat Headliner
Removal Removal
Required Tools Required Tools
Combination/Socket Wrench Phillips screwdriver
1. Raise and secure the cab as described on page
4-2 of this manual.
6-13
6-10
1. Remove all headliner screws with a phillips
screwdriver (fig.6-13).
2. Remove the four nuts securing the seat to the cab
floor (fig. 6-10).
3. Lower the cab to gain access to the seat.
6-11
6-14
4. Lift and move the seat forward slightly to expose
the seat switch harness located behind the seat
(fig. 6-11). 2. Lower the headliner slightly, then disconnect the
dome light and climate controls from the cab
harness. Once disconnected, you may remove the
headliner from the cab (fig. 6-14).
Installation
1. To install the headliner panel, reverse the removal
procedure.
6-12
Installation
1. To install the seat, reverse the removal procedure.
6-4
7. Chassis and Fuel Tank
Place a “Do Not Operate” tag prominently on the machine to Fuel Sending Unit
inform personnel that the machine is being worked on.
7-1
7-1
Skid Steer Loader
7. Chassis & Fuel Tank
Fuel Tank
Removal
Required Tools
Blade Style Screwdriver
Combination/Socket Wrench
7-5a 7-5b
7-3
Fuel Lines
Install Last
Installation
1. To install the fuel sending unit, reverse the removal
procedure (See fig. 7-4 for terminal installation). 7-7 Fuel Lines
7-2
Skid Steer Loader
7. Chassis & Fuel Tank
7-10
10. Lift and remove the tank from the rear as shown
(fig. 7-8).
Installation
1. To install the fuel tank, reverse the removal
procedure.
Pry Off
7-11
Footwell
Removal 5. Pry the throttle cable off of the ball stud on the
foot throttle assembly (fig. 7-11).
Required Tools 6. Remove the floor mat from the floor of the footwell.
Combination/Socket Wrench
7-3
Skid Steer Loader
7. Chassis & Fuel Tank
Installation
1. To install the foot throttle assembly, reverse the
removal procedure.
Hood Assembly
Removal
Required Tools
Allen Wrench
Combination/Socket Wrench
7-12
Installation
1. To install the footwell, reverse the removal
procedure.
7-14
Foot Throttle Assembly
Removal 1. Raise and lock the hood into position as described
on page 7-4. Ask an assistant to support the weight
Required Tools of the hood. Then, remove the bolts from the hood
Screwdriver brackets (both sides) as shown (fig. 7-14).
Combination/Socket Wrench
Bolts
7-15
Pry Off
7-13
7-4
Skid Steer Loader
7. Chassis & Fuel Tank
Installation
1. To install the hood assembly, reverse the removal
procedure.
Rear Door
Removal
Required Tools
Allen Wrench
7-17
7-18
Installation
1. To install the rear door, reverse the removal
procedure.
7-5
8. Radiator and Oil Cooler
Combination Wrench
Machine Preparation Socket Wrench
Accidental machine starting can cause injury or death to
personnel working on a Skid Steer Loader.
8-1
8-1
Skid Steer Loader
8. Radiator and Oil Cooler
8-2 8-5
2. Remove the rearward fan guard screen from the 5. Remove the forward fan guard screen as shown in
machine (fig. 8-2). figure 8-5.
Installation
1. To install the fan guard assembly and fan, reverse
the removal procedure.
Radiator/Oil Cooler
Removal
8-3 Required Tools
Combination Wrench
3. Remove the bolts securing the fan to the engine as Socket Wrench
shown, then remove the fan (fig. 8-3). Blade type screwdriver
Allen Wrench
Top Center Bottom
Note: Collect and contain liquids in suitable containers.
Dispose of all liquids according to mandates.
Drain Valve
8-4a 8-4b
8-2
Skid Steer Loader
8. Radiator and Oil Cooler
8-10
8-8
bolts
8-9
8-3
9. Hydraulic Reservoir
NOTICE
9-1
Skid Steer Loader
9. Hydraulic Reservoir
Top Bottom
9-3
Shoulder 9-4
bolt
11. Loosen hose clamps and disconnect hydraulic inlet
and return hoses from the reservoir (fig. 9-4).
Disconnect
9-2
9-2
Skid Steer Loader
9. Hydraulic Reservoir
Nut
Removed
9-6 9-9
13. Remove one nut from the bracket that secures the 16. Carefully maneuver the hydraulic tank around the
pilot hoses to the front of the hydraulic reservoir pilot hoses and out of the machine with the help
and pivot it aside (fig. 9-6). of an assistant (fig. 9-9).
Installation
1. To install the hydraulic reservoir, reverse the
removal procedure.
Bolts
9-8
9-3
Skid Steer Loader
9. Hydraulic Reservoir
Required Tools
Socket/Combination Wrenches
Installation
1. To install the suction screen, reverse the removal 9-10
procedure.
9-4
10. Lift-Arm/Drive Controls
Prior to performing any type of service work on a Skid Cap and plug all fittings and hoses to prevent fluid loss
Steer Loader, read and understand Chapter 1 and or contamination during service work.
(Product Safety) for personal safety information.
Relax all hydraulic circuits and make sure the
oil is cool before disconnecting any component
or line from the system. Pressurized and or hot
hydraulic fluid can cause personal injury.
10-1
Skid Steer Loader
10. Lift Arm / Drive Controls
10-1
4. Expose and cut the zip tie securing the lower 10-5
portion of the boot to the joystick body, then lift it
upwards (figure 10-1).
8. Disconnect all connectors coming from the joystick
harness. (fig. 10-5)
10-2
10-6
Note: The float magnet is now exposed as well as the
mounting bolts securing the joystick to the bracket
(figure 10-2). 9. Remove the bolts and nuts securing the joystick to
the mounting bracket (fig. 10-6).
Remove (optional)
10-3
10-2
Skid Steer Loader
10. Lift Arm / Drive Controls
10-9
10-7
Installation Installation
1. To install the joystick, reverse the removal 1. To install the float magnet, reverse the removal
procedure. procedure.
10-3
Skid Steer Loader
10. Lift Arm / Drive Control
6 7
2 8
10 9
10-10
NOTICE
Cap and plug all fittings and hoses to prevent fluid loss
and or contamination during service work.
Installation
1. To install the lift arm valve, reverse the removal
procedure.
10-4
11. Hydraulic Pumps/Motors
11-1
Skid Steer Loader
11. Hydraulic Pumps and Motors
Inlet hose
Access
panel
Charge Auxiliary
outlet outlet
11-2
11-1 2. Remove the access panel from the bottom of the
chassis (fig. 11-2).
6. Remove the four bolts securing the inlet hose to
the auxiliary pump and lay it aside.
7. Disconnect charge pump outlet hose from the
fitting. remove
8. Remove the four bolts and split flange clamp from
the auxiliary pump outlet tube and lay it aside.
9. Support the charge/auxiliary pump with a suitable
lifting device.
10. Remove the upper and lower bolts that secure
the auxiliary pump to the drive pump and remove.
11-3
Installation
1. To install the auxiliary pump, reverse the removal 3. Disconnect the drive tubes from the drive pump
procedure. and drive hoses and remove (fig. 11-3).
NOTICE
During disassembly, plug and cap hoses and fittings to
prevent fluid loss and or contamination.
11-2
Skid Steer Loader
11. Hydraulic Pumps and Motors
Drive Chain
Removal
Required Tools
Combination/Socket Wrench
Impact Wrench
5. Disconnect the upper pilot hoses and right side 1. Shut the machine down as described in section
charge outlet hose from the drive pump (fig. 11-5). 5.13 of the operation and maintenance manual,
6. Secure the weight of the transmission with a then elevate and support the front and rear of the
suitable mechanical hoist. machine as described on page 4-2.
Lower
bolt disconnect
11-6
11-8
Top bolt
11-9
11-7
3. Remove the chain case side cover plate to
9. Remove the upper bolt that secures the drive pump access the chains for removal (fig. 11-9).
to the engine (fig. 11-7).
10. Using a suitable mechanical hoist and straps,
carefully lift the pump up and out of the chassis.
Installation
1. To install the transmission pump, reverse the
removal procedure.
11-3
Skid Steer Loader
11. Hydraulic Pumps and Motors
Access Sprocket
panel bolt
11-10a 11-10b
11-13
4. Remove the sprocket access panel (fig. 11-10a),
located next to the drive motor on the inside of 7. Pull on the chain to increase slack. Lift the chain
the chassis, to gain access to the sprocket bolt over and off of the drive sprocket (fig.11-13).
(fig. 11-10b).
loosen
Front
5. Remove sprocket bolt to free sprocket for removal 8. Complete steps 4-5 on the rear wheel pod. The
(fig. 11-11 a & b). rear wheel pod does not need to be removed but it
does need to be loosened and moved forward to
increase slack in the chain (fig. 11-14).
11-12
11-4
Skid Steer Loader
11. Hydraulic Pumps and Motors
11-17
11-16
2. Disconnect all hydraulic tubes & hoses from the
drive motor (fig. 11-17).
10. Remove the sprocket from the drive shaft, then the
chains and driven sprockets may be removed for
inspection or replacement (fig. 11-16).
Installation
1. To install the drive chains, reverse the removal
procedure.
11-5
12. Engine
12-1
Installation
1. To install the battery, reverse the removal
procedure.
12-1
Skid Steer Loader
12. Engine
Exhaust System
Removal
Required Tools
Combination/Socket Wrench
Tension
springs
12-5
Air Cleaner
Removal
Required Tools
Combination Wrenches
Socket Wrench & Extension
12-3
1. Shut the machine down as described in section
5.13 of the operations manual.
3. Remove the bolts that secure the muffler to the 2. Raise and support the rear hood as described on
chassis (fig. 12-3). page 7-4 and open the rear door on page 7-5 to
access exhaust system.
12-2
Skid Steer Loader
12. Engine
Air Cleaner
remove
Latch
12-6
Installation
1. To install the air cleaner assembly reverse the air
cleaner removal procedure.
12-7
Removal
1. Perform the battery, air cleaner, auxiliary pump,
and tandem pump removal procedures (found in
chapters 11and 12 of this manual).
12-8 2. Raise and support the hood as described on
page 7-4 and open the rear door on page 7-5 to
5. Once the primary element has been removed, the access engine compartment.
secondary element should be visible, remove it.
3. Remove the fan and fan guard assemblies as
described on page 8-1 of this manual.
4. Raise and support the operator enclosure (cab) as
described on page 4-2 of this manual.
5. Perform the exhaust removal procedure
on page 12-2 of this manual.
6. Perform the air cleaner removal procedure on page
12-3 of this manual.
12-3
Skid Steer Loader
12. Engine
7. Disconnect engine harness wires from the Note: Take note of the harness connections during dis-
alternator and the starter. assembly to aid during reassembly. The harness is la-
beled to make this process easier.
Ground
Upper Lower
12-10
12-13a 12-13b
8. Locate and disconnect the ground wires connected
to the engine/drive pump adapter plate (fig. 12-10).
11. Locate the upper and lower coolant tube/hose on
the right side of the engine. Remove the bolts
securing the upper cooler tube and remove it (fig.
12.-13a). Then remove the hose clamp on the
Fuel Hose clamp lower cooler hose by loosening hose clamp and
disconnect the hose.(fig. 12-13b).
Ground
U-bolt
Zip ties 12. Disconnect the throttle cable from the throttle
linkage on the engine by removing the retaining
clip. Then remove the u-bolt as shown (fig. 12-14).
Clamp
12-12
12-4
Skid Steer Loader
12. Engine
Installation
Inflow Outflow 1. To install the engine, reverse the removal
procedure.
front
12-16
12-17
12-5
13. Quick Attach
13-1
13-1
SkidSteer Loader
13. Quick Attach
Upper guard
13-5
13-2
5. Remove the pivot link from the quick attach
2. Remove the bolts securing the upper guard to the (fig. 13-5).
quick attach weldment (fig.13-2).
Upper guard
13-6
13-7
Installation
1. To install the quick attach locking pin assembly,
reverse the removal procedure.
13-2
SkidSteer Loader
13. Quick Attach
13-8
Drive out
13-9
Note: There are four pivot pins that connect the quick
attach to the lift arm and cylinders. All four pins are
removed in a similar manner.
Installation
1. To install the quick attach pivot pins, reverse the
removal procedure.
13-3
14. Lift-Arm Components
14-1
Skid Steer Loader
14. Lift Arm Components
14-1
3. Remove the zip tie that secures the hydraulic hose 14-5
to the lift cylinder (fig. 14-1).
4. Release hydraulic pressure by performing step 3 8. Support the cylinder from the underside then
on page 14-7 of this chapter. remove the forward pin assembly (fig. 14-5).
14-2
14-6
5. Remove and cap the hose on the rear end of the
cylinder (fig. 14-2). 9. Remove the bolt and pin from the loader tower
(fig. 14-6).
14-3
14-2
Skid Steer Loader
14. Lift Arm Components
Lift Cylinder/Tilt Cylinder Installation 2. Turn the engine start switch to the OFF position
and remove the key to avoid accidental start.
1. To install the lift/tilt cylinder, reverse the removal
procedure.
2. Add grease to loader pin zerks to ensure
proper lubrication of bushings.
Upper
Friction
Point
Lower
Friction Bushings 14-10
Point
14-7 4. Remove the pins from each side of the chassis
(fig. 14-10).
14-11
14-3
Skid Steer Loader
14. Lift Arm Components
14-12 14-15
7. Compress a replacement bushing to fit the hole 12. Insert the pin into the chassis and then through the
size and start the insertion with a dead blow lift arm (fig. 14-15).
hammer as shown. As you drive the new
bushing into the lift arm, the old bushing will be
forced out of the opposite side of the lift arm
(fig. 14-12).
14-16
14-13
13. Install the bolt and nut to secure the pin to the
chassis (fig. 14-16).
8. Complete the insertion of the bushing with an ap-
propriate socket and hammer until the bushing is 14. Perform steps 12-13 to install the pin on the oppo-
flush with the surface of the lift arm (fig. 14-13). site side of the lift arm.
9. Clean and remove any debris from the inside of the
bushing, then apply anti-seize to the inside of the
bushings.
10. Perform steps 7-9 on opposite side of lift arm to
remove remaining bushings.
14-14
11. Ask an assistant to lower the lift arm back into posi-
tion to re-install pins. A pry bar may be used to aid
in aligning chassis and lift arm pin holes (fig. 14-
14).
14-4
Skid Steer Loader
14. Lift Arm Components
14-17 14-20
15. Add grease to the zerks located on each of the lift 2. Remove bolt from pins that secure the tilt cylinder
pins to lubricate them as shown in figure 14-17. to the quick attach (fig. 14-20).
14-21
14-22
14-19
4. Remove bolt from pins that secure the quick attach
to the lift arm (fig 14-22).
1. Lower lift arms onto a suitable mechanical support,
with quick attach resting about 1 ft. off the ground
(fig. 14-18). Then attach a lifting device to secure
the lift arm in position (fig. 14-19).
14-5
Skid Steer Loader
14. Lift Arm Components
10. Repeat steps 7-9 for opposite side of lower lift arm.
14-23
14-24
14-25
14-6
Skid Steer Loader
14. Lift Arm Components
Collect and contain liquids in a suitable 4. Disconnect and cap each of the hydraulic tubes.
container. Dispose of all liquids according to
mandates.
14-29
14-27
14-7
Skid Steer Loader
14. Lift Arm Components
14-30
14-31
14-8
NOTICE
Disassembly of hydraulic components should only be performed 15. Hydraulic Component
by factory trained personnel experienced in the disassembly and
repair of hydraulic components. Components should not be
serviced during the warranty period without written instruction
Service Procedures
from the Terex service department. Component disassembly
during this period may void the manufacturer’s warranty.
As a precaution, disconnect the battery cables from the Note: When servicing cylinders, the attached components
battery terminals, tape the battery clamps and remove the must be supported in a manner that allows the cylinders to be
key from the ignition switch prior to performing any service safely removed and installed. (lift arms & quick attach)
work on a Skid Steer Loader.
1. With machine off and cool and with hydraulic
Place a “Do Not Operate” tag prominently on the machine to actuators relaxed, disconnect and cap hoses from
inform personnel that the machine is being worked on. the cylinder(s) to be serviced.
NOTICE
When servicing any hydraulic component, keep in mind
that any scratches or damage that can be felt with a
fingernail on surfaces that parts move, slide, roll or
rotate upon indicate a need for part replacement.
The hydraulic system fluid should be changed 2. Secure the cylinder into a vice and remove the end
following any hydraulic component service gland by turning counter clockwise with channel
according to the procedure described on page lock pliers. Be sure to have a container to catch
4-12. draining hydraulic fluid (fig. 15-1).
15-1
Skid Steer Loader
15. Hydraulic Components
Piston
O-ring
15-2
End gland
15-3
O-rings
15-7
15-2
Skid Steer Loader
15. Hydraulic Components
Rod seal
9. Remove the shaft wiper and then the rod seal from 12. To remove cylinder bushings, secure the cylinder in
the inside of the end gland with a small blade type a vice and find a socket that has roughly the same
screwdriver. Pay attention to seal orientation upon outside diameter as the bushing (slightly smaller).
removal to aid during installation of new seals Remove the bushing by tapping it out with a rubber
(fig. 15-8). mallet and the socket. You may need to use a
punch to complete the removal of the bushing
(fig. 15-11).
Back-up ring 13. Thoroughly clean and dry all parts prior to
installation of new seals to prevent contamination
of hydraulic oil when cylinders are reassembled
and installed.
15-9
Piston seal
Wear ring
15-10 Piston
15-3
Skid Steer Loader
15. Hydraulic Components
Note: The procedures for installing the seal kits on the lift
cylinders and tilt cylinders are similar, only the lift cylinder
procedure is described below.
2. Make sure your work area is clean and that all tools
are clean before beginning seal install. Lubricate
all seals with new hydraulic oil prior to install.
15-12
15-4
16. Troubleshooting
Problem 1:
Machine will not crank over.
Possible causes:
1. Power quick-attach switch in unlocked position. (if
equipped)
2. Battery cables loose or corroded.
3. Ignition fuse blown.
4. Main starter fuse blown.
5. Starter relay malfunctioning.
6. Weak or dead battery.
7. Faulty continuous hydraulic flow switch.
8. Faulty power quick attach switch.
9. Faulty ignition switch.
10.Faulty starter.
11. Loose, broken or disconnected wiring at key, relay
or starter.
12.Main power fuse (60-80 amp) blown.
16-1
Skid Steer Loader
16. Troubleshooting
16-2
Skid Steer Loader
16. Troubleshooting
16-3
17. Lubricant & Fuel
Specifications
Chapter Overview
When replacing or replenishing the fluids and lubri- Fuel Specifications
cants in an Terex Skid Steer Loader, use Terex prod- Diesel fuel, distilled from crude oil, identified as No. 1-
ucts. This ensures that the new fluids and lubricants D or No. 2-D in “ASTM D975” and “EN 590” generally
match those originally installed when the machine left meet machine requirements.
the Terex factory. Terex products were developed for,
tested and approved by Terex to assure optimum life
and performance in all Terex Skid Steer Loaders, when
used as recommended.
Fluids
Engine Oil
• SAE 10W-30 (API CH-4)
Capacity: 11.2 quarts (10.6l) including filter
Engine Anti-freeze/Coolant
• Terex Long-Life 50/50 Antifreeze/Coolant
Capacity: 3.5 gallons (13l)
P/N: 0300-766 1 gallon
P/N: 0402-841 6 gallons
Hydraulic Oil
• Mobil DTE 10 Excel 46
Service Capacity: 18 gal.(68l) incl. filters
P/N: 0404-094 2.5 gallons
Grease (general-use)
• Terex Multi-Purpose EP Lithium Grease
P/N: 0300-769 1 tube
P/N: 0402-844 10 tubes
P/N: 0402-834 40 tubes
Gear Lube
• 80/90 gear lube
Service Capacity: 4.25 quarts (4.02l)
17-1
18. Service Aids &
Supplements
18-1
Terex Construction Americas
8800 Rostin Road
Southaven, MS 38671
(888)-201-6008
(662)-393-1800
www.terex.com