Home

PT-30 (PN 2010-513)

1. Figure 10 8 2 Install the bolt on the right side of the auxiliary gear pump Compact Track Loader 10 Transmission and Drive Disassembly and Assembly Install en a Figure 10 9 3 Install the bolt on the left side of the auxiliary gear pump Slide Ho Clamp to Rightand Tighten mission Hose 3 Bll dr Figure 10 10 4 With the end of the lower manifold tube inserted in the transmission hose slide the hose clamp to the right and tighten the clamp 5 Install the fuel tank Refer to Chapter 6 Fuel Tank Installation 6 Install the seat Refer to Chapter 6 Seat Instal lation 7 Add fuel and manufacturer approved hydraulic fluid 10 4 Tandem Pump Removal and Installation The tools required for tandem pump removal and installation are listed in Table 10 2 Use manufactur er recommended tools whenever possible Table 10 2 Required Tools Screwdriver Combination Wrench Socket Wrench Tandem Pump Removal A Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Remove the oil filler cap only when the engine is stopped and has been allowed to cool thoroughly A Collect and contain liquids in a suitable contain er Dispose of all liquids according to local regula tions and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and contamina
2. uusrssmeeerennnene nennen ennennn 13 1 Loader Disassembly and Assembly Procedures 13 1 Lift Cylinder Tilt Cylinder Removal and Installation cccccecceeeeeeceeeeeeeeeeeteeeeeeeeeeees 13 1 Lift Cylinder Tilt Cylinder Removal 13 1 Lift Cylinder Tilt Cylinder Installation 13 3 Lift Cylinder Tilt Cylinder Seal Kit Removal and Installation cccceceecseeceeeeeeeseeeeneeeeeeeeees 13 3 Seal Kit Removal ccceecceeeseeeeeeesteeeesenees 13 3 Seal Kit Installation 0 en 13 5 Lift Arm Bushing Removal and Installation 13 6 Upper Friction Points seeen 13 6 Lower Friction Points 444 13 8 Low Flow Relief Valve Removal and Installation 13 9 Low Flow Relief Valve Removal 13 9 Low Flow Relief Valve Installation 13 10 Quick Attach Disassembly and Assembly Chapter Overview nunnnsensnsennsnnsnnnnnnnnnennnnnnenn nenn 14 1 Personal Safety uursnunnnnennnnnnnnennnnnnnnnennnnnnn 14 1 Machine Preparation uursrmneer nennen nennen ennennn 14 1 Quick Attach Disassembly and Assembly Procedure Secere heran 14 1 Latch Pin Assembly Removal and Installation 14 1 Latch Pin Assembly Removal uu 14 1 Latch Pin Assembly Installation 14 2 Quick Attach Assembly Removal and Installation 14 2 Quick Attach Assembly Removal 14 2
3. Figure 8 2113 2 Reach inside the reservoir and install the two nuts that secure the reservoir gauge to the re servoir 3 Install the filter assembly Refer to Chapter 8 Filter Assembly Installation 4 Add manufacturer approved hydraulic fluid Figure 8 22 i 3 With a magnet centered in an absorbent rag Suction Screen Removal and thoroughly clean the interior of the reservoir to Installation prevent any debris from entering the system when you remove the suction filter The tools required for suction screen removal and installation are listed in Table 8 4 Use manufactur er recommended tools whenever possible Table 8 4 Required Tools Combination Wrench 8 6 Compact Track Loader 8 Hydraulic Reservoir Disassembly and Assembly Hydraulic Reservoir Cleaning Procedures Cleaning procedures are provided for the following hydraulic reservoir components e Hydraulic Reservoir Hydraulic Reservoir Cleaning The tools required for hydraulic reservoir cleaning are listed in Table 8 5 Use manufacturer recommended tools whenever possible Figure 8 23 Table 8 5 4 Reach inside the reservoir and unscrew the suc tion screen Remove the suction screen from the reservoir Tool Name Combination Wrench Suction Screen Installation A Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Remove the oil filler c
4. Note Be careful not to cross the wires or hoses If the fuel sending unit wires are crossed the fuel gauge will not work If the hoses are crossed the engine will not run 4 Install the seat Refer to Chapter 6 Seat Instal lation procedure 6 4 Fuel Tank Removal and Installation The tools required for fuel tank removal and installa tion are listed in Table 6 3 Use manufacturer recommended tools whenever possible Table 6 3 Required Tools Screwdriver Combination Wrench Socket Wrench Fuel Tank Removal 1 Remove the seat Refer to Chapter 6 Seat Re moval procedure Figure 6 13 2 View of fuel tank with seat removed 3 Pump all fuel from the fuel tank A Collect and contain liquids in a suitable contain er Dispose of all liquids according to local regula tions and mandates Compact Track Loader 6 Chassis Disassembly and Assembly Remove Floor E _Pan Bolts 4 bs x y emove gt Filler Piece Tag Figure 6 14 Figure 6 17 the frame tank Figure 6 15 Figure 6 18 5 Remove the floor pan 8 Remove the bolt that fastens the fuel tank to the frame e METER Vi a OM Be Y Figure 6 16 Figure 6 19 6 Remove the hoses and wires from the fuel send ing unit 9 Disconnect the Compact vent hose from the fuel tank 6 5 Compact Track Loader 6 Chassis Disassembly and Assembly
5. 16 4 Track Tension Proper track tension is very important for optimum performance and long track life Tracks that are run too loose can cause misfeeding and ratcheting possibly causing damage to the track During the first 50 hours of operation the tracks will break in and will most likely require adjustment Track Tension Adjustment Procedures N u Track no Tensioner Figure 16 10 1 Locate the jam nut on the track tensioner and clean the threads thoroughly before proceeding 2 Loosen the jam nut Figure 16 11 3 After loosening the jam nut turn the track tensioner until the track tension is within specifications 4 Once proper tension is achieved retighten the jam nut Compact Track Loader 16 Maintenance Checking for Proper Track Adjustment 1 Drive the machine forward five feet to remove slack from the lower and rearward portions of the track Figure 16 12 2 Lay a straightedge along the top of the track between the sprocket and the front idler wheel 3 Using a rope or wire put 50 pounds 23 68 kg of down force on the track at the midpoint of the straightedge Figure 16 13 4 Using aruler measure the distance between the straightedge and track The track should not deflect more than 0 75 inch 1 9 cm between the top of the track and the straightedge 5 If the track deflects more than 0 75 inch 1 9 cm tighten the track 16 5 Fuse Bo
6. retten ee 6 1 Seat Removal and Installation 6 1 Seat Removal ueeensenssnsnenssnnnnenenennnnnnnennnn 6 1 Seat Installation 2220u0444nn nennen 6 2 Fuel Sending Unit Removal and Installation 6 2 Fuel Sending Unit Removal ee 6 3 Fuel Sending Unit Installation 6 3 Fuel Tank Removal and Installation 6 4 Fuel Tank Removal ococoocoococccccccinononoccconncinanannns 6 4 Fuel Tank Installation 6 6 Radiator Oil Cooler Disassembly and Assembly Chapter Overview uuennsnssennsnnennnennsnnnnnnnnnnnnnnnnnn 7 1 Personal Safety nuurssnnnnnnnsannnnnnnnnnnnnnnnnannnnnn 7 1 Machine Preparation eeen 7 1 Radiator Oil Cooler Disassembly and Assembly Proce dOS ne e a a asa a UA A EOT OSRE 7 1 Fan Guard Removal and Installation 7 1 Fan Guard Removal ccccccccccccncccncncncccncncnnnnnnnnnos 7 2 Fan Guard Installation cmoccoccccncccnanccano 7 2 Fan and Fan Shroud Removal and Installation 7 2 Fan and Fan Shroud Removal 7 2 Fan and Fan Shroud Installation 7 3 Radiator Cooler Removal and Installation 7 4 Radiator Cooler Removal cccccnccccccccnncconiccnns 7 4 Radiator Cooler Installation 7 6 Radiator Oil Cooler Adjustment Procedure
7. 4 Install the muffler clamp and secure in place Exhaust Pipe Removal and In stallation The tools required for exhaust pipe removal and in stallation are listed in Table 11 2 Use manufacturer recommended tools whenever possible Table 11 2 Required Tools Socket Combination Wrench Pry Bar Penetrating Lubricant Rubber Mallet Plastic Hammer Exhaust Pipe Removal A The exhaust system gets very hot during opera tion Allow the machine to cool thoroughly prior to performing service on the exhaust system Figure 11 8 1 Loosen the nuts on the muffler clamp Compact Track Loader 11 Engine Components Disassembly and Assembly Exhaust Pipe Installation z6 NM G Bolts Figure 11 9 2 Remove the four bolts that secure the exhaust Figure 11 12 pipe to the exhaust manifold 5 Carefully slide the curved pipe into the muffler inlet You may need to tap it into place with a rubber mallet or similar device NOTICE If it is necessary to tap the pipe section into the muffler do so carefully as the pipe walls are thin and easily distorted Use caution and care as you install the pipe section Figure 11 10 3 Remove the exhaust pipe gasket from the ex haust manifold then remove the retaining springs and center pipe from the assembly Note The gasket may come off with the exhaust pipe Figure 11 13 6 Install the center section of pipe a
8. Faulty operator presence switch a Test continuity through seat lap bar and door switch Adjust or replace as necessary Lap bar and door switch are magnetic switches and should be adjusted to approximately 1 16 inch 16 cm away from steel pickup bracket Poor ground check ground wires on bottom left rear side of hydraulic reservoir Safety relay is not activating Faulty safety solenoid or safety solenoid spool Poor wire connections on fuse relay or safety sole noid Low charge pressure 15 2 Problem 4 Loader operates but tracks will not move Probable cause 1 Leak in feed line to pilot control 2 Pilot control malfunctioning Problem 5 Tracks operate but loader will not operate Probable cause 1 Auxiliary direction switch activated sending oil over relief 2 Check to see if auxiliary flow works If auxiliary flow works skip to number 5 3 Main auxiliary relief malfunction 4 Auxiliary pump bad 5 Leak in feed line to loader control pilot 6 Loader control pilot malfunctioning Problem 6 Auxiliary flow does not work Loader works Probable cause 1 Auxiliary hydraulic fuse blown 2 Faulty ground wire a Clean ground connections on left rear side of hydraulic tank Auxiliary hydraulic direction switch failure 4 Poor wire connections at fuse direction switch or pin connector P17 5 Auxiliary hydraulic pilot generation spool stuck 6 Bad or not fully connected Quick Coup
9. 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 1 Product Safety 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
10. l New Roller Normal Wear 50 life Figure 12 32B Sprocket Removal and Installation The tools required for sprocket removal and installation are listed in table 12 5 below Use manufacturer recommended tools whenever possible Sprocket Removal Table 12 5 Required Tools Socket Wrench Sprocket Puller Impact Driver Sprocket Roller Installation Figure 12 33 1 With the drive sprocket rotated to the desired position position the composite roller and steel pin in the drive sprocket Figure 12 34 2 Insert the sprocket roller bolt from the rear Torque to 62 ft lbs 1 Remove the sprocket bearing plate as described on page 12 7 Puller holes Figure 12 35 2 Install the puller by positioning the push bolt into the end of the sprocket shaft and then threading the puller bolts into the holes in the fac e ofthe drive sprocket fig 12 35 amp 12 36 Figure 12 36 Compact Track Loader 12 Undercarriage Disassembly and Assembly 3 Operate the puller by tightening the push bolt with a wrench until the sprocket is pulled off the drive motor shaft as shown in figure 12 36 Re move sprocket and inspect sprocket rollers for wear If replacement is needed refer to Sprock et roller removal on page 12 8 of this chapter Sprocket Installation Figure 12 37 1 After inspecting and cleaning the shaft spray 7471 Loctite Primer on to the sha
11. sure relief valves on the left side of the tandem pump Figure 0 4 2 Remove the hose coupling from the tandem pump T adapter to allow access to the front charge pressure relief valve locking screw Compact Track Loader 17 Hydraulic Pressure Check amp Adjustment Remove Figure 0 5 3 Unscrew and remove the charge pressure relief valve locking screw The valve piston and o ring will remain attached to the locking screw when the lock ing screw is removed Spring Spring Collar and Shims Locking A 4 Screw 5 Valve Pisto and O ring Figure 0 6 4 Extract the spring spring collar and shims from the charge pressure relief valve cavity The front and rear charge pressure relief valves are identical 5 Adjust the charge pressure by adding or remov ing shims Contact Manufacturer 6 Insert the spring spring collar and shims in the charge pressure relief valve cavity 7 Install the charge pressure relief valve locking screw with valve piston and o ring attached 8 Repeat procedure on remaining charge pres sure relief valve The charge pressure relief valves must have the same number of shims 9 Connect the hose coupling on the tandem pump T adapter 10 Check the charge pressure 11 Install the belly pan Drive Pressure Relief Valve Adjustment The service tools required for drive pressure relief valve adjustment are listed in Table 0 3 Use manu f
12. Light Bar Installation procedure Gauge Removal and Installa tion The tools required for gauge removal and installation are listed in Table 5 3 Use manufacturer recommended tools whenever possible Table 5 3 Required Tools Figure 5 15 Combination wrench 4 Pull the gauge out from the front of the dash panel Gauge Removal 1 Lower the light bar Refer to Chapter 5 Light Bar Gauge Installation Removal procedure Figure 5 16 Figure 5 13 1 Insert the gauge from the front of the dash pan 2 Disconnect the connector from the gauge el Figure 5 14 Figure 5 17 3 Remove the two nuts that secure the gauge to 2 Install the two nuts that secure the gauge to the the retaining bracket retaining bracket 5 4 Compact Track Loader 5 Operator Enclosure Disassembly and Assembly Remove Retaining Clip Figure 5 18 Figure 5 20 3 Reconnect the gauge connector 2 Using a small screwdriver remove the retaining clip from each end of the gas assist spring 4 Install the light bar Refer to Chapter 5 Light Bar Installation procedure Lap Bar Gas Assist Spring Removal and Installation The tools required for gas assist spring removal and installation are listed in Table 5 4 Use manufactur er recommended tools whenever possible Table 5 4 Required Tools Screwdriver Figure 5 21 3 Remove the gas assist spring by pulli
13. Quick Attach Assembly Installation 14 3 Compact Track Loader Table of Contents 15 Troubleshooting Chapter Overview nuennsensnnsnnnnnnnnnnnnnnnnnnnennnnnn 15 1 Personal Safety oocoococinccconccccocccconccnancnnnncnnarannnncnnns 15 1 Machine Preparation ooooooccnnoncccnnnoccnonanannnnnancnnnnns 15 1 Visual INSpectiON oooncccnnnnccnnnoncncnnanncnnnnancnnnnos 15 1 Troubleshooting u44224444H HH nennen nn ernennen 15 2 16 Maintenance Chapter Overview unueensensnnsnnnnnnnnnnnnnnnnnnnnnnnn 16 1 Maintenance Schedule u 22rm nennen 16 1 Engine Oil iii een 16 1 Oil Change Procedures u en nn 16 1 Engine Oil Specifications 16 1 Hydraulic Fluid and Filter 16 2 Hydraulic Fluid and Filter Change Procedures rei 16 2 Fuel Fiter 2 234222 inet 16 3 Fuel Filter Change Procedures 16 3 Fuel Specifications ur 20ser nennen nen 16 3 Ait Cleaner 16 3 Air Filter Change Procedures 16 3 Track Tension disini enei 16 4 Track Tension Adjustment Procedures 16 4 Checking for Proper Track Adjustment 16 4 FUSO BOX O 16 5 Grease FittinS eeeeeeseeeeeeseeeeeeeeseneeteeeesaees 16 5 Lift Arm BUSHINGS oooocccoocccnnnoncnonanancnnnnrncnnanancnnnnos 16 6 17 Hydraulic Pressure Check amp Adjustment Chapter Overview nenssensn
14. entering or exiting the machine Ensure that all personnel are far enough away from lt 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 e i i i eath or serious injury can resul any attachment maintenance testing or adjustments Kam cont AAA J ON Machine Labels and Decals Labels and decals placed on the machine provide Cs safety information and operating instructions 0 Familiarize yourself with the location and significance x EEEE E of these labels to ensure your safety Rotating partscan cause pereonalinuny Semang 0 BES gt Product Identification Number PTT TEREX 5 py Lana Burn Hazard Allow the machine to cool thoroughly Grand Rapids MN 55744 u Hot fluid under pressure can scald before opening MODEL ene res 2030 595 PIN The Product Identification Number PIN is located on nd the left side of the firewall next to the operator seat a Read Operator s manual A A Ire Hazan Keep engine exhaust and chassis figure 1 1 Always provide the PIN when contacting Flammable debris can coles near hot argas foo of debri MG y Compact Track Loader 1 Product Safety ge Crush Hazard Rollover can crush and result in serious injury or death Falling can result in serious injury or death Fall Hazard Fasten Seat Belt Do not use the bucket attachment as a wo
15. 3 Loose or worn sprocket 4 Worn track lugs Chapter Overview This chapter contains maintenance requirements and procedures for the following Compact Track Loader components e Engine oil e Air cleaner e Hydraulic fluid and filter e Fuse box e Fuel filter e Grease fittings e Track tension e Lift Arm Brace e Lift arm bushings Maintenance Schedule Maintenance schedule is listed in Table 16 1 Table 16 1 Item Frequency Lubricant Capacity Hydraulic Fluid 1000 hrs Mobile DTE10 8 gal 30 a Excel Series Hydraulic Filter 250 Mrs 2227 Engine Oil 250 hrs HD Diesel En 4 qt 3 79 gine Oil or ren UO Engine Filter 250 hrs Fuel Filter 500 hrs ear Primary Air Check daily clean and reuse as needed Filter up to 5 times change at least once per a do YSA nt se ss EERENT REN Secondary Air Every 3 cleanings Filter gt gt 2 of primary filter Grease Fittings 10hrs Lithium Grease U Track Tension As needed When replacing engine coolant use Terex Long Life 50 50 Antifreeze Coolant or equivalent antifreeze with the proper SCA Supplemental Cooling Additive 16 1 16 Maintenance Lift Arm Brace The lift arm brace is intended to keep service personnel safe when it is necessary to work on a machine with the lift arms in the raised position It is not safe to rely on the hydraulic system to hold the lift arms in the raised position just as it is not safe to crawl under a machine support only by one jack
16. Loader 10 Transmission and Drive Disassembly and Assembly Figure 10 16 2 Install the mounting bolt with spring lock washer and flat washer on the left hand side of the tan dem pump Figure 10 17 3 Install the mounting bolt with spring lock washer and flat washer on the right hand side of the tandem pump Figure 10 18 4 Install the hoses and tubes on the tandem pump 5 Install the auxiliary gear pump Refer to Chapter 10 Auxiliary Gear Pump Installation 6 Install the fuel tank Refer to Chapter 6 Fuel Tank Installation 7 Install the seat Refer to Chapter 6 Seat Instal lation 8 Add fuel and manufacturer approved hydraulic fluid Pump Drive Coupler Removal and Installation The tools required for pump drive coupler removal and installation are listed in Table 10 3 Use manu facturer recommended tools whenever possible Table 10 3 Required Tools Screwdriver Combination Wrench Socket Wrench Pump Drive Coupler Removal A Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Remove the oil filler cap only when the engine is stopped and has been allowed to cool thoroughly A Collect and contain liquids in a suitable contain er Dispose of all liquids according to local regula tions and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and co
17. Remove the four bolts that fasten the muffler to the chassis They can be accessed from the un A The exhaust system gets very hot during opera derside of the machine right rear corner tion Allow the machine to cool thoroughly prior to performing service on the exhaust system 4 Carefully guide the muffler out of the engine compartment Muffler Installation Position the Muffler If over the four Mounting ve Holes x Figure 11 1 1 Loosen the nuts on the muffler clamp Figure 11 4 1 Guide the muffler outlet pipe into its opening at the rear of the engine compartment then posi tion the muffler over the mounting locations Figure 11 2 2 Spray the joint with penetrating lube then slide the curved pipe out of the muffler inlet A pry bar may be helpful in removing this pipe section Compact Track Loader 11 Engine Components Disassembly and Assembly Install Bolts Figure 11 5 2 From the underside install the four muffler mounting bolts and washers shims as found upon disassembly Figure 11 6 3 Carefully slide the curved pipe into the muffler inlet You may need to tap it into place with a rubber mallet or similar device NOTICE If it is necessary to tap the pipe section into the muffler do so carefully as the pipe walls are thin and easily distorted Use caution and care as you install the pipe section Figure 11 7
18. 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 Load er Place a Do Not Operate tag prominently on the machine to inform personnel that the machine is be ing worked on 5 1 5 Operator Enclosure Disassembly and Assembly Operator Enclosure Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following operator enclosure components e Light Bar e Ignition Switch e Gauges e Lap Bar Gas Assist Spring Note Procedures are provided for only those operator enclosure components listed above However information for removal and installation of other operator enclosure components can be obtained from the machine specific parts manual Light Bar Removal and Installation The tools required for light bar console removal and installation are listed in Table 5 1 Use manufacturer recommended tools whenever possible Table 5 1 Required Tools Combination Wrench Light Bar Removal Figure 5 1 1 Loosen the two cap screws that attach the light bar to the cab frame Compact Track Loader 5 Operator Enclosure Disassembly and Assembly Figure 5 2 2 Carefully lower the light bar with the wire har ness attached Figure 5 3 3 View of light bar interior components Interior components are now accessible for servi
19. each side of the 6 Remove the shroud from the engine compart fan shroud that secure the shroud to the radia ment tor cooler Fan and Fan Shroud Installation Figure 7 5 4 With the shroud pulled back reach between the Figure 7 8 radiator cooler and the fan and remove the four l bolts that secure the fan to the engine 1 Place the fan shroud in the engine compartment Figure 7 6 Figure 7 9 5 Remove the fan from the engine compartment 2 Place the fan in the engine compartment 7 3 Compact Track Loader 7 Radiator Oil Cooler Disassembly and Assembly Figure 7 10 3 Holding the fan in position between the radia tor cooler and the fan shroud install the four bolts that secure the fan to the fan drive motor Install Bolts Figure 7 11 4 Pullthe shroud over the fan and install the three bolts on each side of the fan shroud that secure the shroud to the radiator cooler 5 Install the fan guard Refer to Chapter 7 Fan Guard Installation Figure 7 12 6 Install the upper hose on the oil cooler section Radiator Cooler Removal and Installation The tools required for radiator cooler removal and installation are listed in Table 7 3 Use manufactur er recommended tools whenever possible Table 7 3 Required Tools Combination Wrench Socket Wrench Screwdriver Radiator Cooler Removal A Hot oil can cause personal injury Ma
20. sec tion Cap the hose and fitting Figure 7 17 7 Remove the upper hose from the radiator sec tion Cap the hose and fitting B A Figure 7 18 8 Remove the lower hose from the radiator sec tion Cap the hose and fitting Compact Track Loader 7 Radiator Oil Cooler Disassembly and Assembly Install Figure 7 19 Figure 7 22 9 Remove the three mounting bolts on each side 2 With the radiator cooler in position install the of the radiator cooler three mounting bolts on each side of the radia tor cooler Figure 7 20 x Figure 7 23 10 Remove the radiator cooler from the engine compartment 3 Remove the hose and fitting caps and install the lower hose on the radiator section Radiator Cooler Installation Figure 7 24 Figure 7 21 4 Remove the hose and fitting caps and install the 1 Position the radiator cooler in the engine com upper hose on the radiator section partment 7 6 Compact Track Loader 7 Radiator Oil Cooler Disassembly and Assembly Figure 7 25 5 Remove the hose and fitting caps and install the upper hose on the oil cooler section Figure 7 26 6 Remove the hose and fitting caps and install the lower hose on the oil cooler section Figure 7 27 7 Position the lower engine compartment screen and secure with the mounting bolts 7 7 8 Fill the radiator with coolant and the hydraulic reservoi
21. the filtering and cooling system Fan Guard Removal and In stallation The tools required for fan guard removal and instal lation are listed in Table 7 1 Use manufacturer recommended tools whenever possible Table 7 1 Required Tools Combination Wrench Compact Track Loader 7 Radiator Oil Cooler Disassembly and Assembly Fan Guard Removal Figure 7 1 1 Remove the capscrews that secure the fan guard to the fan guard mounts 2 Remove the fan guard from the engine com partment Fan Guard Installation 1 Position the fan guard over the fan and against the fan shroud Figure 7 2 2 Install the capscrews that secure the fan guard to the fan guard mounts Fan and Fan Shroud Removal and Installation The tools required for fan and fan shroud removal and installation are listed in Table 7 2 Use manufac turer recommended tools whenever possible Table 7 2 Required Tools Combination Wrench Socket Wrench Fan and Fan Shroud Removal A Hot fluids can cause burns Allow the machine to cool thoroughly prior to proceeding Figure 7 3 1 Remove the upper hose from the oil cooler sec tion Cap the hose and fitting 2 Remove the fan guard Refer to Chapter 7 Fan Guard Removal Compact Track Loader 7 Radiator Oil Cooler Disassembly and Assembly Remove Bolts Figure 7 4 Figure 7 7 3 Remove the three bolts from
22. uunnsensnsennsnnsnnnnnnnnsnnnnnnennnnnn 12 1 Personal Safety nnsnnnnnnnnnnnnnnonnnnnnennnnnnnenn 12 1 Machine Preparation uurs2ner rennen rennen een 12 1 Undercarriage Disassembly and Assembly PrOCOQUrES o ticas 12 1 Wheel Removal and Installation 12 1 Wheel Removal occccnnnnncccccncccnccanonccccnnnncnnannnnns 12 2 Wheel Installation 12 3 Track Removal and Installation 12 3 Track Removal 02222244400nnnnnnnnnnnnnnn 12 3 Track Installation 0 nen 12 3 Sprocket Bearing Plate Removal and Installation 12 6 Sprocket Bearing Plate Removal 12 7 Sprocket Bearing Plate Installation 12 8 Sprocket Roller Removal and Installation 12 8 Sprocket Roller Removal 12 8 Sprocket Roller Installation 12 9 Sprocket Removal and Installation 12 9 Sprocket Removal cooncoconnccccccconoccconccnanccnancnn 12 9 Sprocket Installation ee 12 10 Drive Motor Removal and Installation 12 10 Drive Motor Removal 12 11 Drive Motor Installation 12 11 Loader Disassembly and Assembly Chapter Overview nunnsensnsennsnnsnnnnnnnensnnnnnnennnnnn 13 1 Personal Safely 2 2 een 13 1 Machine Preparation
23. 2 PT 30 Auxiliary Circuit System To Coder Then to Tank 7 A 4 Co Loader A Valve o DAE BA E N Relief zy I T Quick ce Naat We a L valve Couplers Reservoir Reservoir Pilot Contral a Manifold Solenoid Drive Loop System The drive loop system Figure 3 3 contains the fol lowing major components Tandem pump Drive motors e Pilot control manifold Drive control joystick Figure 3 3 PT 30 Drive Loop System TO IMPLEMENT DRIVE MOTOR CASE DRAIN CHARGE PRESSURE TEST PORT DRIVE CONTROL 3 3 Compact Track Loader 3 Circuit Diagrams TANDEM PUMP WITH DRIVE AND CHARGE PRESSURE RELIEF VALVES Chapter Overview This chapter contains an overview of the machine con trols and instrumentation For further information regarding machine controls instrumentation or opera tion refer to the operation and maintenance manual for your particular machine Included here are illustra tions of the following controls and instrumentation com ponents and a description of their functions e Machine Controls e Instrument Location and Function e Switch Location and Function Machine Controls fig 4 1 There are three primary machine controls loader con trol 1 drive control 2 and throttle 3 Loader Control The loader control 1 is a pilot operated joystick that allows the operator to raise or lower the loader and dump or curl the quick attach mechanism Drive Control The d
24. 6 Seat Re moval 6 Remove the fuel tank Refer to Chapter 6 Fuel Tank Removal 10 2 ET Gear Pump Figure 10 1 7 View of auxiliary gear pump with seat and fuel tank removed Remove Hose Figure 10 2 8 Remove the hose from the left side of the aux iliary gear pump Loosen Clamp and Slide to Left a S25 Trans mission Hose AL Figure 10 3 9 Loosen the clamp that secures the transmission hose to the lower manifold tube and slide the clamp to the left Compact Track Loader 10 Transmission and Drive Disassembly and Assembly Figure 10 4 10 Remove the bolt on the left side of the auxiliary gear pump Figure 10 5 11 Remove the bolt on the right side of the auxiliary gear pump Figure 10 6 12 Remove the auxiliary gear pump by sliding the lower manifold tube out of the transmission hose 10 3 Note It is not necessary to separate the lower manifold tube from the gear pump this can be done after the pump is removed if necessary Auxiliary Gear Pump Installation X mission N Hose Lower Manifold Tube Figure 10 7 1 With the lower manifold tube attached to the auxiliary gear pump align the mounting bolt holes in the auxiliary gear pump with the holes in the tandem pump It will be necessary to slide the manifold tube into the transmission hose to properly position the auxiliary gear pump
25. A Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Remove the oil filler cap only when the engine is stopped and the machine has been allowed to cool thoroughly Figure 8 15 1 Insert the access cover assembly with the clamping disk extending completely through the opening in the top of the reservoir and into the tank Figure 8 13 8 4 Compact Track Loader 8 Hydraulic Reservoir Disassembly and Assembly Figure 8 16 2 Tighten the access cover bolt Reservoir Gauge Removal and Installation The tools required for reservoir gauge removal and installation are listed in Table 8 3 Use manufactur er recommended tools whenever possible Table 8 3 Required Tools Combination Wrenches Reservoir Gauge Removal Figure 8 17 3 View of hydraulic reservoir with filter assembly removed A Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Remove the oil filler cap only when the engine is stopped and the machine has been allowed to cool thoroughly Figure 8 18 4 Reach inside the reservoir and remove the two nuts that fasten the reservoir gauge to the reser voir A Collect and contain liquids in a suitable contain er Dispose of all liquids according to local regula tions and mandates Note During disassembly cap all hoses a
26. Attach Remove 3 Filler Hose Filler Hose Figure 6 20 Figure 6 23 10 Remove the Compact filler hose from the back 2 Attach the filler hose to the rear of the tank end or the tank Figure 6 24 Figure 6 21 3 Connect the vent hose to the fuel tank 11 Remove the tank carefully from the machine Fuel Tank Installation Bolt and Washer Figure 6 25 4 Insert the bolt and washer that connect the fuel tank to the frame Figure 6 22 1 Place the fuel tank in the machine in approx imately its normal position 6 6 Compact Track Loader 6 Chassis Disassembly and Assembly Install Floor Pan Bolts and Washers Figure 6 26 Figure 6 29 5 Insert the steel filler piece behind the fuel tank 8 Install the four floor pan bolts and washers 9 Install the seat Refer to Chapter 6 Seat Instal lation procedure Figure 6 27 6 Attach the hoses and wiring to the fuel sending unit Figure 6 28 7 Replace the floor pan 6 7 Chapter Overview This chapter provides disassembly and assembly procedures for the radiator oil cooler assembly Ad justment procedures are also included for selected radiator oil cooler components A Personal Safety Improper or incomplete maintenance repair of a Compact Track Loader can be dangerous and may result in ma chine damage injury or death Do not attempt to perform any type of repair or mainten a
27. Figure 12 9 Figure 12 10 1 Loosen the jam nut located on the track tensioner using the correct size wrench Turn the track tensioner until the track has significant slack 12 4 Figure 12 11 2 Remove the nut from the bolt that fastens the track tensioner to the drive sprocket assembly Figure 12 12 3 Using a pry bar pivot the drive table assembly upward and support it until the track tensioner bolt can be removed Remove the bolt Figure 12 13 4 Pry the drive table assembly upward away from the tensioner Then pivot the tensioner forward as shown Once the tensioner is out of the way lower the drive table until it rests on the rail Compact Track Loader 12 Undercarriage Disassembly and Assembly Figure 12 14 5 Locate the wheel marked A in fig 12 14 Figure 12 15 6 Perform steps 1 7 of the wheel removal procedure in this chapter to remove the outer front idler wheel Figure 12 16 7 With the wheel removed and the drive sprocket table lowered the track is ready for removal 8 Pull the track outward as shown 12 5 Track Installation A To remove the tracks the machine must be jacked up and placed on jack stands sturdy enough to support the weight of the machine Terex approved jack stands are recommended Figure 12 17 1 Place the track around the rear wheels and on top of the drive sprocket Make sure the tra
28. Removal eee 10 4 Tandem Pump Installation 0 0 0 0 eee 10 5 Pump Drive Coupler Removal and Installation 10 6 Pump Drive Coupler Removal 10 6 Pump Drive Coupler Installation 10 7 Engine Components Disassembly and As sembly Chapter Overview nennsensneennnnennnnennnnennnnnnnnnnn nn 11 1 Personal Safety uurs2unnnnunrnnnnnnnnnnnnnnnnnnnnnnnn 11 1 Machine Preparation uu z4sers nennen nnnnnnnnnenen nenn 11 1 Engine Components Disassembly and Assembly Procedures ceecee 11 1 Primary Air Filter Removal and Installation 11 1 Safety Air Filter Removal and Installation 11 1 Engine Oil Filter Removal and Installation 11 1 Fuel Filter Removal and Installation 11 1 Muffler Removal and Installation 11 2 Muffler REMOVAlI sseceeesseeeeseseeeeeneeeeeaes 11 2 Muffler Installation 11 2 Exhaust Pipe Removal and Installation 11 3 Exhaust Pipe Removal secen 11 3 Exhaust Pipe Installation oooonnnccnnnnnnininancco 11 4 Battery Removal and Installation 11 5 Battery Removal uuezunnnersnnnnnensnnnnnenennnnn nenne 11 5 Battery Installation 0 0 eeeeeeeeseeeeeenteeeeeees 11 6 Bleeding the Fuel System 0 ceeeeeeeeeeeeee 11 7 12 Undercarriage Disassembly and Assembly 13 14 Chapter Overview
29. TEREX Service Manual Compact Track Loader PT 30 Part Number 2010 513 Printed 1 11 Product Safety Chapter Overview Basic Precautions Safety Labels en ara Personal Protective Equipment uu 1 1 Entering and Exiting 1 2 Eifting 22 en i eee ee eee 1 2 Hot Fluids and Component ne 1 2 Corrosion Inhibitor cccsceceseeceeeesseeeeeeeees 1 2 Batteries aier ae e aran 1 2 Pressurized Items oooooccccccononoccccccnnnccccnnccncnonnnos 1 2 A aeaaeae d a aa aaa e Eea 1 3 Attachments en eener 1 4 Machine Labels and Decals ooocoonoccccnnocccccnocncnnnnnnos 1 4 Product ID Number 4 444 1 4 Safety Label Examples 2 rmse ernennen 1 4 Technical Specifications Chapter Overview ooooccocccccccccncccncconaccnnncnnona nana 2 1 PT 30 Specifications urr20ur4 nn neenenennnnennnnn 2 1 System Diagrams Chapter Overview unnennsennsnnnsnnnnnnnnnnnnnnnnnnnnnnnn nn 3 1 Filtering and Cooling System 2 4 gt 3 1 Auxiliary Circuit System uur22sunsneennnennnennnnnn nn 3 2 Drive Loop SystemM unueenseesnennnennnnnnnnnnnnnnnnnnnnnn 3 3 Machine Controls and Instrumentation Chapter Overview unnnennseensnsnnnnnnnnnnnnnnnnnnnnnannnnn nn 4 1 Machine Controls ooccccccncccncnononinoninoninononininininininos 4 1 Loader Control ccccccccccnininininininininininonininininanans 4 1 Drive Control cc
30. The lift arm brace is used support the weight of the lift arms much mechanical supports bear the vehicle weights To install the lift arm brace 1 Park the machine on level ground in a safe area for performing service work 2 Remove any attachments that may be fastened to the quick attach 3 Have an assistant remove the retaining pins that secure the lift arm brace and remove it from the machine 4 Make sure bystanders are clear of the lift arms and then raise them to the upper limit 5 Have an assistant install the brace around the cylinder shaft as shown and reinstall the pins to secure it to the cylinder as shown in Figure 16 1 6 Lower the lift arms slowly until the come to rest on the brace 7 Itis now safe to shut the engine off and exit the machine To remove the lift arm brace A Do not work on or near the machine with the lift arms in the raised position unless the lift arm brace has been correctly installed 1 Start the machine and raise the lift arms until they are clear of the brace 2 Once clear have an assistant remove the brace for the cylinder and stow it on the machine with the pins 3 Once the brace has been stowed and the assistant is clear of the lift arms lower the arms to the ground and shut the engine off to complete the procedure Compact Track Loader 16 Maintenance Braced position with pins Stowed position with pins Figure 16 2 Engine Oil Regul
31. a 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 1 3 10 11 12 13 14 15 Compact Track Loader 1 Product Safety 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 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 tw
32. achine to cool thoroughly and relax all hydraulic circuits before performing this procedure Extreme care must be taken when changing the hydraulic fluid Before starting the procedure make sure the machine is in a clean working environment Precautions should be taken to prevent any debris from entering the hydrostatic system A Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Compact Track Loader 16 Maintenance Hydraulic Fluid Drain Plug Figure 16 4 1 Locate and remove the hydraulic fluid drain plug and drain the fluid into a suitable container Filter Assamhlv Figure 16 5 2 Clean the area around the filter assembly which is located on the top of the hydraulic reservoir Filter a Element Figure 16 6 3 Remove the retaining bolts and cover and then remove the cover to access the filter 16 3 4 Remove the filter element and replace it Install as found upon removal 5 Fill with manufacturer approved hydraulic fluid Fuel Filter The fuel filter should be changed every 500 service hours or as needed A plugged fuel filter can cause loss of engine power rough running or no start A Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Fuel Filter Change Procedures Figure 16 7 1 Cle
33. acturer recommended tools whenever possible Table 0 3 Required Tools Combination Wrench Socket Wrench A Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Remove the oil filler cap only when the engine is stopped and has been allowed to cool thoroughly A Collect and contain liquids in a suitable contain er Dispose of all liquids according to local regula tions and mandates Note During disassembly plug all hoses and tubes to prevent fluid loss and contamination of the system fluids 1 Remove the seat Refer to Chapter 6 Seat Re moval 2 Remove the fuel tank Refer to Chapter 6 Fuel tank Removal 3 Remove belly pan 17 3 Compact Track Loader 17 Hydraulic Pressure Check amp Adjustment 6 Extract the high pressure relief valve collar valve spring spring loading nut and pressure spring from the valve cavity 7 Adjust the drive pressure by turning the spring dam loading nut Turning Clockwise will increase Dri lich 7 pressure Never adjust by more than a quarter Valves Reverso ya turn before checking pressure 8 Insert the high pressure relief valve collar valve spring spring loading nut and pressure spring in the valve cavity 9 Replace the high pressure relief valve locking Figure 0 7 i screw and o ring 4 Locate the drive pressure relief valves Auxiliary Pressure Che
34. an be obtained from the Compact Track Loader Parts List manual Note Refer to Figure 3 1 for an overview of the filtering and cooling system Filter Element Removal and Installation Refer to Chapter 16 Maintenance Hydraulic Fluid and Filter for removal and installation of the filter Filter Assembly Removal and Installation The tools required for filter assembly removal and installation are listed in Table 8 1 Use manufactur er recommended tools whenever possible Table 8 1 Required Tools Combination Socket Wrenches Needle Nose Pliers Compact Track Loader 8 Hydraulic Reservoir Disassembly and Assembly Filter Assembly Removal A Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Remove the oil filler cap only when the engine is stopped and the machine has been allowed to cool thoroughly Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids Figure 8 3 3 Remove the filter from the reservoir as shown Figure 8 1 1 Remove the screws securing the cover to the filter assembly Figure 8 4 4 Disconnect the hose from the filter assembly Figure 8 2 2 Remove the cap from the filter assembly as shown Figure 8 5 5 Remove the bolts securing the filter head as sembly to the reservoir 8 2 Compact T
35. an the outside of the filter thoroughly 2 Remove the retaining bolt top of assembly securing the filter to the head then removes Pour diesel fuel into the new filter until it is full Install the new filter by reversing step 2 Fuel Specifications In North America diesel fuel distilled from crude oil and identified as NO 1 D or No 2 D in ASTM D975 generally meets the proper specifications Air Cleaner The air cleaner is one of the most important maintenance items on the machine A poorly maintained air cleaner can seriously shorten the life of the engine Compact Track Loader 16 Maintenance Air Filter Change Procedures When working in dusty conditions the air cleaner elements should be checked and changed more frequently than when working under normal conditions Do not clean the primary air cleaner element by bumping and tapping This could damage the seals Do not use elements with damaged pleat gaskets or seals 1 Open the hood release the latches on either side of the air cleaner and then remove the cover Primary SS Figure 16 8 2 Remove the primary element The primary element can be cleaned and reused up to five times but it should be changed at least once a year Secondary Element S Figure 16 9 3 Remove the secondary element The secondary element is not serviceable or washable It should be replaced with every three cleanings of the primary element
36. ap only when the engine is stopped and the machine has been allowed to cool thoroughly A Collect and contain liquids in a suitable contain er Dispose of all liquids according to local regula tions and mandates 1 Drain the hydraulic fluid Refer to Chapter 16 Hydraulic Fluid and Filter Change Figure 8 24 2 Remove the access cover assembly Refer to 1 Insert the suction screen in the reservoir through Chapter 8 Access Cover Assembly Removal the access cover opening 3 Thoroughly wipe out the interior of the hydraulic 2 Reach inside the reservoir and screw the suction reservoir with a magnet and a clean rag screen into the bottom of the reservoir 4 Install the access cover assembly Refer to 3 Install the access cover assembly Refer to Chapter 8 Access Cover Assembly Installation Chapter 8 Access Cover Assembly Installation 5 Add facturer d hydraulic fluid 4 Add manufacturer approved hydraulic fluid A memo 8 7 9 Loader Transmission Controls Chapter Overview This chapter provides disassembly and assembly pro cedures for the loader and transmission controls A Personal Safety Improper or incomplete maintenance repair of a Compact Track Loader can be dangerous and may result in ma chine damage injury or death Do not attempt to perform any type of repair or mainten ance on a Compact Track Loader until you have read and fully understood the information in
37. ar Pump Installation 5 Install the fuel tank Refer to Chapter 6 Fuel Tank Installation 6 Install the seat Refer to Chapter 6 Seat Instal lation 7 Add fuel and manufacturer approved hydraulic fluid Chapter Overview This chapter provides disassembly and assembly procedures for the engine components A Personal Safety Improper or incomplete maintenance repair of a Compact Track Loader can be dangerous and may result in ma chine damage injury or death Do not attempt to perform any type of repair or mainten ance on a Compact Track Loader until you have read and fully understood the information in this manual Refer to the Operation and Maintenance manual for in structions regarding proper machine operation techniques before operating any Compact Track Loader Prior to performing any type of service work ona Compact Track Loader read and understand Chap ter 1 Product Safety for personal safety informa tion Machine Preparation Accidental machine starting can cause injury or 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 Load er Place a Do Not Operate tag prominently on the machine to inform personnel that the machine is be ing worked on 11 Engine Components Disassembly and Ass
38. ar oil changes are necessary to maintain a strong running engine A normal oil change interval of 250 hours or every six months is recommended This recommendation has been made to help ensure proper lubrication during operation and to prolong engine life under typical operating conditions Oil Change Procedures 1 Run the engine for a few minutes to warm the engine oil Figure 16 3 Remove drain plug from bottom of the engine Drain oil into suitable container Remove engine oil filter making sure the gasket is also removed 5 Apply a light coat of fresh oil to the new filter gasket then install new filter 6 Tighten filter to specifications on filter label or box 7 Refill the engine to capacity with engine oil as specified Engine Oil Specifications Due to the variations in the quality and performance of commercially available oils Terex Heavy Duty Diesel Engine Oil 10W30 is recommended If Terex lubricants are not available use a substitute meeting the following qualifications API CH 4 multi grade engine oil Hydraulic Fluid and Filter The hydraulic fluid should be changed every 500 service hours and the hydraulic filter should be changed every 250 hours Hydrostatic components require extremely clean oil for long service life Hydraulic Fluid and Filter Change Procedures A Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Allow the m
39. 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 13 790 kPa Follow all recommended practices provided by the pressure washer manufacturer A Repair 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 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 4 Make sure the work are
40. ccccecececeseseseseseseeeseseseeeeeeess 4 1 A O A 4 1 Instr mentation Wises iia a 4 1 SWITCHES costo asar Bess ehren 4 2 Operator Enclosure Disassembly and Assembly Chapter Overview 00 eter reenter 5 1 Personal Saelices 5 1 Machine Preparation ccceeessseeeeesteeeeeeneeereenes 5 1 Operator Enclosure Disassembly and Assembly Procedures ici aba ta tei 5 1 Light Bar Removal and Installation 5 1 Light Bar Removal oooocconoccccccccnoccninnnanananinanannos 5 1 Light Bar Installation oo ooonnnncccnnoniccnnnccccnnnrncno 5 2 Ignition Switch Removal and Installation 5 2 Ignition Switch Removal enenn 5 2 Ignition Switch Installation 5 3 Gauge Removal and Installation 5 4 Gauge RemoVal ooocncconocccincccnonccnoncnnancnnnncncnncnons 5 4 Gauge Installation ceeeeeeeeeeeeeeeeeeeeeeeeees 5 4 Lap Bar Gas Assist Spring Removal and Installation eorne iinn nea ti 5 5 Lap Bar Gas Assist Spring Removal 5 5 Lap Bar Gas Assist Spring Installation 5 5 Table of Contents 6 Chassis Disassembly and Assembly Chapter Overview cooocoooccciocccnocnconcccnonnconcccnnnnnannnnnnns 6 1 Personal Safety nuurssnnnnnnnnnnnnnennnnnnnnnnnannn nn 6 1 Machine Preparation usrsnseersennnensennnnen ernennen 6 1 Chassis Disassembly and Assembly Procedures
41. cing Figure 5 4 4 View of dome light If removal is required simply insert a lever blade type screw driver at oppo site end of switch in pry pocket and gently pry the light assembly out of the light bar Light Bar Installation Figure 5 5 1 Carefully position the light bar without pinching the wiring harness against the cab roof Figure 5 6 2 Secure the light bar to the cab roof with the two capscrews Ignition Switch Removal and Installation The tools required for ignition switch removal and installation are listed in Table 5 2 Use manufactur er recommended tools whenever possible Table 5 2 Required Tools Combination Wrench Ignition Switch Removal 1 Lower the light bar Refer to Chapter 5 Light Bar Removal procedure Compact Track Loader 5 Operator Enclosure Disassembly and Assembly Ignition Switch Installation Figure 5 7 Figure 5 10 2 ee nut ts secures the ignition switch 1 Insert the ignition switch from the rear of the o the dash panel dash panel Figure 5 8 Figure 5 11 3 nn SMCA out trom Ane Taar EINE 2 Install the nut that secures the ignition switch to REREN the dash panel Figure 5 9 Fe ne Figure 5 12 A Unplug ihe lgniiomswiteh connector 3 Plug in the ignition switch connector 5 3 Compact Track Loader 5 Operator Enclosure Disassembly and Assembly 4 Install the light bar Refer to Chapter 5
42. ck amp Adjustment The service tools required for the auxiliary pressure check and adjustment are listed in Table 0 4 Use manufacturer recommended tools whenever possi ble Table 0 4 Required Tools Pressure Gauge Allen Wrench Emn Figure 0 8 5 Unscrew and remove the necessary drive pressure relief valve locking screw The drive pressure relief valve o ring will remain attached to the locking screw when the locking screw is removed Figure 10 1 Insert the hydraulic gauge into one of the at tachment quick couplers Figure 0 9 17 4 Compact Track Loader 17 Hydraulic Pressure Check amp Adjustment Figure 12 2 Engage the continuous flow switch located on the right side of the dash panel Make sure it is in the direction that sends flow to the gage Figure 13 Loosen the jam nut and turn the adjustment screw in with an allen wrench to increase pressure and turn screw out to decrease pressure Tighten jam nut when after adjustment has been made 17 5 Terex Construction Americas 8800 Rostin Road Southaven MS 38671 888 201 6008 662 393 1800 www terex com
43. ck drive lugs mesh with the sprocket Figure 12 18 2 Using soap lubricate the front inside wheel Pull the track around the outside wheel shaft and onto the front inside wheel The soap will help the track slide onto the wheel Compact Track Loader 12 Undercarriage Disassembly and Assembly Figure 12 19 3 Install the front wheel Refer to Chapter 12 Wheel Installation pg 12 3 Figure 12 20 4 Pry the sprocket up until the holes in the track tensioner and drive table are aligned A floor jack or a second pry bar may be needed to get the drive table off the rail Figure 12 21 5 Install and tighten the track tensioner bolt and nut 12 6 Figure 12 22 6 Install the remaining wheels making sure the bearing washer wheel nuts wheel caps and snap rings are properly installed Refer to Chapter 12 Wheel Installation pg 12 3 Track Ben Tensioner y Figure 12 23 7 Tighten the track by turning the track tensioner When proper track tension has been achieved tighten the jam nut on the track tensioner Check for proper track tension Refer to Chapter 16 Maintenance Checking for Proper Track Adjustment Sprocket Bearing Plate Removal and Installation The tools required for sprocket bearing plate removal and installation are listed in table 12 3 below Use manufacturer recommended tools whenever possible Compact Track Loader 12 Un
44. cotter key Sprocket Roller Removal and Installation The tools required for sprocket roller removal and installation are listed in table 12 4 below Use manufacturer recommended tools whenever possible Sprocket Roller Removal Table 12 4 Required Tools Socket Combination Wrench Note The rollers should be inspected every 50 hours for rotation and wear through The rollers on the drive sprocket are easily replaceable The track DOES NOT need to be removed to replace these rollers Roller ai Sa Note In order to remove the sprocket rollers and pins you must remove the torsion axle retaining bolts and washers then slide the undercarriage away from the chassis slightly approx 1 2 54 cm This will provide clearance for the sprocket bolts to be removed for roller pin replacement Figure 12 29 12 8 A Position Drive Sprocket to Access Reller Figure 12 30 1 Rotate the drive sprocket to allow access to the sprocket roller bolt Remove the bolt Figure 12 31 2 Remove the roller and steel pin from the drive sprocket Figure 12 32A 3 Inspect the rollers for wear and replace as necessary The steel pin will normally not need replacing unless the roller has worn completely away and the steel pin is worn from engaging the track fig 12 32A amp B Compact Track Loader 12 Undercarriage Disassembly and Assembly SteelPins N 088 y
45. d on the outside of the end gland with a small blade type screwdriver paying close attention to the order they are removed to aid during installation of 4 Remove the nut from the rod end using the new seals correct size socket Figure 13 10 Piston Figure 13 14 Figuro Jari 8 Remove the shaft wiper and then the rod seal 5 Remove the piston and the o ring off the rod by from the inside of the end gland with a small sliding them upward and off blade type screwdriver Pay attention to seal orientation upon removal to aid during installation of new seals Figure 13 12 6 Remove the end gland by sliding upward and off the rod 13 4 Compact Track Loader 13 Loader Disassembly and Assembly Back up ring bh Figure 13 15 9 Remove the back up ring on the inside of the end gara with a small blade type screwdriver Piston 7 Figure 13 16 10 Remove piston seal and wear ring from piston using a blade type screwdriver Figure 13 17 13 5 11 To remove cylinder bushings place cylinder in vice and find a socket the same diameter as the bushing Remove the bushing with a rubber mallet and the socket You may need to use a punch tool to complete the removal of the bushing 12 Thoroughly clean and dry all parts prior to installation of new seals to prevent contamination of hydraulic oil when cylinders are reassembled and installed Lift Cylinder Tilt Cylinder Seal Kit Instal
46. d wheel nut to the axle Torque the nut to 110 ft lbs 149Nm 3 Install the cap and secure it with the snap ring Make sure the snap ring is fully seated in its grove Track Removal and Installation The tools required for track removal and installation are listed in Table 12 2 Use manufacturer recommended tools whenever possible Table 12 2 Required Tools Socket Wrench Heavy Duty Floor Jack Combination Wrench Straight Edge Crowbar Tape Measure Jack Stands Track Removal A To remove the tracks the machine must be jacked up and placed on jack stands sturdy enough to support the weight of the machine Terex approved jack stands are recommended Compact Track Loader 12 Undercarriage Disassembly and Assembly NOTE Bearings Tapered Roller Bearing O Ball Bearing LO In the illustration above the rear wheel is shown with a tapered roller style bearing while the center wheel is shown with a ball type bearing It is important to note that these bearings are positioned within the undercarriage as they are in order to adequately bear the differing loads forces applied to them When replacing bearings or removing wheels always make sure the front and rearmost wheels in the undercarriage are equipped with tapered roller type bearings while the eight interior wheels are to be equipped with ball type bearings They are not interchangeable in this application
47. dercarriage Disassembly and Assembly Table 12 3 Required Tools Socket Wrench Bearing Puller Tool Combination Wrench Torque Wrench Sprocket Bearing Plate Removal 1 Remove the track Refer to Chapter 12 Track Removal gt N Cott Figure 12 24 2 Remove the cotter pin from the castle nut on the end of the sprocket assembly Two bolts Figure 12 25 3 Remove the spacer washer 4 Remove the two bolts securing the bearing plate to the drive table 12 7 Figure 12 26 5 Remove the four bolts that secure the bearing assembly to the bearing plate remove the bearing plate Figure 12 27 6 Remove bearing from sprocket with bearing puller tool Inspect sprocket rollers for wear If replacement is needed refer to sprocket roller removal on page 12 8 of this chapter Sprocket Bearing Plate Installation 1 To install the sprocket bearing plate reverse removal procedure with following added instructions Bearing 4 flange w lt zerk Bearing grease track Figure 12 28 Compact Track Loader 12 Undercarriage Disassembly and Assembly 2 Align the grease hole of the bearing flange with zerk and the grease track on the bearing as shown in figure 12 28 3 Ensure that the concave side of the washer is contacting the sprocket 4 Torque castle nut is to 270 ft lb 366 Nm and then rotate until the next hole is visible to install the
48. derstand Chap ter 1 Product Safety for personal safety informa tion Machine Preparation Accidental machine starting can cause injury or 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 Load er Place a Do Not Operate tag prominently on the machine to inform personnel that the machine is be ing worked on 6 1 6 Chassis Disassembly and Assembly Chassis Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following chassis components e Seat e Fuel Sending Unit e Fuel Sending Unit Hose e In Tank Weight e Fuel Tank Note Procedures are provided for only those chassis components listed above However information for re moval and installation of other chassis components can be obtained from the exploded view illustration provided in the machine specific parts manual Seat Removal and Installation The tools required for seat removal and installation are listed in Table 6 1 Use manufacturer recommended tools whenever possible Table 6 1 Required Tools Socket Wrench Seat Removal Figure 6 1 1 Remove the four bolts that fasten the seat mounts to the frame Compact Track Loader 6 Chassis Disassembly and Assembly Un
49. e top and bottom of to the chassis to allow for removal the loader valve Cap and plug all openings to pre vent fluid loss Compact Track Loader 9 Loader Transmission Controls Figure 9 17 Figure 9 20 11 Disconnect the tubes from the side of the loader 14 Remove the valve from the machine valve Cap and plug all openings to prevent fluid loss 15 Installation is the reverse of the removal proce dure 16 Once all components have been reinstalled and are secure add manufacturer approved hydraulic fluid until full mark is reached on the level gauge Note To eliminate trapped air from the system acti vate all hydralic circuits and run machine through its paces including moving the lift arms up and down curl ing and tilting the Q A driving forward and in reverse and activating the auxiliary circuit Then check Figure 9 18 hydraulic fluid level and add as required to reach full mark 12 Disconnect the hoses from the rear and side of the loader valve Cap and plug all openings to prevent fluid loss Figure 9 19 13 Remove the nuts securing the valve to the reser voir as shown Chapter Overview This chapter provides disassembly and assembly procedures for the transmission and drive assembly A Personal Safety Improper or incomplete maintenance repair of a Compact Track Loader can be dangerous and may result in ma chine damage injury or death Do not attempt to perform any type of repair or mai
50. eennnnennnnnnnnnennnennnnnnn 17 1 Personal Safety uur 2unn2nunnnnnnnnnnnnnnnnnnnnnnnnnn 17 1 Machine Preparation 4usr4 Henne nennen nennen nee 17 1 Charge Pressure Check ceeceeeeeeeeeeees 17 1 Charge Pressure Adjustment 17 2 Drive Pressure Adjustment 444444HHH HH 17 3 Auxiliary Pressure Check amp Adjustment 17 4 Chapter Overview This chapter contains product safety information for the Terex PT 30 Compact Track Loaders Read and under stand 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 NOTICE NOTICE Indicates a hazardous situation which if not avoided could result in property or equip ment damage The word Note is used throughout this manual to draw your attention to specific topics or to supplement the information provided in that section
51. embly Engine Components Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following engine components e Muffler e Battery e Exhaust Pipe e Bleeding the Fuel System Note Procedures are provided for only those engine components listed above However information for re moval and installation of other engine components can be obtained from the machine specific parts manual Primary Air Filter Removal and Installation Refer to Chapter 16 Maintenance Air Cleaner for removal and installation of the primary air filter Safety Air Filter Removal and Installation Refer to Chapter 16 Maintenance Air Cleaner for removal and installation of the safety air filter Engine Oil Filter Removal and Installation Refer to Chapter 16 Maintenance Engine Oil for removal and installation of the engine oil filter Fuel Filter Removal and Installation Refer to Chapter 16 Maintenance Fuel Filter for removal and installation of the fuel filter Compact Track Loader 11 Engine Components Disassembly and Assembly Muffler Removal and Installation The tools required for muffler removal and installa tion are listed in Table 11 1 Use manufacturer recommended tools whenever possible Table 11 1 Required Tools Socket Combination Wrenches Pry Bar Penetrating Lubricant Rubber Mallet Plastic Hammer Figure 11 3 Muffler Removal 3
52. er 13 Loader Disassembly and Assembly A Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids 1 Lower the lift arms to the ground 2 Turn the engine start switch to the OFF position and remove the key to avoid accidental start Figure 13 39 3 Press the button on top of the quick coupler block to release hydraulic pressure nn Disconnect Tubes Figure 13 40 4 Disconnect and cap all three hydraulic tubes Remove Bolts Figure 13 41 5 Remove the four bolts that secure the quick coupler block to the loader frame and remove the block Quick Coupler Block Pressure Release Valve Installation Install Bolts Figure 13 42 1 Install the four bolts that secure the quick coupler block to the loader frame Reconnect Tubes Figure 13 43 2 Reconnect all three hydraulic tubes 13 10 Chapter Overview This chapter provides disassembly and assembly procedures for the quick attach assembly Personal Safety 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 maintenance on a Compact Track Loader until you have read and fully
53. es including guards and shields are properly installed and functioning correctly before starting the engine or operating the machine Compact Track Loader 1 Product Safety A A the dealer about parts service warranty or accessories No warranty claims will be processed unless the PIN is provided N Attachments LY A gt Only use attachments that are recommended by Terex LS m Crush Hazard Death or serious Injury can result Keep clear of lift arms and Make sure that all necessary guards and protective fe ven Ma meng Mn attachments J When replacement parts are required for your Avwarnine machine use only genuine Terex replacement O parts or parts that meet or exceed original e gt specifications including but not limited to physical 0 Q dimensions type strength and material m Safety Installing lesser components can lead to premature Contact es can Keep clear of moving machine Label failures product damage personal injury or death result in death or serious injury 2030 583 x equipment are in place and functioning prior to operat e ing any attachment Wear protective glasses and protective equipment as required by conditions or as recommended in the Fall Hazard di n erious injury or death can resul on r attachment s operation manual fone E
54. ety Improper or incomplete maintenance repair of a Compact Track Loader can be dangerous and may result in ma chine damage injury or death Do not attempt to perform any type of repair or mainten ance on a Compact Track Loader until you have read and fully understood the information in this manual Refer to the Operation and Maintenance manual for in structions regarding proper machine operation techniques before operating any Compact Track Loader Prior to performing any type of service work ona Compact Track Loader read and understand Chap ter 1 Product Safety for personal safety informa tion Machine Preparation Accidental machine starting can cause injury or 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 Load er Place a Do Not Operate tag prominently on the machine to inform personnel that the machine is be ing worked on 15 1 15 Troubleshooting Preliminary Inspection A simple visual inspection and operational check can identify many problems without the need for ex tensive troubleshooting If these checks indicate a problem that requires further analysis proceed to Troubleshooting in this section Visual Inspection Prior to troubleshooting perform a visual inspection of the mac
55. evel Then lower the lift arm until the bucket contacts the ground repeatedly Have an assistant look for independent movement between the e Lift arms amp chassis e Lift arms amp lift cylinder e Lift cylinder amp chassis Any movement will be readily noticeable by the attendant If movement is detected bushings will need further inspection as shown in the following step 3 Refer to Chapter 13 of Lift Arm Bushing Removal and Installation procedure to access bushings for measurement inspection Note Inspect the bushing for wear and replace as necessary Maximum recommended wear on the bushing is 50 as shown in figure 16 16 Lift Arm Bushings 063 Service limit l New bushing Max recommended wear 50 Figure 16 16 16 6 Chapter Overview This chapter provides a overview of checking and setting pressures It is important to contact the manufacturer for assistance before beginning these procedures A Personal Safety Improper or incomplete maintenance repair of a Compact Track Loader can be dangerous and may result in ma chine damage injury or death Do not attempt to perform any type of repair or mainten ance on a Compact Track Loader until you have read and fully understood the information in this manual Refer to the Operation and Maintenance manual for in structions regarding proper machine operation techniques before operating any Compact Track Loader Prior to performing any type of serv
56. ft Figure 12 38 2 Once the primer has dried spread 680 Loc tite Retaining Compound onto the shaft The retaining compound is very important it fills in small inconsistencies in the shaft and creates a better bond between the shaft and the sprocket 12 10 Figure 12 39 3 Align the key on the shaft with the key way in the drive sprocket and then slide the sprocket onto the shaft Install the bolt into the end of the sprocket shaft and finger tighten Complete the next step as soon as possible to prevent the Loc tite from drying before the sprocket is tightened Figure 12 40 Note Using a torque wrench tighten the sprocket bolt to275 lb ft 366 Nm 4 Remove the drive motor fittings by turning the motor so that the fittings face upward Then tilt the motor in the table as shown 4 pull upward and outward to remove Drive Motor Removal and Installation Use manufacturer recommended tools whenever possible Table 12 6 Required Tools Socket Combination Wrench Compact Track Loader 12 Undercarriage Disassembly and Assembly Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids Drive Motor Removal Top Large SS Bottom Large Y Figure 12 41 1 Locate four drive motor hoses in back of drive motor Peet marking Figure 12 42 2 Mark the top T and bottom B large hoses to ensu
57. ft lb 81 Nm w Blue Loctite Drive Sprocket Retaining Castle Nut Serial 05001 Current 270 ft lb 366 Nm Service Tools Listed below are common service tools which are iden tified and utilized in the service procedures described in this manual Use tools recommended by Terex whenever possible to reduce risk of injury and or machine damage during service Heavy Duty Hydraulic Jack 5 ton rating Test Gauge Kit P N 0402 935 Long Pry Bar s Chapter Overview This chapter contains diagrams for the following Compact Track Loader systems e Filtering and cooling system e Auxiliary circuit system e Drive loop system Figure 3 1 PT 30 Filtering and Cooling System Hydrauic Reservoir Pilot Control Manifold M24 A a Gear Pump 3 Circuit Diagrams Filtering and Cooling System The filtering and cooling system Figure 3 1 contains the following major components e Hydraulic reservoir e Radiator oil cooler Loader valve e Auxiliary gear pump Pilot control manifold 100psi 689 5 kPa Cooler Relief RadiatoriQil Cooler 10 Micron Return Filter Hot Oil Temp Sending Unit 50 Micron Suction Screen Auxiliary 3 1 Compact Track Loader 3 Circuit Diagrams Auxiliary Circuit System The auxiliary circuit system Figure 3 2 contains the following major components e Loader valve e Pilot control manifold e Auxiliary gear pump e Loader control joystick Figure 3
58. gure 3 2 for an overview of the auxiliary circuit system and Figure 3 3 for an overview of the drive loop system Drive Motor Removal and In stallation Refer to Chapter 12 Undercarriage Disassembly and Assembly Drive Motor Removal and Installa tion for removal and installation of the drive motors Compact Track Loader 10 Transmission and Drive Disassembly and Assembly Auxiliary Gear Pump Removal and Installation The tools required for auxiliary gear pump removal and installation are listed in Table 10 1 Use manu facturer recommended tools whenever possible Table 10 1 Required Tools Screwdriver Combination Wrench Socket Wrench Auxiliary Gear Pump Removal A Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Remove the oil filler cap only when the engine is stopped and has been allowed to cool thoroughly A Collect and contain liquids in a suitable contain er Dispose of all liquids according to local regula tions and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids 1 Lower the lift arms to the ground 2 Turn the engine start switch to the OFF position 3 Relieve hydraulic pressure from the auxiliary circuit 4 Drain the hydraulic fluid Refer to Chapter 16 Hydraulic Fluid and Filter Change 5 Remove the seat Refer to Chapter
59. he battery 90 degrees counter clockwise Tilt up the front of the battery and remove the battery from the machine Battery Installation Figure 11 21 1 Place the battery in position in the engine com partment Install Capscrews Figure 11 22 2 Position the battery holdown bracket and install the two capscrews and nuts 2 Connec 4 AS Positives Figure 11 23 3 Connect the battery cable to the positive battery terminal Figure 11 24 Compact Track Loader 11 Engine Components Disassembly and Assembly 4 Connect the battery cable to the negative battery terminal Bleeding the Fuel System The tools required for muffler removal and installa tion are listed in Table 11 1 Use manufacturer recommended tools whenever possible Table 11 4 Required Tools Combination Wrench If the machine has been run out of fuel it may be necessary to bleed the fuel system There are two types of bleeding methods depending on the serial number of your machine For serial numbers 001 through 1357 Figure 11 26 1 Locate the bleed screw directly above the fuel injectors 2 Loosen the bleed screw two full turns Figure 11 25 1 Locate the bleed screw directly above the fuel injectors 2 Loosen the bleed screw two full turns 3 Turn over the engine from the operators com partment until fuel is flowing from the bleed screw without any a
60. hine Look for missing loose or worn parts Perform the following visual checks e Track tension e Fluid levels e Fan belt tension and condition e Hoses no visible sign of wear e Fittings no leaks e Battery cables e Fuse box fuses in place and operational e Controls for neutral Compact Track Loader 15 Troubleshooting Troubleshooting This section identifies selected problems and sug gests probable causes Problem 1 Machine will not crank over Probable cause 1 0 00 NAT Co IS Auxiliary hydraulic switch activated Weak or dead battery Battery cables loose or corroded Ignition fuse blown Main starter fuse blown Starter relay malfunctioning Bad ignition switch Bad starter Poor wire connections at key relay or starter Problem 2 Machine cranks but will not start Probable cause 1 Injection pump fuse blown 2 Main power fuse B blown 3 Main power relay B not activating 4 Poor wire connection at injection pump or fuse 5 Glow plugs not heating Will see black smoke a Main glow plug fuse blown b Glow plug relay not activating c Poor wire connections at ignition switch relay or glow plug strip d Failed glow plugs e Bad ignition switch Problem 3 Machine starts but hydraulics will not operate Probable cause 1 Lap bar must be in down position operator must be seated in seat and front door if installed must be closed Safety fuse blown
61. ice work ona Compact Track Loader read and understand Chap ter 1 Product Safety for personal safety informa tion Machine Preparation Accidental machine starting can cause injury or 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 Load er Place a Do Not Operate tag prominently on the machine to inform personnel that the machine is be ing worked on 17 1 17 Hydraulic Pressure Check amp Adjustment Hydraulic Pressure Adjustment Procedures Adjustment and test procedures are provided for the following transmission and drive components e Charge Pressure Check amp Adjustment e Drive Pressure Relief Valve Adjustment e Auxiliary Valve Pressure Check amp Adjustment Charge Pressure Check The service tools required for the charge pressure check are listed in Table 0 1 Use manufacturer recommended tools whenever possible Table 0 1 Required Tools Pressure Gauge Combination Wrench Socket Wrench Note The fuel tank SHOULD NOT be removed to per form this procedure Figure 0 1 1 Remove the floor pan Compact Track Loader 17 Hydraulic Pressure Check amp Adjustment Attach Gauge Figure 0 2 2 Attach the gauge to the pilot control manifold
62. in3 rev 5 4 cc rev x2 Relief pressure 360 20 psi 24 82 bar Flow 3 gpm 11 4 lpm combined 1175 rpm Flow 8 1 gpm 30 7 lpm combined 2800 rpm Drive Motors Model Rexroth Sauer Danfoss Displacement 19 215 in3 rev 314 9 cc rev Pilot Controls Joysticks Model Rexroth 4TH6 Auxiliary Pump Make Rexroth Type Gear Displacement 0 87 in3 rev 14 3 cc rev Max Flow 10 gpm 37 9 lpm 2800 rpm Relief pressure 3000 psi 20 684 kPa Cooling filtering Oil is filtered and cooled at all times In auxiliary mode the oil is filtered after the attachment to protect the machine if the attach ment motor fails or contaminants are introduced from the quick couplers Lift Arm Control Valve Make Husco Relief Pressure 3000 psi 20 684 kPa Pilot pressure required to move spools 180 220psi 1241 1517 kPa 2 1 2 Technical Specifications amp Service Tools Oil Cooler Operating pressure 250 psi 1724 kPa Bypass relief pressure 80 psi 551 6 kPa Hot oil sending unit 225 F 107 2 C Avg oil operating temp 50 60 F 10 16 C above ambient extreme application 80 F 27 C above ambient Critical Torque Specs Transmission Mounting Bolts 80 ft lb 108 Nm w Blue Loctite Drive Sprocket Drive Teeth Bolts 62 ft lb 84 Nm Dry Bogie Wheel Retaining Nuts 110 ft lb 149 Nm Dry Drive Sprocket Retaining Bolt Serial 00101 05000 60
63. ir bubbles 4 Tighten the bleed screw 5 Engine should now start within 10 seconds For serial numbers 1358 and higher Figure 11 27 3 Pump the bulb primer with your hand until fuel flows from the bleed screw without any air bub bles 4 Tighten the bleed screw Chapter Overview This chapter provides disassembly and assembly procedures for the following undercarriage assemblies e Track e Suspension A Personal Safety 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 maintenance on a Compact Track Loader until you have read and fully understood the information in this manual Refer to the Operation and Maintenance manual for instructions regarding proper machine operation techniques before operating any Compact Track Loader Prior to performing any type of service work ona Compact Track Loader read and understand Chapter 1 Product Safety for personal safety information Machine Preparation Accidental machine starting can cause injury or 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 performing any service work on a Compact Track Loader Place a Do Not Operate tag prominently on the machine to infor
64. ke sure the oil is cool before removing any components or lines Remove the oil filler cap only when the engine is stopped and has been allowed to cool thoroughly A Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and hoses contain hot coolant and steam Allow the machine to cool tho roughly prior to performing service or repair proce dures to avoid burns Remove the filler cap slowly to relieve pressure only when the engine is stopped and the machine has been allowed to cool thoroughly Cooling system conditioner contains alkali Avoid contact with skin and eyes A Collect and contain liquids in a suitable contain er Dispose of all liquids according to local regula tions and mandates 1 Remove fan and shroud Refer to Chapter 7 2 Drain the hydraulic fluid Refer to Chapter 16 Hydraulic Fluid and Filter Change Compact Track Loader 7 Radiator Oil Cooler Disassembly and Assembly Figure 7 13 3 Remove the bolts from the lower engine com partment screen Drain Coolant Figure 7 14 4 Remove the lower engine compartment screen and drain the coolant using the petcock on the bottom of the radiator Figure 7 15 5 Remove the lower hose from the oil cooler sec tion Cap the hose and fitting 7 5 Figure 7 16 6 Remove the upper hose from the oil cooler
65. l 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 Lift Cylinder Seal Kit P N 2010 552 Tilt Cylinder Seal Kit P N 2010 548 1 Reverse the cylinder seal removal procedure to install seal kits on both the lift and tilt cylinders 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 Socket Figure 13 18 3 Use a rubber mallet and a socket or section of pipe with the same outside diameter as the seal to drive into place 4 Reverse steps 1 6 of the seal removal procedure to reassemble the cylinder 5 Add removable locktite to the nut and torque to 75 ft lbs 6 Torque the cap gland to 100 ft lbs Compact Track Loader 13 Loader Disassembly and Assembly Lift Arm Bushing Removal and Installation The tools required for lift arm and lift arm bushing removal and installation are listed in Table 13 3 Use manufacturer recommended tools whenever possible Table 13 3 Required Tools Socket Dead Blow Hammer Combination Wrench Crescent Wrench Mechanical Support Lifting Device Pry Bar Lift Arm Bushing Placement Upper Friction Point Lower 2 Friction Point 4 7 u Bushings o Figure 13 19 Upper Friction Points Note Each worn bushing will be removed o
66. le Table 14 1 Required Tools Socket Combination Wrench Latch Mechanism Assembly Removal 1 Remove any attachments and place support blocks beneath the quick attach Then tilt the quick attach assembly forward and lower the lift arms until the quick attach assembly rests securely on the blocks approximately 6 inches off the ground Figure 14 1 Compact Track Loader 14 Quick Attach Disassembly and Assembly 2 Turn the engine start switch to the OFF position Figure 14 2 3 Remove the bolt securing the latch mechanism to the quick attach spring block using an allen wrench Figure 14 3 4 Remove the bolt and nut using to two wrenches 5 Slide the latch mechanism out for parts inspection v ey Figure 14 4 6 Disassemble as necessary and replace worn components to ensure proper function Latch Mechanism Installation 1 Latch installation is the reverse of the removal procedure 2 Add removable lock tite to allen bolt threads Quick Attach Assembly Removal and Installation The tools required for quick attach assembly removal and installation is listed in Table 14 2 Use manufacturer recommended tools whenever possible Table 14 2 Required Tools Combination Wrench Quick Attach Assembly Removal 1 Remove any attachments and place support blocks beneath the quick attach Then tilt the quick attach assembly forward and lower the lift ar
67. lean and remove any debris then apply anti seize to the inside of the bushings 11 Perform steps 7 10 on opposite side of lift arm to remove remaining bushings 13 7 Figure 13 26 12 With an assistant lower lifting device to drop lift arm back into position to re install pins A pry bar may be used to aid in aligning chassis and lift arm pin holes A Do not use fingers to align pin holes Figure 13 27 13 Insert the pin into the chassis and through the lift arm Figure 13 28 14 Install bolt and nut to secure pin to chassis 15 Perform steps 12 13 for opposite side of lift arm Compact Track Loader 13 Loader Disassembly and Assembly Figure 13 29 Figure 13 32 16 Add grease to the zerks located on each of the 2 Remove bolt from pins that secure the tilt lift pins to lubricate them cylinder to the quick attach Lower Friction Points Note Each worn bushing will be removed one at a time Figure 13 33 3 Remove pin from the cylinder and quick attach Figure 13 31 Figure 13 34 1 Lower lift arms onto a mechanical support with quick attach resting about 1 ft off the ground Then attach a lifting device to secure the lift arm in position 4 Remove bolt from pins that secure the quick attach to the lift arm 13 8 Compact Track Loader 13 Loader Disassembly and Assembly Figure 13 35 5 Remove pin 6 Perform steps 2 5 on opposite side
68. ler o Problem 7 Auxiliary hydraulic part time thumb switch operates but full time flow direction switch will not operate Probable cause 1 Auxiliary direction switch faulty 2 Poor wire connections at mode switch or direction switch Compact Track Loader 15 Troubleshooting Problem 8 Auxiliary hydraulic full time direction switch operates but part time thumb switch will not operate Probable cause 1 Auxiliary hydraulic thumb switch malfunction 2 Poor wire connections at direction switch thumb switch or pin connector P17 Problem 9 Auxiliary hydraulics will only flow one way Probable cause 1 Auxiliary hydraulic relay 1 or 2 failure 2 Auxiliary hydraulic pilot generation coil faulty 3 Auxiliary hydraulic pilot generation spool faulty 4 Poor wire connections at relay pilot generation so lenoid pin connector P16 or P21 5 Loader valve malfunction Problem 10 No power to numerous auxiliary functions or accessories in ON or RUN position Probable cause 1 Main power relay A or B fuse blown 2 Main relay A or B faulty 3 Ignition switch malfunction 4 Poor wire connections at ignition switch fuse or re lay Problem 11 Battery will not charge and or battery goes dead Probable cause 1 Alternator fuse blown 2 Alternator diode defective or inserted backwards 3 Poor wire connections at battery alternator diode or fuse 4 Excessive draw in off position a Fuel gauge and ho
69. m personnel that the machine is being worked on 12 1 12 Undercarriage Disassembly and Assembly Undercarriage Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following undercarriage components e Wheels also see track procedure e Sprockets e Sprocket rollers e Sprocket bearing plates e Tracks e Drive motors Note Procedures are provided for only those undercarriage components listed above However information for removal and installation of other undercarriage components can be obtained from the machine specific parts manual Wheel Removal and Installation The tools required for wheel removal and installation are listed in Table 12 1 Use manufacturer recommended tools whenever possible Table 12 1 Required Tools Wheel Extractor Channel Lock Pliers Socket Wrench Snap ring Pliers Wheel Removal Note If the track is to be removed perform the track removal process on page 12 3 of this chapter Note For important wheel and bearing information see Bearings in the track removal procedure on page 12 4 prior to removing or reinstalling the idler wheels Note The procedure for removing the Idler wheels and Bogie wheels are similar Only the front outside idler wheel is described here Any exception will be explained in the instructions as a note See figure 12 1 for wheel diagram Compact Track Loader 12 Undercarriage Disasse
70. mbly and Assembly Idler Bogie Idler Wheels Wheels Wheels Figure 12 1 BONES 1 Loosen up the track tensioner as described in 4 Remove the nut that fastens the wheel to the the track removal procedure on page 12 3 steps shaft with the correct size socket Figure 12 2 Figure 12 5 2 Remove the snap ring securing the wheel cap 5 Remove the washer with snap ring pliers Figure 12 3 3 Remove the wheel cap using a large channel Figure 12 6 lock pliers 6 Remove the bearing 12 2 Compact Track Loader 12 Undercarriage Disassembly and Assembly Figure 12 7 7 Remove the idler wheel with a wheel extractor as shown in figure 12 7 Note lf removing a bogie wheel remove the large inside washer 8 Inspect the exposed axle s for wear or damage 9 To remove any idler wheels or bogie wheels located on the inside of the suspension nearest the chassis position the machine securely on jack stands Repeat the wheel removal procedure Wheel Installation Note Refer to bearing illustration on figure 12 9 of this chapter to ensure proper installation of each style of bearing Figure 12 8 1 Mount the outer front idler wheel onto the axle as shown Note During installation carefully slide the wheel onto the axle shaft to prevent seal damage Note Bogie wheels will have a large washer that is installed before the wheel 2 Install the bearing washer an
71. ms until the quick attach assembly rests securely on the blocks approximately 6 inches or 15 24 cm off the ground 2 Turn the engine start switch to the OFF position Compact Track Loader 14 Quick Attach Disassembly and Assembly Remove Pin a amp Remove gt j Figure 14 5 3 Remove the bolt and push out the pin that secures each end of the quick attach assembly to the tilt cylinders Remove Pin Figure 14 6 4 Remove the bolt and push out the pin that secures each end of the quick attach assembly to the loader frame The quick attach assembly is now free and ready to be moved by a forklift Quick Attach Assembly Installation 1 With a forklift move the quick attach assembly in position to be secured to the loader frame and tilt cylinders 14 3 Insert Pin Install Figure 14 7 2 Insert the pin and install the bolt that secures each end of the quick attach assembly to the loader frame Install Insert It Figure 14 8 3 Insert the pin and install the bolt that secures each end of the quick attach assembly to the tilt cylinders Chapter Overview This chapter contains basic troubleshooting proce dures for the Compact Track Loader Additional troubleshooting aids are provided in Chapter 3 System Diagrams and in those chapters containing disassembly and assembly procedures for the appropriate component or assembly A Personal Saf
72. nce on a Compact Track Loader until you have read and fully understood the information in this manual Refer to the Operation and Maintenance manual for in structions regarding proper machine operation techniques before operating any Compact Track Loader Prior to performing any type of service work ona Compact Track Loader read and understand Chap ter 1 Product Safety for personal safety informa tion Machine Preparation Accidental machine starting can cause injury or 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 Load er Place a Do Not Operate tag prominently on the machine to inform personnel that the machine is be ing worked on 7 1 7 Radiator Oil Cooler Disassembly and Assembly Radiator Oil Cooler Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following radiator oil cooler components e Fan Guard e Fan Shroud e Fan e Multi Wing Fan e Radiator Cooler Note Procedures are provided for only those radiator oil cooler components listed above However information for removal and installation of other radiator oil cooler compo nents can be obtained from the machine specific parts manual Note Refer to Figure 3 1 for an overview of
73. nd fittings to prevent fluid loss and contamination of the system fluids 1 Drain the hydraulic fluid Refer to Chapter 16 Hydraulic Fluid and Filter Change 2 Remove the filter assembly Refer to Chapter 8 Filter Assembly Removal Remove Re servoir Gauge ith Mounting Bolts Washers Figure 8 19 5 Pull the reservoir gauge and the two mounting bolts washers off the reservoir DO NOT mis place the Compact washers or the reservoir will leak Compact Track Loader 8 Hydraulic Reservoir Disassembly and Assembly Reservoir Gauge Installation Suction Screen Removal A Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Remove the oil filler cap only when the engine is stopped and the machine has been allowed to cool thoroughly Insert Reser voir Gauge with Mounting Bolts Washers A Collect and contain liquids in a suitable contain er Dispose of all liquids according to local regula tions and mandates Figure 8 20 Note It is normally not necessary to replace the suction 1 Install the reservoir gauge in the reservoir using screen unless there has been a catastrophic failure and the two mounting bolts washers there is debris in the reservoir 1 Drain the hydraulic fluid Refer to Chapter 16 Hydraulic Fluid and Filter Change 2 Remove the access cover assembly Refer to Chapter 8 Access Cover Assembly Removal
74. ne at a time Figure 13 20 1 Lower the lift arm to the chassis stops Then attach suitable lifting device to them as shown to secure them during the procedure 13 6 2 Turn the engine start switch to the OFF position and remove the key to avoid accidental start Figure 13 21 3 Remove the bolts from each side of the lift arm that secure the pins to the chassis Figure 13 22 4 Remove the pins from each side of the chassis Figure 13 23 5 Raise the lifting device until arm has cleared the chassis and the hydraulic hoses Use a pry bar to guide the lift arm upward if necessary 6 Inspect the bushings for wear according to the procedure in page 16 6 step 3 If it is determined that replacement is needed continue onto step 7 of this procedure Compact Track Loader 13 Loader Disassembly and Assembly Figure 13 24 7 Compress a replacement bushing to fit the hole size and start the insertion with a dead blow hammer as shown As you drive the new bushings into the lift arm the old bushings will be forced out of the opposite side of the lift arm Figure 13 25 8 Complete the insertion of the first bushing with a socket and hammer until the bushing is flush with the surface of the lift arm 9 Repeat Step 8 to install the second bushing This action will force the remaining worn bushing out and drive the first replacement bushing to its permanent position 10 C
75. ng both ends out from the ball joints Lap Bar Gas Assist Spring Removal Lap Bar Gas Assist Spring Installation Gas Assist a Spring Gas Assist Ea Spring Location RaiseLapBar U 4 Shownin Downs DE ha a Position Figure 5 19 1 Putthe lap bar in the UP position to relieve ten sion on the lap bar gas assist spring Figure 5 22 1 Put the lap bar in the UP position to minimize tension on the lap bar gas assist spring during installation 5 5 Compact Track Loader 5 Operator Enclosure Disassembly and Assembly Figure 5 23 2 Install the ends of the lap bar gas assist spring onto the ball joints 2 LO Retaining Clip Figure 5 24 3 Slide the retaining clip on to each end of the gas assist spring Chapter Overview This chapter provides disassembly and assembly procedures for the chassis assembly A Personal Safety Improper or incomplete maintenance repair of a Compact Track Loader can be dangerous and may result in ma chine damage injury or death Do not attempt to perform any type of repair or mainten ance on a Compact Track Loader until you have read and fully understood the information in this manual Refer to the Operation and Maintenance manual for in structions regarding proper machine operation techniques before operating any Compact Track Loader Prior to performing any type of service work ona Compact Track Loader read and un
76. ns and mandates Figure 6 9 Fuel PR PD 5 The fuel pickup line will also come out with the sending A Wi fuel sending unit Unit po ir Fuel Sending Unit Installation Figure 6 7 3 Remove the hoses and wires from the fuel send ing unit then remove the screws that fasten the unit to the tank Mark the wires and hoses Note If the fuel sending unit wires are crossed the fuel gauge will not work If the hoses are crossed the engine will not run Figure 6 10 1 Insert the fuel pickup line into the fuel tank open ing The pickup line is attached to the fuel send ing unit Note The weight on the end of the fuel pickup line must rest on the bottom of the tank for proper operation Figure 6 8 4 Remove the fuel sending unit Be careful not to damage the float mechanism when pulling it through the opening in the fuel tank 6 3 Compact Track Loader 6 Chassis Disassembly and Assembly Figure 6 11 2 Insert the fuel sending unit float mechanism into the fuel tank opening Be careful not to damage the float when pushing it through the opening Note Make sure that the wire on the sending unit is not bent and the fuel pickup line does not interfere with the movement of the float Fuel Sending Unit ha Figure 6 12 3 Connect the hoses and wires to the fuel sending unit then install the screws that fasten the unit to the tank
77. ntamination of the system fluids 1 Lower the lift arms to the ground 2 Turn the engine start switch to the OFF position 3 Relieve hydraulic pressure from the auxiliary circuit 4 Drain the hydraulic fluid Refer to Chapter 16 Hydraulic Fluid and Filter Change Compact Track Loader 10 Transmission and Drive Disassembly and Assembly 5 Remove the seat Refer to Chapter 6 Seat Re moval 6 Remove the fuel tank Refer to Chapter 6 Fuel Tank Removal 7 Remove the auxiliary gear pump Refer to Chap ter 10 Auxiliary Gear Pump Removal 8 Remove the tandem pump Refer to Chapter 10 Tandem Pump Removal Pump Drive Coupler Installation Tandem Pump Drive Shaft Pump Drive Coupler Loosen Locking Screw Pump Drive Coupler Figure 10 21 1 Slide the pump drive coupler all the way onto the tandem pump drive shaft Figure 10 19 9 Loosen the locking screw that secures the pump drive coupler to the drive shaft extending from the end of the tandem pump Drive Coupler Tandem Pump Drive Shaft Drive Coupler Figure 10 20 10 Slide the pump drive coupler off the tandem pump drive shaft Figure 10 22 2 Tighten the locking screw that secures the pump drive coupler to the tandem pump drive shaft 3 Install the tandem pump Refer to Chapter 10 Tandem Pump Installation 4 Install the auxiliary gear pump Refer to Chapter 10 Auxiliary Ge
78. nten ance on a Compact Track Loader until you have read and fully understood the information in this manual Refer to the Operation and Maintenance manual for in structions regarding proper machine operation techniques before operating any Compact Track Loader Prior to performing any type of service work ona Compact Track Loader read and understand Chap ter 1 Product Safety for personal safety informa tion Machine Preparation Accidental machine starting can cause injury or 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 Load er Place a Do Not Operate tag prominently on the machine to inform personnel that the machine is be ing worked on 10 1 10 Transmission and Drive Disassembly and Assembly Transmission and Drive Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following transmission and drive components e Drive Motors e Auxiliary Gear Pump e Tandem Pump e Pump Drive Coupler Note Procedures are provided for only those transmission and drive components listed above However information for removal and installation of other transmission and drive components can be obtained from the machine specific parts manual Note Refer to Fi
79. o not attempt to perform any type of repair or mainten ance on a Compact Track Loader until you have read and fully understood the information in this manual Refer to the Operation and Maintenance manual for in structions regarding proper machine operation techniques before operating any Compact Track Loader Prior to performing any type of service work ona Compact Track Loader read and understand Chap ter 1 Product Safety for personal safety informa tion Machine Preparation Accidental machine starting can cause injury or 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 Load er Place a Do Not Operate tag prominently on the machine to inform personnel that the machine is be ing worked on 8 1 8 Hydraulic Reservoir Disassembly and Assembly Hydraulic Reservoir Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following hydraulic reservoir components e Filter Element e Filter Assembly e Filler Cap Assembly e Access Cover Assembly e Reservoir Gauge e Suction Screen Note Procedures are provided for only those hydraulic reservoir components listed above However information for removal and installation of other hydraulic reservoir components c
80. o nuts or bolts completely 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 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 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 Relieve hydraulic system pressure by relaxing all hydraulic actuators prior to attempting any hydraulic maintenance or repair 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 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 devic
81. oader Prior to performing any type of service work on a Compact Track Loader read and understand Chapter 1 Product Safety for personal safety information Machine Preparation Accidental machine starting can cause injury or 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 performing 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 worked on 13 1 13 Lift Arm Disassembly and Assembly Lift Arm Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following loader components e Lift Cylinders e Tilt Cylinders e Pressure Release Valve e Lift Arm Bushings Note Procedures are provided for only those loader components listed above However information for removal and installation of other loader components can be obtained from the machine specific parts manual Lift Cylinder Tilt Cylinder Removal and Installation The tools required for lift cylinder and tilt cylinder removal and installation are listed in Table 13 1 Use manufacturer recommended tools whenever possible Table 13 1 Required Tools Combination Wrench Socket Wrench Lift Cylinder Tilt Cylinder Removal Note The procedures fo
82. oconccconncccnncconocccnncnornccnnnnnorancnnnnnanno 9 1 Machine Preparation ooococcnoncccnoncccnononcncnnnoncnnnnnnos 9 1 Loader Transmission Controls Disassembly and Assembly Procedures ereere 9 1 Loader Control Joystick Drive Control Joystick Removal and Installation 9 1 Loader Control Joystick Drive Control Joystick REMOVal secede eel ce een 9 2 Loader Control Joystick Drive Control Joystick Installation ee tt 9 3 Loader Float Magnet Removal and Installation 9 3 Loader Float Magnet Removal uur nn gt 9 3 Loader Float Magnet Installation 9 4 Loader Valve Removal and Installation 9 4 Loader Valve Removal nnnn 9 4 Loader Valve Installation oo ooconnnccnnnnninonnno 9 6 Transmission and Drive Disassembly and Assembly Chapter Overview eee eects eee tee teeteees 10 1 Personal Safety cccccecsceesseseseeseseeseseeseseeeeeeeees 10 1 Machine Preparation ooooocccononccccnnoncnonanaccnonancnnnnns 10 1 Transmission and Drive Disassembly and Assembly Procedures ceecee 10 1 Brake Cylinder Removal and Installation Drive Motor Removal and Installation Auxiliary Gear Pump Removal and Installation 10 2 Auxiliary Gear Pump Removal 10 2 Auxiliary Gear Pump Installation 10 3 Tandem Pump Removal and Installation 10 4 Tandem Pump
83. of quick attach 7 Inspect the lower lift arm bushings for wear according to the procedure in page 16 6 step 3 If it is determined that replacement is needed continue onto step 8 of this procedure Figure 13 36 8 Compress a replacement bushing to fit the hole size and start the insertion with a dead blow hammer Figure 13 37 13 9 9 Complete insertion of the bushing with a socket and the hammer until the bushing is flush with the surface of the lift arm This action will force the worn bushing out the opposite side of the lift arm for removal 10 Repeat steps 7 9 for opposite side of lower lift arm 11 Clean and remove any debris then apply anti seize to the inside of the bushings 12 Reverse steps 2 6 to install the pins and bolts Figure 13 38 13 Add grease to the zerks located on each of the lift pins and lubricate them Quick Coupler Block Pressure Release Valve Removal and Installation The tools required for quick coupler block removal and installation are listed in Table 13 4 Use manufacturer recommended tools whenever possible Table 13 4 Required Tools Combination Wrench Socket Wrench Quick Coupler Block Removal A Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Remove the oil filler cap only when the engine is stopped and the machine has been allowed to cool thoroughly Compact Track Load
84. olyte 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 1 2 Pressurized ltems 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 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 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 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 Pressurized air or water can also
85. pin assembly bolt Figure 13 5 8 Support the cylinder from the underside then remove the forward pin assembly Compact Track Loader 13 Loader Disassembly and Assembly Remove bolt and then pin Figure 13 6 9 Remove the bolt and pin from the loader tower 10 Again support the cylinder from the underside then remove the lift cylinder from the machine Lift Cylinder Tilt Cylinder Installation 1 To install the lift tilt cylinder reverse the removal procedure Add removable locktite to all fittings Add grease to loader pin zerks to ensure lubrication of bushings Lift Cylinder Tilt Cylinder Seals Removal Table 13 2 Required Tools Channel Lock Pliers Bench Vice Blade Type Screwdriver Socket Rubber Mallet Lift Cylinder Tilt Cylinder Seal Removal Note The procedures for removing seals on the lift cylinders and tilt cylinders are similar only the lift cylinder procedure is described below End gland Figure 13 7 1 Secure the cylinder into a vice and remove the end gland by turning counter clockwise with channel lock pliers Be sure to have a container to catch draining hydraulic fluid Figure 13 8 2 Remove the rod from cylinder by pulling outward using both hands as shown Figure 13 9 3 Secure the rod in the bench vice as shown Compact Track Loader 13 Loader Disassembly and Assembly Figure 13 13 7 Remove the three o rings locate
86. plug Connector Figure 6 2 2 Tilt the seat forward and reach behind the seat to unplug the seat switch wiring harness Figure 6 3 3 Remove the seat Be careful not to scratch the control panel or sides of the cab Seat Installation Figure 6 4 1 With the seat mounts attached place the seat in the cab Be careful not to scratch the control panel or sides of the cab 6 2 Plug in the Connector DI Figure 6 5 2 Tilt the seat forward and reach behind the seat to plug in the seat switch connector Note The machine will not operate unless the seat switch connector is plugged in Figure 6 6 3 Position the seat so the holes in the seat mounts are aligned with the holes in the frame Insert the four seat mount bolts and washers Fuel Sending Unit Removal and Installation The tools required for fuel sending unit removal and installation are listed in Table 6 2 Use manufactur er recommended tools whenever possible Table 6 2 Required Tools Screwdriver Combination Wrench Socket Wrench Compact Track Loader 6 Chassis Disassembly and Assembly Fuel Sending Unit Removal 1 Remove the seat Refer to Chapter 6 Seat Re moval procedure 2 Pump fuel from the tank until there is no fuel remaining above the sending unit A Collect and contain liquids in a suitable contain er Dispose of all liquids according to local regula tio
87. pre heat showing nor mal operation Compact Track Loader 4 Machine Controls and Instrumentation PT 30 Switches The various switches Figure 4 3 are positioned to provide good access and visibility The standard and optional switches are listed below 1 Work lights 2 Heater fan optional 3 Front wiper optional 4 Beacon light optional 5 Ignition glow plug pre heat 6 Auxiliary hydraulics Chapter Overview This chapter provides disassembly and assembly procedures for the operator enclosure assembly Personal Safety Improper or incomplete maintenance repair of a Compact Track Loader can be dangerous and may result in ma chine damage injury or death Do not attempt to perform any type of repair or mainten ance on a Compact Track Loader until you have read and fully understood the information in this manual Refer to the Operation and Maintenance manual for in structions regarding proper machine operation techniques before operating any Compact Track Loader Prior to performing any type of service work ona Compact Track Loader read and understand Chap ter 1 Product Safety for personal safety informa tion Machine Preparation Accidental machine starting can cause injury or death to personnel working on a Compact Track Loader As a precaution disconnect the
88. r removing the lift cylinders and tilt cylinders are very similar as a result only the lift cylinder procedure is described below A Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Compact Track Loader 13 Loader Disassembly and Assembly A Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids 1 To remove lift cylinders raise the lift arms and support them with the lift arm brace as described in Ch 16 of this manual Note When removing tilt cylinder s lower the loader arms onto a mechanical support with the arms resting about 6 inches off the ground 2 Turn the ignition switch to the OFF position and remove the key to avoid accidental start Figure 13 1 3 Remove the zip tie that secures the hydraulic hose to the lift cylinder 4 Release hydraulic pressure by performing step 3 on page 13 6 of this chapter j Lift Cylinder O Disconnect Hose Figure 13 2 13 2 5 Disconnect and cap the hose on the rear end of the cylinder ag un EN 1 i rola En A Hose De Figure 13 3 6 Disconnect and cap the hose on the forward end of the cylinder Figure 13 4 7 Remove the forward
89. r with oil Radiator Oil Cooler Adjustment Procedures Adjustment procedures are provided for the follow ing radiator oil cooler components e Fan Shroud e Fan Guard Fan Shroud Adjustment The tools required for fan shroud adjustment are listed in Table 7 4 Use manufacturer recommended tools whenever possible Table 7 4 Tool Name Combination Wrench Figure 7 28 1 The fan shroud can adjusted upward or down ward To adjust loosen the bolts on each side of the shroud and move the shroud in the desired direction Tighten the bolts when finished Compact Track Loader 7 Radiator Oil Cooler Disassembly and Assembly Fan Guard Adjustment The tools required for fan guard adjustment are listed in Table 7 5 Use manufacturer recommended tools whenever possible Table 7 5 Tool Name Combination Wrench Loosen Capscrews to Adjust Figure 7 29 1 The fan guard can adjust forward or rearward To adjust loosen the capscrews that fasten the fan guard to the fan guard mounts Tighten the capscrews when finished 7 8 Chapter Overview This chapter provides disassembly and assembly procedures for the hydraulic reservoir assembly Cleaning procedures are also included for the hy draulic reservoir A Personal Safety Improper or incomplete maintenance repair of a Compact Track Loader can be dangerous and may result in ma chine damage injury or death D
90. rack Loader 8 Hydraulic Reservoir Disassembly and Assembly Figure 8 6 Figure 8 9 6 Remove the filter head and gasket from the re 3 Reconnect the hose to the filter head and se servoir cure Filter Assembly Installation p Figure 8 10 Figure 8 7 4 Reinstall the filter and filter tube into the reser 1 Place the filter assembly gasket in position on voiras Shown top of the reservoir Replace if damaged Figure 8 11 Figure 8 8 5 Install the cap onto the filter head as shown 2 Position the filter head onto the gasket with the mounting holes aligned install bolts 8 3 Compact Track Loader 8 Hydraulic Reservoir Disassembly and Assembly 1 Slightly loosen the access cover bolt to separate the upper cap from the oval shaped clamping disk on the underside of the assembly This will allow the assembly to be removed Do nat re move the bolt entirely or the oval shaped clamp will fall into the reservoir Figure 8 12 6 Install the cap bolts and tighten to secure Access Cover Removal and Installation The tools required for access cover removal and Figure 8 14 installation are listed in Table 8 2 Use manufactur er recommended tools whenever possible 2 Remove the access cover assembly from the reservoir Table 8 2 Required Tools Combination Wrench Access Cover Assembly Installation Access Cover Assembly Removal
91. re 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 Electr
92. re proper re installation For ease of removal remove hoses in this order angled small top large straight small bottom large It is important to cap fittings and plug drive hoses to ensure hydraulic systems is free from debris 12 11 Figure 12 43 3 Remove the four bolts that secure the drive motor to the drive table using a thin wall socket Fittings on top MEN e Figure 12 44 4 Remove drive motor by turning motor with the hydraulic hose fittings facing upward and angle the motor out of the table weldment and pull in upward motion Drive Motor Installation 1 Position the drive motor so the hydraulic fittings enter in the correct location Install the drive motor bolts Clean and inspect the drive motor shaft 2 Re install all hoses and fitting in the same order instructions direct in removal 3 Re install drive sprocket as outlined above Chapter Overview This chapter provides disassembly and assembly procedures for the loader assembly Personal Safety 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 maintenance on a Compact Track Loader until you have read and fully understood the information in this manual Refer to the Operation and Maintenance manual for instructions regarding proper machine operation techniques before operating any Compact Track L
93. re the oil is cool before removing any components or lines Remove the oil filler cap only when the engine is stopped and the filler cap is cool enough to touch with your hands Collect and contain liquids in a suitable con tainer Dispose of all liquids according to local regulations and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system flu ids Figure 9 10 4 Lift the joystick out of the mounting bracket slightly 1 Lower the lift arms to the ground to allow the magnet connector to pass between them then remove the magnet i i 2 Turn the engine start switch to the OFF position 5 To install the float magnet reverse the removal procedure 3 Relieve hydraulic pressure from the auxiliary cir cuit 4 Drain the hydraulic fluid Refer to Chapter 16 Hydraulic Fluid and Filter Change 9 4 Compact Track Loader 9 Loader Transmission Controls Figure 9 11 Figure 9 14 5 Disconnect the gas springs then press the spring 8 Carefully remove the rear valance from the latches inward as shown to remove the hood machine to allow access to the loader valve Figure 9 12 Figure 9 15 6 Carefully remove the hood from the machine and 9 Locate the loader valve on the side of the set it aside hydraulic reservoir Remove er Figure 9 13 Figure 9 16 7 Remove the bolts securing the rear valance panel 10 Disconnect the tubes from th
94. rive control 2 is also a pilot operated joystick It allows the operator to change the direction and speed of the machine Throttle The hand throttle 3 controls engine rpm 4 Machine Controls and Instrumentation Instrumentation The Instruments Figure 4 2 are positioned in the overhead dash panel for ease of access and visibility when seated inside the operator enclosure Instruments include the following components 1 Fuel Gauge 2 Tachometer optional 3 Engine Coolant Temp Gauge optional 4 Hour Meter 5 Warning Indicator Display e Engine Oil Pressure Warning Light Engine Temperature Warning Light e Hydraulic Oil Temperature Warning Light e Battery Voltage Warning Light NOTICE If the engine temperature engine oil pressure or hydraulic oil temperature lights illuminate or should the eng coolant temp gauge read excessive temperatures during normal machine operation shut the machine down immediately in a safe location Diagnose the problem and make any necessary repairs before resuming normal operation If the battery low voltage light should illuminate during opera tion drive the machine to a suitable location and shut the engine off Diagnose the problem and make any needed repairs before resuming operation NOTICE The glow plug operation light illuminates only when the key switch is turned to engine
95. rk platform Improper operation or maintenance can re sult in serious injury or death Fall Hazard Falling from a machine can result in serious injury or death Read Operator s Manual Read and understand the operator s manual and all safety signs prior to operating or maintaining the machine 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 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 Escaping fluid under pressure can doctor familiar with this type of injury penetrate skin causing serious injury or gangrene will result Injection Hazard PT 30 Specifications Engine Model Perkins 403 D15 Displacement 1 5 liter Gross horsepower 33 7 hp 25 1 kW Peak Torque 64 39 Ib ft 87 Nm Idle rpm 1175 low idle 2800 high idle Average water thermostat temperature 190 F 87 8 C Transmission Model A10VG18 tandem Rexroth Drive Pumps Displacement 1 098 in3 rev 18 cc rev Relief pressure 3800 psi 26 200 kPa Flow 13 gpm 11 4lpm 2800 rpm per pump Charge Pumps 2 Displacement 33
96. s 7 7 Fan Shroud AdjuStMeMt coooccnncccnocccccccnoncncnnncnnno 7 7 Fan Guard AdjustMeNt cooooococinoccccnnonccnnononcnnnnnns 7 8 Hydraulic Reservoir Disassembly and Assembly Chapter Overview ooccoccccccococnconaconancnacnnnnanconincnanos 8 1 Personal Safety nunrssnnnnennsnnnnnnnnnnnnnnnnnnannnn nn 8 1 Machine Preparation uusrssseeesennnersennnnen ernennen 8 1 Hydraulic Reservoir Disassembly and Assembly Proceduress 2 22 30 TO 8 1 Filter Element Removal and Installation 8 1 Filter Assembly Removal and Installation 8 1 Filter Assembly Removal 8 2 Filter Assembly Installation o 8 3 Access Cover Assembly Removal and Installation 8 4 Access Cover Assembly Removal 8 4 Access Cover Assembly Installation 8 4 Reservoir Gauge Removal and Installation 8 5 Reservoir Gauge Removal oooococinccccocccccccconccnnns 8 5 Reservoir Gauge Installation 8 6 Suction Screen Removal and Installation 8 6 Suction Screen Removal ccceeeceeeseeeeeeeeeees 8 6 Suction Screen Installation 8 7 Hydraulic Reservoir Cleaning Procedures 8 7 Compact Track Loader Table of Contents 9 10 11 Loader Transmission Controls Disassembly and Assembly Chapter Overview oooooocconcccocccoccnacanoncarn nano terre tenes 9 1 Personal Safety o
97. s found upon disassembly and install the retaining springs Then position the exhaust gasket for reinstalla tion and start one bolt to hold it in place Figure 11 11 4 Spray the joint with penetrating lube then slide the curved pipe out of the muffler inlet A pry bar may be helpful in removing this pipe section Compact Track Loader 11 Engine Components Disassembly and Assembly Battery Removal Negative Terminal Figure 11 14 7 With the exhaust pipe gasket in place install the Figure 11 16 remaining bolts that secure the exhaust pipe to the exhaust manifold 1 Identify the positive and negative battery termin als Tighten Nujs Figure 11 15 Figure 11 17 8 Reinstall the muffler clamp then tighten the nuts to secure 2 Disconnect the battery cable from the negative battery terminal Battery Removal and Installa tion The tools required for battery removal and installa tion are listed in Table 11 3 Use manufacturer recommended tools whenever possible Table 11 3 Required Tools Combination Wrench Socket Wrench Figure 11 18 3 Disconnect the battery cable from the positive battery terminal Compact Track Loader 11 Engine Components Disassembly and Assembly Remove Capscrews Figure 11 19 4 Remove the two capscrews from the battery holdown bracket and remove the bracket Figure 11 20 5 Rotate t
98. te ports on the joystick and that they are tight and leak free Compact Track Loader 9 Loader Transmission Controls Note If it is neccessary to remove the left joystick on a machine equipped with a heater you must disconnect the heater lines at the heater unit in order to remove the side panel Cap and plug hoses and ports to mini mize coolant loss Loader Float Magnet Removal and Installation The tools required for loader float magnet removal and installation are listed in Table 9 2 Use manufacturer recommended tools whenever possible Table 9 2 Required Tools Allen hex Wrenches Combination Wrenches Screwdriver Loader Float Magnet Removal Figure 9 7 1 Remove the zip tie securing the lower portion of the joystick boot to the joystick as shown Figure 9 8 2 Lift the boot to expose the magnet and joystick mounting bolts Remove the joystick mounting bolts to allow the joystick to be moved upward within the bracket Compact Track Loader 9 Loader Transmission Controls Loader Valve Removal and Installation The tools required for loader valve removal and in stal lation are listed in Table 9 3 Use manufacturer recom mended tools whenever possible Table 9 3 Required Tools Combination Wrenches Loader Valve Removal Figure 9 9 3 Use an allen hex wrench to remove the bolt securing the magnet to the joystick Hot oil can cause personal injury Lower all attach ments and make su
99. test port Located under the fuel tank you will not need to remove the fuel tank 3 Start the engine 4 Check the pressure with the engine at wide open throttle Make sure the engine is properly warmed up before running wide open 5 Turn the engine start switch to the OFF position 6 Remove the gauge from the pilot control mani fold test port 7 Install the floor pan Charge Pressure Relief Valve Adjust ment The service tools required for charge pressure relief valve adjustment are listed in Table 0 2 Use manu facturer recommended tools whenever possible Table 0 2 Required Tools Combination Wrench Socket Wrench Note In the following procedure some components are shown detached from the machine to facilitate the descrip tion However the charge pressure check is normally per formed from under the machine with only the center skid plate removed 17 2 A Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Remove the oil filler cap only when the engine is stopped and has been allowed to cool thoroughly A Collect and contain liquids in a suitable contain er Dispose of all liquids according to local regula tions and mandates Note During disassembly plug all hoses and tubes to prevent fluid loss and contamination of the system fluids DE Figure 0 3 1 Remove belly pan and locate the charge pres
100. this manual Refer to the Operation and Maintenance manual for in structions regard ing proper machine operation techniques before operating any Compact Track Loader Prior to performing any type of service work on a Compact Track Loader read and understand Chapter 1 Product Safety for personal safety information A Machine Preparation Accidental machine starting can cause injury or death to per sonnel working on a Compact Track Loader As a precaution disconnect the battery cables from the bat tery 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 be ing worked on Disassembly and Assembly Loader Transmission Controls Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following loader transmission control compo nents Drive Control Joystick e Loader Control Joystick Loader Float Magnet e Loader Valve Note Procedures are provided for only those loader transmission control components listed above However information for removal and installation of other loader transmission control components can be obtained from the Compact Track Loader Parts List manual Note Refer to Figure 3 2 for an overview of the auxil iary circuit system and Figure 3 3 for an overview of the dri
101. tion of the system fluids 1 Lower the lift arms to the ground 2 Turn the engine start switch to the OFF position 3 Relieve hydraulic pressure from the auxiliary circuit 4 Drain the hydraulic fluid Refer to Chapter 16 Hydraulic Fluid and Filter Change 5 Remove the seat Refer to Chapter 6 Seat Re moval 6 Remove the fuel tank Refer to Chapter 6 Fuel Tank Removal 7 Remove the auxiliary gear pump Refer to Chap ter 10 Auxiliary Gear Pump Removal Compact Track Loader 10 Transmission and Drive Disassembly and Assembly Pump Drive Coupler Mounting Plate Figure 10 111 Figure 10 14 8 Remove all hoses and tubes from the tandem pump Cap the hoses and tubes 11 Remove the tandem pump with pump drive coupler attached from the pump mounting plate Tandem Pump Installation Pump Drive Coupler lt Gear 6 Pump Figure 10 12 i ee Mounting Plate 9 Remove the mounting bolt with spring lock washer and flat washer from the right hand side of the tandem pump Figure 10 15 1 With the pump drive coupler attached to the tan dem pump position the tandem pump against the pump mounting plate Make sure the teeth on the pump drive coupler mesh properly with the flywheel gear teeth Figure 10 13 10 Remove the mounting bolt with spring lock washer and flat washer from the left hand side of the tandem pump 10 5 Compact Track
102. trols are nearly identical as a result only the right con trol joystick procedure is described below Note During disassembly cap and plug all hoses and fittings to prevent fluid loss and contamination of the system fluids Relax all hydraulic circuits controls and make sure the oil is cool before disconnecting any component or line from the system Pressurized and or hot hydraulic fluid can cause per sonal injury 1 Remove the seat from the machine according to the procedure in chapter 6 seat removal 2 Lower the lift arms to the ground 3 Turn the ignition switch to the OFF position 4 Relax all hydraulic circuits abe Figure 9 1 5 Remove the various screws holding the plastic side consoles to the cab enclosure as shown Figure 9 2 6 Pivot the panel away from the joystick then lift and remove it from the machine Figure 9 3 7 Remove the three nuts securing the joystick mount to the cab enclosure from the outside of the machine 9 2 Figure 9 4 Figure 9 5 9 The hydraulic hoses are now accessible Label them and the ports they connect to to aid during reassembly then disconnect them and cap and plug the openings to prevent spills Figure 9 6 10 Disconnect the electrical connections shown to free the joystick from the machine then remove 11 Reverse the removal procedure to reinstall the joy stick Take care to ensure all connections are to the appropria
103. understood the information in this manual Refer to the Operation and Maintenance manual for instructions regarding proper machine operation techniques before operating any Compact Track Loader Prior to performing any type of service work ona Compact Track Loader read and understand Chapter 1 Product Safety for personal safety information Machine Preparation Accidental machine starting can cause injury or 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 performing 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 worked on 14 1 14 Quick Attach Disassembly and Assembly Quick Attach Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following quick attach components e Latch Mechanism e Quick Attach Assembly Note Procedures are provided for only those quick attach components listed above However information for removal and installation of other quick attach components can be obtained from the machine specific parts manual Latch Mechanism Removal and Installation The tools required for latch mechanism removal and installation are listed in Table 14 1 Use manufacturer recommended tools whenever possib
104. ur meter should draw only 0 01 amps in off position 5 Bad battery 6 Bad alternator Problem 12 Loader control will not lock in float position Probable cause 1 Float magnet fuse blown 2 Poor wire connections at fuse float detent magnet or pin connector P18 3 Faulty float detent magnet 15 3 Problem 13 Loader will not float labors engine and has down pressure when detented into float Probable cause 1 Engine RPM too low a Float must be operated at a minimum of half throttle 2 Lowcharge pressure 3 Pilot control malfunction 4 Loader valve malfunction Problem 14 Hot oil light illuminates hydraulic system operating hot Probable cause 1 Auxiliary hydraulic switch activated sending oil over relief Low oil level Debris plugging oil cooler limiting airflow Broken fan blades Loose fan belt Improper attachment a Attachment must be rated at a minimum of 10 gallons per minute 37 8 lpm and 3000 psi 20 680 kPa b Attachment hose size must be a minimum of 3 8 inch 95 cm 7 Faulty hot oil sending unit a Hot oil light should illuminate at 225 F 107 2 C 8 Faulty quick coupler 9 Cooler bypass relief a Cooler bypass relief should open at 100 psi 689 5 kPa DaRoN Problem 15 Track makes popping noise Probable cause 1 Track too loose Refer to track adjustment section 2 Worn or stuck drive teeth Outer roller should pivot as lug comes into sprocket
105. ve loop system Loader Control Joystick Drive Control Joystick Removal and Installation There are two joysticks that control the operation of the machine a drive control joystick and a loader control joystick Drive Control Joystick Operation The left hand joystick controls the speed and direction of the ma chine The further the joystick is pushed the faster the machine travels The joystick operates on hy draulic charge pressure When the joystick is moved oil is sent to the hydrostatic transmission The transmission then delivers oil in the correct amount to the drive motors Compact Track Loader 9 Loader Transmission Controls Loader Control Joystick Operation The right hand joystick controls the loader arm and the at tachment tilt cylinder It allows the operator to raise lower and pivot the attachment The joystick operates on hydraulic charge pressure The loader control also has a float position which is activated by moving the joystick completely forward until it is held in detent The joystick is held in the for ward float position by an electromagnet The tools required for loader drive control joystick removal and installation are listed in Table 9 1 Use manufacturer recommended tools whenever possible Table 9 1 Required Tools Combination Socket Wrenches Screwdriver phillips Loader Control Joystick Drive Control Joystick Removal Note The procedures for removing both joystick con
106. x Figure 16 14 The fuse box is located on the left side of the engine compartment The machine should never be operated with the fuse box cover removed Grease Fittings GREASE FITTING LOCATIONS AXLE SWING JOINT LOWER AXLE SWING JOINT UPPER FRONT AXLE PIVOT POINT QUICK ATTACH HINGE POINT QUICK ATTACH PIN QUICK ATTACH LEVER PIVOT QUICK ATTACH CYLINDER PIVOT QUICK ATTACH CYLINDER PIVOT LIFT CYLINDER PIVOT LIFT CYLINDER PIVOT LIFT ARM HINGE POINT L DRIVE SPROCKET BEARING A B c D E F G H de K Figure 16 15 The locations of the grease fittings for the left side of the machine are shown above An identical set of fittings is located on the right side of the machine These fitting should be lubricated at least after every 10 hours of operation using Terex Multi Purpose EP Lithium Grease or other high quality low temperature grease Compact Track Loader 16 Maintenance Lift Arm Bushings Quick Attach Wear Inspection Daily inspection can be carried out by performing the following steps 1 Lower the lift arm until it makes contact with the chassis stops Rotate the bucket against the ground repeatedly Have an assistant look for independent movement between the bucket and the lift arm Any movement should be readily noticeable by the attendant If movement is detected bushing will need further inspection 2 Rotate the bucket downward to approximately 45 from l
107. you choose Basic Precautions A 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 Compact Track Loader 1 Product Safety 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 Ib 23 kg or more to avoid back injury Make sure all chains hooks slings etc are in good condition and a

PT-30 (PN 2010-513)

Contents

Download Pdf Manuals

Related Search

Related Contents