ASV SR-70 Service manual

ASV SR-70 Service manual
Service Manual
Rubber Track Loader
PT-70/80
Part Number: 2046-310
Printed (4-10)
Table of Contents
1. Product Safety
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . 1-1
Information Messages . . . . . . . . . . . . . . . . . 1-1
Basic Precautions . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . 1-1
Protective Equipment . . . . . . . . . . . . . . . . 1-1
Entering and Exiting . . . . . . . . . . . . . . . . . 1-2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hot Fluids and Components . . . . . . . . . . . 1-2
Corrosion Inhibitor . . . . . . . . . . . . . . . . . . . 1-2
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Pressurized Items . . . . . . . . . . . . . . . . . . . 1-2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Asbestos Information . . . . . . . . . . . . . . . . . . 1-4
Machine Labels and Decals . . . . . . . . . . . . . 1-4
Product Identification Number . . . . . . . . . . 1-4
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . 1-4
3. Circuit Diagrams
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 3-1
Hydraulic Charge Circuit . . . . . . . . . . . . . . . . 3-1
Hydraulic Auxiliary Circuit . . . . . . . . . . . . . . . 3-2
Hydraulic Drive Circuit . . . . . . . . . . . . . . . . . 3-3
Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 3-4
Hydraulic Pilot Generation Solenoid Block . . 3-5
Electrical Attachment Outlet . . . . . . . . . . . . . 3-6
Drive Control (line routing) . . . . . . . . . . . . . . 3-7
Lift Arm Control (line routing) . . . . . . . . . . . . 3-8
4. Maintenance
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 4-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 4-1
Lift-Arm Brace . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Tilt-up Cab . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Jacking Procedure . . . . . . . . . . . . . . . . . . . . 4-2
Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . 4-3
Undercarriages . . . . . . . . . . . . . . . . . . . . . . . 4-3
Track Tension . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Drive Sprocket Rollers . . . . . . . . . . . . . . . . . 4-5
Track Removal . . . . . . . . . . . . . . . . . . . . . . . 4-6
Track Installation . . . . . . . . . . . . . . . . . . . . . . 4-8
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Water Separator . . . . . . . . . . . . . . . . . . . . . . 4-11
Accessory Belt Tension . . . . . . . . . . . . . . . . 4-12
Fan Belt Removal/Installation . . . . . . . . . . . . 4-13
A/C Belt Removal/Installation . . . . . . . . . . . . 4-13
Engine Oil/FIlter Change . . . . . . . . . . . . . . . 4-14
Engine Oil Specifications . . . . . . . . . . . . . . . 4-15
Oil Level Check . . . . . . . . . . . . . . . . . . . . . . 4-15
Hydraulic Fluid/Filter Change . . . . . . . . . . . . 4-16
Radiator/Oil Cooler (cleaning) . . . . . . . . . . . 4-17
Engine (cleaning) . . . . . . . . . . . . . . . . . . . . . 4-17
Case Drain Filter . . . . . . . . . . . . . . . . . . . . . . 4-18
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Maintenance Schedule . . . . . . . . . . . . . . . . . 4-19
2. Technical Specifications
Specifications (PT-70) . . . . . . . . . . . . . . . . . . 2-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Transmission . . . . . . . . . . . . . . . . . . . . . . . 2-1
Drive Pumps . . . . . . . . . . . . . . . . . . . . . . 2-1
Charge Pump . . . . . . . . . . . . . . . . . . . . . 2-1
Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . 2-1
Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 2-1
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Critical Torque Specifications . . . . . . . . . . . . 2-1
Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Specifications (PT-80) . . . . . . . . . . . . . . . . . . 2-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Transmission . . . . . . . . . . . . . . . . . . . . . . . 2-2
Drive Pumps . . . . . . . . . . . . . . . . . . . . . . 2-2
Charge Pump . . . . . . . . . . . . . . . . . . . . . 2-2
Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . 2-2
Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 2-2
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Critical Torque Specifications . . . . . . . . . . . . 2-2
Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . 2-2
5. Machine Controls and Instrumentation
Chapter Overview . . . . . . . . . . . . . . . . . . . . .
Machine Controls . . . . . . . . . . . . . . . . . . . . .
Lift Arm Control . . . . . . . . . . . . . . . . . . . . . . .
Drive Control . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrumentation . . . . . . . . . . . . . . . . . . . . . . .
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I
5-1
5-1
5-1
5-1
5-1
5-1
5-2
Rubber Track Loader
Table of Contents
6. Operator Enclosure
Chapter Overview . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . .
Machine Preparation . . . . . . . . . . . . . . . . . . .
Removal & Installation . . . . . . . . . . . . . . . . .
Door Gas Spring . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Pillar Switch Panels . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Side Panels/Gauges . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Interior Panel, Rear . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
6-1
6-1
6-1
6-1
6-1
6-1
6-1
6-2
6-2
6-2
6-3
6-3
6-3
6-4
6-4
6-4
6-4
6-4
6-4
7. Chassis and Fuel Tank
Chapter Overview . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . .
Machine Preparation . . . . . . . . . . . . . . . . . . .
Removal & Installation . . . . . . . . . . . . . . . . .
Fuel Sending Unit . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Footwell . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Foot Throttle Assembly . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Hood Assembly . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
7-1
7-1
7-1
7-1
7-1
7-1
7-2
7-2
7-2
7-3
7-4
7-4
7-4
7-5
7-5
7-5
7-5
7-5
7-6
8. Radiator and Oil Cooler
Chapter Overview . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . .
Machine Preparation . . . . . . . . . . . . . . . . . . .
Removal & Installation . . . . . . . . . . . . . . . . .
Fan Guard . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Fan & Shroud . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Radiator/Oil Cooler . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . .
8-1
8-1
8-1
8-1
8-1
8-1
8-2
8-2
8-2
8-3
8-3
8-3
8-4
9. Hydraulic Reservoir
Chapter Overview . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . .
Machine Preparation . . . . . . . . . . . . . . . . . . .
Removal & Installation . . . . . . . . . . . . . . . . .
Hydraulic Reservoir . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Suction Screen . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
9-1
9-1
9-1
9-1
9-1
9-1
9-7
9-8
9-8
9-8
10. Lift Arm/Drive Controls
Chapter Overview . . . . . . . . . . . . . . . . . . . . .10-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . .10-1
Machine Preparation . . . . . . . . . . . . . . . . . . .10-1
Removal & Installation . . . . . . . . . . . . . . . . .10-1
Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
Removal Procedure . . . . . . . . . . . . . . . .10-1
Installation Procedure . . . . . . . . . . . . . .10-3
Lift Arm Float Magnet . . . . . . . . . . . . . . . .10-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . .10-3
Installation . . . . . . . . . . . . . . . . . . . . . . .10-3
Lift Arm Control Valve . . . . . . . . . . . . . . . .10-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . .10-4
Installation . . . . . . . . . . . . . . . . . . . . . . .10-4
11. Hydraulic Pumps/Motors
Chapter Overview . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . .
Machine Preparation . . . . . . . . . . . . . . . . . . .
Removal & Installation . . . . . . . . . . . . . . . . .
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . . . .
Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . . . .
Tandem Drive Pump . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . . . .
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . . . .
II
11-1
11-1
11-1
11-1
11-1
11-1
11-2
11-3
11-3
11-4
11-4
11-4
11-5
11-6
11-6
11-8
Rubber Track Loader
Table of Contents
12. Engine
Chapter Overview . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . .
Removal & Installation . . . . . . . . . . . . . . . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Exhaust System . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
16. Hydraulic Component Service
Chapter Overview . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . .
Disassembly & Assembly . . . . . . . . . . . . . . .
Hydraulic Cylinder . . . . . . . . . . . . . . . . . . .
Disassembly Procedure . . . . . . . . . . . . .
Assembly Procedure . . . . . . . . . . . . . . .
Lift Arm Control Valve . . . . . . . . . . . . . . . .
Disassembly Procedure . . . . . . . . . . . . .
Assembly Procedure . . . . . . . . . . . . . . .
Drive Motor (brake portion) . . . . . . . . . . . .
Disassembly Procedure . . . . . . . . . . . . .
Assembly Procedure . . . . . . . . . . . . . . .
Drive Motor (motor portion) . . . . . . . . . . . .
Disassembly Procedure . . . . . . . . . . . . .
Assembly Procedure . . . . . . . . . . . . . . .
Drive Pump (Drive Relief Valves) . . . . . . .
Disassembly & Adjustment . . . . . . . . . .
Posi-Power Relief Valve . . . . . . . . . . . . .
Drive Pump . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly Procedure . . . . . . . . . . . . .
Assembly Procedure . . . . . . . . . . . . . . .
Auxiliary Pump . . . . . . . . . . . . . . . . . . . . .
Disassembly Procedure . . . . . . . . . . . . .
Assembly Procedure . . . . . . . . . . . . . . .
12-1
12-1
12-1
12-1
12-1
12-2
12-2
12-2
12-4
12-4
12-4
12-5
12-5
12-5
12-7
13. Undercarriage
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 13-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 13-1
Machine Preparation . . . . . . . . . . . . . . . . . . . 13-1
Removal & Installation . . . . . . . . . . . . . . . . . 13-1
15” Idler Wheel (PT-80) . . . . . . . . . . . . . . . 13-1
Removal Procedure . . . . . . . . . . . . . . . . 13-1
Installation Procedure . . . . . . . . . . . . . . 13-2
10’’ & 15” Wheel (PT-70) . . . . . . . . . . . . . . 13-3
Removal & Installation Procedure . . . . . 13-3
10” Bogie Wheel & Hub (PT-80) . . . . . . . 13-4
Removal & Service Procedure . . . . . . . . 13-4
Idler Hub . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Removal & Service Procedure . . . . . . . . 13-8
14. Lift Arm Components
Chapter Overview . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . .
Machine Preparation . . . . . . . . . . . . . . . . . . .
Removal & Installation . . . . . . . . . . . . . . . . .
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Bucket/Tilt Cylinder . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Q/C Block PRV . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
14-1
14-1
14-1
14-1
14-1
14-1
14-3
14-3
14-3
14-5
14-5
14-5
14-5
15. Quick Attach
Chapter Overview . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . .
Machine Preparation . . . . . . . . . . . . . . . . . . .
Removal & Installation . . . . . . . . . . . . . . . . .
Locking Pin . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . . .
15-1
15-1
15-1
15-1
15-1
15-1
15-2
15-3
15-3
15-3
16-1
16-1
16-1
16-1
16-1
16-3
16-4
16-4
16-6
16-6
16-6
16-7
16-8
16-8
16-9
16-9
16-9
16-10
16-10
16-10
16-12
16-14
16-14
16-15
17. Hydraulic Pressure & Flow
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 17-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 17-1
Contamination Inspection . . . . . . . . . . . . . . . 17-1
Pressure/Flow Test and Troubleshooting . . . 17-1
Charge Pressure Check & Adjust . . . . . . . 17-1
Auxiliary Pressure Check & Adjust . . . . . . 17-3
Lift Arm Pressure Check . . . . . . . . . . . . . . 17-4
Drive Pressure Check . . . . . . . . . . . . . . . . 17-4
Troubleshooting . . . . . . . . . . . . . . . . . . . 17-5
Posi-Power Pressure Check & Adjust . . . . 17-5
Auxiliary Flow Test . . . . . . . . . . . . . . . . . . . 17-6
Troubleshooting . . . . . . . . . . . . . . . . . . . 17-7
18. Troubleshooting
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 18-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 18-1
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . 18-1
General Troubleshooting Scenarios . . . . . . . 18-1
Engine/Machine Troubleshooting . . . . . . . . . 18-3
19. Lubricant and Fuel Specifications
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 19-1
Fluids & Fuel Specifications . . . . . . . . . . . . . 19-1
III
1. Product Safety
Chapter Overview
This chapter contains product safety information for the
Terex PT-70/80 Rubber Track Loaders. Read and
understand all product safety information before
attempting to service any Rubber 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 publication are identified by the signal word "NOTICE".
The person(s) in charge of servicing a Rubber 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 hazard. The safety messages included in this document and displayed on the machine are not allinclusive. They are intended to make you aware of
potential risks and encourage a safe approach to
performing service work. If you use a tool, procedure, work method or operating technique that is
not specifically recommended by Terex, you must
satisfy yourself that it is safe for you and others.
You must also ensure that the machine will not be
damaged or be made unsafe by the operation,
lubrication, maintenance or repair procedures that
you choose.
Basic Precautions
NOTICE
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 Rubber
Track Loader before attempting to operate, maintain or
repair it. Replace any damaged, illegible or missing
labels immediately, prior to service.
“NOTICE” Indicates a hazardous situation which,
if not avoided, could result in property or equipment 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.
Improper or incomplete maintenance/repair of a
Rubber Track Loader can be dangerous and
may result in machine damage, injury or death.
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 others around you as you work.
Do not attempt to perform any type of repair or maintenance on a Rubber 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 Rubber Track Loader.
1-1
Rubber Track Loader
1. Product Safety
Entering and Exiting
Pressurized Items
Always use steps and handholds when entering or
exiting a Rubber Track Loader. Clean any mud or
debris from steps or work platforms before using them.
Always face the machine when using steps and handholds. 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.
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 penetrate 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.
Lifting
Use a hoist when lifting components that weigh 50 lb
(23 kg) or more, to avoid back injury. Make sure all
chains, hooks, slings, etc., are in good condition and
are of the correct capacity. Be sure hooks are positioned correctly and equipped with a spring latch.
Lifting eyes are not to be side loaded during a lifting
operation.
2. Relieve pressure from the hydraulic system before
disconnecting or removing any lines, fittings or
related items. Do this by relaxing all hydraulic
actuators. If the lift arms are raised, make sure
they are securely braced. Be alert for possible
pressure release when disconnecting any device
from a pressurized system.
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
3. Lower the lift arms before performing any work on
the machine. If this cannot be done, make sure
they are securely braced to prevent them from
dropping unexpectedly during service.
4. Loose or damaged fuel, oil, hydraulic, lines, tubes
and hoses can cause fires. Do not bend or strike
high pressure lines or install ones that have been
bent or damaged. Check lines, tubes and hoses
carefully. See item 1 for precautions on checking
for fluid leaks.
5. Pressurized air or water can also cause injury.
When pressurized air or water is used for cleaning, wear a protective face shield, protective clothing, and protective shoes. The recommended maximum air pressure for cleaning purposes is 30 psi
(205 kPa). When using a pressure washer, keep in
mind that nozzle pressures are typically very high.
Generally, pressures are well above 2000 psi
(13790 kPa). Follow all recommended practices
provided by the pressure washer manufacturer.
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 battery circuit cable from the battery when the charging
unit is operating. A spark can cause an explosion from
the flammable vapor mixture of hydrogen and oxygen
that is released from the electrolyte through the battery
outlets. Do not let electrolyte solution make contact
with skin or eyes. Electrolyte solution is an acid. In
case of contact, immediately wash skin with soap and
water. For eyes, flush with large amounts of water for
at least 15 minutes. Call Physician. Keep out of reach
of children.
1-2
Rubber Track Loader
1. Product Safety
8. Be prepared to stop an engine if it has been recently 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.
Repair
Accidental machine starting can cause injury
or even death to personnel working on a
Rubber 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 Rubber Track Loader.
9. Be careful when removing cover plates. Gradually
back off the last two bolts or nuts located on opposite sides of the cover. Then, pry the cover loose
to relieve any spring or other pressure before
removing the last two nuts or bolts completely.
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is
being serviced.
1. Disconnect the battery and discharge any capacitor before beginning work on a machine. Attach a
Do Not Operate tag in the cab to alert any operator that service is in progress.
10. Repairs requiring welding should be performed
only by personnel adequately trained and knowledgeable in welding procedures and with the guidance 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.
2. If possible, make all repairs with the machine
parked on a level, hard surface. Use blocks to prevent the machine from rolling while working on or
under the machine.
3. Do not work on or under any machine that is supported only by a hydraulic jack or hoist. Always
use some sort of mechanical support to ensure
that the machine will not fall. Terex jack stands
work well to support the machine while performing
maintenance or repair work.
11. Take precautions to avoid damaging wiring during
removal and installation operations. Carefully route
wires so that they will not contact sharp corners,
objects or hot surfaces during operation.
12. When performing service that requires the lift arms
to be in the raised position, always utilize the lift
arm brace located on the rear of the loader tower.
4. Make sure the work area around the machine is
safe and make yourself aware of any hazardous
conditions that may exist. If the engine needs to
be started inside an enclosure, make sure that the
engine’s exhaust is properly vented.
13. Relieve hydraulic system pressure by relaxing all
hydraulic actuators prior to attempting any
hydraulic maintenance or repair.
5. Be sure all protective devices including guards and
shields are properly installed and functioning correctly 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 fastener if replacements are necessary.
14. Always tighten connections to the correct torque
specification. Make sure that all shields, clamps
and guards are installed correctly to avoid excessive heat, vibration or unwanted contact between
parts during operation. Shields that protect
exhaust components from oil spray in event of a
line, tube or seal failure must be correctly installed.
15. Do not operate a machine if any rotating part is
damaged or contacts other parts during operation.
Any high speed rotating component that has been
damaged or altered should be checked for balance
before reusing. Make sure all protective devices,
including guards and shields, are properly installed
and functioning correctly before starting the engine
or operating the machine.
1-3
Rubber Track Loader
1. Product Safety
Safety Label Examples
Attachments
Only use attachments that are recommended by Terex.
Examples of the labels and decals displayed on the
machine are shown on this page.
Make sure that all necessary guards and protective
equipment are in place and functioning prior to operating any attachment.
WARNING
Wear protective glasses and protective equipment as
required by conditions or as recommended in the
attachment’s operation manual.
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment.
When replacement parts are required for your
machine, use only genuine Terex replacement
parts or parts that meet or exceed original
specifications including, but not limited to physical
dimensions, type, strength and material.
Keep clear of lift arms and
attachments.
WARNING
Installing lesser components can lead to premature
failures, product damage, personal injury or death.
CRUSH HAZARD
Contact with moving machine can
result in death or serious injury.
Keep clear of moving machine.
2030-593
WARNING
Ensure that all personnel are far enough away from
the work area so they will not be struck by flying objects.
Stay clear of the cutting edges, pinching surfaces or
crushing surfaces of the attachment while performing
any attachment maintenance, testing or adjustments.
Fall Hazard
Serious injury or death can result
from falling.
Use the provided access system when
entering or exiting the machine.
WARNING
Machine Labels and Decals
•
Labels and decals placed on the machine provide
safety information and operating instructions.
Familiarize yourself with the location and significance
of these labels to ensure your safety.
Injection Hazard
Escaping fluid under pressure can
penetrate skin, causing serious injury.
Relieve internal pressure before
disconnecting any line or fitting.
• Keep away from leaks or pinholes.
• Use cardboard to check for leaks.
Fluid injected into skin must be surgically removed within a few hours by a
doctor familiar with this type of injury
or gangrene will result.
WARNING
Product Identification Number
The Product Identification Number (PIN) is located on
the front of the cab enclosure (figure 1-1). Always provide the PIN when contacting the dealer about parts,
service, warranty or accessories. No warranty claims
will be processed unless the PIN is provided.
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment.
Install lift arm brace prior to servicing.
WARNING
Entanglement Hazard
Rotating parts can cause personal injury.
Keep away from fan and belt while the
engine is running. Stop engine before
servicing.
2030-600
WARNING
1-1
Burn Hazard
Hot fluid under pressure can scald.
Allow the machine to cool thoroughly
before opening.
2030-595
1-4
Rubber Track Loader
1. Product Safety
WARNING
Improper operation or maintenance
can result in serious injury or death.
WARNING
Crush Hazard
Rollover can crush and result in
serious injury or death.
Read and understand the operator’s manual and all safety signs
prior to operating or maintaining
the machine.
WARNING
DANGER
Explosion/Burn Hazard
Will cause death, burns or
blindness due to ignition of
explosive gasses or contact
with corrosive acid.
Fasten Seat Belt
WARNING
•
•
•
Fall Hazard
Falling can result in serious injury
or death.
Do not use the bucket/attachment
as a work platform.
NOTICE
Fire Hazard
Fall Hazard
Keep all flames/sparks
away!
No Smoking!
Read and understand
all manuals prior to
operation.
Falling from a machine can result
in serious injury or death
No Riders
WARNING
Rollover/Ejection Hazard
Serious injury or death can result.
Flammable debris can collect near
hot components and lead to a fire.
Read Operator’s Manual
Keep the engine, exhaust and
chassis areas free of debris.
Carry loads low. Load unload and
turn on level ground. Travel on
inclines with heaviest end of
machine uphill.
1-5
1-6
2. Technical Specifications
& Service Tools
PT-70 Specifications
Engine
Oil Cooler
-
-
Model: Perkins 804C-33T
Displacement: 3.3 liter
Gross horsepower: 71 hp (53 kW)
Torque: 173 lb-ft. (234 Nm)
Idle rpm: 1000 (low idle), 2600 (high idle)
Average water /thermostat temperature: 190°F,
87.8°C
Critical Torque Specs
Transmission
-
-
Model: Cat A22VG45 tandem (Rexroth)
-
Drive Pumps
-
-
Displacement: 2.7459 in3/rev (45 cc/rev)
Relief pressure: 5500 psi (380 bar)
Flow: 30.91 gpm (117 lpm) @ 2600 rpm (per
pump)
-
Charge Pump
-
-
Displacement: 1.373 in3/rev (22.5 cc/rev)
Relief pressure: 475 +/- 30 psi (32.75 bar)
Flow: 15.4 gpm (58.3 lpm) @2600 rpm
•
•
•
•
Model: Rexroth MCR 05 C
Displacement: 37.8 in3/rev (620 cc/rev)
Pilot Controls (Joysticks)
-
Listed below are common service tools which are identified and utilized in the service procedures described
in this manual. Use tools recommended by ASV whenever possible to reduce risk of injury and or machine
damage during service.
Make: Rexroth
Type: Axial Piston, Variable Load Sense
Displacement: 2.75 in3/rev (45 cc/rev)
Max Flow: 30 gpm (113.6 lpm) @ 2600 rpm
Relief pressure: 3000 psi (20,680 kPa)
Marginal (Standby) Pressure: 218 psi (1,503 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 attachment motor fails or contaminants are introduced
from the quick couplers.
•
•
•
•
•
•
Lift Arm Control Valve
-
Lift-Arm up: 3.5 seconds (+/- .35 seconds)
Lift-Arm Down: 3.3 seconds (+/- .33 seconds)
Bucket Curl: 1.7 seconds (+/- .17 seconds)
Bucket Dump: 1.9 seconds (+/- .19 seconds)
Service Tools
Model: Rexroth 08-351
Auxiliary Pump
-
Transmission Mounting Bolts
-- 85 ft-lb. w/Blue Loctite
Drive Sprocket Drive Teeth Bolts
-- 88 ft-lb. -Dry
10” Idler Wheel Retaining Nut
-- 350 ft-lb. -Dry
15” Idler Wheel Retaining Nut
-- 350 ft-lb. / 475 Nm -Dry
Drive Sprocket Lug Nut
-- 129 ft-lb. / 175 Nm -Dry
Drive Motor Mounting Bolts
-- 177 ft-lbs. / 240 Nm -Dry
Cycle Times
Drive Motors
-
Operating pressure: 150 psi (1034 kPa)
Bypass relief pressure: 80 psi (689 kPa)
Hot oil sending unit: 225°F (107.2°C)
Avg. oil operating temp. 50-60°F / 28-33°C above
ambient.
(High flow application 80°F / 44°C above ambient.)
Make: Rexroth
Type: Load Sense
2-1
TEREX Jack Stands (2) (TEREX P/N: 0402-900)
Heavy Duty Hydraulic Jack (5-ton rating)
Test Gauge Kit (TEREX P/N: 0402-935)
Ratchet Strap
Long Pry Bar(s)
TEREX Service Cart (0402-871)
Rubber Track Loader
2. Technical Specifications & Service Tools
PT-80 Specifications
Engine
Oil Cooler
-
-
Model: Perkins 804D-33T
Displacement: 3.3 liter
Gross horsepower:80 hp (60 kW)
Torque: 186 lb-ft. (253 Nm)
Idle rpm: 1200 (low idle), 2600 (high idle)
Average water /thermostat temperature: 190°F,
87.8°C
Transmission
-
Critical Torque Specs
-
Model: Cat A22VG tandem (Rexroth)
-
Drive Pumps
-
Displacement: 2.349 in3/rev (38.5cc/rev)
Relief pressure: 5500 psi (380 bar)
Flow: 26.4 gpm (100 lpm) @ 2600 rpm (per pump)
-
Charge Pump
-
-
-
Displacement: 1.373 in3/rev (22.5 cc/rev)
Relief pressure: 475 +/- 30 psi (32.75 bar)
Flow: 15.4 gpm (58.3 lpm) @2600 rpm
Drive Motors
-
Model: Rexroth MCR 5 (2-speed)
Displacement: 50 in3/rev (820 cc/rev)
Pilot Controls (Joysticks)
-
Model: Rexroth 08-351
Auxiliary Pump
-
Make: Rexroth
Type: Axial Piston, Variable Load Sense
Displacement: 2.75 in3/rev (45 cc/rev)
Max Flow: 30 gpm (113.6 lpm) @ 2600 rpm
Relief pressure: 3000 psi (20,680 kPa)
Marginal (Standby) Pressure: 218 psi (1,503 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 attachment motor fails or contaminants are introduced
from the quick couplers.
Transmission Mounting Bolts
-- 85 ft-lb. / 115 Nm - w/Blue Loctite
Drive Sprocket Drive Teeth Bolts
-- 85 ft-lb. / 115 Nm - Dry
Bogie Wheel (10” Idler) Retaining Bolt
-- 180 ft-lb. / 244 Nm - w/Red Loctite
15” Idler Wheel Retaining Nut
-- 350 ft-lb. / 475 Nm -Dry
Drive Sprocket Lug Nut
-- 177 ft-lb. / 240 Nm -Dry
Drive Motor Mounting Bolts
-- 177 ft-lbs. / 240 Nm -Dry
Cycle Times
•
•
•
•
Lift-Arm up: 3.5 seconds (+/- .35 seconds)
Lift-Arm Down: 3.3 seconds (+/- .33 seconds)
Bucket Curl: 1.7 seconds (+/- .17 seconds)
Bucket Dump: 1.9 seconds (+/- .19 seconds)
Service Tools
Listed below are common service tools which are identified 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.
•
•
•
•
•
•
Lift Arm Control Valve
-
Operating pressure: 150 psi (1034 kPa)
Bypass relief pressure: 80 psi (689 kPa)
Hot oil sending unit: 225°F (107.2°C)
Avg. oil operating temp. 50-60°F / 28-33°C above
ambient.
(High flow application 80°F / 44°C above ambient.)
Make: Rexroth
Type: Load Sense
2-2
TEREX Jack Stands (2) (TEREX P/N: 0402-900)
Heavy Duty Hydraulic Jack (5-ton rating)
Test Gauge Kit (TEREX P/N: 0402-935)
Ratchet Strap
Long Pry Bar(s)
TEREXService Cart (0402-871)
3. Circuit Diagrams
Chapter Overview
Hydraulic Charge Circuit
This chapter contains diagrams for the following PT70/80 circuits: hydraulic charge circuit, hydraulic auxiliary circuit, hydraulic drive circuit, loader valve,
hydraulic pilot generation (solenoid) block and electrical attachment outlet. It also contains hose routing
information for the control configurations for the drive
and lift arm pilot controls.
Figure 3-1 PT-70/80 Hydraulic Charge Circuit
OIL COOLER
CHECK VALVE
(15 PSI / 103 kPa) CHECK VALVE
(0 PSI / 0 kPa)
TO HYD Q/A (OPTIONAL PT-70)
CHARGE PRESSURE
RELIEF VALVE
(475 +/- 30 PSI /
3275 kPa)
TANK
FLOW
CHARGE PUMP
TANK
PILOT GEN BLOCK
TANK
INLET
5 MICRON FILTER
3-1
CHARGE PRESSURE
TEST PORT
(475 +/- 30 PSI /
3275 kPa)
Rubber Track Loader
3. Circuit Diagrams
Hydraulic Auxiliary Circuit
Figure 3-2 PT-70/80 Hydraulic Auxiliary Circuit
OIL COOLER
TO ATTACHMENT
CASE DRAIN Q/C
TO TANK
TO BUCKET CYL.
CHECK VALVE
(80 PSI / 552 kPa)
FLOW
TO TANK
LOADER CONTROL
TO LIFT ARM CYL.
TO AUXILIARY Q/C
TO LIFT ARM CYL.
LIFT ARM VALVE
TO TANK
LOAD SENSE
AUXILIARY PUMP
CHARGE PUMP INLET
AUXILIARY PUMP INLET
PILOT GEN. BLOCK
3-2
Rubber Track Loader
3. Circuit Diagrams
Hydraulic Drive Circuit
Figure 3-3 PT-70/80 Hydraulic Drive Circuit
DRIVE PRESSURE
RELIEF VALVES (4)
(5500 PSI / 37920 kPa)
DRIVE CONTROL
DRIVE MOTOR
DRIVE PUMP
DRIVE MOTOR
CASE DRAIN
TO COOLER
TANK
BRAKE
(PT-80 2-SPEED SHIFT)
3-3
Rubber Track Loader
3. Circuit Diagrams
Lift Arm Control Valve
Figure 3-4 PT-70/80 Lift Arm Control Valve
RELIEF VALVE SETTINGS
(B3) 3307 PSI
(22800 kPa)
(A3) 3307 PSI
(22800 kPa)
(B2) 3147 PSI
(21700 kPa)
(A2) 3669 PSI
(25300 kPa)
(A1) Anti-Cavitation
Check Valve
(B1) 3640 PSI
(25100 kPa)
3-4
Rubber Track Loader
3. Circuit Diagrams
Hydraulic Pilot Generation
Block
Figure 3-5 PT-70/80 Hyd. Pilot Generation Block
3-5
Rubber Track Loader
3. Circuit Diagrams
Electrical Attachment Outlet
Figure 3-6 PT-70/80 Electrical Attachment Outlet
3-6
Rubber Track Loader
3. Circuit Diagrams
Drive Control
(line routing)
Figure 3-7 PT-70/80 Standard Drive Control
3-7
Rubber Track Loader
3. Circuit Diagrams
Lift Arm Control
(line routing)
Figure 3-8 PT-70/80 Lift Arm Control
3-8
4. Maintenance
Chapter Overview
Lift Arm Brace
This chapter provides information on general maintenance procedures for the PT-70/80. If there is an issue
that requires troubleshooting, refer to Chapter 18,
Troubleshooting.
The lift arm brace (A) 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 supported only by a jack. The lift arm brace is
used to support the weight of the lift arms much like
jack stands are used to mechanically support vehicle
weight.
Personal Safety
Improper or incomplete maintenance/repair of a
Rubber 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 Rubber 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 Rubber Track Loader.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
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 (B)
securing the lift arm brace and remove it from the
machine.
4. Make sure bystanders are clear of the lift arms,
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.
6. Lower the lift arms slowly until they come to rest
on the brace.
7. It is now safe to shut the engine off and exit the
machine.
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.
4-1
To remove the lift arm brace:
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
from 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.
B
4-2
4-1
Rubber Track Loader
4. Maintenance
C
B
A
4-4
4-3
Tilt-Up Cab
The ROPS/FOPS approved cab (A) tilts up to allow
easier access while performing maintenance. It features a gas spring assist and a brace mechanism to
hold it in place while tilted.
To tilt the cab:
1. Remove any attachments that may be fastened to
the machine.
4-5
2. (Optional) Raise the lift arms and secure them with
the lift arm brace. (See page 4-1.)
Jacking Procedure
Occasionally, your machine may need to be suspended off of the ground to perform maintenance. Exercise
caution when jacking the machine. Always use a jack
that is capable of lifting the machine and support its
weight with Terex approved jack stands while suspended. Never work on or under a machine supported only
by a jack.
3. Remove the two bolts that fasten the cab to the
chassis. They are located inside the cab, one in
each of the front corners.
4. Once the bolts have been removed, tilt the cab
slowly upwards. The cab brace (B) should fall
onto the shoulder bolt (C) locking the cab in its
upright position.
To safely jack your machine:
1. Remove any attachments that may be fastened to
the machine and raise the lift arms.
The cab is now secure.
To lower the cab:
1. Raise the cab brace so that the locking channel is
clear of the shoulder bolt.
2. Install the lift arm brace as instructed on page 4-1.
2. Hold the brace upwards and lower the cab until the
locking channel is clear of the shoulder bolt then
release the brace.
3. The cab is now free to be lowered into operating
position.
4. Lower the cab completely and then fasten it to the
chassis with the two bolts removed previously.
3. Once the lift arms are secured, carefully exit the
machine.
4. Roll or slide your jack under the front of the
machine and center the lifting pad directly under
the middle of the front torsion axle.
5. Once in place, jack the machine upward making
sure it remains stable until it has reached sufficient
height to install an Terex jack stand beneath the
machine. (fig. 4-4)
6. Slide the jack stand into place making sure it is
centered under the machine (left to right when
viewed from the front) and far enough back for the
machine to remain stable when the jack is lowered
and the front of the machine rests on the stand.
(fig. 4-5)
7. Once the stand is in place, slowly lower the
machine onto the stand and then remove the jack.
Repeat steps 4-7 at the rear of the machine should
both ends of the machine need to be off of the ground
for service.
4-2
Rubber Track Loader
4. Maintenance
Grease Fitting Locations
A.
B.
C.
D.
E.
F.
G.
H.
Lower Bucket Cylinder Pivot (2)
Upper Bucket Cylinder Pivot (2)
Front Lift Cylinder Pivot (2)
Lift Arm Pivot (2)
Rear Lift Cylinder Pivot (2)
Rear Axle Pivot (2)
Front Axle Pivot (2)
Lower Bucket Pivot (2)
4-6
D
E
C
B
A
H
G
F
Grease Fittings
The PT-70/80 are equipped with grease fittings at pivot points throughout the machine. The illustration above
shows the locations of all fittings on the left side of the machine. An identical fitting exists on the right side of the
machine for each one identified in the illustration. Lubricate all fittings DAILY or after every 10 hours of operation
to maximize component life and ensure proper machine function. (fig. 4-6)
Undercarriages
The undercarriage assemblies in Rubber Track Loaders typically operate in harsh working conditions. They
work in mud, gravel, debris and various other abrasive materials during operation. Terex recommends a daily
inspection of the undercarriage assemblies and cleaning if necessary.
Materials that are particularly sticky or abrasive like clay, mud, or gravel should be cleaned from the undercarriages more often to minimize component wear. A pressure washer works well for cleaning materials from the
undercarriages. At times when a pressure washer is not available, use a bar, shovel or similar device to remove
foreign materials.
When cleaning, pay particular attention to the drive tables, sprockets, and the front and rear wheels where
debris is likely to accumulate. If working in scrap or debris, inspect more often and remove foreign objects that
may wrap around or lodge themselves between components causing premature wear and damage.
Operation in loamy sand or on turf or other finished surfaces may require less frequent cleaning, but daily
inspection is still advised.
4-3
Rubber Track Loader
4. Maintenance
Track Tension
Straight-Edge
Proper track tension must be maintained for optimal
performance and track/undercarriage life. Running a
track that is too loose may cause the track to misfeed
possibly causing damage to the track and or undercarriage components. Running a track that is too tight
may cause track stretch, premature bearing failure, or
other preventable damage to the machine. As a rule, a
track should only be tightened to the point where there
is no visible sag. Never tighten your tracks beyond this
point.
4-7
Note: During the first 50 hours of operation the tracks
will "break-in" and will most likely require adjustment.
To check track tension: (fig. 4-7, 4-8)
1. Drive the machine forward 5 feet to remove belt
slack from the lower and rearward portions of the
track.
2. Lay a straight edge along the top of the track
bridging the drive sprocket and front idler wheel.
3. Apply 90 lbs (41kg). of force to the track by either
placing weight on top or hanging it using rope or
wire midway between the drive sprocket and front
idler.
4-8
4. Measure from the bottom of the straight edge to
the lug surface (top) of the track. The deflection
should measure between 3/4" and 1" (1.9-2.5cm).
To adjust track tension: (fig. 4-9)
1. Loosen the lock nut (A) on the turnbuckle (B) and
adjust by turning the turn buckle itself until proper
tension has been achieved.
B
A
2. Then tighten the turnbuckle lock nut to complete
the procedure.
3. Repeat the adjustment procedure on the other side
of the machine if necessary.
4-9
4-4
Rubber Track Loader
4. Maintenance
Steel Pin
(.088”)
F
New Roller Normal Wear
35% life
C
E
D
J
I
H
G
4-10
K
A
B
Note: You may need to pry or lift the track upwards
with a hoist above the drive sprocket to provide clearance for removal.
Drive Sprocket Rollers
Terex rubber track loaders utilize rollers on the drive
sprockets to drive the track. These rollers help minimize friction between the track and the drive sprocket
to prolong track life.
The rollers rotate around hardened steel pins and usually wear on their inside surfaces. As they wear, the
rollers become thinner, but will continue to function as
long as they rotate freely around the pins. Sprocket
rollers should be inspected every 50 hours of operation
and replaced if cracked or worn to less than 35% of
original thickness. (.088”/.22cm)
To replace worn rollers:
1. Begin by performing steps 1-4 in the track removal
procedure on page 4-6 to allow the sprocket to be
removed.
2. Remove the seven bearing plate mounting bolts
(A, I), then remove the plate (B) from the drive
table.
7. Remove one bolt (F) holding the steel pins (D) and
rollers (E) in place. Install the new rollers over
the pins, then slide the bolt back through the
sprocket and pins and secure it with the nut (K).
8. Repeat this process as required throughout the
sprocket.
9. Reinstall the sprocket by reversing steps 2-6.
Note: During removal of the bearing cap (step 3) the
bulged area of the cap is beaten inward. When reinstalling, orient the cap so that the domed area is facing
outward. Then tap the center of the cap with a ball
peen hammer or similar device to reset the cap. Do
this gently. Too much inward force can damage (mushroom) the bearing shaft.
10. Repeat steps 1-9 on the other side of the machine
if necessary.
3. Remove the bearing cap (G) by tapping around the
bulged area of the cap with a hammer. This will
relieve the outward pressure on the cap and allow
for removal.
11. Perform the track tension adjustment and check
procedures on page 4-4.
Note: Replace rollers as a set to simplify inspection
and maintain proper sprocket function.
4. Remove the external snap ring (H) from the bear
ing shaft.
5. Using a puller, remove the bearing assembly (J)
from the shaft.
6. Remove the sprocket mounting bolts (C), then
remove the sprocket.
4-5
Rubber Track Loader
4. Maintenance
Track Removal/Installation
Tracks may need to be removed periodically to inspect
undercarriage components or for replacement if worn
or damaged. This section covers the procedure to
remove and install a track on PT-70/ 80 machines.
Tools required:
• Socket/impact wrench
• Ratchet strap
• Heavy duty hydraulic jack
• Combination wrench
• Long pry bar(s)
• Terex approved jack stands (2)
• Spray lubricant
• Shop vac or Pressure washer
Cavity
4-12
Track Removal
1. Break up and remove any foreign material from the
cavity between the suspension rail and the drive
table support. (fig. 4-12)
Note: A shop vac or pressure washer will work well to
remove material from this cavity.
2. Clean the threads on the turnbuckle thoroughly
using a stiff bristle brush.
4-13
3. Loosen the lock nut on the turnbuckle and spin it
to the end of the threaded shaft to allow clearance
when the drive table is lowered.(fig. 4-13)
4. Rotate the turnbuckle and lower the drive table as
far as it will go. (fig. 4-14)
5. Remove the bolts securing the outer front wheel to
the hub. Then remove the wheel. (fig. 4-11, 4-15,
4-16)
Turnbuckle
4-14
4-11
Drive Table
4-15
4-6
Rubber Track Loader
4. Maintenance
4-19
4-16
6. Remove the outer scraper plate from the suspen
sion rail. (fig. 4-17)
7. Remove the bolts securing the inner wheel to the
hub, then remove the wheel.
(fig. 4-18, 4-19)
8. Use a pry bar to peel the track over the inner
wheel(s) toward the outside of the machine.
(fig. 4-20)
9. Once the track is off of the front wheel(s), pull the
rear of the track clear of the suspension.
(fig. 4-21, 4-22)
4-20
4-17
4-21
4-18
4-22
4-7
Rubber Track Loader
4. Maintenance
Track Installation
1. Slide the track over the drive sprocket at the rear
of the machine. (fig. 4-23, 4-24)
2. Slide the front of the track into position for installa
tion. (fig. 4-25)
3. Lubricate the inner front wheel(s) and the inside of
the front portion of the track with a spray lubricant.
(fig. 4-26)
4. Attach a ratchet strap to the upper front portion of
the track and the other end to one of the tow
hooks on the front of the machine. (fig. 4-27)
4-25
5. Tighten the strap until the track is pulled upward
slightly and in position to slide over the inner idler
wheel(s) at the front. (fig. 4-27)
6. Pull all of the slack forward and make sure the
track drive lugs are properly meshed with the
sprocket to provide as much slack as possible for
installation.
7. If you have an assistant, have them pull the track
forward while you push inward on the track. Work
the track over the wheel(s) and into place.
8. If you do not have an assistant, push the track for
ward in inward in a quick forceful motion to slide
the track into place. The ratchet strap will help to
keep the track in place while you work it over
the idler(s). (fig. 4-28)
4-26
4-27
4-23
4-28
4-24
4-8
Rubber Track Loader
4. Maintenance
9. Once the track is in position over the idler wheels,
install the inner idler wheel onto the hub and
secure it in place with the mounting bolts. Torque
them to 90 +/- 10 Lb. Ft. (122 Nm)
(fig. 4-29, 4-30, 4-31)
Note: You may need to use a bar to keep the wheel
from spinning as you torque the mounting bolts to
spec. (fig. 4-31)
10. Install the scraper onto the suspension rail and
tighten the bolts to secure it in place. (fig. 4-32)
4-31
11. Install the outer idler wheel and secure it in place
with the mounting bolts. Torque them to 90 +/- 10
Lb. Ft. (122 Nm) (fig. 4-33, 4-34)
12. Perform the track tension adjustment and check
procedures on page 4-4 to complete installation.
4-32
4-29
4-33
4-30
4-34
4-9
Rubber Track Loader
4. Maintenance
Air Cleaner
The PT-70/80 are equipped with two air filter elements
to remove contaminants from the air used for combustion. Regular inspection and replacement is necessary
to ensure proper performance and to prolong engine
life.
A
To remove and inspect your air cleaner elements:
1. Turn the engine off.
2. Open the hood at the rear of the machine to gain
access to the engine compartment.
3. Locate the black air cleaner enclosure near the top
left of the engine compartment (when viewed from
the rear).
4-35
4. Twist the tension screw (A) counter-clockwise until
the band is loose enough to remove the cover,
then remove the cover. The primary element (B)
should be exposed.
5. Remove the primary element and inspect it. If it
appears damaged in any way, replace it. If the element is heavily soiled, replace it. If it appears to be
in good condition, clean if necessary and re-install.
6. Once the primary element has been removed, the
secondary element (C) should be visible. Remove
and inspect it. If the element is damaged or heavily
soiled, replace it.
4-36
Note: The secondary element is not serviceable. It
should be replaced after every three cleanings of the
primary filter.
Note: The primary element may be cleaned and reused
up to five times if properly maintained, but should be
replaced at least once a year.
B
4-37
C
4-38
4-10
Rubber Track Loader
4. Maintenance
Fuel Filter
The fuel filter removes contaminants from the fuel as it
enters the engine for combustion. Over time the filter
can become plugged and cause the engine to lose
power, run roughly or fail to start. The fuel filter should
be changed every 500 hours or more often if needed
to prevent these conditions from occurring.
To change the fuel filter:
1. Clean the outside of the filter assembly thoroughly
to reduce the chances of contaminants being intro
duced into the fuel system.
4-39
7. Once the inspection has been performed, install
the new secondary filter element into the enclosure
as found upon disassembly. (fig. 4-39)
8. Install the primary element by sliding it into place
in the enclosure as found upon disassembly.
2. Twist the water separator catch bowl (A) counter
clockwise (when viewed from the bottom) and
remove it from the assembly. Take care not to lose
the o-ring that seals it to the filter base.
3. Twist the upper lock ring (B) counter clockwise
(when viewed from the bottom) and remove it from
the assembly.
9. Install and secure the cover by sliding it into place
and positioning the band over the retaining lip.
Then turn the tension screw clockwise until tight.
Gently wiggle the cover to make sure it is secure.
4. Slide the filter (C) downward to remove it. Note the
position of the raised tabs on the upper portion of
the filter to simplify reassembly.
5. Install the new filter element into the assembly by
reversing steps 2-4.
To clean your primary filter element:
1. Remove loose dirt from the filter element with compressed air or water hose.
Compressed air: 100 P.S.I.(689 kPa) max. 1/8"
(.3175 cm) diameter nozzle at least 2" (5.1 cm)
away.
Water: 40 (276 kPa) P.S.I. max. without nozzle.
2. Soak the filter in a non-sudsing detergent solution
for at least 15 minutes moving it gently through the
solution to further clean the element. (Never soak
for more than 24 hours.)
Water Separator
The water separator removes water from the fuel supply as the engine runs. Drain the water separator daily
to maintain proper function.
To drain the water separator:
1. Loosen the black screw on the bottom of the
separator.
2. Re-tighten the screw after the water has been
drained from the catch bowl.
3. Rinse the filter thoroughly with a gentle stream of
water to remove all dirt and remaining detergent.
4. Allow the filter to dry completely before re-installing
it into the machine.
NOTICE
B
Do not use any heat source other than warm air at
less than 160°F (71° C) to dry the filter.
C
Do not clean air filter elements while engine warranty is in effect. During the warranty period, Terex
recommends replacing air filter elements instead
of cleaning them. Heavy-duty air filter manufacturers will not warrant the air filter once it has been
cleaned.
4-11
4-40
A
Rubber Track Loader
4. Maintenance
Accessory Belt Tension
Drive belts typically stretch and wear during their service life. The fan and A/C belts should be checked for
tension, condition and presence daily prior to operating
your machine.
To check fan or A/C belt tension:
1. With the engine cold and off, remove the key from
the ignition to avoid accidental start.
2. Lift the hood at the rear of the machine and check
to make sure the fan and A/C belts are present
and in good condition. If they appear excessively
worn, or cracked, replace them.
4-41
3. Lay a straight edge across the alternator and crank
pulleys (crank and A/C pulleys for A/C belt) and
apply a force of 10 lbs. midway between the pul
leys. (fig. 4-41, 4-42)
4. Measure the distance from the bottom of the
straight edge to the top surface of each belt
(deflection). Fan belt deflection should measure 3/8” (.95cm) (7/16” / 1.11cm A/C) if properly
tensioned.
5. If the belts are loose or tight, adjust tension until
correct.
4-42
To adjust fan or A/C belt tension:
1. Make sure the engine is cold, off, and the key has
been removed from the ignition to avoid accidental
start.
2. Lift the hood at the rear of the machine and loosen
the bolts securing the alternator or A/C pump
slightly to allow the alternator or A/C pump
to pivot. (fig. 4-43, 4-44)
3. Once loose, use a small pry bar as a lever to force
the alternator or A/C pump against the belt(s) to
increase belt tension to appropriate level then
tighten bolts to specification. (fig. 4-43, 4-44)
4. Check the belt tension.
5. Adjust belt tension as necessary until correct.
4-12
Bolts
Pry-bar
4-43
Rubber Track Loader
4. Maintenance
Fan Belt Removal & Installation
Pry-bar
To remove the fan belt:
1. Follow steps 1 and 2 of the belt adjustment proce
dure.
2. Once loose, pivot the alternator towards the
engine to increase slack.
Bolt
3. Then, remove the three bolts securing the fan
cage (half) to the fan shroud. Remove that portion
of the cage. (fig. 4-45, 4-46)
4. Slip the belt off of the engine pulleys and work it
around the fan until it is clear of the blades.
4-44
To install the fan belt:
1. Reverse the steps of the removal procedure.
1/2 cage
2. Perform the belt tension check and adjustment
procedures on page 4-12 to complete the
installation.
A/C Belt Removal & Installation
To remove the A/C belt:
1. Follow steps 1 and 2 of the belt adjustment proce
dure.
Bolts
4-45
2. Once loose, pivot the A/C pump towards the
engine to increase slack.
3. Slip the belt off of the pulleys and remove
it from the machine.
To install the A/C belt:
1. Reverse the steps of the removal procedure to
reinstall the belt.
2. Perform the belt tension check and adjustment
procedures on page 4-12 to complete the
installation.
4-46
4-13
Bolt
Rubber Track Loader
4. Maintenance
Engine Oil/Filter Change
Regular oil changes are necessary to maintain a
strong running engine. Terex recommends a normal oil
change interval of 250 hours or every six months. This
recommendation has been made to help ensure proper
lubrication during operation and to prolong engine life
under typical operating conditions.
To change the oil and filter:
1. Start and run the engine for a few minutes to warm
the oil. Then turn the engine off before proceeding.
4-47
2. Place a suitable container under the engine oil
drain plug to catch the used oil as it drains.
3. Remove the belly pan beneath the engine.
(fig. 4-47)
4. Then remove the drain plug from the oil pan and
allow the used oil to drain completely from the
engine. Make sure to use the correct size combi
nation/socket wrench to keep the drain plug in
reusable condition. (fig. 4-48)
5. Remove the engine oil filter by hand or with strap if
necessary. (fig. 4-49)
4-48
6. Once the filter has been removed, check to make
sure the rubber gasket has come off of the filter
head with the old filter. If it is not on the old filter,
check the filter head. If it is still on the filter head,
remove it prior to installing the new filter.
(fig. 4-50)
NOTICE
If the old filter gasket (A) is not removed from the
filter head and the new filter is installed on top of
it, an oil leak will result when the engine is started.
If unnoticed, the engine can run itself out of oil
causing engine failure.
4-49
7. Prepare new filter for installation by rubbing fresh
oil on the exposed surface of the filter gasket.
A
8. Thread the new filter onto the filter head. Tighten
the filter by hand as instructed by the label located
on the filter or filter box.
9. Re-install the oil drain plug into the pan and tighten
to 50 +/- 10 lb ft (67.8Nm).
4-50
4-14
Rubber Track Loader
4. Maintenance
4-51
10. Remove the oil filler cap and fill the engine
crankcase with Terex 10W-30 Heavy Duty Engine
Oil (capacity: 9 qt./8.5l including filter). (fig. 4-51)
Low
11. Install the oil filler cap.
Full
12. Perform a visual inspection to make sure the drain
plug, filter and oil filler cap are in place and tight.
13. Start the engine and watch the oil pressure gauge
located in the lap bar instrument display. The needle should rise up into the green range as soon as
oil pressure has been established. If the needle
doesn’t rise above the red zone shortly after startup, turn the engine off immediately and look for
potential problems. If the needle does move into
the green zone as expected, oil pressure has been
achieved.
Oil Level Check
14. Once the engine is running, perform a visual
inspection to make sure there are no leaks or other
visible problems.
3. Locate and remove the engine oil dipstick from
its tube. (fig. 4-52)
15. If everything looks like it should, shut the engine
down and exit the machine.
16. Re-install the belly pan.
Engine Oil Specifications
Terex recommends using Terex 10W-30 Heavy Duty
Engine Oil for most conditions. In the event of an alternate working environment, the following chart may be
used as a guide to oil viscosity grades.
• API CH-4 multigrade engine oil.
4-53
To check the oil level:
1. Park the machine on level ground.
2. Open the hood to gain access to the engine compartment.
4. Wipe the dipstick with a clean shop cloth and reinsert it into the tube until it comes to rest in its
seated position.
5. Remove the dipstick once again and inspect the
end for oil on the level indicator. (fig. 4-53)
17. Perform the oil level check procedure.
You may also use a quality engine oil substitute meeting the following minimum specification:
4-52
6. Oil should be present on the dipstick up to, but
not over the upper (full) level indicator notch. If
the level is correct, reinstall the dipstick and
then close and latch the hood to complete the
procedure.
7. If the level is low, add the proper grade and viscos
ity engine oil and re-check as necessary until the
proper level has been achieved. Then re-install the
dipstick and filler cap and close and latch the hood
to complete the procedure.
4-15
Rubber Track Loader
4. Maintenance
Hydraulic Fluid/Filter Change
Hydrostatic components require extremely clean oil in
order to have a long service life. Use extreme caution
when changing the hydraulic oil. Introducing dirt or
debris could be detrimental to the hydraulic system.
Terex recommends service intervals of 500 hours for
hydraulic fluid and 250 hours for hydraulic fluid filters.
To change the hydraulic fluid:
1. Locate the hydraulic system drain access situated
in the belly pan between the axles on the right side
of the machine. (fig. 4-54)
4-54
4-55
2. Remove the drain plug using the correct size allen
type wrench or allen socket to avoid damaging the
drain plug. (fig. 4-54, 4-55)
3. Drain the hydraulic fluid into a suitable catch con
tainer.
4. Locate the two hydraulic filters underneath the cab
on the left side of the machine. (fig. 4-56)
5. Thoroughly clean around the filters to prevent dirt
or debris from entering the system and remove the
filters by hand or with a strap as required.
4-56
6. Check to make sure the filter gaskets are still pres
ent on the old filters. If not, check the filter heads
to make sure they are free from old gasket materi
al prior to installing the new filters.
7. Prepare the new filters by rubbing a small amount
of fresh hydraulic oil onto the filter gasket surface
and then threading them onto their respective filter
heads. Tighten filters by hand as instructed by the
label located on the filter or filter box.
8. Install the hydraulic system drain plug and tighten.
9. Remove the hydraulic reservoir filler cap (black)
and fill the hydraulic system with Terex Premium
All Season MV Hydraulic Oil or equivalent until the
full mark on the hydraulic fluid sight gauge is
reached (approx. 12.5 gal. (47l). (fig. 4-57,4-58)
4-57
Note: When checking or adding to the hydraulic fluid
level, do so with the lift arms in the lowered position. If
the level is checked with the lift arms in the raised
position, an inaccurate reading will result.
Full
Note: When adding hydraulic fluid, add fluid slowly
until it is visible in the sight gauge. Once visible, add
fluid in one quart increments until the full mark has
been reached.
4-58
10. Install and secure the hydraulic reservoir filler cap.
11. Start the machine and operate all hydraulic circuits
to work any trapped air out of the system.
•
Drive the machine forward and backward.
•
Raise and lower the lift arms(unloaded).
•
Dump and curl bucket/quick attach.
Low
12. Once you have purged the air from the system,
check the level on the hydraulic fluid level sight
gauge. If the level is low repeat step 9 and 10 to
complete the procedure.
4-16
Rubber Track Loader
4. Maintenance
Radiator/Oil Cooler
The Radiator and Oil Cooler must be kept clean to
ensure proper operation. Engine and hydraulic system
overheating, damage and even failure can result if the
radiator/oil cooler is not kept clean. A pressure washer
or compressed air nozzle work well to blow debris
clear of the fins in the oil cooler and radiator.
Note: If hydraulic oil or engine coolant temperature
gauges indicate abnormally high temperatures during
operation, increase cleaning intervals.
4-59
Note: In brush cutting applications check and clean
the coolers often to avoid overheating.
To clean radiator/oil cooler:
1. Make sure the engine is off, and cool.
2. Using compressed air or a pressure washer, thoroughly clean radiator/oil cooler as shown.
Note: Make sure water nozzle is at least 12 in. /
30.5cm (8 in. / 20.3cm for air) from the cooler and that
the spray is directed straight through the cooler or the
cooling fins may be damaged (bent over) which will
decrease cooling performance.
4-60
Engine
Periodic cleaning of the chassis area beneath the cab
and engine compartment are also necessary to maintain safe operation. Clean as required.
1. Remove the belly pans on the underside of the
machine.
2. Tilt the cab up and raise the hood at the rear of the
machine.
3. Pressure wash any debris from the engine com
partment and chassis area out through the lower
opening.
4-61
4-17
Rubber Track Loader
4. Maintenance
4-62
4-63
Case Drain Filter
Fuse Panel
The PT machines are also equipped with a filter in the
auxiliary circuit case drain line. It protects the main
hydraulic system in the event of catastrophic failure in
an attachment. This filter is designed to last the life of
the vehicle. The only instance where this filter should
be replaced is if an attachment equipped with a case
drain has a drive motor failure during use. (fig. 4-62)
The electrical systems in the PT machines are
equipped with fuses that protect the electrical components from damage. They are located on the fuse
panel behind the access cover on the lower right side
of the cab interior. (fig. 4-63)
In the event of an electrical malfunction, the most logical place to start is at the fuse panel. Check the fuse
related to the problem you are having and inspect it. If
the fuse appears black and burned, it needs to be
replaced. Replace fuses with the correct amperage
replacement fuse only. Replacing a fuse with one of a
lower amperage rating may lead to premature fuse failure. Replacing a fuse with one of a higher amperage
rating may burn out the electrical component the fuse
was meant to protect. See the troubleshooting section
in this manual for an additional resource to aid in tracking suspected electrical problems.
4-18
Rubber Track Loader
4. Maintenance
Maintenance
Item
Grease fittings
Service
required
Lubricate
Fluid levels
Check
Daily
Fan-A/C belt
tension
Check
Daily
Adjust tension as
necessary.
Fan-A/C belt
condition
Inspect
Daily
Replace as a pair if
worn or damaged.
Water separator
Drain
Daily
Track condition
Inspect
Daily
Replace if severely
damaged.
Track tension
Inspect
Daily
Adjust tension as
necessary.
Air cleaners
Inspect
Daily
Replace if damaged or
heavily soiled.
Radiator/oil
cooler
Inspect
Daily
Clean often
(as necessary).
Undercarriages
Inspect
Daily
Clean often
(as necessary).
Engine
compartment
Inspect
Daily
Clean often
(as necessary).
Drive sprocket
rollers
Inspect
50 hr.
Replace if damaged or
worn. (35% min.)
Engine oil and
filter
Replace
250 hr. or
6 Mo.
Hydraulic filter
Replace
250 hr.
Hydraulic oil
Replace
500 hr.
Water separatorReplace
fuel filter
500 hr.
Replace fuel filter
element.
Radiator coolant
3000 hr.
Coolant with SCA
additive required.
Replace
Interval
Notes
Daily
Grease often.
Adjust levels as
necessary.
4-19
Service
Capacity
9 qt.
/ 8.5l
9 qt.
Service refill capacity 12.25 gal. /
12.25
46.4lgal.
only. (Dry: 21 gallons)
3.125 gal. /
3.125
11.8lgal
4-20
5. Machine Controls and
Instrumentation
Chapter Overview
Instrumentation
This chapter contains an overview of the machine controls and instrumentation. For further information
regarding machine controls, instrumentation or operation, refer to the operation and maintenance manual
for the PT-70/80. Included here are illustrations of the
following controls and instrumentation components and
a description of their functions.
The Instruments (Figure 5-2) are positioned in the lap
bar for good visibility and when seated inside the operator enclosure. Instruments include the following components.
•
•
•
Machine Controls
Guage Location and Function
Switch Location and Function
Machine Controls
(fig. 5-1)
There are three primary machine controls: lift arm control (1), drive control (2) and throttle (3).
Lift Arm Control
(1) Engine Temperature Gauge
(2) Multi-Gauge
• Oil Pressure Gauge
• Hyd. Oil Temperature Gauge
• Fuel Gauge
• Voltmeter
(3) Tachometer
(4) Indicator Light Display
• High Range Indicator
• Low Range Indicator
• Glow Plug Operation Indicator
• Parking Brake Indicator
The lift arm control (1) is a pilot operated joystick that
allows the operator to raise or lower the lift arms and
dump or curl the quick attach mechanism.
1
Drive Control
4
3
2
The drive control (2) is also a pilot operated joystick. It
allows the operator to change the direction and speed
of the machine.
5-2
Throttle
NOTICE
The foot throttle (3) controls engine rpm.
If the engine coolant temperature, engine oil pressure or
hydraulic oil temperature gauges read above normal (or
below normal for engine oil pressure) during normal machine
operation, shut the machine down immediately. Diagnose the
problem and make any necessaryrepairs before continuing to
operate the machine.
3
2
1
NOTICE
If the voltmeter reads less than 12 volts with the machine
running, drive the machine to a suitable location and shut the
engine off. Diagnose the problem and make needed repairs
before continuing to operate.
5-1
The glow plug operation light illuminates only when the
key switch is turned to engine pre-heat, showing normal operation.
5-1
Rubber Track Loader
5. Machine Controls and Instrumentation
Switches
The various switches (Figure 5-3, 5-4, 5-5) are positioned to provide good access and visibility. The standard and optional switches are listed below.
1
3
2
4
5-3
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Parking Brake
Power Quick Attach
High Flow Auxiliary
Low Flow Auxiliary
Hour meter
Heater Fan (optional)
Heater Temperature Control (optional)
Work Lights
Bucket Positioning (optional)
5
5-4
6
7
8
5-5
5-2
9
6. Operator Enclosure
Chapter Overview
Removal and Installation
This chapter provides information on the assembly and
disassembly of the operator enclosure assembly. If
there is an issue that requires troubleshooting, refer to
Chapter 18, Troubleshooting.
Removal and installation procedures are provided for
the following operator enclosure components.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in ma-chine
damage, injury or death.
•
•
•
•
•
Cab Door Gas Spring
Forward Pillar Switches
Side Panels/Gauges
Seat
Interior panels side/rear
Note: Procedures are provided for only the operator enclosure components listed above. However, exploded parts diagrams exist in the PT-70/80 Parts manuals to serve as visual
aids in the removal or installation of other operator enclosure
components.
Do not attempt to perform any type of repair or maintenance
on a Rubber 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 Rubber Track Loader.
Door Gas Spring
Removal
Prior to performing any type of service work on a Rubber
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
Required Tools
Machine Preparation
Blade Type Screwdriver
Accidental machine starting can cause injury or death to personnel working on a Rubber Track Loader.
Retaining Clip
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 Rubber Track Loader.
Place a “Do Not Operate” tag prominently on the machine to
inform personnel that the machine is be-ing worked on.
6-1
1. Pry the retaining clip holding the forward end of
the gas spring to the ball stud outward. (fig. 6-1)
6-2
2. Pry the gas spring off of the ball stud. (fig. 6-2)
3. Repeat this procedure on the rear of the gas
spring to remove the spring completely.
Installation
1. To reinstall, reverse the removal procedure.
6-1
Rubber Track Loader
6. Operator Enclosure
Pillar Switch Panels
Removal
Required Tools
Open or Box end Wrenches
6-6
6-3
1. Remove the screws/bolts securing the pillar switch
panel to the cab enclosure. (fig. 6-3)
6-7
4. Pivot the panel further backward to expose the
connectors on the lower switches and disconnect
them. You may then remove the panel.
(fig. 6-6, 6-7)
6-4
2. Remove the forward end of the gas spring from
the ball stud by following steps 1-2 in the Cab
Door Gas Spring removal procedure on page 6-1.
Then remove the ball stud. (fig. 6-4)
Note: The connectors on the harness are labeled as
are the switches in the panel. Use these labels to
properly identify (match up) and reconnect the harness
to the switches during installation.
Note: At this point in the disassembly process, the
activation switches in the panel may be removed and
replaced if necessary. (fig. 6-8)
6-5
3. Once the ball stud has been removed, begin
removing the panel by pulling back on the top to
expose the wires connected to the dome light activation switch. Carefully disconnect them from the
switch. (fig. 6-5)
6-8
Installation
1. To reinstall either panel, reverse the steps of the
removal procedure.
6-2
Rubber Track Loader
6. Operator Enclosure
Side Panels/Gauges
Removal
Required Tools
Phillips Type Screwdriver
Combination/Socket Wrenches
6-12
4. Remove the screws securing the rear side panel
section to the cab enclosure. (fig. 6-12)
6-9
1. Remove the screws securing the forward side
panel to the operator enclosure. (fig. 6-9)
6-13
5. Disconnect any switches from the harness (unbolt
the heater control if removing left side) then
remove the panel from the machine (fig. 6-13)
6-10
2. Pull the side panel away from the cab as shown,
disconnect the gauges/switches from the wire harness, then remove it from the machine. (fig. 6-10)
6-14
6. If gauges need to be removed, remove the nuts
securing the bracket to the back of the gauge,
then remove the bracket and gauge from the
opposite sides of the panel. (fig. 6-14)
6-11
3. Remove the arm rests by first loosening the retaining bolts from the outside of the cab, then slide the
rests up and out from the inside. (fig. 6-11)
Side Panels/Gauges
Installation
1. To install the side panels or gauges, reverse the
removal procedure.
6-3
Rubber Track Loader
6. Operator Enclosure
Seat
Removal
Required Tools
Combination/Socket Wrench
6-18
5. Disconnect the harness and then remove the seat
from the machine. (fig. 6-18)
6-15
Installation
1. To install the seat, reverse the removal procedure.
1. Remove the bolts (2) securing the cab to the chassis. They are located inside the cab in the upper
front corners of the foot well. (fig. 6-15)
Rear Interior Panel
Removal
Required Tools
2. Raise and secure the cab as described on page 42 of this manual.
Phillips Type Screwdriver
6-19
6-16
3. Remove the four nuts securing the seat to the cab.
1. Remove the screws holding the rear panel to the
cab. (fig. 6-19)
6-20
6-17
4. Remove the seat partially to expose the seat
switch harness located behind the seat. (fig. 6-17)
2. Disconnect the rear power point from the harness,
then remove the panel from the cab. (fig. 6-20)
Installation
1. To re-install the rear interior panel, reverse the
removal procedure.
6-4
7. Chassis and Fuel Tank
Chapter Overview
Removal and Installation
This chapter provides information on the assembly and
disassembly of the chassis. If there is an issue that
requires troubleshooting, refer to Chapter 18,
Troubleshooting.
Removal and installation procedures are provided for
the following chassis components.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
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 Rubber 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 Rubber Track Loader.
Prior to performing any type of service work on a Rubber
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
•
•
•
•
•
Fuel Sending Unit
Fuel Tank
Footwell
Foot Throttle Assembly
Hood Assembly
Note: Procedures are provided for only those chassis components listed above. However, exploded parts diagrams
exist in the PT-70/80 Parts manual to serve as visual aids in
the assembly and disassembly of other chassis components.
Required Tools
Screwdriver
Combination/Socket Wrench
Fuel Sending Unit
Removal
Machine Preparation
Accidental machine starting can cause injury or death to personnel working on a Rubber 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 Rubber Track Loader.
1. Raise and support the lift arms as described on
page 4-1 of this manual.
2. Tilt and support the operator enclosure (cab) as
described on page 4-2 of this manual. (optional)
Fuel Sending Unit
Place a “Do Not Operate” tag prominently on the machine to
inform personnel that the machine is be-ing worked on.
7-1
3. Locate the fuel sending unit on the left side of the
machine in the upper front corner of the fuel tank.
(fig. 7-1)
4. Remove the nuts and associated hardware securing the leads to the sending unit. (fig. 7-1)
Note: Record the order of assembly and polarity of the
leads to ensure proper function when reassembled.
7-1
Rubber Track Loader
7. Chassis and Fuel Tank
Fuel Tank
Removal
Remove Screws
Required Tools
Screwdriver
Combination/Socket Wrench
1. Raise and support the lift arms as described on
page 4-1 of this manual.
2. Tilt and support the operator enclosure (cab) as
described on page 4-2 of this manual. (optional)
7-2
5. Remove the screws securing the fuel sending unit
to the tank. (fig. 7-2)
7-5
3. Loosen the hose clamps securing the vent hoses
to the left rear tank end. (fig. 7-5)
7-3
6. Remove the sending unit by pulling it through the
opening in the fuel tank. (fig. 7-3)
Installation
7-6
1. To install the fuel sending unit, reverse the removal
procedure. (See fig. 7-4 for terminal installation)
4. Disconnect and plug the hoses. (fig. 7-6)
-- Neg
Install First
+ Pos
Install Last
7-7
7-4
5. Remove the bolts securing the forward belly pan
and remove it from the machine. (fig. 7-7)
7-2
Rubber Track Loader
7. Chassis and Fuel Tank
7-8
6. Loosen the hose clamp securing the main fuel line
to the tank outlet in the front right corner of the
machine. (fig. 7-8)
7-11
9. Remove the bolts (3) securing the fuel tank to the
front mounting plate. (fig. 7-11)
7-12
7-9
7. Disconnect this line and drain the fuel into a suitable catch container. (fig. 7-9)
10. Now that the tank is loose and empty, loosen the
hose clamp and disconnect the filler tube from the
right rear end of the tank. (fig. 7-12)
Note: Collect and contain flammable liquids in suitable
containers. Dispose of all liquids in accordance with
local regulations and mandates.
out
7-13
7-10
8. Remove the bolts securing the fuel tank to the
fenders. (fig. 7-10)
up
11. Lift and remove the tank from the machine.
(fig. 7-13)
Installation
1. To install the fuel tank, reverse the removal procedure.
7-3
Rubber Track Loader
7. Chassis & Fuel Tank
Footwell
Bolts
Removal
Required Tools
Screwdriver
Combination/Socket Wrench
1. Raise and support the lift arms as described on
page 4-1 of this manual. (optional)
2. Tilt and support the operator enclosure (cab) as
described on page 4-2 of this manual.
7-16
5. Remove the bolts (4) securing the footwell assembly to the chassis. (fig. 7-16)
7-14
3. Remove the bolts (4) securing the foot pedal cover
to the pedal, then remove the cover. (fig. 7-14)
Ball Stud
7-17
Pry Off
6. Remove the footwell from the chassis as shown.
(fig. 7-17)
Installation
7-15
Throttle Cable
1. To install the footwell, reverse the removal procedure.
4. Pry the throttle cable off of the ball stud on the foot
pedal. (fig. 7-15)
7-4
Rubber Track Loader
7. Chassis & Fuel Tank
Foot Throttle Assembly
Hood Assembly
Removal
Removal
Required Tools
Screwdriver
Combination/Socket Wrench
Required Tools
Screwdriver
Combination/Socket Wrench
Note: The foot throttle assembly may be removed with
the footwell still installed in the machine.
1. Perform steps 3 and 4 of the footwell removal procedure on page 7-4.
Bolts
7-19
Pry Off
7-18
2. Remove the bolts (2) and associated hardware
securing the foot throttle assembly to the footwell.
(fig. 7-18)
Note: Record the order of assembly during removal to
ensure proper operation when re-installed.
7-20
1. Remove the bolts (4) securing the fluid filler tray
and hoses to the hood assembly. (fig. 7-19, 7-20)
3. Remove the foot throttle from the machine.
Installation
1. To install the foot throttle assembly, reverse the
removal procedure.
7-21
7-22
2. Remove the bolts (6) that secure the hood to the
chassis. (fig 7-21, 7-22)
7-5
Rubber Track Loader
7. Chassis & Fuel Tank
7-23
3. Have an assistant help you to remove the hood
assembly from the machine. (fig. 7-23)
7-24
4. Carefully set the hood assembly aside. (fig. 7-24)
Installation
1. To install the hood assembly, reverse the removal
procedure.
7-6
8. Radiator and Oil Cooler
Chapter Overview
Removal and Installation
This chapter provides information on the disassembly
and assembly of the radiator/oil cooler and associated
components. If there is an issue that requires troubleshooting, refer to chapter 18, Troubleshooting.
Removal and installation procedures are provided for
the following radiator/oil cooler components.
•
•
•
•
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in machine
damage, injury or death.
Fan Guard
Fan
Fan Shroud
Radiator/Oil Cooler
Note: Procedures are provided for only those radiator/oil
cooler components listed above. However, exploded parts
diagrams exist in the PT-70/80 Parts manuals to serve as
visual aids in the assembly and disassembly of other system
components.
Do not attempt to perform any type of repair or maintenance
on a Rubber 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 Rubber Track Loader.
Note: Refer to pages 3-1 and 3-2 for pictorial views of the filtering and cooling system components.
Prior to performing any type of service work on a Rubber
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
Fan Guard
Removal
Required Tools
Machine Preparation
Accidental machine starting can cause injury or death to personnel working on a Rubber Track Loader.
Combination Wrench
Socket Wrench
Socket Wrench Extension (optional)
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 Rubber Track Loader.
Place a “Do Not Operate” tag prominently on the machine to
inform personnel that the machine is be-ing worked on.
8-1
1. Remove the air cleaner end cap and elements to
provide clearance for guard removal. (fig. 1)
8-1
Rubber Track Loader
8. Radiator and Oil Cooler
Fan & Fan Shroud
Removal
Required Tools
Combination Wrench
Socket Wrench
8-2
8-5
8-3
1. Remove the bolts (2) securing the fuel pump/filter
assembly to the radiator support and lay it aside
over the bumper to allow clearance to remove the
shroud and fan. (fig. 8-5)
2. Remove bolts (5) securing the fan guard halves to
the fan shroud. (fig. 8-2, 8-3)
8-6
8-4
2. Remove the bolts (6) securing the radiator and
shroud to the radiator support. (fig. 8-6)
3. Remove both halves of the guard from the
machine. (LT side shown, fig. 8-4)
Installation
1. To install the fan guard halves, reverse the
removal procedure.
8-7
3. Push the shroud forward to allow access the fan
mounting bolts. (fig. 8-7)
8-2
Rubber Track Loader
8. Radiator and Oil Cooler
Radiator/Oil Cooler
Removal
Personal injury can result from exposure to hot
fluids and components. Allow the machine to
cool thoroughly before attempting any type of
service on the cooling or hydraulic systems.
Cooling system conditioner contains alkali.
Avoid contact with skin and eyes.
8-8
Note: Collect and contain liquids in suitable containers.
Dispose of all liquids according to local regulations and mandates.
Required Tools
Socket Wrench
Pliers
Screwdriver
Hydraulic Caps/Plugs (various sizes)
1. Perform the fan guard and fan/shroud removal procedures.
8-9
4. Remove the bolts securing the fan and spacer to
the engine, then remove the fan and spacer from
between the shroud and radiator as shown.
(fig. 8-8, 8-9)
8-11
2. Remove the bolts securing the rear belly plates to
the chassis and remove them. (fig. 8-11)
Catch Container
Drain Valve
8-10
5. Remove the radiator shroud from the machine.
(fig. 8-10)
8-12
Installation
1. To install the fan and fan shroud, reverse the
removal procedure.
3. Attach a piece of 3/8” fuel line to the drain valve,
outlet, then twist the valve control counter clockwise to drain the cooling system. (fig. 8-12)
8-3
Rubber Track Loader
8. Radiator and Oil Cooler
8-16
8-13
4. Remove the bolts (6) securing the outer shroud to
the chassis, then remove the shroud. (fig. 8-13)
8-17
8-14
7. Loosen the clamps securing the upper and lower
coolant hoses to the radiator, then disconnect the
hoses from the radiator. (fig. 8-16, 8-17)
5. Remove the upper hydraulic cooler hose. Cap or
plug the hose upon removal. (fig. 8-14)
8-18
8-15
6. Loosen and disconnect the lower hydraulic line
from the cooler. Cap and plug the line and cooler
opening upon disassembly. (fig. 8-15)
8. Tilt the radiator rearward and then remove it from
the machine. (fig. 8-18)
Installation
1. To install the radiator/oil cooler, reverse the
removal procedure.
8-4
9. Hydraulic Reservoir
Chapter Overview
Removal and Installation
This chapter provides removal and installation procedures for the hydraulic reservoir.
Removal and installation procedures are provided for
the following hydraulic components.
•
•
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in machine
damage, injury or death.
Hydraulic Reservoir (tank)
Suction Screen
Note: Procedures are provided for only those hydraulic components listed above. However, exploded parts diagrams
exist in the PT-70/80 Parts manuals to serve as visual aids in
the removal and installation of other system components.
Do not attempt to perform any type of repair or maintenance
on a Rubber 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 Rubber Track Loader.
Note: Refer to pages 3-1, 3-2 and 3-3 for additional
hydraulic circuit and system information.
Hydraulic Reservoir
Prior to performing any type of service work on a Rubber
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
Removal (in event of contamination)
Required Tools
Machine Preparation
Accidental machine starting can cause injury or death to personnel working on a Rubber 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 Rubber Track Loader.
Screwdriver
Combination/Socket Wrench
Pry Bar(s)
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 personal injury.
Place a “Do Not Operate” tag prominently on the machine to
inform personnel that the machine is be-ing worked on.
Note: Collect and contain liquids in suitable containers.
Dispose of all liquids according to local regulations and mandates.
NOTICE
During disassembly, plug and cap all hoses and fittings to
prevent system fluid loss or contamination.
9-1
Rubber Track Loader
9. Hydraulic Reservoir
1. Remove the center and rear belly pans from the
machine.
2. Drain the hydraulic fluid. Refer to page 4-16 for the
hydraulic fluid and filter change procedure.
3. Remove the engine as described on page 12-5 of
this manual.
Disconnect
4. Remove the auxiliary and drive pumps (for inspection, repair, or replacement) according to the procedures in section 11 of this manual.
9-4
6. Remove the clamps securing the quick attach hard
lines and the test port line that run from the pilot
generation block down the left side of the machine
to the engine compartment. (fig. 9-4)
9-1
9-5
7. Disconnect the quick attach hoses from the hard
lines (if equipped). (fig. 9-5)
9-2
Disconnect
9-6
8. Disconnect the quick attach and test port lines
from the pilot generation block. (fig. 9-6)
9-3
5. Disconnect the hoses and lines attached to the two
upright portions of the tank. (fig. 9-1, 9-2, 9-3)
9-2
Rubber Track Loader
9. Hydraulic Reservoir
9-7
9-10
9. Gently move the hard lines out of the way to allow
for reservoir removal then zip tie them to the motor
mount to keep them secure. (fig. 9-7)
9-8
10. Disconnect the bucket cylinder hoses from the
hard lines in the upper right portion of the engine
compartment. Remove all line clamps. (fig. 9-8)
9-11
12. Disconnect the bucket cylinder hard lines from the
lift arm control valve and then remove them from
the machine. (fig. 9-10, 9-11)
Retainer
9-9
11. Disconnect the lift cylinder hoses from the hard
lines to allow the bucket cylinder lines to be
removed. (fig. 9-9)
9-12
13. Remove the hose retainer or move it aside as
shown. (fig. 9-12)
9-3
Rubber Track Loader
9. Hydraulic Reservoir
9-16
9-13
14. Disconnect the main oil cooler line from the fitting
at the filter. (fig. 9-13)
16. Remove the clamps securing the auxiliary
hydraulic lines to the chassis. (fig. 9-16)
Disconnect
9-17
9-14
9-18
9-15
17. Disconnect the auxiliary hydraulic lines from the lift
arm control valve and the hoses leading to the
quick coupler lines on the lift arm. (fig. 9-17, 9-18)
15. Disconnect the main oil cooler line from the junction block, then remove it from the machine.
(fig. 9-14, 9-15)
9-4
Rubber Track Loader
9. Hydraulic Reservoir
9-19
9-22
fuel lines
20. Remove the auxiliary hydraulic tubes from the
machine.
9-20
18. Slide the two fuel lines through the chassis opening and into the engine compartment so that the
aux. hyd. tubes can be removed. (fig. 9-19, 9-20)
9-23
21. Disconnect the lower portions of the cab support
gas springs from the chassis. (fig. 9-23)
9-21
19. Disconnect the fuel sender from the main harness
at the connector.
Note: If there is anything else that is routed behind the
auxiliary hydraulic tubes that will prevent them from
being removed, disconnect or carefully remove these
items at this time to allow the tubes to be removed.
9-24
22. Label, then disconnect any control hoses coming
from the joysticks that are still attached to components to allow them to be pulled up through the
chassis opening for clearance. (fig. 9-24)
Note: Refer to the individual hydraulic component
removal and installation procedures if additional information is needed to properly connect hoses during
reassembly.
9-5
Rubber Track Loader
9. Hydraulic Reservoir
9-28
9-25
23. Remove the lower hose restraints to allow the
hoses to be pulled through the chassis. (fig. 9-25)
26. Remove the bolts securing the metal tank restraint
straps, them remove them from the machine.
(fig. 9-28)
9-26
9-29
24. Pull the hoses up through the chassis opening and
lay them aside as shown (both sides). (fig. 9-26)
27. Slide the quick attach and test port tubes forward
so that they do not interfere with the reservoir
(tank) moving upwards in the chassis. (fig. 9-29)
9-27
25. Disconnect the wiring running through the hose
passageway and pull it through the opening as
shown. (fig. 9-27)
9-30
28. Slide the various control hoses to the side of the
reservoir (tank) so that they do not interfere with
the tank moving upwards in the chassis. (fig. 9-30)
9-6
Rubber Track Loader
9. Hydraulic Reservoir
29. Make sure there is nothing that would visibly prevent the reservoir from being removed or is still
attached to other components within the machine,
then proceed.
Reservoir
Pry-bar
9-31
30. Use a long pry bar to pry the tank upward and
rearward from the front as shown. (fig. 9-31)
Note: You may need to pry the tank upwards within
the chassis from the rear if it isn’t already to prepare
the tank to be moved in step 30.
9-34
31. Once the tank is over the axle mounts lift and
remove it from the chassis as shown. (fig. 9-32, 933, 9-34)
Installation
1. To install the hydraulic reservoir, reverse the
removal procedure.
Note: The only service issue warranting the removal of
the reservoir is hydraulic system contamination. Upon
installation, the tank must be clean and free of any dirt
or debris that may contaminate the hydraulic oil. If you
are unable to successfully flush the tank clean of all
dirt or debris, replace the tank.
9-32
9-33
9-7
Rubber Track Loader
9. Hydraulic Reservoir
Suction Screen
Suction screen
Removal
Required Tools
Small Pry Bar (hose removal if necessary)
Socket Wrench & Extension
Combination Wrenches (to remove lines)
Note: The suction screen may be removed with the
reservoir (tank) still in the machine. If this is necessary,
remove the center belly pan and tilt and support the
cab to gain access, then follow the procedure
described below to remove the suction screen.
1. If the tank is still in the machine, drain the
hydraulic fluid as described on page 4-16 of this
manual.
2. If the tank is still in the machine,
remove/disconnect any hoses connected to the
flange weldment that may interfere with removal.
9-37
4. Slide the assembly out of the reservoir as shown
in fig. 9-36 and 9-37.
5. The suction screen is now accessible for inspection or replacement.
Note: If removal is necessary, thread the suction
screen off of the flange weldment and remove.
Installation
1. To install the suction screen, reverse the removal
procedure.
Note: It is important to inspect the screen for pieces of
metal or other debris that may have been generated by
a worn or defective component. If there is debris present on the screen, the hydraulic system (including the
reservoir) must be flushed clean to remove any and all
contamination (debris). The screen should be replaced
as well as any components found to be defective.
9-35
3. Remove the bolts securing the flange to the
hydraulic reservoir. (fig. 9-35)
o-ring
9-36
9-8
10. Lift-Arm/Drive Controls
Chapter Overview
Removal and Installation
This chapter provides removal and installation procedures for the lift-arm and drive control components.
Removal and installation procedures are provided for
the following lift-arm/drive control components.
•
•
•
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
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 Rubber 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 Rubber Track Loader.
Prior to performing any type of service work on a Rubber
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
Pilot Control Joystick
Lift Arm Float Magnet
Lift Arm Control (loader) Valve
Note: Procedures are provided for only those lift-arm/drive
control components listed above. However, exploded parts
diagrams exist in the PT-70/80 Parts manuals to serve as
visual aids in the assembly and disassembly of other system
components.
Note: Refer to page 3-2 and 3-3 for pictorial views of the
hydraulic auxiliary and drive systems and components.
Pilot Control Joystick
Removal
Machine Preparation
Accidental machine starting can cause injury or death to personnel working on a Rubber 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 Rubber Track Loader.
Place a “Do Not Operate” tag prominently on the machine to
inform personnel that the machine is be-ing worked on.
Required Tools
Side Cutter
Combination/Open End/Socket Wrenches
Hydraulic Caps/Plugs (various sizes)
Note: The procedures for removing and installing the right
and left joysticks are basically identical. As a result, only the
procedures for the right joystick are described in this section.
NOTICE
Cap and plug all fittings and hoses to prevent fluid loss
and or contamination during service work.
Remove any attachment, lower the lift arms and
make sure the hydraulic oil is cool before
removing any components or lines. Hot or
pressurized oil can cause personal injury.
10-1
Rubber Track Loader
10. Lift-Arm/Drive Controls
1. Relax all hydraulic actuators to relieve pressure in
the hydraulic system prior to service.
2. Turn the ignition switch to the OFF position,
remove the key and disconnect the battery to
avoid accidental start.
Remove (optional)
3. Perform the interior side panel removal procedure
that addresses the joystick you plan to remove in
chapter 6 of this manual.
10-3
5. Remove the bolts (3) securing the joystick mounting bracket to the cab from the outside. (fig. 10-3)
(optional)
6. Label the hydraulic hoses to aid in reassembly
(see page 3-7 or 3-8 for routing and identification).
10-1
4. Expose and cut the zip tie securing the lower portion of the boot to the joystick body, then lift it
upwards. (figure 10-1)
10-4
Magnet
10-5
10-2
7. Disconnect the hydraulic hoses from the various
joystick fittings and lay them aside. (fig. 10-4,10-5)
Note: The float magnet is now exposed as well as the
mounting bolts securing the joystick to the bracket.
(figure 10-2)
10-6
8. Disconnect all connectors coming from the joystick
harness. (fig. 10-6)
10-2
Rubber Track Loader
10. Lift-Arm/Drive Controls
Lift Arm Float Magnet
Removal
Required Tools
Fittings
Socket Wrench
Combination/Open End Wrench
Allen Wrench
1. Perform steps 3, 4 and 11 of the lift arm joystick
control removal process.
10-7
9. Remove the fittings on the back of the joystick (lift
arm control joystick only). (fig. 10-7)
10-10
2. Remove the allen bolt from the underside of the
magnet. (fig. 10-10)
10-8
10. Remove the bolts and nuts securing the joystick to
the mounting bracket. (fig. 10-8)
3. Disconnect the magnet harness connector from
the machine.
10-11
10-9
11. Lift the joystick through the opening in the bracket
and remove it from the machine. (fig. 10-9)
Installation
1. To install the joystick, reverse the removal procedure.
4. Lift the joystick within the bracket slightly, then pull
the magnet harness and connector through the
bracket past the joystick to remove it. (fig. 10-11)
Installation
1. To install the float magnet, reverse the removal
procedure.
10-3
Rubber Track Loader
10. Lift-Arm/Drive Controls
Lift Arm Control Valve
Removal
Required Tools
Socket Wrench
Combination/Open End Wrench
Screwdriver (hose clamps)
1. Perform the footwell removal procedure on page 74 of this manual.
10-15
2. Drain the hydraulic system as described on page
4-16 of this manual.
10-16
10-12
3. Label all lines and hoses as necessary to aid in
reassembly. (fig. 10-12)
5. Disconnect all lines and hoses from the valve to
allow for removal. (figure 10-15, 10-16)
10-13
10-17
6. Remove the carriage bolts (3) securing the loader
valve to the chassis, Then remove the valve.
Note: The bolts have a square shank that mates with
a square hole in the chassis to keep them from rotating upon removal.
10-14
4. Disconnect the hose from the barb type fitting on
the auxiliary pump and the large hard line that
sweeps across the front of the pumps and connects to the filter head to provide additional clearance for line removal. (fig. 10-13, 10-14)
Installation
1. To install the lift arm control valve, reverse the
removal procedure.
10-4
11. Hydraulic Pumps/Motors
Chapter Overview
Removal and Installation
This chapter provides removal and installation procedures for the hydraulic pumps and motors.
Removal and installation procedures are provided for
the following hydraulic components.
• Charge Pump
• Auxiliary Pump
• Tandem (Drive) Pump
• Drive Motor
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
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 Rubber 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 Rubber Track Loader.
Prior to performing any type of service work on a Rubber
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
Note: Procedures are provided for only those hydraulic components listed above. However, exploded parts diagrams
exist in the PT-70/80 Parts manuals to serve as visual aids in
the removal and installation of other system components.
Note: Refer to pages 3-1, 3-2 and 3-3 for additional motor,
pump and hydraulic system information.
Charge Pump
Removal
Machine Preparation
Accidental machine starting can cause injury or death to personnel working on a Rubber 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 Rubber Track Loader.
Required Tools
Screwdriver
Combination Wrench
Socket Wrench
Remove any attachment, relax all actuators and
make sure the hydraulic oil is cool before
removing any components or lines. Hot or
pressurized oil can cause personal injury.
Place a “Do Not Operate” tag prominently on the machine to
inform personnel that the machine is be-ing worked on.
NOTICE
The hydraulic system fluid should be changed following
any hydraulic component service according
to the procedure described on page 4-16.
Note: Collect and contain liquids in suitable containers.
Dispose of all liquids according to local regulations and mandates.
NOTICE
During disassembly, plug and cap all hoses and fittings to
prevent system fluid loss or contamination.
11-1
Rubber Track Loader
11. Hydraulic Pumps/Motors
1. Lower the lift arms to the ground and relax the
bucket tilt/curl cylinders to relieve pressure within
the hydraulic system.
2. Turn the ignition switch to the OFF position and
remove the key to avoid accidental start.
3. Drain the hydraulic fluid. Refer to page 4-16 for the
hydraulic fluid and filter change procedure.
4. Raise the hood at the rear of the machine.
Upper Hose
11-3
8. Remove the charge pump from the engine. (fig.
11-3)
Installation
Gasket
Lower Hose
11-1
5. Disconnect the hose from the upper charge pump
fitting. (fig. 11-1)
6. Loosen the hose clamp and disconnect the hose
from the barb type inlet tube on the underside of
the charge pump. (fig. 11-1)
1. To install the charge pump, reverse the removal
procedure.
Note: The front bearing on the charge pump uses
engine oil for lubrication. It must be kept extremely
clean. Make sure to shield it as well as the opening to
the engine from dirt or debris while disassembled.
The gasket that seals the pump to the engine housing
should be replaced whenever the charge pump is
removed and installed to prevent oil leaks and or
dirt/debris from entering the engine during operation.
Bolt
11-2
7. Remove the upper and lower 12 point bolts securing the charge pump to the engine. (fig. 11-2)
11-2
Rubber Track Loader
11. Hydraulic Pumps/Motors
Auxiliary Pump
Removal
Required Tools
Combination Wrench
Socket Wrench & Extension
Pry bar
Allen socket
11-6
4. Loosen the clamp securing the hose onto the
barbed fitting on the right side of the pump, then
disconnect it. (fig. 11-6)
11-4
1. Loosen the bolts securing the spilt flange clamp to
the upper front port on the aux. pump. (fig. 11-4)
Weldment
2. Remove the clamp and lay the hose aside.
11-7
5. Loosen the clamps securing the hoses to the inlet
weldment attached to the bottom of the pump. (fig.
11-7)
11-5
3. Disconnect the hose connected to the relief valve
assembly and lay it aside. (fig. 11-5)
11-8
6. Loosen and remove the split flange clamp securing
the inlet weldment to the bottom of the pump similarly to the one previously removed on the top of
the pump. (fig. 11-8)
11-3
Rubber Track Loader
11. Hydraulic Pumps/Motors
Tandem (Drive) Pump
Removal
Required Tools
Screwdriver
Combination/Open End Wrenches
Personal injury can result from exposure to hot
fluids and components. Allow the machine to
cool thoroughly before attempting any type of
service on the cooling or hydraulic systems.
11-9
Note: Collect and contain liquids in a suitable container.
Dispose of all fluids according to local regulations and mandates.
7. Use a pry-bar to pry the inlet weldment out of the
hoses. (This can be difficult, lubricating the inlet
tubes with a penetrating lubricant may make
removal easier.) (fig. 11-9)
NOTICE
During disassembly, plug and cap hoses and fittings to
prevent fluid loss and or contamination.
1. Perform the auxiliary pump removal procedure on
page 11-3 of this manual.
11-10
8. Remove the upper and lower pump mounting bolts
with an allen socket and extension. You may need
to separate the pumps slightly to remove the bolts
completely. (fig. 11-10)
11-12
2. Label and disconnect all hoses from the tandem
drive pump. (fig. 11-12, 11-13, 11-14, 11-15)
Note: You may need to remove the pump mounting
bolts and twist the pump to access and disconnect
some of the hoses connected to the drive pump.
Note: Use figures 11-13, 11-14, and 11-15 to aid in
hose removal and installation and identification.
11-11
9. Carefully remove the pump from the machine. (fig.
11-11)
Installation
1. To install the auxiliary pump, reverse the removal
procedure.
11-4
Rubber Track Loader
11. Hydraulic Pumps/Motors
Top & Bottom Drive Pump Hoses
To
Oil Cooler
(return)
TOP
BTM
BTM
BTM
BTM
To
Drive Motor
(RT)
From
Charge
Filter
BTM
To
Drive Motor
(LT)
FRONT
RIGHT
LEFT
REAR
• View is from the top.
• The pump is to be perceived as transparent.
• Ports are labeled top or bottom as they are on the pump.
11-13
11-16
3. Support the pump with a hoist or floor jack to prevent it from falling as the mounting bolts are
removed. (fig. 11-16)
Top & Bottom Control Hoses
E
TOP
C
BTM
Remove Bolts (2)
FRONT
F
TOP
D
BTM
RIGHT
LEFT
REAR
11-14
• View is from the top.
• The pump is to be perceived as transparent.
• Ports are labeled top or bottom as they are on the pump.
Side Drive Pump Hoses
11-17
4. Remove the upper and lower mounting bolts from
the drive pump. (fig. 11-17)
From
Pilot Gen
Block
To
Pilot Gen
Block
FRONT
RIGHT
LEFT
11-15
• View is from the top.
REAR
11-18
5. Remove the drive pump from the machine.
Installation
1. To install the drive pump, reverse the removal procedure.
Note: Torque the tandem pump mounting bolts to 85 lb. ft.
(115 Nm) and use blue Loc-tite or equivalent to secure the
bolts in position.
11-5
Rubber Track Loader
11. Hydraulic Pumps/Motors
Drive Motor
Removal
Required Tools
Combination/Socket Wrench
Impact Wrench
3-Jaw Puller
Snap Ring Pliers
Hammer/Mallet
1. Remove the track from the undercarriage by performing the track removal procedure on page 4-6
of this manual.
Remove Bolts
11-21
4. Remove the bearing support plate from the undercarriage. (fig. 11-21)
11-19
2. Remove the three bolts securing the outer bearing
support plate to the drive table. (fig. 11-19)
11-22
5. Use a hammer to drive a screwdriver in along the
edge of the rubber cap, then pry the cap out as
shown. (the cap must be replaced after service)
11-20
3. Remove the four bolts securing the outer bearing
support plate to the bearing assembly. (fig. 11-20)
11-23
6. Remove the bearing cap from the assembly. (fig.
11-23)
11-6
Rubber Track Loader
11. Hydraulic Pumps/Motors
11-27
11-24
7. Remove the snap ring securing the bearing
assembly to the outer sprocket shaft. (fig. 11-24)
10. Remove the sprocket assembly from the undercarriage. (fig. 11-27)
11-28
11-25
8. Use a jaw style puller and an impact wrench to
remove the bearing assembly from the sprocket
shaft. (fig. 11-25)
11. Remove the bolts securing the drive motor to the
drive table. (fig. 11-28)
11-29
11-26
9. Remove the bolts securing the sprocket to the
drive motor. (fig. 11-26)
12. Lift the drive motor straight upward until it clears
the drive table, then forward to expose the
hydraulic hoses for removal. (fig. 11-29)
Note: There are two large bolts near the front of the
drive motor support securing it to the lower drive table
from the inside (near the chassis). Remove these bolts
prior to lifting the motor to provide additional clearance
for the hoses as you lift the motor upward. (fig. 11-29)
11-7
Rubber Track Loader
11. Hydraulic Pumps/Motors
11-30
13. Note the orientation of the hoses as they are connected to the drive motor. Label them to ensure
correct installation and proper orientation during
reassembly. (fig. 11-30)
11-31
14. Disconnect the hoses from the drive motor making
sure to cap and plug all openings to avoid contamination. Remove the drive motor from the undercarriage. (fig. 11-31)
Installation
1. To install the drive motor into the undercarriage,
reverse the removal procedure.
11-8
12. Engine
Chapter Overview
Removal and Installation
This chapter provides procedures for the removal and
installation of the engine and associated components.
Removal and installation procedures are provided for
the following engine related components.
•
•
•
•
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
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 Rubber 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 Rubber Track Loader.
Battery
Exhaust
Air Cleaner
Engine
Note: Procedures are provided for only those engine associated components listed above. However, exploded parts diagrams exist in the PT-70/80 parts manuals to serve as visual
aids in the assembly and disassembly of other system components.
Battery
Prior to performing any type of service work on a Rubber
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
Removal
Machine Preparation
Accidental machine starting can cause injury or death to personnel working on a Rubber 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 Rubber Track Loader.
12-1
Place a “Do Not Operate” tag prominently on the machine to
inform personnel that the machine is be-ing worked on.
1. Open the hood at the rear of the machine.
2. Disconnect the negative and positive battery
cables from the battery terminals. (fig. 12-1)
12-2
3. Remove the wingnuts securing the battery hold
down strap. (fig. 12-2)
12-1
Rubber Track Loader
12. Engine
Exhaust System
Removal
Required Tools
Pry Bar(s)
Combination/Socket Wrench
Rubber Mallot
Penetrating Lubricant
12-3
The exhaust system is very hot at operating temperature. Make sure the machine is
off and cool before attempting to service
the exhaust system.
4. Remove the two tension (L) rods by twisting and
maneuvering them out of the chassis mounting
holes. (fig. 12-3)
12-6
12-4
1. Perform the radiator/oil cooler removal procedure
on page 8-3 to provide access to the exhaust system components.
5. Lift and remove the battery from the battery tray.
(fig. 12-4)
12-7
2. Remove the bolts securing the rear belly pan and
remove it from the machine. (fig. 12-6)
3. Remove the nuts securing the head-pipe to the
turbo, then pull it away from the studs. (fig. 12-7)
12-5
6. If necessary, remove the battery tray by sliding it
upwards and then pulling it away from the chassis.
(fig. 12-5)
Installation
1. To install the battery, reverse the removal procedure.
12-2
Rubber Track Loader
12. Engine
Spring
12-8
12-11
4. Remove the tension springs that secure the middle
pipe section to the head (upper) pipe and muffler
inlet (lower) pipe. (fig. 12-8)
7. Remove the inlet pipe from the muffler. It may be
necessary to use levers to force the inlet pipe section out of the muffler. (fig. 12-11)
Note: Use caution not to damage the pipe or connection point during removal.
12-9
5. Remove the upper and middle pipe sections from
the machine. (fig. 12-9)
12-12
8. Remove the tail pipes from the muffler. If necessary, tap the pipes lightly with a rubber mallot or
dead blow hammer to loosen the joints. (fig. 12-12)
Note: Use caution when striking the pipes with a mallot. The pipes are easily damaged and may be disfigured by the blows.
12-10
6. Remove the clamps that secure the inlet and outlet
pipes to the muffler. (fig. 12-10)
Note: Thoroughly coat all clamped exhaust pipe joints
with a penetrating lubricant prior to attempting to
remove the pipe sections from the muffler. This will
make removal significantly easier.
12-13
9. Remove the four bolts (and nuts) securing the muffler to the chassis, then remove the muffler. (fig,
12-13).
12-3
Rubber Track Loader
12. Engine
Air Cleaner
Removal
Required Tools
Combination Wrenches
Socket Wrench & Extension
12-14
10. You may now remove the tail pipes by sliding them
forward within the chassis, then out. (fig, 12-14).
Installation
12-15
1. To install the exhaust system, reverse the removal
procedure.
1. Remove the cover and the filter elements from the
air cleaner assembly. (fig. 12-15)
12-16
2. Loosen the clamp securing the intake hose to the
air cleaner housing. (fig. 12-16)
12-17
3. Remove the bolts and nuts securing the air cleaner
housing to the chassis. (fig. 12-17)
12-4
Rubber Track Loader
12. Engine
Engine
Removal
Required Tools
Combination/Socket Wrenches
Angle Iron or Similar (approx. 43” / 109cm long)
Tie Down or Ratchet Strap
Forklift/Engine Hoist
Pry Bar
12-18
4. Remove the air cleaner housing from the machine.
(fig. 12-18)
1. Perform the battery, air cleaner, and charge pump,
removal procedures in sections 11 and 12 of this
manual prior to starting this procedure.
Installation
2. Remove the hood assembly as described on page
7-5 of this manual.
1. To install the air cleaner assembly, reverse the
removal procedure.
3. Raise and support the operator enclosure (cab) as
described on page 4-2 of this manual.
4. Perform steps 2-7 of the exhaust removal procedure on page 12-2 of this manual.
5. Remove the center belly pan from the machine.
12-19
6. Remove the front motor mount bolts (2) from the
machine. (fig. 12-19)
12-20
7. Remove the rear motor mount bolts (2) from the
machine. (fig. 12-20)
12-5
Rubber Track Loader
12. Engine
Ballstud
Bolts
Cable
12-24
12-21
8. Disconnect the throttle cable from the engine.
Note: Once loose, you may want to pull the throttle
cable forward through the chassis to make sure it is
clear of the engine during removal.
Engine
11. Disconnect the case drain filter and bracket from
the engine adapter plate and lay it aside. It is situated beneath the drive pump. (fig. 12-24)
Bolts
Wire Harness
Restraint
Restraint
12-25
12-22
Rear Axle
12. Remove the two bolts securing the drive pump to
the engine adapter plate. (fig. 12-25)
9. Disconnect the cable restraints holding the wire
harness to the lower chassis crossmember.
(fig. 12-22)
12-26
12-23
13. Loosen and disconnect the fuel lines (2) from the
engine. (fig. 12-26)
10. Disconnect the wire harness connections in the
upper right hand portion of the engine compartment. (when viewed from the rear) (fig. 12-23)
12-6
Rubber Track Loader
12. Engine
12-27
12-31
14. Lay the angle iron across the fenders (or fuel tank
if still in place) and attach one or two tie down
straps to serve as a sling to hold the hydraulic
pumps up in position during engine removal. (fig.
12-27)
Note: The rear cab window is directly over the lift point
of the engine. It is important to use an engine lifting
device that is low in profile and can reach forward
between the engine and chassis (as shown in fig. 1230) or the rear window could be damaged. (fig. 12-31)
12-28
15. Disconnect the ground strap from the upper crossmember. (fig. 12-28)
12-32
18. Slide the engine rearward to clear the forward
motor mounts, then up and out between the radiator supports. (fig. 12-32)
12-29
Installation
1. To install the engine, reverse the removal procedure.
16. Attach a lifting chain or cable to the lift points on
the engine. (fig. 12-29)
Note: When reinstalling the engine, lightly grease the
rubber motor mount surfaces to allow the engine to
slide onto them without snagging or disfiguring them.
NOTICE
Once the engine has been installed, make sure to
properly reconnect and install all items removed during
engine removal to ensure proper operation.
12-30
17. Attach a device capable of safely lifting the engine
to the lifting chain as shown. (fig. 12-30) (see note)
Prior to starting, make sure all fluids are at appropriate
levels and that they have not been contaminated with
dirt or debris during service. Change fluids or adjust
fluid levels as needed to ensure proper operation.
12-7
12-8
13. Undercarriage
Chapter Overview
Removal and Installation
This chapter provides removal and installation procedures for the undercarriages.
Removal and installation procedures are provided for
the following undercarriage components.
• Idler Wheels (Removal and installation)
• Bogie Wheels (Removal and installation)
• Hub Assembly Service Procedures
Note: For track removal and installation procedures, refer to
pages 4-6 through 4-9 of this manual.
Note: For drive sprocket removal and roller inspection and
replacement, refer to page 4-5 of this manual.
Note: Procedures are provided for only those components
listed above. However, exploded parts diagrams exist in the
PT-70/80 parts manuals to serve as visual aids in the
removal and installation of other system components.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in machine
damage, injury or death.
15” Idler Wheel
Do not attempt to perform any type of repair or maintenance
on a Rubber 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 Rubber Track Loader.
Prior to performing any type of service work on a Rubber
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 Rubber Track Loader.
Note: The 15” idler and 10” bogie wheels may be
removed from the PT-70/80 undercarriages without
removing the tracks.
Removal
Required Tools
Socket/impact wrench
Heavy duty hydraulic jack
Combination wrench
Terex approved jack stands (2)
Shop vac or Pressure washer
1. Raise and support the machine by following the
jacking procedure on page 4-2.
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 Rubber Track Loader.
Place a “Do Not Operate” tag prominently on the machine to
inform personnel that the machine is be-ing worked on.
Cavity
13-1
2. Break up and remove any foreign material from the
cavity between the suspension rail and the drive
table support. (fig. 13-1)
Note: A shop vac or pressure washer will work well to
remove material from this cavity.
13-1
Rubber Track Loader
13. Undercarriage
3. Clean the threads on the turnbuckle thoroughly
using a stiff bristle brush.
13-2
13-6
7. Remove the outer scraper plate from the suspension rail. (fig. 13-6)
13-3
13-7
4. Loosen the lock nut on the turnbuckle and spin it
to the end of the threaded shaft to allow clearance
when the drive table is lowered. (fig. 13-2)
5. Rotate the turnbuckle and lower the drive table as
far as it will go. (fig. 13-3)
13-8
13-4
8. Remove the bolts securing the inner wheel to the
hub, then remove the wheel. (fig. 13-7, 13-8)
9. Repeat this procedure as necessary to remove the
15” idler wheels throughout the undercarriage.
Note: To remove the 10” bogie wheels undercarriages,
refer to page 13-4 of this manual.
Installation
13-5
1. To install the 15” idler wheels, reverse the removal
procedure. Torque the wheel mounting bolts
upon installation to 90 +/- 10 Lb. Ft / 122 Nm.
6. Remove the bolts securing the outer wheel to
the hub. Then remove the wheel. (fig. 13-4, 13-5)
13-2
Rubber Track Loader
13. Undercarriage
10” & 15” Wheels (PT-70)
4. Repeat as necessary to remove the idler and
bogie wheels throughout the undercarriages.
Note: The 15” idler and 10” bogie wheels may be
removed from the PT-70 and PT-80 undercarriages
without removing the tracks.
Installation
Removal
Required Tools
Socket/impact wrench
Heavy duty hydraulic jack
Combination wrench
ASV approved jack stands (2)
Shop vac or Pressure washer
1. To install the idler wheels on the PT-70, reverse
the removal procedure. Torque the 15” wheel
mounting bolts upon installation to 90 +/- 10
Lb. Ft. Torque the 10” wheel mounting bolts
upon installation to 37 +/- 5 Lb. Ft.
1. Perform steps 1-5 of the PT-80 15” idler wheel
removal procedure on page 13-1.
Remove bolts
13-11
13-9
2. Remove the bolts securing the wheel to the hub.
(fig. 13-9)
13-12
13-10
3. Remove the wheel from the undercarriage.
(fig. 13-10)
Note: Steps 2 and 3 are accurate for the removal of
both the 10” and 15” wheels throughout the PT-70
undercarriages.
13-3
Rubber Track Loader
13. Undercarriage
Bogie Wheel (PT-80 only)
Removal & Service Procedure
Required Tools
Combination/Socket Wrenches (including Allen)
Press & Various Press Tooling
Torque Wrench
Bench Vise
13-12
4. The inner and or outer bogie wheels may now be
removed with an impact wrench and allen socket
as shown in (fig. 13-12). If necessary, clamp one
wheel in a vise to keep the axle from spinning
while you remove the bolts.
13-9
Note: The wheel assemblies in the PT machines use
metal face seals to keep dirt/debris out of the wheel
bearings. During wheel removal/replacement, it is necessary to remove, inspect and clean all components
prior to reassembly to ensure proper function.
1. Perform steps 1-5 of the 15” idler wheel removal
procedure on page 13-1 to loosen the track and
provide clearance for bogie wheel removal.
1/2 of face seal
Bolts
13-10
13-13
Hub
5. Remove both wheels from the hub. (fig. 13-13)
Note: Take care not to drop the metal face seal halves.
The sealing surfaces are surface ground and have an
extremely fine finish. If scratched or disfigured, the
seal will not function as intended.
13-11
2. Remove the outer plate securing the assemblies to
the shaft. (Most plates will be a two bolt design.
The one bolt version is shown here.) (fig. 13-9)
3. Loosen and remove the 4 bolts securing the bogie
assemblies together around the mounting shaft.
(fig. 13-10, 13-11)
Also, take care not to lose the keys for indexing the
wheels onto the shaft.
Note: Now is a good time to inspect the components
for damage or wear. If the bearings do not roll smoothly when rotated, replace them. If the seals appear worn
or damaged, replace them. If the wheels are worn or
damaged, replace them. If the components appear to
be in good working condition, you may reuse them.
13-4
Rubber Track Loader
13. Undercarriage
Sealing Surfaces
Face Seal Halves
13-14
Rubber Seals
13-17
6. Once the wheels have been removed, use a press
to push the axle and far side bearing out of the
hub as shown. (fig. 13-16, 13-17)
7. If it is necessary to remove the other bearing for
replacement, press it out as well. If not, you may
leave this bearing in the hub during cleaning.
13-15
Note: The metal face seals are a 4-piece design with
one rubber outer seal and one metal face seal fitted
into each wheel and one rubber outer seal and one
metal face seal fitted into each hub. As they are
assembled, the metal halves mate and ride against
each other on a thin layer of oil to seal out dirt and
debris. Figure 13-14 shows the various components
that make up a face seal. Figure 13-15 shows the seal
as a mated assembly.
13-18
8. Clean all parts (including wheels) thoroughly with
parts cleaning solution and dry them prior to
reassembly. Wipe the inner hub surfaces to
remove any solvent or oil residue. (fig. 13-18)
13-16
13-19
9. Reinstall the bearing and shaft into the hub as
found upon disassembly, then press the bearing
back into the hub over the shaft. (fig. 13-19)
13-5
Rubber Track Loader
13. Undercarriage
10. Disassemble and clean the face seals and their
rubber outer seals thoroughly, then wipe them dry
to ensure a good seal when assembled.
13-23A
13-20
11. Once the seals and hub have been thoroughly
cleaned and dried, reinstall the hub portion of the
face seal into the hub as shown. Make sure to
work the rubber seal down into place within the
hub (until it seats) to ensure a good seal.
(fig. 13-20)
13-23B
13. Once the seals are in place, wipe the mating surfaces of the face seals with a clean shop cloth and
alcohol in a circular motion ending in a gentle
sweep from the inside to the outside of the face
until clear of the face.This will ensure a clean mating surface and a good seal. (fig. 13-22, 13-23)
14. Apply a very thin coating of fresh 10W30 engine
oil onto the seal faces (faces only) in a circular
motion to provide lubrication and help them seal.
Seal Surfaces
13-21
12. Similarly, reinstall the wheel portion of the face
seal into the (clean) wheel. Make sure to work the
rubber seal down into place within the wheel (until
it seats) to ensure a good seal. (fig. 13-21)
13-24
15. Align the wheel hub and axle, then slide the wheel
back onto the axle/hub assembly as shown in figure 13-24.
13-25
16. Install the key into the opening in the axle/hub
assembly as shown. (fig. 13-25)
13-22
13-6
Rubber Track Loader
13. Undercarriage
13-26
13-30
17. Apply red (high strength) thread locking compound
to the wheel retaining bolt as shown. (fig. 13-26)
21. Remove the allen plug from the center of the hub
assembly and fill it with 2 ounces of Terex 10W-30
Heavy Duty Engine Oil. Then reinstall the plug.
(fig. 13-29, 13-30)
22. Repeat this procedure on the other half of the
bogie assembly if necessary prior to installing the
two halves back onto the undercarriage.
13-27
18. Install the bolt and tighten it. (fig. 13-27)
19. If you haven’t already, repeat steps 10-18 of this
procedure on the other side of the hub/wheel
assembly to secure the second wheel in place.
13-31
23. Place the rubber rods back into position on the
square shaft, then tape them in place to keep
them secure while installing the bogie assemblies
around them. (fig. 13-31)
13-28
20. Once the hub/wheel assembly is together as
shown, torque the wheel retaining bolts to 180 ft.
lbs. / 244 Nm to secure them in place. (fig. 13-28)
24. Reverse steps 1-3 of this procedure to reinstall the
bogie assembly back onto the undercarriage and
complete the procedure.
25. Repeat this procedure as necessary throughout
the PT-80 undercarriage to restore proper function.
13-29
13-7
Rubber Track Loader
13. Undercarriage
Hub Tool Kits
PT-80: 0403-339
13-32
Idler Hub
Service Procedure PT-80
Note: If you are removing the outer or rear hub
assemblies you will be able to remove the hub assembly once step three is complete.
Required Tools
Socket Wrench & Sockets (including Allen)
Press & Tool Kit (PT-80: 0403-339)
Snap Ring Pliers
1. Remove the hub assemblies from the undercarriages as required first by following steps 1-7 of
the track removal procedure on page 4-6. Then
proceed to the steps below.
Part #: 0403-336
2. Remove the snap ring (item 25) securing the cap
(item 24) in the hub assembly. (fig. 13-32)
13-34
3. Remove the nut (item 23) and the washer (item
22), then remove the hub assembly from the axle
shaft. (fig. 13-32) (see note below)
Axle
13-35
13-33
Note: If you are removing the inner front hub assembly, you will have to slide the axle (item 41) out of the
main rail weldment to remove it. (fig. 13-32, 13-33)
4. Using a press and tool # 0403-336, press the
bearing sleeve out of the hub assembly. (fig. 1334, 13-35)
13-8
Rubber Track Loader
13. Undercarriage
Part #: 0403-337
Rear race
13-36
Part #: 0403-333
13-39
5. Remove the bearing out of the front of the hub as
shown. (fig. 13-36)
7. If bearings are to be replaced, press the rear bearing race out of the assembly from the front of the
hub with tools 0403-337 and 0403-333. (fig. 13-39)
Center seal
Front race
Part #: 0403-336
13-37
13-40
Part #: 0403-337
Part #: 0403-334
8. Press the bearing sleeve out of the rear bearing
using tool 0403-336. (fig. 13-40)
Center seal
Retaining ring
Front race
13-38
6. Press the center seal and front bearing race out of
the assembly from the rear of the hub using tools
0403-337 and 0403-334. (fig. 13-37, 13-38)
Note: The center seal will be destroyed during removal
and must be replaced upon reassembly.
13-41
9. Remove the face seals and retaining ring from the
bearing sleeve for cleaning and or replacement.
(fig. 13-41)
13-9
Rubber Track Loader
13. Undercarriage
Note: Take care not to drop the metal face seal halves.
The sealing surfaces are surface ground and have an
extremely fine finish. If scratched or disfigured, the
seal will not function as intended.
Note: Now is a good time to inspect the components
for damage or wear. If the bearings do not roll smoothly when rotated, replace them. If the seals appear worn
or damaged, replace them. If the wheels are worn or
damaged, replace them. If the components appear to
be in good working condition, you may reuse them.
10. Thoroughly clean all parts with parts cleaning solution and gently blow them clean with air if necessary, then wipe dry.
Part #: 0403-330
13-44
14. If the rear race has been removed, press it into the
hub from the rear until properly seated with tool #:
0403-330, then install the clean, dry bearing.
(fig. 13-44)
11. Disassemble and clean the face seals and their
rubber outer seals thoroughly, then wipe them dry
to ensure a good seal when assembled.
Part #: 0403-337
Part #: 0403-338
13-45
13-42
12. Once components are clean and dry, install half of
the rear face seal into the bearing sleeve. Make
sure to work the rubber seal down into place within
the seal recess (until it seats) to ensure a good
seal. (fig. 13-42)
13-46
15. Install the seal/retaining ring assembly into the rear
of the hub and press into place until seated using
the tools shown above. (fig. 13-45, 13-46)
13-43
13. Install the other half of the rear face seal into the
retaining ring. Make sure to work the rubber seal
down into place within the ring (until it seats) to
ensure a good seal. (fig. 13-43)
13-47
13-10
Rubber Track Loader
13. Undercarriage
Part #: 0403-335
13-48
13-51
16. Once the seals are in place, wipe the mating surfaces of the face seals with a clean shop cloth and
alcohol in a circular motion ending in a gentle
sweep from the inside to the outside of the face
until clear of the face.This will ensure a clean mating surface and a good seal. (fig. 13-47, 13-48)
19. Flip the hub over, support the bearing sleeve from
the bottom with tool 0403-335 and set it onto the
press for center seal installation. (fig. 13-51)
13-52
20. Install the center seal into the hub. Work the lip
around the bearing sleeve with your fingers prior
to pressing it into place. (fig. 13-52)
13-49
17. Apply a very thin coating of fresh 10W30 engine
oil onto the now clean seal faces (faces only) in a
circular motion. (fig. 13-49)
13-53
21. Install the race into the hub as shown above the
seal. When the race is pressed into place, it will
push the seal into position. (fig. 13-53)
13-50
18. Press the bearing sleeve assembly (with face seal
clean, installed, and oiled) into the hub with tool
0403-336 until seated. (fig. 13-50)
Note: See step 22 for tool information and race installation instructions.
13-11
Rubber Track Loader
13. Undercarriage
Part #: 0403-330
13-54
13-57
22. Press the outer bearing race into the hub with tool
# 0403-330 until it seats. (fig. 13-54)
26. Remove the allen plug in the center portion of the
hub. (fig. 13-57)
Part #: 0403-333
13-55
13-58
23. Pack the bearing with Terex Multi-Purpose EP
Lithium Grease and then install it onto the bearing
sleeve using tool 0403-333. (fig. 13-55)
27. Add 2 oz. of Terex 10W-30 Heavy Duty Engine Oil
to the hub as shown, then reinstall the plug and
tighten. (fig. 13-58)
24. Press it into the assembly until it gently seats into
the bearing race. (fig. 13-55)
13-59
13-56
25. If necessary, use a needle dispenser to fill any
places in the bearing that are not full of grease to
ensure adequate lubrication. (fig. 13-56)
28. The hub assembly is now ready to be reinstalled.
To install it onto the machine, reverse steps 1-3 on
page 13-7 of this procedure. Make sure to read
the note below step 3 prior to reinstalling.
(fig. 13-59)
29. Repeat this procedure throughout the undercarriage as necessary to repair worn or damaged
components and restore proper function.
13-12
14. Lift-Arm Components
Chapter Overview
Removal and Installation
This chapter provides removal and installation procedures for the lift-arm components.
Removal and installation procedures are provided for
the following lift-arm components.
•
•
•
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
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 Rubber 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 Rubber Track Loader.
Prior to performing any type of service work on a Rubber
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
Lift Cylinder
Bucket/Tilt Cylinder
Quick Coupler Block PRV
Note: Procedures are provided for only those lift-arm components listed above. However, exploded parts diagrams exist
in the PT-70/80 Parts manual to serve as visual aids in the
assembly and disassembly of other system components.
Note: Refer to page 3-1 through 3-3 for pictorial views of
the hydraulic systems and components.
Lift Cylinder
Removal
Machine Preparation
Accidental machine starting can cause injury or death to personnel working on a Rubber 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 Rubber Track Loader.
Place a “Do Not Operate” tag prominently on the machine to
inform personnel that the machine is be-ing worked on.
Required Tools
Combination/Open End/Socket Wrenches
Hydraulic Caps/Plugs (various sizes)
Terex Approved Jack Stand (or equivalent)
Pin Removal Tool (P/N: 2045-277)
NOTICE
Cap and plug all fittings and hoses to prevent fluid loss
and or contamination during service work.
Remove any attachment, lower or safely support the lift arms and make sure the hydraulic
oil is cool before removing any components or
lines. Hot or pressurized oil can cause personal injury.
NOTICE
The hydraulic system fluid should be changed following any hydraulic component service according to the
procedure described on page 4-16.
14-1
Rubber Track Loader
14. Lift-Arm Components
14-4
14-1
1. Rest the lift arms on an Terex approved jack stand
to provide clearance for lift cylinder removal. (fig.
14-1)
4. Remove the bolts securing the front and rear lift
arm cylinder pivot pins to the lift arm and lift arm
tower. (fig. 14-4)
14-5
5. Remove the grease fitting from the pivot pins to
allow the installation of the pin removal tool. (fig.
14-5)
14-2
2. Disconnect the inlet and outlet hoses from the
cylinder. (fig. 14-2)
14-6
6. Thread the removal tool into each pin, then use
the slide hammer to extract them. (fig. 14-6)
14-3
3. Label the hoses according to right and left orientation to simplify reassembly, then cap and plug the
hoses and fittings to prevent fluid loss and or system contamination. (fig. 14-3)
14-2
Rubber Track Loader
14. Lift-Arm Components
Bucket/Tilt Cylinder
Removal
Required Tools
Socket Wrench
Combination/Open End Wrench
Hammer
Punch (brass)
14-7
7. Remove the cylinder from the machine for service
or inspection. (fig. 14-7)
Note: At this time the pivot bushings and pivot pins are
easily accessible for replacement. Inspect them for visible wear or damage and replace them as necessary .
14-8
1. Raise the lift arms and support them with the lift
arm brace as described on page 4-1. (fig. 14-8)
Installation
1. To install the lift arm cylinder, reverse the removal
procedure.
14-9
2. Place a suitable catch container beneath the cylinder fittings, then disconnect the inlet and outlet
hoses from the cylinders. (fig. 14-9)
3. Cap and plug the hoses and fittings to prevent fluid
loss and or system contamination.
14-3
Rubber Track Loader
14. Lift-Arm Components
14-13
14-10
4. Remove the bolt securing the lower pin to the
quick attach. (fig. 14-10)
7. Use a pry bar to slide the lower pin out of the cylinder end allowing it to be removed. (fig. 14-13)
14-11
14-14
5. Remove the bolt securing the upper pin to the lift
arm weldment. (fig. 14-11)
Disconnect
8. Use a pry bar to pry the lower cylinder eyelet out
of the upper Q/A mount as shown. (fig. 14-14)
14-12
6. Disconnect the outer quick attach cylinder hose (if
equipped) to allow the lower pin to be removed.
(fig. 14-12)
14-15
9. Use a hammer and a brass punch to tap the upper
pin most of the way out of the lift arm weldment.
(fig. 14-15)
Note: Make sure to support the cylinder (have an
assistant support it if necessary) while removing the
upper pin to prevent it from falling and being damaged
or from causing injury to anyone standing underneath.
14-4
Rubber Track Loader
14. Lift-Arm Components
Quick Coupler Block PRV
Removal
Required Tools
Combination Wrench
14-16
10. Remove the pin from the cylinder while supporting
the cylinder. (fig. 14-16)
14-18
1. With the machine off and cool and with all
hydraulic actuators relaxed, loosen the pressure
release valve on the top of the auxiliary quick coupler block. (fig. 14-18)
14-17
11. Remove the cylinder from the machine. (fig. 14-17)
Installation
1. To install a bucket/tilt cylinder, reverse the removal
procedure.
14-19
2. Once loose, remove the valve from the block by
twisting it counter-clock-wise until free. (fig. 14-19)
Installation
1. To install the Q/C PRV, reverse the removal procedure.
14-5
14-6
15. Quick Attach
Chapter Overview
Removal and Installation
This chapter provides removal and installation procedures for the quick attach and associated components.
Removal and installation procedures are provided for
the following quick attach components.
•
•
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
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 Rubber 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 Rubber Track Loader.
Quick Attach locking Pin Assemblies
Quick Attach Pivot Pins
Note: Procedures are provided for only those quick attach
components listed above. However, exploded parts diagrams
exist in the PT-70/80 Parts manuals to serve as visual aids in
the assembly and disassembly of other system components.
Locking Pin Assembly
Removal
Required Tools
Combination/Open End/Socket Wrenches
Terex Approved Jack Stand (or equivalent)
Prior to performing any type of service work on a Rubber
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
Machine Preparation
Remove any attachment, lower or safely support the lift arms and make sure the hydraulic
oil is cool before removing any components or
lines. Hot or pressurized oil can cause personal injury.
Accidental machine starting can cause injury or death to personnel working on a Rubber 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 Rubber Track Loader.
Place a “Do Not Operate” tag prominently on the machine to
inform personnel that the machine is be-ing worked on.
15-1
1. Rest the lift arms on an Terex approved jack stand
to provide clearance for quick attach disassembly.
(fig. 15-1)
15-1
Rubber Track Loader
15. Quick Attach
Upper guard
15-5
15-2
5. Remove the pivot link from the quick attach.
(fig. 15-5)
2. Remove the bolts (3) securing the upper guard to
the quick attach weldment. (fig. 15-2)
Upper guard
15-6
6. Slide the locking pin assembly out of the quick
attach. (fig. 15-6)
15-3
3. Remove the upper guard from the quick attach.
(fig. 15-3)
15-7
Note: At this time the locking pin assembly components are easily accessible for replacement. Inspect
them for visible wear or damage and replace them as
necessary .
15-4
4. Remove the bolt securing the locking pin assembly
to the locking cylinder or latch handle. (fig. 15-4)
Pay attention to the quantity and position(s) of each
component to aid during reassembly. (fig. 15-7)
Installation
1. To install the quick attach locking pin assembly,
reverse the removal procedure.
15-2
Rubber Track Loader
15. Quick Attach
Pivot Pin (quick attach)
Removal
Required Tools
Combination/Open End/Socket Wrenches
Terex Approved Jack Stand (or equivalent)
Hammer
Punch (brass)
15-8
1. Rest the lift arms on an Terex approved jack stand
to provide clearance for quick attach disassembly.
(fig. 15-8)
Remove bolt & nut
Drive out
15-9
2. Remove the bolt securing the pivot pin to the quick
attach weldment, then drive the pin out with a
hammer and brass drift punch. (fig. 15-9)
Note: There are four pivot pins that connect the quick
attach to the lift arm and cylinders. All four pins are
removed in a similar manner.
Installation
1. To install the quick attach pivot pins, reverse the
removal procedure.
2. Repeat this process as necessary to remove and
replace worn or damaged quick attach pins.
15-3
15-4
NOTICE
16. Hydraulic Component
Service Procedures
Disassembly of hydraulic components should only be performed
by factory trained personnel experienced in the disassembly
and repair of hydraulic components. Components should not be
serviced during the warranty period without written instruction
from the Terex service department. Component disassembly
during this period may void the manufacturer’s warranty.
Chapter Overview
Disassembly & Assembly
This chapter provides information on inspection, disassembly and assembly of major hydraulic components.
Disassembly and assembly procedures are provided
for the following components:
• Hydraulic Cylinders
• Lift Arm Control Valve
• Drive motor
• Drive Pump
• Auxiliary Pump
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
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 Rubber 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 Rubber Track Loader.
Note: Procedures are provided for only those components
listed above. However, exploded parts diagrams exist in the
PT-70/80 parts manual to serve as visual aids in the assembly and disassembly of other system components.
Hydraulic Cylinder
Disassembly
Prior to performing any type of service work on a Rubber
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
When servicing any hydraulic component,
make sure the machine is off and cool and that
all of the hydraulic actuators are relaxed prior
to disconnecting or removing any component from the
system.
Required Tools
Bench Vise
Pipe Wrench
Socket or Impact Wrench
Screwdriver (blade type)
Rubber or Dead Blow Hammer
Small Pry Bar
NOTICE
When servicing any hydraulic component, keep in
mind that any scratches or damage that can be felt
with a fingernail on surfaces that parts move, slide, roll
or rotate upon indicate a need for part replacement.
Hydraulic components must be kept extremely clean to
ensure proper function and service life. Do not assemble any components that have not been inspected for
damage and thoroughly cleaned prior to assembly.
The hydraulic system fluid should be changed following any hydraulic component service according
to the procedure described on page 4-16.
16-1
1. With machine off and cool and with hydraulic actuators relaxed, disconnect and cap hoses from the
cylinder(s) to be serviced.
Note: When servicing cylinders, the attached components
must be supported in a manner that allows the cylinders to
be safely removed and installed. (lift arms & quick attach)
2. Remove the cylinder(s) and secure it in a bench
vise to aid in disassembly. (figure 16-1)
3. Place a suitable catch container beneath the rod
end of the cylinder to catch any hydraulic oil that
may leak out upon disassembly.
16-1
Rubber Track Loader
16. Hydraulic Component Service
Cylinder Tube Weldment
16-2
16-5
4. Use an open end or pipe wrench to turn and
remove the end gland. (figure 16-2)
7. With the piston and rod removed from the cylinder,
inspect the cylinder bore for scratches or other
damage. If any are present that are deep enough
to catch with your fingernail, the cylinder tube
weldment should be replaced. (figure 16-5)
End Gland
Rod
16-3
16-6
5. Use a pry bar or similar device to pull the rod and
piston from the cylinder. (figure 16-3)
8. Remove the nut from the rod end. (figure 16-6)
Piston
16-4
Ring
Seals
16-7
6. Inspect the piston surface, seals and ring for wear
or damage. If any component appears to be damaged in any way, replace it. When inspecting the
piston surface, look for scratches. If any are present that are deep enough to catch with your fingernail, the piston should be replaced. (figure 16-4)
Note: Seal imperfections or scratches on the piston, bore or
rod or will cause internal/external leakage and impaired function. Defective components must be repaired or replaced.
9. Support the piston loosely from the underside (figure 16-7), thread the nut partially on to protect the
threads and tap the rod end with a rubber or dead
blow hammer to free the piston from the rod.
10. Once loose, remove the nut and piston from the
rod.
16-2
Rubber Track Loader
16. Hydraulic Component Service
16-8
16-11
13. Remove the tandem seals from the end gland paying close attention to the order of removal to aid
during installation of the new seals. (fig. 16-11)
16-9
11. Remove the seals and piston ring taking care not
to scratch the piston. Also, pay close attention to
seal and ring orientation and position to aid when
installing new parts. (figures 16-8, 16-9)
16-12
14. Remove the inner seal from the end gland. Pay
attention to the seal orientation upon removal to
aid during installation of the new seal. (fig. 16-12)
15. Remove the end gland outer seal from the end
gland. (figure 16-10)
Outer Seal
16. Thoroughly clean all parts to prevent contamination of hydraulic oil when reinstalled.
Assembly
16-10
12. Gently tap the end gland off of the cylinder rod.
(figure 16-10)
1. Install new seals and components in place of the
originals paying close attention to orientation and
location to ensure proper operation.
2. Lubricate the piston, ring, and seals with fresh
hydraulic oil prior to assembly to avoid damage.
3. Reassemble components by reversing the disassembly process.
Note: During reassembly, use an impact wrench to tighten
the piston retaining lock nut. Make sure the nut is tight and
that there is no independent movement between the piston
and rod before reassembling.
16-3
Rubber Track Loader
16. Hydraulic Component Service
4. Remove each valve section and inspect the seals
for damage, replace if necessary. (figure 16-15)
Lift Arm Control Valve
Disassembly
Required Tools
Socket Wrench
Combination Wrench
Screwdriver (blade type)
Low Profile Needle Nose Pliers
O-ring
1. With machine off and cool and with hydraulic actuators relaxed, remove the lift arm control valve
according to the procedure on page 10-4.
16-16
2. Place the valve on a bench in a clean work area.
16-17
5. Remove the inlet port assemblies and inspect the
seals for damage, replace if necessary.
(figure 16-16, 16-17)
16-13
16-18
16-14
3. Remove the nuts holding the valve stack together.
(figure 16-13, 16-14)
6. Once the inlet port covers have been removed
from both sides of a spool, the spool may be
removed. (fig. 16-18)
O-ring
16-15
16-4
Rubber Track Loader
16. Hydraulic Component Service
16-22
16-19
8. Remove the spring from the spool. (fig. 16-22)
Note: Figure 16-19 displays the assembly order of the
spool and associated components.
Spool
Load Check
Spool
Spring
Cap
16-20
Note: The lift arm and bucket control spools are each
equipped with a unique load check spool. The load
check spools provide bucket positioning (self-Leveling).
The components can be seen above in figure 16-20.
16-23
9. Remove the load check spool with a low profile
needle nose pliers. (fig. 16-23)
The load check spools are similar, but they are not
identical. The main spools are also unique. All
spools must be reinstalled as found upon disassembly to function properly.
Clamp
16-24
16-21
Cap
Spool
7. To remove the load check spool, use a clamp to
hold the spool in place in a vice without damaging
the spool and remove the end cap with an allen
wrench. (fig. 16-21)
Note: There is a passageway in the load check spool
that must be kept clear to ensure proper operation. It
leads from the small hole in the side of the spool to the
end of the spool. If you cannot blow air through this
passageway, it must either be cleaned or the load
check spool must be replaced to restore proper function. (fig. 16-24)
16-5
Rubber Track Loader
16. Hydraulic Component Service
Assembly
Drive Motor (brake portion)
1. Install new seals and components in place of the
originals as necessary paying close attention to
location and orientation to ensure proper function.
Disassembly
2. Thoroughly clean all components to prevent system contamination.
3. Reassemble components by reversing the disassembly process.
Required Tools
Allen Wrench/Socket
Rubber Mallot (seal removal if needed)
Screwdriver (blade type) (seal removal if needed)
1. With machine off and cool and with hydraulic actuators relaxed, remove the drive motor from the
undercarriage by following the procedure in section 13.
16-25
2. Remove all but four of the allen bolts (on opposite
sides of the cover) holding the rear cover onto the
drive motor, then back the remaining four out
evenly to release the light spring pressure against
the cover. (fig. 16-25)
16-26
3. Remove the rear cover to expose the brake
assembly. (fig. 16-26)
16-6
Rubber Track Loader
16. Hydraulic Component Service
Shims
Seal
Bolts
16-27
Spring
16-30
4. Remove the brake spring and shims. Make sure to
note the order of assembly to ensure correct
reassembly. (fig. 16-27)
9. Inspect the seal for any damage. (fig. 16-30)
10. Remove the allen bolts securing the upper casting
to the drive motor. (fig. 16-30)
16-28
16-31
5. Insert an air nozzle into the port closest to the rear
of the pump as shown. (fig. 16-28)
11. Remove the upper casting from the drive motor to
expose the clutch discs. (fig. 16-31)
6. Cover the opening with a shop cloth and apply
moderate pressure to the top of the brake piston to
keep it in place when air is applied. (fig. 16-28)
7. Apply air to the port and the piston should slide
upwards so that it can be removed.
Note: There is a seal around the outer edge of the piston so it may pop loose rather than gently slide out.
16-32
12. Inspect the discs for discoloration (blueing) or for
signs of excessive wear. (fig. 16-32)
Note: If any of the individual discs measure less than
.015” (.38mm) replace them as a set.
Seal
Assembly
16-29
1. Replace worn or damaged components, thoroughly clean all parts, then reassemble the motor by
reversing the disassembly procedure.
8. Remove the piston from the motor. Inspect the
seal for any damage. (fig. 16-29)
16-7
Rubber Track Loader
16. Hydraulic Component Service
Drive Motor (motor portion)
Disassembly
Required Tools
Allen Wrench/Socket
Snap Ring Pliers
Screwdriver (blade type) (seal removal if needed)
Surfaces
16-36
3. Lift and remove the piston block to expose the
sealing surfaces. Inspect these surfaces to ensure
there is no scratching or abrasion that may affect
operation. (fig. 16-36)
16-33
Surfaces
1. Mark the casing across the parting lines as shown
to ensure correct reassembly of the drive motor.
(fig. 16-33)
Bolts
16-37
4. Inspect the surfaces of the cam ring and the piston
rollers for imperfections. Any damage found indicates a need for component replacement.
(fig. 16-37)
16-34
16-38
16-35
2. Remove the allen bolts securing the output end of
the drive motor to the main casting and remove it
from the motor as shown. (fig. 16-34, 16-35)
5. Using a snap ring pliers, remove the snap and
retaining rings on both sides of the piston block to
allow for removal and inspection of the block, pistons, piston rings, and rollers. (fig. 16-38)
16-8
Rubber Track Loader
16. Hydraulic Component Service
Drive Pump (Drive Relief Valves)
Disassembly & Adjustment
Required Tools
Allen Wrench/Socket
Combination/Socket wrench
1. With machine off and cool and with hydraulic actuators relaxed, remove the drive pump from the
machine by following the procedure in section 11.
16-39
Ring Groove
Ring
16-42
16-40
6. Once the snap rings and retainers are removed,
slide the piston assemblies out one at a time and
inspect them for damage. (fig. 16-39, 16-40)
16-43
Note: While inspecting the piston assemblies, pay
close attention to the piston ring. Look for any signs of
damage or cracking. (fig. 16-40)
2. Remove the drive pressure relief valves as shown
in fig. 16-42 and 16-43.
16-41
16-44
7. Inspect the rollers and sleeves as well to make
sure there are no scratches or other damage that
may affect operation.
3. If adjustment is needed (see drive pressure check
procedure in section 17), loosen the allen type set
screw on the valve.
Assembly
1. Replace worn or damaged components, thoroughly clean all parts, then reassemble the motor by
reversing the disassembly procedure.
16-9
Rubber Track Loader
16. Hydraulic Component Service
Drive Pump
Disassembly
Required Tools
Combination/Socket wrench
Allen Wrench/Socket
Rubber Mallot
Screwdriver (blade type)
Snap RIng Pliers
16-45
4. Flip the valve over, then tighten the nut to increase
the pressure setting (CW) or loosen it to decrease
the pressure setting (CCW).
Assembly & Test
1. Retighten the locking set screw and reinstall by
reversing the disassembly procedure. Retest the
pressure through the affected relief to check for
proper adjustment. If it is still not correct, repeat
the adjustment procedure until correct.
16-47
Note: The drive pump is a tandem design where two
pumps share one housing. The disassembly and
assembly procedures are identical for both pumps.
Drive Pump (Posi-Power Relief Valve)
Removal
1. Remove the allen bolts securing the end cap onto
the pump. (fig. 16-47)
Required Tools
Combination/Socket wrench
16-48
16-46
Note: The posi-power relief valve is usually a remove
and replace item. However, If adjustment is required,
please see the posi-power relief valve adjustment procedure in section 17 of this manual.
2. Remove the end of the pump as an assembly
(fig. 16-48)
1. Remove the valve from the drive pump as shown
in figure 16-46.
Installation
1. To install, reverse the removal procedure.
16-10
Rubber Track Loader
16. Hydraulic Component Service
Bearings
Swash Plate
16-49
16-52
3. Remove the valve plate and inspect it for damage
or wear, specifically, scratches that can be felt with
a fingernail. (fig. 16-49)
Surfaces
Barrel Face
16-53
5. Remove the swash plate along with the bearings
and inspect them for any damage or scratching
that could affect operation. (fig. 16-52, 16-53)
16-50
Slipper Faces
16-54
16-51
4. Inspect the end of the barrel (face) and the slipper
faces for similar scratches. (fig. 16-50, 16-51)
Note: To inspect the slipper faces, slide the barrel off
of the assembly, then slide the slippers and pistons off
of the shaft as an assembly, then inspect.
6. Remove the snap ring holding the shaft, seal and
bearing into the casing, then remove the seal.
(fig. 16-54)
Note: If you are repairing the existing pump, you will
need to replace the outer seal as it will be destroyed
upon removal.
16-11
Rubber Track Loader
16. Hydraulic Component Service
Drive Pump
Assembly
Required Tools
Combination/Socket wrench
Allen Wrench/Socket
Rubber Mallot
Screwdriver (blade type)
Snap RIng Pliers
16-55
7. Using a rubber mallot, gently tap the shaft and
bearing out of the casing for inspection or replacement. (fig. 16-55)
16-56
1. Using a rubber mallot, gently tap the shaft and
bearing into the casing until seated. (fig. 16-56)
16-57
2. Replace the seal with a new one and install taking
care not to damage it upon installation. (fig. 16-57)
3. Install the snap ring that secures the shaft, bearing, and seal in place. (fig. 16-57)
16-12
Rubber Track Loader
16. Hydraulic Component Service
16-58
16-61
4. Flip the assembly over and lay it on a table, then
remove the pivot caps from both sides as shown.
(fig. 16-58)
Note: Behind each cap is a pivot that aligns with the
two small pivot wires attached to the swash plate.
Remove these from their cavities while installing the
swash plate.
7. Once the pivots are installed, check to make sure
both of them are properly mated with the pins.
Using a blade type screwdriver, turn the pivots
slightly to the right or left. The swash plate should
move with the pivot as each one is turned. If it
does not move, repeat step 6, then recheck. Once
correct, reinstall the caps to secure them in place
(fig. 16-61)
Long end
Pin
16-59
16-62
5. Assemble the bearing halves to the bottom of the
swash plate, orient the pins so that they are vertical and then lower the assembly into place over
the shaft. (fig. 16-59)
8. Reassemble the piston and barrel portion of the
pump as found upon disassembly, then slide it
back into the housing. (fig. 16-62, 16-63)
Note: Make sure the long end of the swash plate
alignment bar is pointing inward to ensure proper operation. (fig. 16-62)
Pin
16-60
6. Once installed, make sure each pin is centered in
its opening, then slide the pivot into the hole so
that it mates with the pin. (fig. 16-60)
16-63
9. Reinstall and tighten the cover bolts to secure the
cover. (fig. 16-63)
16-13
Rubber Track Loader
16. Hydraulic Component Service
Auxiliary Pump
Disassembly
Required Tools
Allen Wrench/Socket
Snap Ring Pliers
O-ring
1. With machine off and cool and with hydraulic actuators relaxed, remove the drive pump from the
machine by following the procedure in section 11.
16-67
5. Lift the cover off to expose the pump components
and the o-ring seal. Inspect the o-ring for damage,
replace if necessary. (fig. 16-67)
16-64
Inspect Face
2. Remove the bolts securing the relief valve to the
housing. (fig. 16-64)
O-rings
16-68
6. Inspect the valve plate face (both sides) for
scratches or any other damage that can be felt
with a fingernail. (fig. 16-68)
16-65
Inspect Face
3. Inspect o-rings for proper shape and condition.
Replace if necessary. (fig. 16-65)
16-69
7. Inspect the barrel face for scratches or any other
damage that can be felt with a fingernail.
(fig. 16-69)
16-66
4. Remove the Allen bolts securing the cover onto the
pump. (fig. 16-66)
16-14
Rubber Track Loader
16. Hydraulic Component Service
Inspect Faces
16-70
8. Remove the piston/barrel assembly and inspect
the slipper faces for scratches or any other damage that can be felt with a fingernail. (fig. 16-70)
Assembly
1. To reassemble, reverse the disassembly procedure.
16-15
16-16
17. Hydraulic Pressure/Flow
Test & Troubleshooting
Chapter Overview
Hydraulic Pressure/Flow Test &
Troubleshooting Procedures
This chapter provides hydraulic pressure and flow
check, adjustment and troubleshooting procedures.
Test and troubleshooting procedures are provided for
the following Hydraulic system components.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
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 Rubber 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 Rubber Track Loader.
Prior to performing any type of service work on a Rubber
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
NOTICE
Hydraulic oil must be at operating temperature to
obtain accurate readings during the pressure and flow
test procedures described in this section. Start and
warm the engine and hydraulic oil prior to performing
the test and troubleshooting procedures in this section.
Contamination Inspection
The hydraulic system can become contaminated when
one or more of it’s dynamic components fails or begins
to wear excessively. This can introduce significant
amounts of debris into the hydraulic oil.
•
•
•
•
•
Charge Pressure Check & Adjustment
Auxiliary Valve Pressure Check & Adjustment
Lift Arm Pressure Check & Troubleshooting
Drive Pressure Check & Troubleshooting
Auxiliary Flow Test & Troubleshooting
When checking hydraulic system pressures, you are
essentially reading the relief valve settings of each circuit tested. If your hydraulic system and components
are functioning properly, your readings should match
those specified. If they differ, adjustment and or repair
may be required to restore proper function.
The procedures in this section are listed in the
order they are to be performed. When a pressure
issue is suspected, perform these procedures to help
diagnose and or repair the problem.
Charge Pressure Check
Charge pressure is used to prime the various circuits,
including the joysticks, with hydraulic oil for operation.
Low charge pressure could lead to sluggish operation
of any and all functions.
Required Tools
Pressure Gauge 0-1000p.s.i. (0-6895 kPa)
In the event of contamination, the defective component(s) must be replaced, the remaining components
must be inspected and thoroughly cleaned (if found to
be reusable) and the system lines and reservoir must
be thoroughly flushed to restore original function.
Test Port (A)
The hydraulic filters remove contaminants from the oil.
Small amounts of debris found within the filters are to
be expected, but If there is significant metallic debris
found in either filter, certain components of your
hydraulic system may be contaminated. To inspect for
contamination, label the hydraulic filters by location
and remove them. Cut them apart approx. halfway
between the top and bottom of the filter and inspect
them for debris. If contamination is suspected, contact
the Terex service department at 1-800-346-4367.
17-1
Note: The quick coupler (test port A) located in the engine
compartment just inside the left lift arm tower can be used for
general pressure checks and troubleshooting.
17-1
Rubber Track Loader
17. Hydraulic Pressure & Flow
1. Attach the gauge to test port A. (fig. 17-1) Route
the gauge so that you or an assistant can read it
during testing.
Charge Relief
2. Make sure any bystanders are clear of moving
components, then start the engine.
3. Allow the engine to warm up to operating temperature, then with the engine at idle, check the charge
pressure. Record your reading. It should read 475
+/- 30 psi (3275 kPa) at this test port. If your reading differs, adjustment is necessary.
17-2
4. If necessary, adjust the charge relief pressure.
To adjust:
a) Tilt the cab as described on page 4-2 of this
manual to access the pump.
b) Locate the charge relief valve on the top of the
drive pump. (fig. 17-2)
c) Remove the relief valve from the top of the
pump as shown in figure 17-3.
17-3
d) Add shims to increase the pressure setting, or
remove shims to decrease the setting until
within specification. (figure 17-4)
5. Retest once adjustments have been made to make
sure pressure is correct. Readjust as necessary
until correct.
17-4
17-2
Rubber Track Loader
17. Hydraulic Pressure & Flow
6. If necessary, adjust the relief settings on the auxiliary standby or high pressure valves. (figure 17-7)
To adjust:
a) Remove the cap covering the affected relief
valve.
Auxiliary Pressure Check
Required Tools
Pressure Gauges 0-1000 p.s.i. (0-6895 kPa) &
0-6000 p.s.i. (0-41370 kPa)
Auxiliary pressure is used to drive flow style attachments. Low auxiliary pressure can produce poor performance in attachments while high pressure can
cause component damage/failure in the machine or the
attachment being utilized.
b) Using an allen wrench, turn the adjustment
screw clockwise to increase the setting or
counter-clock wise to reduce it until within
specification.
Note: Make sure charge pressure is set correctly prior to
testing this function.
Test Port (B)
1. Tilt the cab as described on page 4-2 of this
manual to access the valve.
2. Locate the test port on the top of the lift arm control valve. (fig. 17-5)
3. Attach the low pressure hydraulic gauge to test
port (B) on the top of the valve. Route the gauge
so that you or an assistant can read the gauge
while performing the test procedures. (figure 17-5,
17-6)
17-5
4. Start the machine and with the auxiliary hydraulic
switch off (no functions activated) and the engine
at idle, you should read 218 psi (1503 kPa) at test
port (B).
5. Attach the high pressure gauge to test port B, then
activate the low or high flow auxiliary hydraulics
with no auxiliary attachment fastened to the quick
couplers. This action will send oil over relief and
you will read the actual pressures required to activate the relief valve for each circuit. Do this for
both the high and low flow circuits in both directions. Record the pressure readings.
17-6
Check your readings against those stated below. If
your readings differ, an adjustment and or repair may
be required.
High Pressure
Pressures should read: (at test port B)
• 218 +/- 10 PSI (1503 kPa) (standby).
• 3000 +/- 100 PSI (20680 kPa) Low Flow activated.
• 3000 +/- 100 PSI (20680 kPa) High Flow activated.
17-3
Standby
17-7
Rubber Track Loader
17. Hydraulic Pressure & Flow
Lift Arm Pressure Check
Drive Pressure Check
Required Tools
Pressure Gauge 0-6000 p.s.i. (0-41370 kPa)
Required Tools
Pressure Gauge 0-6000 p.s.i. (0-41370 kPa)
Lift arm pressure is used to lift loads or “break-out”.
Low lift arm pressure can produce a weak lift arm function while high lift arm pressure can damage lift arm
and hydraulic components.
Note: Make sure auxiliary circuit pressures are set correctly
prior to testing this function.
NOTICE
This procedure should only be performed if you suspect
a drive pump or drive motor is faulty. The procedure is
difficult and in performing it, you risk contaminating
your hydraulic system if your equipment and working
environment is not clean.
1. Attach a hydraulic gauge to test port B. Route the
gauge so that you or an assistant can read the
gauge while testing these functions. (figure 17-6)
Make certain all couplers, fittings and hoses used during
this process are clean and free of contaminants that may
potentially cause damage to the hydraulic pump and or
system components!
2. Raise the lift arms all the way up and continue
holding the joystick even when the lift arms stop.
Record the pressure readings. Then lower the lift
arms to the stops and continue holding the joystick. Record the pressure readings. Repeat this
process with the bucket dump/curl functions.
Drive pressure is used to turn the drive motors that
power your tracks. Low pressure can cause decreased
drive motor performance resulting in sluggish maneuvering, decreased speed and or uneven forward or
reverse motion.
3. Check your readings against those stated below. If
your readings differ, adjustment or repair may be
necessary. (figure 17-8)
1. Remove the plug from the port you would like to
test and insert a quick coupler similar to the one in
port A or B.
Pressures should read: (at test port B)
• 3000 +/- 100 PSI (20680 kPa) the lift arms or
bucket are in the up/curl position.
• 3000 +/- 100 PSI (20680 kPa) the lift arms or
bucket are in the down/dump position.
4. If any of the readings are low, reverse the function
and recheck. If reading is within specification in
that direction, replace the opposing relief valve.
Relief Valves
Port (B)
Note: There are 4 drive pump test ports. The left side ports
are shown in figure 17-10 and the right side ports are located
to the right of the drive ports they test.
2. Attach the hydraulic gauge to the port(s) you are
trying to test and route the gauge so you or an
assistant can read the gauge during testing.
3. Position the machine so that the lift arms are resting against the chassis stops and the front edge of
the bucket is facing, centered on and in contact
with an IMMOVABLE object.
4. Move the drive control fully forward in an attempt
to drive the machine forward. This will force oil
over the relief valve and give you a reading for the
circuit you are tapped into.
5. Attach a heavy-duty chain capable of restraining
the machine securely to the bucket and an
IMMOVABLE object.
6. Move the drive control fully rearward in an attempt
to drive the machine in reverse. This will force oil
over the relief valve and give you a reading for the
circuit you are tapped into.
17-8
Relief Valves
7. Check all four ports in this same manner and
record your readings.
17-4
Rubber Track Loader
17. Hydraulic Pressure & Flow
Check your readings against that stated below. If your
readings differ, relief replacement and or component
repair may be required.
Posi-Power Pressure Check
Posi-power is a function of the tandem drive pump
assembly. The posi-power control reads charge flow
(which is directly related to engine rpm) and adjusts
drive pump flow to maximize torque and prevent
engine stall during high load conditions.
Pressures should read:
• 5500 PSI (37920 kPa) the relief is reached in
attempted forward or reverse motion.
NOTICE
Drive pressure troubleshooting:
8. If one reading is low, swap the relief valve with a
similar one and recheck. If the reading improves,
replace the faulty relief valve.
This procedure should only be performed if you
suspect that the Posi-Power relief valve is faulty. In
performing this procedure you risk contaminating
your hydraulic system if your equipment and working environment is not clean.
9. If two readings are low, but on different circuits
(pumps), perform step 8 for both.
10. If both readings are low on one pump, disconnect
the drive hoses from the suspected ports and plug
them at the pump. Cap the hoses to prevent contamination and then recheck the pressures at
those ports. If the reading improves, the drive
motor is at fault. If the reading does not improve,
one pump (in the tandem assembly) is at fault.
Make certain all couplers, fittings and hoses used
during this process are clean and free of contaminants that may potentially cause damage to the
hydraulic pump and or system components!
11. If all 4 readings are low, it is unlikely that all four
relief valves are faulty. The tandem pumps are
most likely not working properly.
Posi-Power
Adjustment
Relief Valves
Posi-Power
Outlet
17-11
17-9
To check Posi-Power pressure:
1. With the engine off and cool, disconnect and cap
the posi-power outlet hose from the port on the top
of the drive pump assembly. (figure 17-11)
Test Ports
(see note)
2. Remove the fitting from the pump assembly and
install a quick coupler similar to the one installed in
test port A or B in its place.
3. Attach a gauge to the quick coupler and route it so
that you or an assistant can read the gauge during
operation.
17-10
4. Make sure all bystanders are clear of moving parts
and start the engine.
5. At low rpm, posi-power pressure should read 180
+/- 40 psi (1241 kPa). (475 +/- 40 (3275 kPa) at
high rpm)
17-5
Rubber Track Loader
17. Hydraulic Pressure & Flow
6. If your reading is low, remove the cap and loosen
the jam nut on the posi-power adjustment screw
and turn it counter clockwise until it stops then
retighten the jam nut. (figure 17-11)
Auxiliary Flow Test
The PT-70/80 is equipped with both high and low flow
auxiliary circuits. If an auxiliary flow problem is suspected, the following procedures should be performed.
a) If the screw was already turned completely
out and pressure reads lower than specified,
the posi-power relief valve is faulty and should
be replaced.
Required Tools
Flow Meter (with variable loading valve)
GPM (readings are +/- 1) (7.6 lpm)
b) If you were able to turn the screw out, recheck
posi-power pressure to see if the reading is
now within specification. If it is, the system
should function properly. If it did not improve,
the posi-power relief valve is faulty and should
be replaced.
Note: If an auxiliary circuit problem is suspected, perform all pressure test and adjustment procedures as
necessary prior to attempting to perform the flow test
procedure. Most issues will be solved with the pressure test and adjustment procedures, but if a problem
still persists after all pressures are correctly set, proceed with the flow test.
To Adjust Posi-Power:
1. Loosen the jam nut and then turn the screw to
adjust for more or less posi-power function.
(figure 17 -11)
a) Turn the screw clockwise to increase function
and limit pump flow during high load conditions. (less likely to stall)
PT-70/80
Low
Flow
Auxiliary
CE/ROW
PT-80
Low
Flow
Auxiliary
25
20 (76 lpm)
20
19 (72 lpm)
18 (68 lpm)
17 (64 lpm)
15
10
5
0
0
2. Tighten the jam nut while holding the set screw in
place to keep desired setting.
System
load
GPM (readings arre +/-2) (7.6 lpm)
b) Turn counter-clockwise to decrease function
and maximize pump flow during high load conditions. (more likely to stall)
0 psi
1000 psi
2000 psi
2500 psi
3000 psi
0 kPa
6895 kPa
System
13790 Load
kPa
17240 kPa
20680 kPa
ROW
PT-80
HighFlow
FlowAuxiliary
Auxiliary
PT-70/80
High
35
31 (117 lpm)
31 (117 lpm)
30 (114 lpm)
30
26 (98 lpm)
25
20
15
10
5
0
0
System
load
17-6
0 psi
1000 psi
0 kPa
6895 kPaSystem13790
Load kPa
2000 psi
2500 psi
3000 psi
17240 kPa
20680 kPa
Rubber Track Loader
17. Hydraulic Pressure & Flow
Note: The charts pictured give the acceptable ranges
for fluid flow when loaded to the levels indicated. The
low flow values are to be understood as acceptable if
within 1 gpm (3.8 lpm) of the specified value. The high
flow values are acceptable if within 2 gpm (7.6 lpm) of
the specified value. (Oil at operating temperature)
To test flow:
1. Attach a flow meter to the quick couplers of the circuit to be tested. (high or low flow)
2. Start the machine, warm to operating temperature,
then activate the circuit with the engine operating
at 2600 RPM.
3. Record and compare your readings with those of
the charts on page 17-6 in both directions.
Flow Troubleshooting
If your readings differ from those listed on the charts,
identify the symptom you are experiencing in the list of
possible problems below and follow the steps to identify and correct the problem.
Problem 1:
Both high and low flow readings are less than
specified.
Possible causes:
1. Auxiliary relief valve pressure setting incorrectly
(see page 17-3)
2. Quick coupler block pressure release valve stuck in
down (release) position.
3. Auxiliary pump malfunctioning or faulty.
4. Engine RPM too low.
Problem 2:
High flow readings are less than specified (low
flow is within specification).
Possible causes:
1. Low charge pressure.
2. Control valve spool malfunction.
Note: Make sure that the high flow reading is greater
than the low flow reading. If they are equal, the problem is most likely electrical.
Problem 4:
Low flow readings are less than specified (high
flow is within specification).
To correct:
1. Turn the adjustment screw on the pilot generation
block pressure reducing valve clockwise to increase
the flow within the low flow circuit until correct.
(see page 3-5, view D, item 5 to locate)
Problem 5:
Low flow readings are higher than specified (High
flow is within specification).
To correct:
1. Turn the adjustment screw on the pilot generation
block pressure reducing valve counter clockwise to
decrease the flow within the low flow circuit until
correct. (see page 3-5, view D, item 5 to locate)
Problem 6:
High and low flow functions only work in one
direction.
Possible causes:
1. Wire broken or disconnected at the pilot generation
block.
2. Solenoid coil malfunction. (see page 3-5)
3. Solenoid spool malfunction. (see page 3-5)
4. Faulty auxiliary hydraulic switch.
Problem 7:
Low flow works as intended when using the continuous switch, but does not work when using the
variable flow thumb switch.
Possible causes:
1. Variable flow fuse blown.
2. Power wire to variable flow switch broken or disconnected. (BU-16 see electrical schematic)
3. Variable flow switch malfunction.
4. If the switch works in one direction, but not the
other, check the pressure reducing proportional
valves and the wires that connect them to the
wiring harness for proper condition and function.
(see page 3-5, view B item 6, view D item 4)
Problem 3:
Flow is within specifications in one direction, but
lower than specified in the other.
Possible causes:
1. Auxiliary line relief valve in need of replacement.
(see page 17-4 for test instructions and figure 17-8
for location)
2. Control valve spool malfunction.
17-7
17-8
18. Troubleshooting
Chapter Overview
Visual Inspection
This chapter contains basic troubleshooting procedures for PT-70/80 Rubber Track Loaders.
Prior to troubleshooting, walk around the machine and
perform an overall visual inspection. Look for missing,
loose, worn or broken parts. Pay particular attention to
the following items:
Additional troubleshooting aids are provided in Chapter
3 (Circuit Diagrams) and in chapters containing disassembly and assembly procedures for the appropriate
component or assembly.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
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 Rubber 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 Rubber Track Loader.
Prior to performing any type of service work on a Rubber
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
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•
•
•
•
•
•
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Track tension
Fluid levels
Fan belt tension and condition
Hoses (no visible sign of wear)
Fittings (no apparent leaks)
Battery cables
Fuse panel (fuses in place and operational)
Controls (for neutral)
A simple visual inspection and operational check can
identify many problems without the need for extensive
troubleshooting. However, if these checks indicate a
problem that requires further analysis, proceed to
Troubleshooting.
General Troubleshooting
The most effective way to prevent a malfunction from
occurring is to closely follow the recommended maintenance schedule and instructions throughout the life of
the machine. However, if a malfunction does occur,
finding the problem and fixing it quickly are important.
This section covers a select set of symptoms that may
occur and suggests possible causes.
Problem 1:
Machine will not crank over.
Possible causes
1. Continuous high flow switch activated.
2. Continuous low flow switch activated.
3. Power quick-attach switch in unlocked position. (if
equipped)
4. Battery cables loose or corroded.
5. Ignition fuse blown.
6. Main starter fuse blown.
7. Starter relay malfunctioning.
8. Weak or dead battery.
9. Faulty continuous hydraulic flow switch.
10.Faulty power quick attach switch.
11. Faulty ignition switch.
12.Faulty starter.
13.Loose, broken or disconnected wiring at key, relay
or starter.
14.Main power fuse (60-80 amp) blown.
18-1
Rubber Track Loader
18. Troubleshooting
Problem 2:
Machine cranks, but will not start.
Possible causes
1. Fuel tank empty, fuel filter plugged or fuel line
restricted.
2. Battery discharged (engine rotates slowly).
3. Injection pump fuse blown.
4. Power relay (B) fuse blown (40 amp).
5. Faulty power relay (B).
6. Loose, broken or disconnected wiring at injection
pump, fuel pump or fuse.
7. Glow plugs not pre-heating (look for black smoke).
a) Main glow plug fuse blown.
b) Glow plug relay malfunctioning.
c) Loose, broken, or disconnected wiring at ignition
switch, relay or glow plug ground strip.
d) Faulty glow plugs.
8. Faulty ignition switch.
9. Loose, broken or disconnected wiring in starting circuit.
10.Loose, broken or disconnected wiring at fuel shutoff
solenoid.
11. Air in fuel system or defective fuel injection pump.
Problem 3:
Machine starts, but hydraulics will not operate.
Possible causes
1. Operator not in seat.
2. Seat belt not fastened.
3. Safety relay fuse and or or safety solenoid fuse for
seat belt or operator presence safety switches
blown.
4. Faulty operator presence safety switch.
a) Test for continuity through operator presence
and seat belt switches. Adjust or replace as necessary.
5. Loose, broken or disconnected ground wires (check
ground connections behind the operator seat, from
cab to chassis and on the chassis crossmember.)
6. Faulty safety relay.
7. Faulty safety solenoid or safety solenoid spool.
8. Loose, broken or disconnected wiring at fuse, relay,
or safety solenoid.
9. Low charge pressure.
Problem 4:
Lift arm/bucket controls are operational, but tracks
will not move.
Possible causes
1. Leak in feed line to drive control joystick (pilot control).
2. Loose, broken or disconnected wire to DA control
solenoid.
3. Drive control joystick (pilot control) malfunction.
4. Low charge pressure.
5. Parking brake switch in on position.
6. Faulty parking brake switch.
Problem 5:
Tracks are operational, but lift arms will not move.
Possible causes
1. Continuous hydraulic flow switch activated, sending
oil over relief. (lift arms work, but move slowly)
If auxiliary flow hydraulics work check for:
a) Leak in feed line to lift arm control joystick (pilot
control).
b) Lift arm control joystick (pilot control) malfunc
tion.
c) Lift arm control valve assembly malfunction.
If auxiliary flow hydraulics do not work check for:
a) Main auxiliary relief malfunction.
b) Faulty auxiliary pump.
.
Problem 6:
Lift arms are operational, but high/low flow auxiliary circuits are not.
Possible causes
1. Auxiliary hydraulic fuse blown.
2. Faulty ground in at chassis crossmember.
3. Faulty auxiliary hydraulic switch.
4. Faulty auxiliary hydraulic solenoid at pilot generation block.
5. Loose, broken or disconnected wire at fuse, auxiliary hydraulic switch, pin connector P10.
6. Auxiliary hydraulic pilot generation spool stuck in
closed position.
7. Faulty or improperly connected quick coupler.
8. Quick coupler block pressure release stuck in down
(open) position.
Problem 7:
Multiple switches/electrical accessories are not
operational in ON or RUN position.
Possible causes
1. Power A or B fuse blown.
2. Faulty power relay (A or B).
3. Faulty ignition switch.
4. Loose, broken or disconnected wiring at ignition
switch, fuse or relay.
Problem 8:
Battery will not charge/maintain charge.
Possible causes:
1. Loose alternator belt.
2. Alternator fuse blown.
3. Faulty alternator diode.
4. Loose, broken or disconnected wiring at battery,
alternator, diode or fuse.
5. Excessive current draw with key in "off" position.
6. Faulty battery.
7. Faulty alternator.
18-2
Rubber Track Loader
18. Troubleshooting
Problem 9:
Lift arm control joystick will not lock into float
position.
Possible causes
Engine/Machine Troubleshooting
1. Float magnet fuse blown.
2. Loose, broken, or disconnected wiring at fuse, float
detent magnet, or pin connector P8.
3. Faulty float detent magnet.
Problem 10:
Lift arms will not float, engine labors and lift arms
create down pressure when float is engaged.
Possible causes
1.
2.
3.
4.
Engine RPM too low.
Low charge pressure.
Lift arm control joystick malfunction (pilot control).
Lift arm control valve malfunctioning.
Problem 11:
Hydraulic oil temperature elevated; hydraulic system overheating.
Possible causes
1. Debris plugging oil cooler, limiting airflow.
2. Low hydraulic oil level.
3. Loose or missing fan belt.
4. Damaged or missing cooling fan blades.
5. Incompatible attachment.
a) Attachment must match machine flow capabili
ties.
b) Attachment hose inside diameter must be at
least ½" (1.3 cm) for low flow and ¾" (1.9 cm)
for high flow.
c) Low flow attachment coupled to high flow circuit.
6. Faulty hydraulic oil temperature sending unit.
7. Faulty quick coupler.
8. Cooler bypass relief open.
Note: Cooler bypass should open at 80 PSI / 552 kPa.
Problem 12:
Engine coolant temperature elevated; engine overheating.
Possible causes:
1. Low coolant level.
2. Debris plugging radiator, limiting airflow.
3. Damaged or missing cooling fan blades.
4. Loose or missing fan belt.
5. Faulty engine coolant temperature gauge.
6. Thermostat stuck in closed position.
When a problem occurs that effects engine performance or function, it is important to determine whether
or not the problem lies with the machine itself, or with
the engine. A machine problem should be repaired by
an Terex dealer, while an engine specific problem
should only be repaired by a representative of the
engine manufacturer. Making this determination will
ensure timely and appropriate service to help minimize
down-time.
Problem:
Hard starting
check for:
1. 12V power to glow plugs. (With test light or multimeter, measure voltage at green glow plug common power lead.)
a) If power is not present, see problem 1, step 7.
2. Water in fuel.
3. Proper grade and quality fuel.
Problem:
Low power
check for:
1. Dirty, clogged, or restricted fuel filter.
2. Adequate supply of fuel to engine (fuel lines).
3. Water in fuel.
4. Proper grade and quality fuel.
5. Air filter clogged.
Problem:
No start
check for:
1. 12V power at fuel shutoff solenoid. (With test light
or multi-meter, measure voltage at white power
lead entering the solenoid.)
a) If no power is present, see problem 1, step 3-6)
2. Ensure 12V power to fuel pump. (With test light or
multi-meter, measure voltage at white power lead
entering the electronic fuel pump.)
3. Low fuel.
4. Out of fuel. (ensure proper gauge/sending unit
function. Inspect tank for fuel)
5. Blocked or restricted fuel line. (try alternate/remote
fuel supply to pump.)
6. Water in fuel.
7. Proper grade and quality fuel.
If any of the above conditions are present, the problem
lies with the machine and should be serviced by an
Terex dealer. If the conditions listed above are not
present, the problem lies with the engine and it should
be serviced by a Perkins engine repair facility to comply with the conditions of the engine warranty.
18-3
18-4
19. Lubricant & Fuel
Specifications
Chapter Overview
Fuel Specifications
When replacing or replenishing the fluids and lubricants in an Terex Rubber Track Loader, use Terex
products. This ensures that the new fluids and lubricants match those originally installed when the
machine left the Terex factory. Terex products were
developed for, tested and approved by Terex to assure
optimum life and performance in all Terex Rubber
Track Loaders, when used as recommended.
Diesel fuel, distilled from crude oil, identified as No. 1D or No. 2-D in “ASTM D975” and “EN 590” generally
meet machine requirements.
Fluids
Engine Oil
• TerexHeavy Duty Engine Oil, 10W-30
Capacity: 9 quarts (8.5l) including filter
P/N: 0300-767 1 quart
P/N: 0402-838 12 quarts
P/N: 0402-839 1 gallon
P/N: 0402-840 6 gallons
Engine Anti-freeze/Coolant
• Terex Long-Life 50/50 Antifreeze/Coolant
Capacity: 3.125 gallons (11.8l)
P/N: 0300-766 1 gallon
P/N: 0402-841 6 gallons
Hydraulic Oil
• Terex Premium All Season MV Hydraulic Oil
Service Capacity: 12.25 gal.(46.4l) incl. filters
P/N: 0400-253 5 gallons
P/N: 0402-833 55 gallons
Grease (general-use)
• Terex Multi-Purpose EP Lithium Grease
P/N: 0300-769 1 tube
P/N: 0402-844 10 tubes
P/N: 0402-834 40 tubes
If Terex products are not available, use high quality
substitutions that meet or exceed factory installed fluid
specifications.
19-1
19-2
20. Service Aids &
Supplements
General Torque Specifications
Inch Fasteners
Metric Fasteners
Thread Size Standard Torque
Thread Size Standard Torque
1/4"
9 +/- 2 lb ft
M6
12 +/- 3 Nm
5/16"
18 +/- 4 lb ft
M8
28 +/- 7 Nm
3/8"
35 +/- 7lb ft
M10
55 +/- 10 Nm
7/16"
50 +/- 11 lb ft
M12
100 +/- 20 Nm
1/2"
75 +/- 15 lb ft
M14
160 +/- 30 Nm
9/16"
120 +/- 22 lb ft
M16
240 +/- 40 Nm
5/8"
160 +/- 30 lb ft
M20
460 +/- 60 Nm
3/4"
275 +/- 37 lb ft
M24
800 +/- 100 Nm
7/8"
460 +/- 60 lb ft
M30
1600 +/- 200 Nm
1"
660 +/- 75 lb ft
M36
2700 +/- 300 Nm
1-1/8"
960 +/- 110 lb ft
1-1/4"
1320 +/- 150 lb ft
1-3/8"
1780 +/- 220 lb ft
1-1/2"
2280 +/- 260 lb ft
20-1
Terex Construction Americas
8800 Rostin Road
Southaven, MS 38671
(888)-201-6008
(662)-393-1800
www.terex.com
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