PT-30 (PN 2010-513)

PT-30 (PN 2010-513)
Service Manual
Compact Track Loader
PT-30
Part Number: 2010-513
Printed (1-11)
Table of Contents
1. Product Safety
6. Chassis Disassembly and Assembly
Chapter Overview ................................................... 1-1
Basic Precautions ................................................... 1-1
Safety Labels ..................................................... 1-1
Personal 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 ............................................................ 1-4
Machine Labels and Decals .................................... 1-4
Product ID Number ............................................ 1-4
Safety Label Examples ...................................... 1-4
Chapter Overview ................................................... 6-1
Personal Safety....................................................... 6-1
Machine Preparation ............................................... 6-1
Chassis Disassembly and Assembly
Procedures.............................................................. 6-1
Seat Removal and Installation ................................ 6-1
Seat Removal .................................................... 6-1
Seat Installation ................................................. 6-2
Fuel Sending Unit Removal and Installation ........... 6-2
Fuel Sending Unit Removal ............................... 6-3
Fuel Sending Unit Installation ............................ 6-3
Fuel Tank Removal and Installation ....................... 6-4
Fuel Tank Removal ........................................... 6-4
Fuel Tank Installation......................................... 6-6
7. Radiator/Oil Cooler Disassembly
and Assembly
2. Technical Specifications
Chapter Overview ................................................... 2-1
PT-30 Specifications ............................................... 2-1
Chapter Overview ................................................... 7-1
Personal Safety....................................................... 7-1
Machine Preparation ............................................... 7-1
Radiator/Oil Cooler Disassembly and Assembly
Procedures.............................................................. 7-1
Fan Guard Removal and Installation ....................... 7-1
Fan Guard Removal .......................................... 7-2
Fan Guard Installation ....................................... 7-2
Fan and Fan Shroud Removal and Installation ....... 7-2
Fan and Fan Shroud Removal ........................... 7-2
Fan and Fan Shroud Installation ........................ 7-3
Radiator/Cooler Removal and Installation ............... 7-4
Radiator/Cooler Removal .................................. 7-4
Radiator/Cooler Installation ............................... 7-6
Radiator/Oil Cooler Adjustment Procedures .......... 7-7
Fan Shroud Adjustment ..................................... 7-7
Fan Guard Adjustment....................................... 7-8
3. System Diagrams
Chapter Overview ................................................... 3-1
Filtering and Cooling System .................................. 3-1
Auxiliary Circuit System .......................................... 3-2
Drive Loop System .................................................. 3-3
4. Machine Controls and Instrumentation
Chapter Overview ................................................... 4-1
Machine Controls .................................................... 4-1
Loader Control ................................................... 4-1
Drive Control ...................................................... 4-1
Throttle .............................................................. 4-1
Instrumentation ....................................................... 4-1
Switches .................................................................. 4-2
8. Hydraulic Reservoir Disassembly
and Assembly
5. Operator Enclosure Disassembly
and Assembly
Chapter Overview ................................................... 8-1
Personal Safety....................................................... 8-1
Machine Preparation ............................................... 8-1
Hydraulic Reservoir Disassembly and Assembly
Procedures.............................................................. 8-1
Filter Element Removal and Installation .................. 8-1
Filter Assembly Removal and Installation ............... 8-1
Filter Assembly Removal ................................... 8-2
Filter Assembly Installation ................................ 8-3
Access Cover Assembly Removal and Installation . 8-4
Access Cover Assembly Removal ..................... 8-4
Access Cover Assembly Installation .................. 8-4
Reservoir Gauge Removal and Installation ............. 8-5
Reservoir Gauge Removal ................................ 8-5
Reservoir Gauge Installation ............................. 8-6
Suction Screen Removal and Installation ............... 8-6
Suction Screen Removal ................................... 8-6
Suction Screen Installation ................................ 8-7
Hydraulic Reservoir Cleaning Procedures ............. 8-7
Chapter Overview ................................................... 5-1
Personal Safety ....................................................... 5-1
Machine Preparation ............................................... 5-1
Operator Enclosure Disassembly and Assembly
Procedures .............................................................. 5-1
Light Bar Removal and Installation.......................... 5-1
Light Bar Removal ............................................. 5-1
Light Bar Installation .......................................... 5-2
Ignition Switch Removal and Installation ................. 5-2
Ignition Switch Removal .................................... 5-2
Ignition Switch Installation ................................. 5-3
Gauge Removal and Installation ............................. 5-4
Gauge Removal ................................................. 5-4
Gauge Installation .............................................. 5-4
Lap Bar Gas Assist Spring Removal
and Installation ........................................................ 5-5
Lap Bar Gas Assist Spring Removal .................. 5-5
Lap Bar Gas Assist Spring Installation ............... 5-5
i
Compact Track Loader
Table of Contents
9. Loader/Transmission Controls Disassembly
and Assembly
12. Undercarriage Disassembly and Assembly
Chapter Overview ................................................. 12-1
Personal Safety..................................................... 12-1
Machine Preparation ............................................. 12-1
Undercarriage Disassembly and Assembly
Procedures............................................................ 12-1
Wheel Removal and Installation........................... 12-1
Wheel Removal ............................................... 12-2
Wheel Installation ............................................ 12-3
Track Removal and Installation ............................. 12-3
Track Removal ............................................... 12-3
Track Installation ............................................ 12-3
Sprocket Bearing Plate Removal and Installation . 12-6
Sprocket Bearing Plate Removal ................... 12-7
Sprocket Bearing Plate Installation ................ 12-8
Sprocket Roller Removal and Installation ............. 12-8
Sprocket Roller Removal............................... 12-8
Sprocket Roller Installation............................ 12-9
Sprocket Removal and Installation ........................ 12-9
Sprocket Removal ......................................... 12-9
Sprocket Installation .................................... 12-10
Drive Motor Removal and Installation ................ 12-10
Drive Motor Removal.................................. 12-11
Drive Motor Installation............................... 12-11
Chapter Overview ................................................... 9-1
Personal Safety ....................................................... 9-1
Machine Preparation ............................................... 9-1
Loader/Transmission Controls Disassembly and
Assembly Procedures ............................................. 9-1
Loader Control Joystick/Drive Control Joystick
Removal and Installation ......................................... 9-1
Loader Control Joystick/Drive Control Joystick
Removal ............................................................ 9-2
Loader Control Joystick/Drive Control Joystick
Installation.......................................................... 9-3
Loader Float Magnet Removal and Installation ....... 9-3
Loader Float Magnet Removal........................... 9-3
Loader Float Magnet Installation........................ 9-4
Loader Valve Removal and Installation .................. 9-4
Loader Valve Removal ...................................... 9-4
Loader Valve Installation ................................... 9-6
10. Transmission and Drive Disassembly
and Assembly
Chapter Overview ................................................. 10-1
Personal Safety ..................................................... 10-1
Machine Preparation ............................................. 10-1
Transmission and Drive Disassembly
and Assembly Procedures .................................... 10-1
Brake Cylinder Removal and Installation .............. 10-1
Drive Motor Removal and Installation ................... 10-1
Auxiliary Gear Pump Removal and Installation ..... 10-2
Auxiliary Gear Pump Removal ......................... 10-2
Auxiliary Gear Pump Installation ...................... 10-3
Tandem Pump Removal and Installation .............. 10-4
Tandem Pump Removal .................................. 10-4
Tandem Pump Installation ............................... 10-5
Pump Drive Coupler Removal and Installation ...... 10-6
Pump Drive Coupler Removal ......................... 10-6
Pump Drive Coupler Installation ...................... 10-7
13. Loader Disassembly and Assembly
Chapter Overview ................................................. 13-1
Personal Safety..................................................... 13-1
Machine Preparation ............................................. 13-1
Loader Disassembly and Assembly Procedures .. 13-1
Lift Cylinder/Tilt Cylinder Removal
and Installation ...................................................... 13-1
Lift Cylinder/Tilt Cylinder Removal ................... 13-1
Lift Cylinder/Tilt Cylinder Installation ................ 13-3
Lift Cylinder/Tilt Cylinder Seal Kit Removal
and Installation ...................................................... 13-3
Seal Kit Removal ............................................ 13-3
Seal Kit Installation ......................................... 13-5
Lift Arm Bushing Removal and Installation ........... 13-6
Upper Friction Points ....................................... 13-6
Lower Friction Points ....................................... 13-8
Low-Flow Relief Valve Removal and Installation .. 13-9
Low Flow Relief Valve Removal ...................... 13-9
Low Flow Relief Valve Installation ................. 13-10
11. Engine Components Disassembly and Assembly
Chapter Overview ................................................. 11-1
Personal Safety ..................................................... 11-1
Machine Preparation ............................................. 11-1
Engine Components Disassembly and
Assembly Procedures ........................................... 11-1
Primary Air Filter Removal and Installation ........... 11-1
Safety Air Filter Removal and Installation ............. 11-1
Engine Oil Filter Removal and Installation ............ 11-1
Fuel Filter Removal and Installation ..................... 11-1
Muffler Removal and Installation .......................... 11-2
Muffler Removal............................................... 11-2
Muffler Installation............................................ 11-2
Exhaust Pipe Removal and Installation ................. 11-3
Exhaust Pipe Removal .................................... 11-3
Exhaust Pipe Installation ................................. 11-4
Battery Removal and Installation........................... 11-5
Battery Removal .............................................. 11-5
Battery Installation ........................................... 11-6
Bleeding the Fuel System………………………….11-7
14. Quick Attach Disassembly and Assembly
Chapter Overview ................................................. 14-1
Personal Safety..................................................... 14-1
Machine Preparation ............................................. 14-1
Quick Attach Disassembly and Assembly
Procedures............................................................ 14-1
Latch Pin Assembly Removal and Installation ...... 14-1
Latch Pin Assembly Removal .......................... 14-1
Latch Pin Assembly Installation ....................... 14-2
Quick Attach Assembly Removal and Installation . 14-2
Quick Attach Assembly Removal ..................... 14-2
Quick Attach Assembly Installation .................. 14-3
ii
Compact Track Loader
Table of Contents
15. Troubleshooting
Chapter Overview ................................................. 15-1
Personal Safety ..................................................... 15-1
Machine Preparation ............................................. 15-1
Visual Inspection.............................................. 15-1
Troubleshooting .................................................... 15-2
16. Maintenance
Chapter Overview ................................................. 16-1
Maintenance Schedule .......................................... 16-1
Engine Oil ............................................................. 16-1
Oil Change Procedures ................................... 16-1
Engine Oil Specifications ................................. 16-1
Hydraulic Fluid and Filter ...................................... 16-2
Hydraulic Fluid and Filter Change
Procedures ...................................................... 16-2
Fuel Filter .............................................................. 16-3
Fuel Filter Change Procedures ........................ 16-3
Fuel Specifications ........................................... 16-3
Air Cleaner ............................................................ 16-3
Air Filter Change Procedures........................... 16-3
Track Tension ....................................................... 16-4
Track Tension Adjustment Procedures ............ 16-4
Checking for Proper Track Adjustment ............ 16-4
Fuse Box ............................................................... 16-5
Grease Fittings ...................................................... 16-5
Lift Arm Bushings .................................................. 16-6
17. Hydraulic Pressure Check & Adjustment
Chapter Overview ................................................. 17-1
Personal Safety ..................................................... 17-1
Machine Preparation ............................................. 17-1
Charge Pressure check……………………………. 17-1
Charge Pressure Adjustment………………………17-2
Drive Pressure Adjustment…………………………17-3
Auxiliary Pressure Check & Adjustment…………..17-4
iii
1. Product Safety
Chapter Overview
This chapter contains product safety information for the
Terex PT-30 Compact Track Loaders. Read and understand all product safety information before attempting
to service any Compact Track Loader.
Safety Alert Symbol
This symbol means: Attention! Be
alert! Your safety is involved!
The safety alert symbol is used to alert you to potential
personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or
death.
This symbol is used as an attention-getting device
throughout this manual as well as on decals and labels
fixed to the machinery to assist in potential hazard
recognition and prevention.
The person(s) in charge of servicing a Compact Track
Loader may be unfamiliar with many of the systems on
the machine. This makes it especially important to use
caution when performing service tasks. Familiarize
yourself with the affected system(s) and components
before attempting any type of maintenance or service.
It is not possible to anticipate every potential 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
Property or equipment damage warnings in this publication are identified by the signal word "NOTICE".
Safety Labels
NOTICE
Safety labels have been included and are displayed in
various places throughout the machine to serve as
warnings of potentially dangerous conditions. Read
and understand all "Safety" labels on any Compact
Track Loader before attempting to operate, maintain or
repair it. Replace any damaged, illegible or missing
labels immediately, prior to service.
“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.
Personal Protective Equipment
Improper or incomplete maintenance/repair of a
Compact Track Loader can be dangerous and
may result in machine damage, injury or death.
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 Compact Track Loader until you have
read and fully understood both this manual and the
machine specific operation and maintenance manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation and
maintenance techniques before operating or servicing
any Compact Track Loader.
1-1
Compact Track Loader
1. Product Safety
Entering and Exiting
Pressurized Items
Always use steps and handholds when entering or
exiting a Compact Track Loader. Clean any mud or
debris from steps or work platforms before using them.
Always face the machine when using steps and 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 Ib
(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
(13,790 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
Compact 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
Compact Track Loader.
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to performing any service work on a Compact Track Loader.
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.
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.
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.
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.
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.
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.
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.
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.
13. Relieve hydraulic system pressure by relaxing all
hydraulic actuators prior to attempting any
hydraulic maintenance or repair.
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
Compact Track Loader
1. Product Safety
the dealer about parts, service, warranty or
accessories. No warranty claims will be
processed unless the PIN is provided.
WARNING
Attachments
Only use attachments that are recommended by Terex.
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment.
Make sure that all necessary guards and protective
Keep clear of lift arms and
attachments.
WARNING
WARNING
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.
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
equipment are in place and functioning prior to operating any attachment.
Wear protective glasses and protective equipment as
required by conditions or as recommended in the
attachment’s operation manual.
Ensure that all personnel are far enough away from
the work area so they will not be struck by flying objects.
Fall Hazard
Serious injury or death can result
from falling.
Use the provided access system when
entering or exiting the machine.
WARNING
WARNING
Stay clear of the cutting edges, pinching surfaces or
crushing surfaces of the attachment while performing
any attachment maintenance, testing or adjustments.
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment.
Machine Labels and Decals
Install lift arm brace prior to servicing.
WARNING
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.
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
Product Identification Number
WARNING
Burn Hazard
Hot fluid under pressure can scald.
Allow the machine to cool thoroughly
before opening.
2030-595
NOTICE
1-1
The Product Identification Number (PIN) is located on
the left side of the firewall next to the operator seat.
(figure 1-1). Always provide the PIN when contacting
Fire Hazard
Flammable debris can collect near hot
components and lead to a fire.
1-4
Read Operator’s manual
Keep engine, exhaust and chassis
areas free of debris.
Safety
Label
Compact Track Loader
1. Product Safety
WARNING
WARNING
Fall Hazard
Crush Hazard
Falling can result in serious injury or death.
Rollover can crush and result in serious injury or death.
Do not use the bucket/attachment as a work platform.
Fasten Seat Belt
WARNING
Improper operation or maintenance can result in serious injury or death.
WARNING
Fall Hazard
Falling from a machine can result in serious
injury or death.
WARNING
Rollover/Ejection Hazard
Serious injury or death can result.
Read Operator’s Manual
Read and understand the operator’s manual
and all safety signs prior to operating or
maintaining the machine.
No Riders
Carry loads low. Load unload and turn on
level ground. Travel on inclines with heaviest
end of machine uphill.
WARNING
•
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.
1-5
1-6
2. Technical Specifications
& Service Tools
PT-30 Specifications
Engine
Oil Cooler
-
-
Model: Perkins 403-D15
Displacement: 1.5 liter
Gross horsepower: 33.7 hp (25.1 kW)
Peak Torque: 64.39 lb-ft. (87 Nm)
Idle rpm: 1175 (low idle), 2800 (high idle)
Average water /thermostat temperature: 190°F,
87.8°C
Critical Torque Specs
Transmission
-
-
Model: A10VG18 tandem (Rexroth)
-
Drive Pumps
-
-
Displacement: 1.098 in3/rev (18 cc/rev)
Relief pressure: 3800 psi (26,200 kPa)
Flow: 13 gpm ( 11.4lpm) @ 2800 rpm (per pump)
-
Charge Pumps (2)
-
-
Displacement: .33 in3/rev (5.4 cc/rev) x2
Relief pressure: 360 +/- 20 psi (24.82 bar)
Flow: 3 gpm (11.4 lpm combined) @1175 rpm
Flow: 8.1 gpm (30.7 lpm combined) @2800 rpm
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.
Model: Rexroth Sauer Danfoss
Displacement: 19.215 in3/rev (314.9 cc/rev)
Pilot Controls (Joysticks)
-
Model: Rexroth 4TH6
• Heavy Duty Hydraulic Jack (5-ton rating)
• Test Gauge Kit (P/N: 0402-935)
• Long Pry Bar(s)
Auxiliary Pump
-
Make: Rexroth
Type: Gear
Displacement: 0.87 in3/rev (14.3 cc/rev)
Max Flow: 10 gpm (37.9 lpm) @ 2800 rpm
Relief pressure: 3000 psi (20,684 kPa)
Cooling/filtering: Oil is filtered and cooled at all
times. In auxiliary mode, the oil is filtered after the
attachment to protect the machine if the attachment motor fails or contaminants are introduced
from the quick couplers.
Lift Arm Control Valve
-
Transmission Mounting Bolts
-- 80 ft-lb (108 Nm). w/Blue Loctite
Drive Sprocket Drive Teeth Bolts
-- 62 ft-lb (84 Nm). -Dry
Bogie Wheel Retaining Nuts
-- 110 ft-lb (149 Nm). - Dry
Drive Sprocket Retaining Bolt
(Serial # 00101-05000)
-- 60 ft-lb (81 Nm). w/Blue Loctite
Drive Sprocket Retaining Castle Nut
(Serial # 05001-Current)
-- 270 ft-lb (366 Nm)
Service Tools
Drive Motors
-
Operating pressure: 250 psi (1724 kPa)
Bypass relief pressure: 80 psi (551.6 kPa)
Hot oil sending unit: 225°F (107.2°C)
Avg. oil operating temp. 50-60°F (10-16°C) above
ambient. (extreme application 80°F , 27°C above
ambient.)
Make: Husco
Relief Pressure: 3000 psi (20,684 kPa)
Pilot pressure required to move spools: 180-220psi
(1241-1517 kPa)
2-1
3. Circuit Diagrams
Chapter Overview
Filtering and Cooling System
This chapter contains diagrams for the following
Compact Track Loader systems.
The filtering and cooling system (Figure 3-1) contains
the following major components.
•
•
•
•
•
•
•
•
Filtering and cooling system
Auxiliary circuit system
Drive loop system
Figure 3-1 PT-30 Filtering and Cooling System
Hydraulic reservoir
Radiator/oil cooler
Loader valve
Auxiliary gear pump
Pilot control manifold
100psi (689.5 kPa)
3-1
Compact Track Loader
3. Circuit Diagrams
Auxiliary Circuit System
The auxiliary circuit system (Figure 3-2) contains the
following major components.
• Loader valve
• Pilot control manifold
• Auxiliary gear pump
• Loader control joystick
Figure 3-2 PT-30 Auxiliary Circuit System
3-2
Compact Track Loader
3. Circuit Diagrams
Drive Loop System
The drive loop system (Figure 3-3) contains the following major components.
• Tandem pump
• Drive motors
• Pilot control manifold
• Drive control joystick
Figure 3-3 PT-30 Drive Loop System
TO IMPLEMENT
VALVE
TANDEM PUMP (WITH DRIVE
AND CHARGE PRESSURE
RELIEF VALVES.)
BRAKE
DRIVE MOTOR
TANK
Drive Reliefs
CASE DRAIN
Charge Reliefs
CASE DRAIN
CHARGE PRESSURE
TEST PORT
DRIVE MOTOR
DRIVE CONTROL
3-3
4. 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 your particular machine. Included here are illustrations of the following controls and instrumentation components and a description of their functions.
The Instruments (Figure 4-2) are positioned in the
overhead dash panel for ease of access and visibility
when seated inside the operator enclosure.
Instruments include the following components.
•
•
•
Machine Controls
Instrument Location and Function
Switch Location and Function
Machine Controls (fig. 4-1)
There are three primary machine controls: loader control (1), drive control (2) and throttle (3).
(1)
(2)
(3)
(4)
(5)
Fuel Gauge
Tachometer (optional)
Engine Coolant Temp. Gauge (optional)
Hour Meter
Warning Indicator Display
• Engine Oil Pressure Warning Light
• Engine Temperature Warning Light
• Hydraulic Oil Temperature Warning Light
• Battery Voltage Warning Light
1
Loader Control
5
4
The loader control (1) is a pilot operated joystick that
allows the operator to raise or lower the loader and
dump or curl the quick attach mechanism.
Drive Control
4-2
The drive control (2) is also a pilot operated joystick. It
allows the operator to change the direction and speed
of the machine.
NOTICE
Throttle
If the engine temperature, engine oil pressure or hydraulic oil
temperature lights illuminate or should the eng. coolant temp.
gauge read excessive temperatures during normal machine
operation, shut the machine down immediately (in a safe
location). Diagnose the problem and make any necessary
repairs before resuming normal operation.
If the battery low-voltage light should illuminate during operation, drive the machine to a suitable location and shut the
engine off. Diagnose the problem and make any needed
repairs before resuming operation.
The hand throttle (3) controls engine rpm.
1
2
NOTICE
The glow plug operation light illuminates only when the
key switch is turned to engine pre-heat, showing normal operation.
3
4-1
4-1
Compact Track Loader
4. Machine Controls and Instrumentation
PT-30 Switches
1
2
3
5
4
4-3
The various switches (Figure 4-3) are positioned to
provide good access and visibility. The standard and
optional switches are listed below.
(1)
(2)
(3)
(4)
(5)
(6)
Work lights
Heater fan (optional)
Front wiper (optional)
Beacon light (optional)
Ignition, glow plug (pre-heat)
Auxiliary hydraulics
4-2
6
5. Operator Enclosure
Disassembly and Assembly
Chapter Overview
Operator Enclosure
Disassembly and Assembly
Procedures
This chapter provides disassembly and assembly
procedures for the operator enclosure assembly.
Disassembly and assembly procedures are provided
for the following operator enclosure components.
Personal Safety
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in machine damage, injury or death.
Do not attempt to perform any type of repair or maintenance on a Compact Track Loader until you have read and
fully understood the information in this manual.
•
Light Bar
•
Ignition Switch
•
Gauges
•
Lap Bar Gas Assist Spring
Note: Procedures are provided for only those operator
enclosure components listed above. However, information
for removal and installation of other operator enclosure
components can be obtained from the machine specific
parts manual.
Refer to the Operation and Maintenance manual for instructions regarding proper machine operation techniques
before operating any Compact Track Loader.
Prior to performing any type of service work on a
Compact Track Loader, read and understand Chapter 1 (Product Safety) for personal safety information.
Light Bar Removal and
Installation
Machine Preparation
The tools required for light bar console removal and
installation are listed in Table 5-1. Use manufacturer
recommended tools whenever possible.
Accidental machine starting can cause injury or
death to personnel working on a Compact Track
Loader.
Table 5-1
Required Tools
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to performing any service work on a Compact Track Loader.
Combination Wrench
Light Bar Removal
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is being worked on.
Figure 5-1
1. Loosen the two cap screws that attach the light
bar to the cab frame.
5-1
Compact Track Loader
5. Operator Enclosure Disassembly and Assembly
Light Bar Installation
Figure 5-2
2. Carefully lower the light bar with the wire harness attached.
Figure 5-5
1. Carefully position the light bar, without pinching
the wiring harness against the cab roof.
Figure 5-3
3. View of light bar interior components. Interior
components are now accessible for servicing.
Figure 5-6
2. Secure the light bar to the cab roof with the two
capscrews
Ignition Switch Removal and
Installation
The tools required for ignition switch removal and
installation are listed in Table 5-2. Use manufacturer-recommended tools whenever possible.
Figure 5-4
4. View of dome light. If removal is required, simply
insert a lever (blade-type screw driver) at opposite end of switch in pry-pocket, and gently pry
the light assembly out of the light bar.
Table 5-2
Required Tools
Combination Wrench
Ignition Switch Removal
1. Lower the light bar. Refer to Chapter 5. Light Bar
Removal procedure.
5-2
Compact Track Loader
5. Operator Enclosure Disassembly and Assembly
Ignition Switch Installation
Remove Nut
Figure 5-7
Figure 5-10
2. Remove the nut that secures the ignition switch
to the dash panel.
1. Insert the ignition switch from the rear of the
dash panel.
Install Nut
Figure 5-8
Figure 5-11
3. Pull the ignition switch out from the rear of the
dash panel.
2. Install the nut that secures the ignition switch to
the dash panel.
Figure 5-9
Figure 5-12
4. Unplug the ignition switch connector.
3. Plug in the ignition switch connector.
5-3
Compact Track Loader
5. Operator Enclosure Disassembly and Assembly
4. Install the light bar. Refer to Chapter 5. Light Bar
Installation procedure.
Gauge Removal and Installation
The tools required for gauge removal and installation
are listed in Table 5-3. Use manufacturerrecommended tools whenever possible.
Table 5-3
Required Tools
Figure 5-15
Combination wrench
4. Pull the gauge out from the front of the dash
panel.
Gauge Removal
Gauge Installation
1. Lower the light bar. Refer to Chapter 5. Light Bar
Removal procedure.
Figure 5-16
Figure 5-13
2. Disconnect the connector from the gauge.
1. Insert the gauge from the front of the dash panel.
Figure 5-14
Figure 5-17
3. Remove the two nuts that secure the gauge to
the retaining bracket.
2. Install the two nuts that secure the gauge to the
retaining bracket.
5-4
Compact Track Loader
5. Operator Enclosure Disassembly and Assembly
Remove
Retaining Clip
Figure 5-18
Figure 5-20
3. Reconnect the gauge connector.
2. Using a small screwdriver, remove the retaining
clip from each end of the gas assist spring.
4. Install the light bar. Refer to Chapter 5. Light Bar
Installation procedure.
Lap Bar Gas Assist Spring
Removal and Installation
The tools required for gas assist spring removal and
installation are listed in Table 5-4. Use manufacturer-recommended tools whenever possible.
Table 5-4
Required Tools
Figure 5-21
Screwdriver
3. Remove the gas assist spring by pulling both
ends out from the ball joints.
Lap Bar Gas Assist Spring Removal
Lap Bar Gas Assist Spring Installation
Gas Assist
Spring
Gas Assist
Spring Location
Raise Lap Bar
(Shown in Down
Position)
Raise Lap Bar
(Shown in Down
Position)
Figure 5-19
1. Put the lap bar in the UP position to relieve tension on the lap bar gas assist spring.
Figure 5-22
1. Put the lap bar in the UP position to minimize
tension on the lap bar gas assist spring during
installation.
5-5
Compact Track Loader
5. Operator Enclosure Disassembly and Assembly
Install Ends on
Ball Joints
Figure 5-23
2. Install the ends of the lap bar gas assist spring
onto the ball joints.
Insert
Retaining Clip
Figure 5-24
3. Slide the retaining clip on to each end of the gas
assist spring.
5-6
6. Chassis
Disassembly and Assembly
Chapter Overview
Chassis Disassembly and
Assembly Procedures
This chapter provides disassembly and assembly
procedures for the chassis assembly.
Disassembly and assembly procedures are provided
for the following chassis components.
Personal Safety
•
Seat
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in machine damage, injury or death.
•
Fuel Sending Unit
•
Fuel Sending Unit Hose
Do not attempt to perform any type of repair or maintenance on a Compact Track Loader until you have read and
fully understood the information in this manual.
•
In-Tank Weight
•
Fuel Tank
Refer to the Operation and Maintenance manual for instructions regarding proper machine operation techniques
before operating any Compact Track Loader.
Note: Procedures are provided for only those chassis
components listed above. However, information for removal and installation of other chassis components can be
obtained from the exploded view illustration provided in
the machine specific parts manual.
Prior to performing any type of service work on a
Compact Track Loader, read and understand Chapter 1 (Product Safety) for personal safety information.
Seat Removal and Installation
The tools required for seat removal and installation
are listed in Table 6-1. Use manufacturerrecommended tools whenever possible.
Machine Preparation
Accidental machine starting can cause injury or
death to personnel working on a Compact Track
Loader.
Table 6-1
Required Tools
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to performing any service work on a Compact Track Loader.
Socket Wrench
Seat Removal
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is being worked on.
Remove Seat Bolts
Figure 6-1
1. Remove the four bolts that fasten the seat
mounts to the frame.
6-1
Compact Track Loader
6. Chassis Disassembly and Assembly
Unplug
Connector
Plug in the Connector
Figure 6-2
Figure 6-5
2. Tilt the seat forward and reach behind the seat
to unplug the seat switch wiring harness.
2. Tilt the seat forward and reach behind the seat
to plug in the seat switch connector
Note: The machine will not operate unless the seat switch
connector is plugged in.
insert Seat Bolts
Figure 6-3
3. Remove the seat. Be careful not to scratch the
control panel or sides of the cab.
Figure 6-6
Seat Installation
3. Position the seat so the holes in the seat mounts
are aligned with the holes in the frame. Insert
the four seat mount bolts and washers.
Fuel Sending Unit Removal
and Installation
The tools required for fuel sending unit removal and
installation are listed in Table 6-2. Use manufacturer-recommended tools whenever possible.
Table 6-2
Required Tools
Figure 6-4
Screwdriver
Combination Wrench
Socket Wrench
1. With the seat mounts attached, place the seat in
the cab. Be careful not to scratch the control
panel or sides of the cab.
6-2
Compact Track Loader
6. Chassis Disassembly and Assembly
Fuel Sending Unit Removal
1. Remove the seat. Refer to Chapter 6. Seat Removal procedure.
2. Pump fuel from the tank until there is no fuel
remaining above the sending unit.
Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates.
Figure 6-9
Fuel
Sending
Unit
5. The fuel pickup line will also come out with the
fuel sending unit.
Fuel Sending Unit Installation
Figure 6-7
3. Remove the hoses and wires from the fuel sending unit, then remove the screws that fasten the
unit to the tank. Mark the wires and hoses.
Note: If the fuel sending unit wires are crossed, the fuel
gauge will not work. If the hoses are crossed, the engine
will not run.
Figure 6-10
1. Insert the fuel pickup line into the fuel tank opening. The pickup line is attached to the fuel sending unit.
Note: The weight on the end of the fuel pickup line must
rest on the bottom of the tank for proper operation.
Figure 6-8
4. Remove the fuel sending unit. Be careful not to
damage the float mechanism when pulling it
through the opening in the fuel tank.
6-3
Compact Track Loader
6. Chassis Disassembly and Assembly
Fuel Tank Removal and
Installation
The tools required for fuel tank removal and installation are listed in Table 6-3. Use manufacturerrecommended tools whenever possible.
Table 6-3
Required Tools
Screwdriver
Combination Wrench
Socket Wrench
Figure 6-11
2. Insert the fuel sending unit float mechanism into
the fuel tank opening. Be careful not to damage
the float when pushing it through the opening.
Fuel Tank Removal
1. Remove the seat. Refer to Chapter 6. Seat Removal procedure.
Note: Make sure that the wire on the sending unit is not
bent and the fuel pickup line does not interfere with the
movement of the float.
Fuel
Sending
Unit
Figure 6-13
2. View of fuel tank with seat removed.
Figure 6-12
3. Pump all fuel from the fuel tank.
3. Connect the hoses and wires to the fuel sending
unit, then install the screws that fasten the unit
to the tank.
Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates.
Note: Be careful not to cross the wires or hoses. If the
fuel sending unit wires are crossed, the fuel gauge will not
work. If the hoses are crossed, the engine will not run.
4. Install the seat. Refer to Chapter 6. Seat Installation procedure.
6-4
Compact Track Loader
6. Chassis Disassembly and Assembly
Remove Floor
Pan Bolts
Remove
Filler Piece
Figure 6-14
Figure 6-17
4. Remove the four bolts that hold the floor pan to
the frame.
7. Remove the steel filler piece behind the fuel
tank.
Remove
Bolt
Figure 6-15
Figure 6-18
5. Remove the floor pan.
8. Remove the bolt that fastens the fuel tank to the
frame.
Fuel
Sending
Unit
Disconnect
Vent Hose
Figure 6-16
Figure 6-19
6. Remove the hoses and wires from the fuel sending unit.
9. Disconnect the Compact vent hose from the fuel
tank.
6-5
Compact Track Loader
6. Chassis Disassembly and Assembly
Attach
Filler Hose
Remove
Filler Hose
Figure 6-20
Figure 6-23
10. Remove the Compact filler hose from the back
end or the tank.
2. Attach the filler hose to the rear of the tank.
Connect
Vent Hose
Figure 6-24
Figure 6-21
3. Connect the vent hose to the fuel tank.
11. Remove the tank carefully from the machine.
Fuel Tank Installation
Insert
Bolt and
Washer
Figure 6-25
4. Insert the bolt and washer that connect the fuel
tank to the frame.
Figure 6-22
1. Place the fuel tank in the machine in approximately its normal position.
6-6
Compact Track Loader
6. Chassis Disassembly and Assembly
Install Floor Pan
Bolts and Washers
Insert
Filler Piece
Figure 6-26
Figure 6-29
5. Insert the steel filler piece behind the fuel tank.
8. Install the four floor pan bolts and washers.
9. Install the seat. Refer to Chapter 6. Seat Installation procedure.
Fuel
Sending
Unit
Figure 6-27
6. Attach the hoses and wiring to the fuel sending
unit.
Figure 6-28
7. Replace the floor pan.
6-7
7. Radiator/Oil Cooler
Disassembly and Assembly
Chapter Overview
Radiator/Oil Cooler
Disassembly and Assembly
Procedures
This chapter provides disassembly and assembly
procedures for the radiator/oil cooler assembly. Adjustment procedures are also included for selected
radiator/oil cooler components.
Disassembly and assembly procedures are provided
for the following radiator/oil cooler components.
Personal Safety
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in machine damage, injury or death.
Do not attempt to perform any type of repair or maintenance on a Compact Track Loader until you have read and
fully understood the information in this manual.
•
Fan Guard
•
Fan Shroud
•
Fan
•
Multi-Wing Fan
•
Radiator/Cooler
Note: Procedures are provided for only those radiator/oil
cooler components listed above. However, information for
removal and installation of other radiator/oil cooler components can be obtained from the machine specific parts
manual.
Refer to the Operation and Maintenance manual for instructions regarding proper machine operation techniques
before operating any Compact Track Loader.
Prior to performing any type of service work on a
Compact Track Loader, read and understand Chapter 1 (Product Safety) for personal safety information.
Note: Refer to Figure 3-1 for an overview of the filtering
and cooling system.
Machine Preparation
Fan Guard Removal and Installation
Accidental machine starting can cause injury or
death to personnel working on a Compact Track
Loader.
The tools required for fan guard removal and installation are listed in Table 7-1. Use manufacturerrecommended tools whenever possible.
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to performing any service work on a Compact Track Loader.
Table 7-1
Required Tools
Combination Wrench
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is being worked on.
7-1
Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly
Fan Guard Removal
Fan and Fan Shroud Removal
and Installation
The tools required for fan and fan shroud removal
and installation are listed in Table 7-2. Use manufacturer-recommended tools whenever possible.
Table 7-2
Fan
Guard
Mount
Required Tools
Combination Wrench
Socket Wrench
Fan
Guard
Figure 7-1
Fan and Fan Shroud Removal
1. Remove the capscrews that secure the fan
guard to the fan guard mounts.
Hot fluids can cause burns. Allow the machine
to cool thoroughly prior to proceeding.
2. Remove the fan guard from the engine compartment.
Remove
Hose
Fan Guard Installation
1. Position the fan guard over the fan and against
the fan shroud.
Figure 7-3
Fan
Guard
Mount
1. Remove the upper hose from the oil cooler section. Cap the hose and fitting.
Fan
2. Remove the fan guard. Refer to Chapter 7. Fan
Guard Removal.
Guard
Figure 7-2
2. Install the capscrews that secure the fan guard
to the fan guard mounts.
7-2
Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly
Remove
Bolts
Figure 7-4
Figure 7-7
3. Remove the three bolts from each side of the
fan shroud that secure the shroud to the radiator/cooler.
6. Remove the shroud from the engine compartment.
Fan and Fan Shroud Installation
Fan
Shroud
Remove
Bolts
Figure 7-5
Figure 7-8
4. With the shroud pulled back, reach between the
radiator/cooler and the fan and remove the four
bolts that secure the fan to the engine.
1. Place the fan shroud in the engine compartment.
Figure 7-9
Figure 7-6
2. Place the fan in the engine compartment.
5. Remove the fan from the engine compartment.
7-3
Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly
Radiator/Cooler Removal and
Installation
The tools required for radiator/cooler removal and
installation are listed in Table 7-3. Use manufacturer-recommended tools whenever possible.
Table 7-3
Required Tools
Install
Bolts
Combination Wrench
Socket Wrench
Screwdriver
Figure 7-10
3. Holding the fan in position between the radiator/cooler and the fan shroud, install the four
bolts that secure the fan to the fan drive motor.
Radiator/Cooler Removal
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and has been allowed to cool thoroughly.
Install
Bolts
Personal injury can result from hot coolant,
steam and alkali.
At operating temperature, engine coolant is hot and
under pressure. The radiator and hoses contain hot
coolant and steam. Allow the machine to cool thoroughly prior to performing service or repair procedures to avoid burns.
Figure 7-11
Remove the filler cap slowly to relieve pressure only
when the engine is stopped and the machine has been
allowed to cool thoroughly.
4. Pull the shroud over the fan and install the three
bolts on each side of the fan shroud that secure
the shroud to the radiator/cooler.
Cooling system conditioner contains alkali. Avoid
contact with skin and eyes.
5. Install the fan guard. Refer to Chapter 7. Fan
Guard Installation.
Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates.
Install
Hose
1. Remove fan and shroud. Refer to Chapter 7.
2. Drain the hydraulic fluid. Refer to Chapter 16.
Hydraulic Fluid and Filter Change.
Figure 7-12
6. Install the upper hose on the oil cooler section.
7-4
Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly
Remove
Hose
Figure 7-13
Figure 7-16
3. Remove the bolts from the lower engine compartment screen.
6. Remove the upper hose from the oil cooler section. Cap the hose and fitting.
Drain
Coolant
Figure 7-14
Figure 7-17
4. Remove the lower engine compartment screen
and drain the coolant using the petcock on the
bottom of the radiator.
7. Remove the upper hose from the radiator section. Cap the hose and fitting.
Figure 7-15
Figure 7-18
5. Remove the lower hose from the oil cooler section. Cap the hose and fitting.
8. Remove the lower hose from the radiator section. Cap the hose and fitting.
7-5
Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly
Install
Bolts
Remove
Bolts
Figure 7-19
Figure 7-22
9. Remove the three mounting bolts on each side
of the radiator/cooler.
2. With the radiator/cooler in position, install the
three mounting bolts on each side of the radiator/cooler.
Figure 7-20
Figure 7-23
10. Remove the radiator/cooler from the engine
compartment.
3. Remove the hose and fitting caps and install the
lower hose on the radiator section.
Radiator/Cooler Installation
Figure 7-24
Figure 7-21
4. Remove the hose and fitting caps and install the
upper hose on the radiator section.
1. Position the radiator/cooler in the engine compartment.
7-6
Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly
8. Fill the radiator with coolant and the hydraulic
reservoir with oil.
Install
Hose
Radiator/Oil Cooler
Adjustment Procedures
Adjustment procedures are provided for the following radiator/oil cooler components.
•
Fan Shroud
•
Fan Guard
Figure 7-25
5. Remove the hose and fitting caps and install the
upper hose on the oil cooler section.
Fan Shroud Adjustment
The tools required for fan shroud adjustment are
listed in Table 7-4. Use manufacturer-recommended
tools whenever possible.
Table 7-4
Tool Name
Combination Wrench
Loosen
Bolts
to Adjust
Figure 7-26
6. Remove the hose and fitting caps and install the
lower hose on the oil cooler section.
Figure 7-28
1. The fan shroud can adjusted upward or downward. To adjust, loosen the bolts on each side of
the shroud and move the shroud in the desired
direction. Tighten the bolts when finished.
Figure 7-27
7. Position the lower engine compartment screen
and secure with the mounting bolts.
7-7
Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly
Fan Guard Adjustment
The tools required for fan guard adjustment are
listed in Table 7-5. Use manufacturer-recommended
tools whenever possible.
Table 7-5
Tool Name
Combination Wrench
Loosen
Capscrews
to Adjust
Figure 7-29
1. The fan guard can adjust forward or rearward.
To adjust, loosen the capscrews that fasten the
fan guard to the fan guard mounts. Tighten the
capscrews when finished.
7-8
8. Hydraulic Reservoir
Disassembly and Assembly
Chapter Overview
Hydraulic Reservoir
Disassembly and Assembly
Procedures
This chapter provides disassembly and assembly
procedures for the hydraulic reservoir assembly.
Cleaning procedures are also included for the hydraulic reservoir.
Disassembly and assembly procedures are provided
for the following hydraulic reservoir components.
Personal Safety
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in machine damage, injury or death.
Do not attempt to perform any type of repair or maintenance on a Compact Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for instructions regarding proper machine operation techniques
before operating any Compact Track Loader.
•
Filter Element
•
Filter Assembly
•
Filler Cap Assembly
•
Access Cover Assembly
•
Reservoir Gauge
•
Suction Screen
Note: Procedures are provided for only those hydraulic
reservoir components listed above. However, information
for removal and installation of other hydraulic reservoir
components can be obtained from the Compact Track
Loader Parts List manual.
Prior to performing any type of service work on a
Compact Track Loader, read and understand Chapter 1 (Product Safety) for personal safety information.
Note: Refer to Figure 3-1 for an overview of the filtering
and cooling system.
Machine Preparation
Filter Element Removal and
Installation
Accidental machine starting can cause injury or
death to personnel working on a Compact Track
Loader.
Refer to Chapter 16. Maintenance – Hydraulic Fluid
and Filter for removal and installation of the filter.
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to performing any service work on a Compact Track Loader.
Filter Assembly Removal and
Installation
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is being worked on.
The tools required for filter assembly removal and
installation are listed in Table 8-1. Use manufacturer-recommended tools whenever possible.
Table 8-1
Required Tools
Combination/Socket Wrenches
Needle Nose Pliers
8-1
Compact Track Loader
8. Hydraulic Reservoir Disassembly and Assembly
Filter Assembly Removal
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and the machine has been allowed to cool
thoroughly
Note: During disassembly, cap all hoses and fittings to
prevent fluid loss and contamination of the system fluids.
Figure 8-3
3. Remove the filter from the reservoir as shown.
Figure 8-1
1. Remove the screws securing the cover to the
filter assembly.
Figure 8-4
4. Disconnect the hose from the filter assembly.
Figure 8-2
2. Remove the cap from the filter assembly as
shown.
Figure 8-5
5. Remove the bolts securing the filter head assembly to the reservoir.
8-2
Compact Track Loader
8. Hydraulic Reservoir Disassembly and Assembly
Figure 8-6
Figure 8-9
6. Remove the filter head and gasket from the reservoir.
3. Reconnect the hose to the filter head and secure.
Filter Assembly Installation
Figure 8-10
Figure 8-7
4. Reinstall the filter and filter tube into the reservoir as shown.
1. Place the filter assembly gasket in position on
top of the reservoir. Replace if damaged.
Figure 8-11
Figure 8-8
5. Install the cap onto the filter head as shown.
2. Position the filter head onto the gasket with the
mounting holes aligned, install bolts.
8-3
Compact Track Loader
8. Hydraulic Reservoir Disassembly and Assembly
1. Slightly loosen the access cover bolt to separate
the upper cap from the oval-shaped clamping
disk on the underside of the assembly. This will
allow the assembly to be removed. Do not remove the bolt entirely or the oval-shaped clamp
will fall into the reservoir.
Figure 8-12
6. Install the cap bolts and tighten to secure.
Access Cover Removal and
Installation
The tools required for access cover removal and
installation are listed in Table 8-2. Use manufacturer-recommended tools whenever possible.
Figure 8-14
2. Remove the access cover assembly from the
reservoir.
Table 8-2
Required Tools
Access Cover Assembly Installation
Combination Wrench
Access Cover Assembly Removal
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and the machine has been allowed to cool
thoroughly
Figure 8-15
1. Insert the access cover assembly with the
clamping disk extending completely through the
opening in the top of the reservoir and into the
tank.
Figure 8-13
8-4
Compact Track Loader
8. Hydraulic Reservoir Disassembly and Assembly
Figure 8-16
Figure 8-17
2. Tighten the access cover bolt.
3. View of hydraulic reservoir with filter assembly
removed.
Reservoir Gauge Removal and
Installation
The tools required for reservoir gauge removal and
installation are listed in Table 8-3. Use manufacturer-recommended tools whenever possible.
Table 8-3
Required Tools
Combination Wrenches
Reservoir Gauge Removal
Figure 8-18
4. Reach inside the reservoir and remove the two
nuts that fasten the reservoir gauge to the reservoir.
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and the machine has been allowed to cool
thoroughly
Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates.
Remove Reservoir Gauge
with Mounting
Bolts/Washers
Note: During disassembly, cap all hoses and fittings to
prevent fluid loss and contamination of the system fluids.
1. Drain the hydraulic fluid. Refer to Chapter 16.
Hydraulic Fluid and Filter Change.
Figure 8-19
5.
2. Remove the filter assembly. Refer to Chapter 8.
Filter Assembly Removal.
8-5
Pull the reservoir gauge and the two mounting
bolts/washers off the reservoir. DO NOT misplace the Compact washers or the reservoir will
leak.
Compact Track Loader
8. Hydraulic Reservoir Disassembly and Assembly
Reservoir Gauge Installation
Suction Screen Removal
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and the machine has been allowed to cool
thoroughly
Insert Reservoir Gauge
with Mounting
Bolts/Washers
Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates.
Figure 8-20
Note: It is normally not necessary to replace the suction
screen unless there has been a catastrophic failure and
there is debris in the reservoir.
1. Install the reservoir gauge in the reservoir using
the two mounting bolts/washers.
1. Drain the hydraulic fluid. Refer to Chapter 16.
Hydraulic Fluid and Filter Change.
2. Remove the access cover assembly. Refer to
Chapter 8. Access Cover Assembly Removal.
Figure 8-2113
2. Reach inside the reservoir and install the two
nuts that secure the reservoir gauge to the reservoir.
3. Install the filter assembly. Refer to Chapter 8.
Filter Assembly Installation.
4. Add manufacturer-approved hydraulic fluid.
Figure 8-22
Suction Screen Removal and
Installation
3. With a magnet centered in an absorbent rag,
thoroughly clean the interior of the reservoir to
prevent any debris from entering the system
when you remove the suction filter.
The tools required for suction screen removal and
installation are listed in Table 8-4. Use manufacturer-recommended tools whenever possible.
Table 8-4
Required Tools
Combination Wrench
8-6
Compact Track Loader
8. Hydraulic Reservoir Disassembly and Assembly
Hydraulic Reservoir Cleaning
Procedures
Cleaning procedures are provided for the following
hydraulic reservoir components.
•
Hydraulic Reservoir
Hydraulic Reservoir Cleaning
The tools required for hydraulic reservoir cleaning
are listed in Table 8-5. Use manufacturerrecommended tools whenever possible.
Figure 8-23
Table 8-5
4. Reach inside the reservoir and unscrew the suction screen. Remove the suction screen from the
reservoir.
Tool Name
Combination Wrench
Suction Screen Installation
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and the machine has been allowed to cool
thoroughly
Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates.
1. Drain the hydraulic fluid. Refer to Chapter 16.
Hydraulic Fluid and Filter Change.
Figure 8-24
2. Remove the access cover assembly. Refer to
Chapter 8. Access Cover Assembly Removal.
1. Insert the suction screen in the reservoir through
the access cover opening.
3. Thoroughly wipe out the interior of the hydraulic
reservoir with a magnet and a clean rag.
2. Reach inside the reservoir and screw the suction
screen into the bottom of the reservoir.
4. Install the access cover assembly. Refer to
Chapter 8. Access Cover Assembly Installation.
3. Install the access cover assembly. Refer to
Chapter 8. Access Cover Assembly Installation.
5. Add manufacturer-approved hydraulic fluid.
4. Add manufacturer-approved hydraulic fluid.
8-7
9. Loader/Transmission Controls
Disassembly and Assembly
Chapter Overview
Loader/Transmission Controls
Disassembly and Assembly
Procedures
This chapter provides disassembly and assembly procedures for the loader and transmission controls.
Personal Safety
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in ma-chine
damage, injury or death.
Do not attempt to perform any type of repair or mainten-ance
on a Compact Track Loader until you have read and fully
understood the information in this manual. Refer to the
Operation and Maintenance manual for in-structions regarding proper machine operation techniques before operating
any Compact Track Loader.
Prior to performing any type of service work on a Compact
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
Machine Preparation
Accidental machine starting can cause injury or death to personnel working on a Compact Track Loader.
As a precaution, disconnect the battery cables from the battery terminals, tape the battery clamps and remove the key
from the ignition switch prior to per-forming any service work
on a Compact Track Loader.
Disassembly and assembly procedures are provided
for the following loader/transmission control components.
• Drive Control Joystick
• Loader Control Joystick
• Loader Float Magnet
• Loader Valve
Note: Procedures are provided for only those
loader/transmission control components listed above.
However, information for removal and installation of
other loader/transmission control components can be
obtained from the Compact Track Loader Parts List
manual.
Note: Refer to Figure 3-2 for an overview of the auxiliary circuit system and Figure 3-3 for an overview of
the drive loop system.
Loader Control Joystick/Drive
Control Joystick Removal and
Installation
Place a “Do Not Operate” tag prominently on the machine to
inform personnel that the machine is be-ing worked on.
There are two joysticks that control the operation of the
machine: a drive control joystick and a loader control
joystick.
Drive Control Joystick Operation – The left-hand
joystick controls the speed and direction of the machine. The further the joystick is pushed, the faster the
machine travels. The joystick operates on hy-draulic
charge pressure. When the joystick is moved, oil is
sent to the hydrostatic transmission. The transmission
then delivers oil, in the correct amount, to the drive
motors.
9-1
Compact Track Loader
9. Loader/Transmission Controls
Loader Control Joystick Operation – The right-hand
joystick controls the loader arm and the at-tachment tilt
cylinder. It allows the operator to raise, lower and pivot
the attachment. The joystick operates on hydraulic
charge pressure.
The loader control also has a float position, which is
activated by moving the joystick completely forward
until it is held in detent. The joystick is held in the forward float position by an electromagnet.
The tools required for loader/drive control joystick
removal and installation are listed in Table 9 1. Use
manufacturer recommended tools whenever possible.
Figure 9-1
5. Remove the various screws holding the plastic
side consoles to the cab enclosure as shown.
Table 9-1
Required Tools
Combination/Socket Wrenches
Screwdriver (phillips)
Loader Control Joystick/Drive Control
Joystick Removal
Note: The procedures for removing both joystick controls are nearly identical, as a result, only the right control joystick procedure is described below.
Note: During disassembly, cap and plug all hoses and
fittings to prevent fluid loss and contamination of the
system fluids.
Figure 9-2
6. Pivot the panel away from the joystick, then lift and
remove it from the machine.
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.
1. Remove the seat from the machine according to
the procedure in chapter 6, seat removal.
2. Lower the lift arms to the ground.
Figure 9-3
3. Turn the ignition switch to the OFF position.
4. Relax all hydraulic circuits.
7. Remove the three nuts securing the joystick mount
to the cab enclosure from the outside of the
machine.
9-2
Compact Track Loader
9. Loader/Transmission Controls
Note: If it is neccessary to remove the left joystick on a
machine equipped with a heater, you must disconnect
the heater lines at the heater unit in order to remove
the side panel. Cap and plug hoses and ports to minimize coolant loss.
Loader Float Magnet Removal and
Installation
Figure 9-4
8. Pull the joystick away from the cab wall as shown.
The tools required for loader float magnet removal and
installation are listed in Table 9-2. Use manufacturer
recommended tools whenever possible.
Table 9-2
Required Tools
Allen (hex) Wrenches
Combination Wrenches
Screwdriver
Loader Float Magnet Removal
Figure 9-5
9. The hydraulic hoses are now accessible. Label
them and the ports they connect to to aid during
reassembly, then disconnect them and cap and
plug the openings to prevent spills.
Figure 9-7
1. Remove the zip tie securing the lower portion of
the joystick boot to the joystick as shown.
Remove
Figure 9-6
10. Disconnect the electrical connections shown to
free the joystick from the machine, then remove.
11. Reverse the removal procedure to reinstall the joy
stick. Take care to ensure all connections are to
the appropriate ports on the joystick and that they
are tight and leak free.
Figure 9-8
2. Lift the boot to expose the magnet and joystick
mounting bolts. Remove the joystick mounting
bolts to allow the joystick to be moved upward
within the bracket.
9-3
Compact Track Loader
9. Loader/Transmission Controls
Loader Valve Removal and
Installation
The tools required for loader valve removal and in-stallation are listed in Table 9 3. Use manufacturer-recommended tools whenever possible.
Table 9-3
Required Tools
Combination Wrenches
Figure 9-9
Loader Valve Removal
Hot oil can cause personal injury. Lower all
attach-ments and make sure the oil is cool
before removing any components or lines.
3. Use an allen (hex) wrench to remove the bolt
securing the magnet to the joystick.
Remove the oil filler cap only when the engine is
stopped and the filler cap is cool enough to touch
with your hands.
Collect and contain liquids in a suitable container. Dispose of all liquids according to local
regulations and mandates.
Note: During disassembly, cap all hoses and fittings to
prevent fluid loss and contamination of the system fluids.
Figure 9-10
4. Lift the joystick out of the mounting bracket slightly
to allow the magnet connector to pass between
them, then remove the magnet.
5. To install the float magnet, reverse the removal
procedure.
1. Lower the lift arms to the ground.
2. Turn the engine start switch to the OFF position.
3. Relieve hydraulic pressure from the auxiliary cir
cuit.
4. Drain the hydraulic fluid. Refer to Chapter 16.
Hydraulic Fluid and Filter Change.
9-4
Compact Track Loader
9. Loader/Transmission Controls
Figure 9-11
Figure 9-14
5. Disconnect the gas springs, then press the spring
latches inward as shown to remove the hood.
8. Carefully remove the rear valance from the
machine to allow access to the loader valve.
Figure 9-12
Figure 9-15
6. Carefully remove the hood from the machine and
set it aside.
9. Locate the loader valve on the side of the
hydraulic reservoir.
Figure 9-13
Figure 9-16
7. Remove the bolts securing the rear valance panel
to the chassis to allow for removal.
10. Disconnect the tubes from the top and bottom of
the loader valve. Cap and plug all openings to prevent fluid loss.
9-5
Compact Track Loader
9. Loader/Transmission Controls
Figure 9-17
Figure 9-20
11. Disconnect the tubes from the side of the loader
valve. Cap and plug all openings to prevent fluid
loss.
14. Remove the valve from the machine.
15. Installation is the reverse of the removal procedure.
16. Once all components have been reinstalled and
are secure, add manufacturer approved hydraulic
fluid until full mark is reached on the level gauge.
Figure 9-18
12. Disconnect the hoses from the rear and side of the
loader valve. Cap and plug all openings to prevent
fluid loss.
Note: To eliminate trapped air from the system, activate all hydralic circuits and run machine through its
paces including moving the lift arms up and down, curling and tilting the Q/A, driving forward and in reverse,
and activating the auxiliary circuit. Then, check
hydraulic fluid level and add as required to reach full
mark.
Figure 9-19
13. Remove the nuts securing the valve to the reser
voir as shown.
9-6
10. Transmission and Drive
Disassembly and Assembly
Chapter Overview
Transmission and Drive
Disassembly and Assembly
Procedures
This chapter provides disassembly and assembly
procedures for the transmission and drive assembly.
Disassembly and assembly procedures are provided
for the following transmission and drive components.
Personal Safety
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in machine damage, injury or death.
Do not attempt to perform any type of repair or maintenance on a Compact Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for instructions regarding proper machine operation techniques
before operating any Compact Track Loader.
•
Drive Motors
•
Auxiliary Gear Pump
•
Tandem Pump
•
Pump Drive Coupler
Note: Procedures are provided for only those transmission
and drive components listed above. However, information
for removal and installation of other transmission and drive
components can be obtained from the machine specific
parts manual.
Prior to performing any type of service work on a
Compact Track Loader, read and understand Chapter 1 (Product Safety) for personal safety information.
Note: Refer to Figure 3-2 for an overview of the auxiliary
circuit system and Figure 3-3 for an overview of the drive
loop system.
Machine Preparation
Drive Motor Removal and Installation
Accidental machine starting can cause injury or
death to personnel working on a Compact Track
Loader.
Refer to Chapter 12. Undercarriage Disassembly
and Assembly – Drive Motor Removal and Installation for removal and installation of the drive motors.
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to performing any service work on a Compact Track Loader.
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is being worked on.
10-1
Compact Track Loader
10. Transmission and Drive Disassembly and Assembly
Auxiliary Gear Pump Removal
and Installation
The tools required for auxiliary gear pump removal
and installation are listed in Table 10-1. Use manufacturer-recommended tools whenever possible.
Table 10-1
Auxiliary
Gear
Pump
Required Tools
Screwdriver
Combination Wrench
Socket Wrench
Figure 10-1
Auxiliary Gear Pump Removal
7. View of auxiliary gear pump with seat and fuel
tank removed.
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and has been allowed to cool thoroughly.
Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates.
Remove
Hose
Note: During disassembly, cap all hoses and fittings to
prevent fluid loss and contamination of the system fluids.
Figure 10-2
1. Lower the lift arms to the ground.
8. Remove the hose from the left side of the auxiliary gear pump.
2. Turn the engine start switch to the OFF position.
Loosen
Clamp and
Slide to
Left
3. Relieve hydraulic pressure from the auxiliary
circuit.
4. Drain the hydraulic fluid. Refer to Chapter 16.
Hydraulic Fluid and Filter Change.
Transmission
Hose
Lower
Manifold
Tube
5. Remove the seat. Refer to Chapter 6. Seat Removal.
6. Remove the fuel tank. Refer to Chapter 6. Fuel
Tank Removal.
Figure 10-3
9. Loosen the clamp that secures the transmission
hose to the lower manifold tube and slide the
clamp to the left.
10-2
Compact Track Loader
10. Transmission and Drive Disassembly and Assembly
Note: It is not necessary to separate the lower manifold
tube from the gear pump: this can be done after the pump
is removed, if necessary.
Remove
Bolt
Auxiliary Gear Pump Installation
Tandem
Pump
Auxiliary
Gear
Pump
Figure 10-4
Transmission
Hose
10. Remove the bolt on the left side of the auxiliary
gear pump.
Lower
Manifold
Tube
Figure 10-7
1. With the lower manifold tube attached to the
auxiliary gear pump, align the mounting bolt
holes in the auxiliary gear pump with the holes in
the tandem pump. It will be necessary to slide
the manifold tube into the transmission hose to
properly position the auxiliary gear pump.
Remove
Bolt
Figure 10-5
11. Remove the bolt on the right side of the auxiliary
gear pump.
Install
Bolt
Figure 10-8
2. Install the bolt on the right side of the auxiliary
gear pump.
Figure 10-6
12. Remove the auxiliary gear pump by sliding the
lower manifold tube out of the transmission
hose.
10-3
Compact Track Loader
10. Transmission and Drive Disassembly and Assembly
Tandem Pump Removal and
Installation
The tools required for tandem pump removal and
installation are listed in Table 10-2. Use manufacturer-recommended tools whenever possible.
Install
Bolt
Table 10-2
Required Tools
Screwdriver
Combination Wrench
Socket Wrench
Figure 10-9
Tandem Pump Removal
3. Install the bolt on the left side of the auxiliary
gear pump.
Slide Hose
Clamp to
Right and
Tighten
Transmission
Hose
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and has been allowed to cool thoroughly.
Lower
Manifold
Tube
Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates.
Note: During disassembly, cap all hoses and fittings to
prevent fluid loss and contamination of the system fluids.
Figure 10-10
1. Lower the lift arms to the ground.
4. With the end of the lower manifold tube inserted
in the transmission hose, slide the hose clamp to
the right and tighten the clamp.
2. Turn the engine start switch to the OFF position.
3. Relieve hydraulic pressure from the auxiliary
circuit.
5. Install the fuel tank. Refer to Chapter 6. Fuel
Tank Installation.
4. Drain the hydraulic fluid. Refer to Chapter 16.
Hydraulic Fluid and Filter Change.
6. Install the seat. Refer to Chapter 6. Seat Installation.
5. Remove the seat. Refer to Chapter 6. Seat Removal.
7. Add fuel and manufacturer-approved hydraulic
fluid.
6. Remove the fuel tank. Refer to Chapter 6. Fuel
Tank Removal.
7. Remove the auxiliary gear pump. Refer to Chapter 10. Auxiliary Gear Pump Removal.
10-4
Compact Track Loader
10. Transmission and Drive Disassembly and Assembly
Pump Drive
Coupler
Remove
Hoses and
Tubes
Pump
Mounting
Plate
Figure 10-11
Figure 10-14
8. Remove all hoses and tubes from the tandem
pump. Cap the hoses and tubes.
11. Remove the tandem pump (with pump drive
coupler attached) from the pump mounting plate.
Tandem Pump Installation
Pump Drive
Coupler
Flywheel
Gear
Remove
Bolt
Pump
Mounting
Plate
Figure 10-12
9. Remove the mounting bolt (with spring lock
washer and flat washer) from the right-hand side
of the tandem pump.
Figure 10-15
1. With the pump drive coupler attached to the tandem pump, position the tandem pump against
the pump mounting plate. Make sure the teeth
on the pump drive coupler mesh properly with
the flywheel gear teeth.
Remove
Bolt
Figure 10-13
10. Remove the mounting bolt (with spring lock
washer and flat washer) from the left-hand side
of the tandem pump.
10-5
Compact Track Loader
10. Transmission and Drive Disassembly and Assembly
5. Install the auxiliary gear pump. Refer to Chapter
10. Auxiliary Gear Pump Installation.
Install
Bolt
6. Install the fuel tank. Refer to Chapter 6. Fuel
Tank Installation.
7. Install the seat. Refer to Chapter 6. Seat Installation.
8. Add fuel and manufacturer-approved hydraulic
fluid.
Figure 10-16
Pump Drive Coupler Removal
and Installation
2. Install the mounting bolt (with spring lock washer
and flat washer) on the left-hand side of the tandem pump.
The tools required for pump drive coupler removal
and installation are listed in Table 10-3. Use manufacturer-recommended tools whenever possible.
Table 10-3
Required Tools
Screwdriver
Combination Wrench
Socket Wrench
Install
Bolt
Pump Drive Coupler Removal
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Figure 10-17
Remove the oil filler cap only when the engine is
stopped and has been allowed to cool thoroughly.
3. Install the mounting bolt (with spring lock washer
and flat washer) on the right-hand side of the
tandem pump.
Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates.
Note: During disassembly, cap all hoses and fittings to
prevent fluid loss and contamination of the system fluids.
1. Lower the lift arms to the ground.
Install
Hoses and
Tubes
2. Turn the engine start switch to the OFF position.
Figure 10-18
3. Relieve hydraulic pressure from the auxiliary
circuit.
4. Install the hoses and tubes on the tandem
pump.
4. Drain the hydraulic fluid. Refer to Chapter 16.
Hydraulic Fluid and Filter Change.
10-6
Compact Track Loader
10. Transmission and Drive Disassembly and Assembly
Pump Drive Coupler Installation
5. Remove the seat. Refer to Chapter 6. Seat Removal.
Tandem Pump
Drive Shaft
6. Remove the fuel tank. Refer to Chapter 6. Fuel
Tank Removal.
7. Remove the auxiliary gear pump. Refer to Chapter 10. Auxiliary Gear Pump Removal.
Pump
Drive
Coupler
8. Remove the tandem pump. Refer to Chapter 10.
Tandem Pump Removal.
Figure 10-21
Loosen
Locking
Screw
1. Slide the pump drive coupler all the way onto the
tandem pump drive shaft.
Tighten
Locking
Screw
Pump
Drive
Coupler
Tandem
Pump
Pump
Drive
Coupler
Figure 10-19
9. Loosen the locking screw that secures the pump
drive coupler to the drive shaft extending from
the end of the tandem pump.
Tandem
Pump
Figure 10-22
2. Tighten the locking screw that secures the pump
drive coupler to the tandem pump drive shaft.
Tandem Pump
Drive Shaft
3. Install the tandem pump. Refer to Chapter 10.
Tandem Pump Installation.
4. Install the auxiliary gear pump. Refer to Chapter
10. Auxiliary Gear Pump Installation.
Pump
Drive
Coupler
5. Install the fuel tank. Refer to Chapter 6. Fuel
Tank Installation.
Figure 10-20
6. Install the seat. Refer to Chapter 6. Seat Installation.
10. Slide the pump drive coupler off the tandem
pump drive shaft.
7. Add fuel and manufacturer-approved hydraulic
fluid.
10-7
11. Engine Components
Disassembly and Assembly
Chapter Overview
Engine Components
Disassembly and Assembly
Procedures
This chapter provides disassembly and assembly
procedures for the engine components.
Disassembly and assembly procedures are provided
for the following engine components.
Personal Safety
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in machine damage, injury or death.
Do not attempt to perform any type of repair or maintenance on a Compact Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for instructions regarding proper machine operation techniques
before operating any Compact Track Loader.
•
Muffler
•
Battery
•
Exhaust Pipe
•
Bleeding the Fuel System
Note: Procedures are provided for only those engine
components listed above. However, information for removal and installation of other engine components can be
obtained from the machine specific parts manual.
Prior to performing any type of service work on a
Compact Track Loader, read and understand Chapter 1 (Product Safety) for personal safety information.
Primary Air Filter Removal and
Installation
Refer to Chapter 16. Maintenance – Air Cleaner for
removal and installation of the primary air filter.
Machine Preparation
Accidental machine starting can cause injury or
death to personnel working on a Compact Track
Loader.
Safety Air Filter Removal and
Installation
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to performing any service work on a Compact Track Loader.
Refer to Chapter 16. Maintenance – Air Cleaner for
removal and installation of the safety air filter.
Engine Oil Filter Removal and
Installation
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is being worked on.
Refer to Chapter 16. Maintenance – Engine Oil for
removal and installation of the engine oil filter.
Fuel Filter Removal and
Installation
Refer to Chapter 16. Maintenance – Fuel Filter for
removal and installation of the fuel filter.
11-1
Compact Track Loader
11. Engine Components Disassembly and Assembly
Muffler Removal and
Installation
Remove
Bolts
The tools required for muffler removal and installation are listed in Table 11-1. Use manufacturerrecommended tools whenever possible.
Table 11-1
Required Tools
Socket/Combination Wrenches
Pry Bar
Penetrating Lubricant
Rubber Mallet/Plastic Hammer
Figure 11-3
Muffler Removal
3. Remove the four bolts that fasten the muffler to
the chassis. They can be accessed from the underside of the machine (right rear corner).
The exhaust system gets very hot during operation! Allow the machine to cool thoroughly prior to
performing service on the exhaust system.
4. Carefully guide the muffler out of the engine
compartment.
Loosen
Nuts
Muffler Installation
Position
the Muffler
over the
four
Mounting
Holes
Figure 11-1
1. Loosen the nuts on the muffler clamp.
Figure 11-4
1. Guide the muffler outlet pipe into its opening at
the rear of the engine compartment, then position the muffler over the mounting locations.
Figure 11-2
2. Spray the joint with penetrating lube, then slide
the curved pipe out of the muffler inlet. A pry bar
may be helpful in removing this pipe section.
11-2
Compact Track Loader
11. Engine Components Disassembly and Assembly
Tighten
Nuts
Install
Bolts
Figure 11-5
Figure 11-7
2. From the underside, install the four muffler
mounting bolts and washers/shims as found
upon disassembly.
4. Install the muffler clamp and secure in place.
Exhaust Pipe Removal and Installation
The tools required for exhaust pipe removal and installation are listed in Table 11-2. Use manufacturerrecommended tools whenever possible.
Table 11-2
Required Tools
Socket/Combination Wrench
Pry Bar
Penetrating Lubricant
Rubber Mallet/Plastic Hammer
Figure 11-6
Exhaust Pipe Removal
3. Carefully slide the curved pipe into the muffler
inlet. You may need to tap it into place with a
rubber mallet or similar device.
The exhaust system gets very hot during operation! Allow the machine to cool thoroughly prior to
performing service on the exhaust system.
NOTICE
Loosen
Nuts
If it is necessary to tap the pipe section into the muffler, do
so carefully as the pipe walls are thin and easily distorted.
Use caution and care as you install the pipe section.
Figure 11-8
1. Loosen the nuts on the muffler clamp
11-3
Compact Track Loader
11. Engine Components Disassembly and Assembly
Exhaust Pipe Installation
Remove
Bolts
Figure 11-9
2. Remove the four bolts that secure the exhaust
pipe to the exhaust manifold.
Figure 11-12
5. Carefully slide the curved pipe into the muffler
inlet. You may need to tap it into place with a
rubber mallet or similar device.
NOTICE
If it is necessary to tap the pipe section into the muffler, do
so carefully as the pipe walls are thin and easily distorted.
Use caution and care as you install the pipe section.
Figure 11-10
3. Remove the exhaust pipe gasket from the exhaust manifold, then remove the retaining
springs and center pipe from the assembly.
Note: The gasket may come off with the exhaust pipe.
Figure 11-13
6. Install the center section of pipe as found upon
disassembly and install the retaining springs.
Then, position the exhaust gasket for reinstallation and start one bolt to hold it in place.
Figure 11-11
4. Spray the joint with penetrating lube, then slide
the curved pipe out of the muffler inlet. A pry bar
may be helpful in removing this pipe section.
11-4
Compact Track Loader
11. Engine Components Disassembly and Assembly
Battery Removal
Install
Bolts
Negative
Terminal
Positive
Terminal
Figure 11-14
7. With the exhaust pipe gasket in place, install the
remaining bolts that secure the exhaust pipe to
the exhaust manifold.
Figure 11-16
1. Identify the positive and negative battery terminals.
Tighten
Nuts
Disconnect
Negative
Cable
Figure 11-15
Figure 11-17
8. Reinstall the muffler clamp, then tighten the nuts
to secure.
2. Disconnect the battery cable from the negative
battery terminal.
Battery Removal and Installation
The tools required for battery removal and installation are listed in Table 11-3. Use manufacturerrecommended tools whenever possible.
Disconnect
Positive
Cable
Table 11-3
Required Tools
Combination Wrench
Socket Wrench
Figure 11-18
3. Disconnect the battery cable from the positive
battery terminal.
11-5
Compact Track Loader
11. Engine Components Disassembly and Assembly
1. Place the battery in position in the engine compartment.
Remove
Capscrews
Install
Capscrews
Figure 11-19
4. Remove the two capscrews from the battery
holdown bracket and remove the bracket.
Figure 11-22
2. Position the battery holdown bracket and install
the two capscrews and nuts.
Connect
Positive
Cable
Figure 11-20
5. Rotate the battery 90 degrees counterclockwise. Tilt up the front of the battery and
remove the battery from the machine.
Figure 11-23
3. Connect the battery cable to the positive battery
terminal.
Battery Installation
Connect
Negative
Cable
Figure 11-24
Figure 11-21
11-6
Compact Track Loader
11. Engine Components Disassembly and Assembly
4. Connect the battery cable to the negative battery
terminal.
Bleeding the Fuel System
The tools required for muffler removal and installation are listed in Table 11-1. Use manufacturerrecommended tools whenever possible.
Table 11-4
Required Tools
Combination Wrench
Figure 11-26
If the machine has been run out of fuel, it may be
necessary to bleed the fuel system. There are two
types of bleeding methods depending on the serial
number of your machine.
1. Locate the bleed screw directly above the fuel
injectors.
2. Loosen the bleed screw two full turns.
For serial numbers 001 through 1357.
Figure 11-25
Figure 11-27
1. Locate the bleed screw directly above the fuel
injectors.
3.
2. Loosen the bleed screw two full turns
Pump the bulb primer with your hand until fuel
flows from the bleed screw without any air bubbles.
4. Tighten the bleed screw.
3. Turn-over the engine from the operators compartment until fuel is flowing from the bleed
screw without any air bubbles.
4. Tighten the bleed screw.
5. Engine should now start within 10 seconds.
For serial numbers 1358 and higher.
11-7
12. Undercarriage
Disassembly and Assembly
Chapter Overview
Undercarriage Disassembly
and Assembly Procedures
This chapter provides disassembly and assembly
procedures for the following undercarriage
assemblies.
•
Track
•
Suspension
Disassembly and assembly procedures are provided
for the following undercarriage components.
Personal Safety
•
Wheels (also see track procedure)
•
Sprockets
•
Sprocket rollers
•
Sprocket bearing plates
Improper or incomplete maintenance/repair of a
Compact Track Loader can be dangerous and may
result in machine damage, injury or death.
•
Tracks
•
Drive motors
Do not attempt to perform any type of repair or
maintenance on a Compact Track Loader until you
have read and fully understood the information in
this manual.
Note: Procedures are provided for only those
undercarriage components listed above. However,
information for removal and installation of other
undercarriage components can be obtained from the
machine specific parts manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation
techniques before operating any Compact Track
Loader.
Wheel Removal and
Installation
Prior to performing any type of service work on a
Compact Track Loader, read and understand
Chapter 1 (Product Safety) for personal safety
information.
The tools required for wheel removal and installation
are listed in Table 12-1. Use manufacturerrecommended tools whenever possible.
Table 12-1
Machine Preparation
Required Tools
Wheel Extractor
Channel Lock Pliers
Socket Wrench
Snap-ring Pliers
Accidental machine starting can cause injury or
death to personnel working on a Compact Track
Loader.
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to
performing any service work on a Compact Track
Loader.
Wheel Removal
Note: If the track is to be removed, perform the track
removal process on page 12-3 of this chapter.
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is
being worked on.
Note: For important wheel and bearing information, see
“Bearings” in the track removal procedure on page 12-4,
prior to removing or reinstalling the idler wheels.
Note: The procedure for removing the Idler wheels and
Bogie wheels are similar. Only the front outside idler wheel
is described here. Any exception will be explained in the
instructions as a note. See figure 12-1 for wheel diagram.
12-1
Compact Track Loader
12. Undercarriage Disassembly and Assembly
Rear
Idler
Wheels
Bogie
Wheels
Front
Idler
Wheels
Figure 12-4
Figure 12-1
Remove the nut that fastens the wheel to the
shaft with the correct size socket.
1. Loosen up the track tensioner as described in
the track removal procedure on page 12-3, steps
1-4.
4.
Figure 12-2
Figure 12-5
2. Remove the snap ring securing the wheel cap
with snap ring pliers.
5. Remove the washer.
Figure 12-3
3. Remove the wheel cap using a large channel
lock pliers.
Figure 12-6
6. Remove the bearing.
12-2
Compact Track Loader
12. Undercarriage Disassembly and Assembly
Note: Bogie wheels will have a large washer that is
installed before the wheel.
2. Install the bearing, washer, and wheel nut to the
axle. Torque the nut to 110 ft-lbs (149Nm).
3. Install the cap and secure it with the snap-ring.
Make sure the snap-ring is fully seated in its
grove.
Track Removal and
Installation
Figure 12-7
7.
Remove the idler wheel with a wheel
extractor as shown in figure 12-7.
The tools required for track removal and installation
are listed in Table 12-2. Use manufacturerrecommended tools whenever possible.
Note: If removing a bogie wheel, remove the large
inside washer.
Table 12-2
8. Inspect the exposed axle(s) for wear or damage.
Required Tools
9. To remove any idler wheels, or bogie wheels,
located on the inside of the suspension nearest
the chassis; position the machine securely on
jack-stands. Repeat the wheel removal
procedure.
Socket Wrench
Combination Wrench
Crowbar
Jack Stands
Heavy Duty Floor Jack
Straight Edge
Tape Measure
Track Removal
Wheel Installation
To remove the tracks, the machine must be jacked
up and placed on jack stands sturdy enough to support the
weight of the machine. Terex approved jack stands are
recommended.
Note: Refer to bearing illustration on figure 12-9 of this
chapter to ensure proper installation of each style of
bearing.
Figure 12-8
1. Mount the outer front idler wheel onto the axle
as shown.
Note: During installation carefully slide the wheel
onto the axle shaft to prevent seal damage.
12-3
Compact Track Loader
12. Undercarriage Disassembly and Assembly
NOTE: Bearings
Tapered Roller Bearing
Ball Bearing
Figure 12-11
2. Remove the nut from the bolt that fastens the
track tensioner to the drive sprocket assembly.
In the illustration above, the rear wheel is shown
with a tapered roller style bearing while the center
wheel is shown with a ball type bearing. It is
important to note that these bearings are positioned
within the undercarriage as they are, in order to
adequately bear the differing loads/forces applied to
them.
When replacing bearings or removing wheels,
always make sure the front and rearmost wheels
in the undercarriage are equipped with tapered
“roller” type bearings, while the eight interior
wheels are to be equipped with “ball” type
bearings. They are not interchangeable in this
application.
Figure 12-12
Figure 12-9
3. Using a pry bar, pivot the drive table assembly
upward and support it until the track
tensioner bolt can be removed. Remove the bolt.
Jam nut
Figure 12-10
1. Loosen the jam nut located on the track
tensioner using the correct size wrench. Turn
the track tensioner until the track has significant
slack.
Figure 12-13
4. Pry the drive table assembly upward, away from
the tensioner. Then pivot the tensioner forward
as shown. Once the tensioner is out of the way,
lower the drive table until it rests on the rail.
12-4
Compact Track Loader
12. Undercarriage Disassembly and Assembly
Track Installation
To remove the tracks, the machine must be jacked
up and placed on jack stands sturdy enough to support the
weight of the machine. Terex approved jack stands are
recommended.
A
Figure 12-14
5. Locate the wheel marked “A” in fig. 12-14.
Track
Drive
Lugs
Figure 12-17
1. Place the track around the rear wheels and on
top of the drive sprocket. Make sure the track
drive lugs mesh with the sprocket.
Figure 12-15
6. Perform steps 1-7 of the wheel removal
procedure in this chapter to remove the outer
front idler wheel.
Apply
Soap
Figure 12-18
2. Using soap, lubricate the front inside wheel. Pull
the track around the outside wheel shaft and
onto the front inside wheel. The soap will help
the track slide onto the wheel.
Track
Drive
Lugs
Figure 12-16
7. With the wheel removed and the drive sprocket
table lowered, the track is ready for removal.
8. Pull the track outward as shown.
12-5
Compact Track Loader
12. Undercarriage Disassembly and Assembly
Figure 12-19
Figure 12-22
3. Install the front wheel. Refer to Chapter 12.
Wheel Installation pg 12-3.
6. Install the remaining wheels making sure the
bearing, washer, wheel nuts, wheel caps, and
snap-rings are properly installed. Refer to
Chapter 12. Wheel Installation pg 12-3.
Align
Holes
Jam Nut
Track
Tensioner
Figure 12-20
4. Pry the sprocket up until the holes in the track
tensioner and drive table are aligned. A floor
jack or a second pry bar may be needed to get
the drive table off the rail.
Figure 12-23
7. Tighten the track by turning the track
tensioner. When proper track tension has been
achieved, tighten the jam nut on the track
tensioner.
8. Check for proper track tension. Refer to
Chapter 16. Maintenance – Checking for Proper
Track Adjustment
Tighten
Bolt
Sprocket Bearing Plate
Removal and Installation
The tools required for sprocket bearing plate
removal and installation are listed in table 12-3
below. Use manufacturer-recommended tools
whenever possible.
Figure 12-21
5. Install and tighten the track tensioner bolt and
nut.
12-6
Compact Track Loader
12. Undercarriage Disassembly and Assembly
Table 12-3
Required Tools
Socket Wrench
Bearing Puller Tool
Combination Wrench
Torque Wrench
Sprocket Bearing Plate Removal
1. Remove the track. Refer to Chapter 12. Track
Removal.
Figure 12-26
5. Remove the four bolts that secure the bearing
assembly to the bearing plate, remove the
bearing plate.
Castle nut
Cotter pin
Figure 12-24
2. Remove the cotter pin from the castle nut on the
end of the sprocket assembly.
Figure 12-27
6. Remove bearing from sprocket with bearing
puller tool. Inspect sprocket rollers for wear. If
replacement is needed, refer to sprocket roller
removal on page 12-8 of this chapter.
Spacer
Sprocket Bearing Plate Installation
1. To install the sprocket bearing plate, reverse
removal procedure with following added
instructions.
Bearing
flange w/
zerk
Two bolts
Figure 12-25
Bearing
grease
track
3. Remove the spacer washer.
4. Remove the two bolts securing the bearing plate
to the drive table.
Figure 12-28
12-7
Compact Track Loader
12. Undercarriage Disassembly and Assembly
2. Align the grease hole of the bearing flange with
zerk and the grease track on the bearing as
shown in figure 12-28.
3. Ensure that the concave side of the washer is
contacting the sprocket.
4. Torque castle nut is to 270 ft-lb (366 Nm) and
then rotate until the next hole is visible to install
the cotter key.
Position Drive
Sprocket to
Access Roller
Sprocket Roller Removal and
Installation
Figure 12-30
The tools required for sprocket roller removal and
installation are listed in table 12-4 below. Use
manufacturer-recommended tools whenever
possible.
1. Rotate the drive sprocket to allow access to the
sprocket roller bolt. Remove the bolt.
Sprocket Roller Removal
Table 12-4
Required Tools
Socket/Combination Wrench
Note: The rollers should be inspected every 50 hours for
rotation and wear-through. The rollers on the drive
sprocket are easily replaceable. The track DOES NOT
need to be removed to replace these rollers.
Figure 12-31
Roller
Pin
Washer
2. Remove the roller and steel pin from the drive
sprocket.
Sprocket
Steel Pin
Roller
Figure 12-32A
3. Inspect the rollers for wear and replace as
necessary. The steel pin will normally not need
replacing unless the roller has worn completely
away and the steel pin is worn from engaging
the track (fig. 12-32A & B).
Note: In order to remove the sprocket rollers and pins, you
must remove the torsion axle retaining bolts and washers,
then slide the undercarriage away from the chassis slightly
(approx. 1”, 2.54 cm). This will provide clearance for the
sprocket bolts to be removed for roller/pin replacement.
Figure 12-29
12-8
Compact Track Loader
12. Undercarriage Disassembly and Assembly
Sprocket Removal and
Installation
The tools required for sprocket removal and
installation are listed in table 12-5 below. Use
manufacturer-recommended tools whenever
possible.
Sprocket Removal
Table 12-5
Required Tools
Socket Wrench
Sprocket Puller
Figure 12-32B
Sprocket Roller Installation
Impact Driver
1. Remove the sprocket bearing plate as described
on page 12-7.
Puller holes
Figure 12-33
Figure 12-35
1. With the drive sprocket rotated to the desired
position, position the composite roller and steel
pin in the drive sprocket.
2. Install the puller by positioning the push bolt into
the end of the sprocket shaft and then threading
the puller bolts into the holes in the fac e of the
drive sprocket. (fig. 12-35 & 12-36).
Figure 12-34
2. Insert the sprocket roller bolt from the rear.
Torque to 62 ft. lbs.
Figure 12-36
12-9
Compact Track Loader
12. Undercarriage Disassembly and Assembly
3. Operate the puller by tightening the push bolt
with a wrench until the sprocket is pulled off the
drive motor shaft as shown in figure 12-36. Remove sprocket and inspect sprocket rollers for
wear. If replacement is needed, refer to Sprocket roller removal on page 12-8 of this chapter.
Sprocket Installation
Figure 12-39
3. Align the key on the shaft with the key-way in
the drive sprocket, and then slide the sprocket
onto the shaft. Install the bolt into the end of the
sprocket shaft and finger- tighten. Complete the
next step as soon as possible to prevent the
Loc-tite from drying before the sprocket is
tightened.
Figure 12-37
1. After inspecting and cleaning the shaft, spray
7471 Loctite Primer on to the shaft.
Figure 12-40
Note: Using a torque wrench, tighten the sprocket bolt
to275 lb-ft (366 Nm).
Figure 12-38
4. Remove the drive motor fittings by turning the
motor so that the fittings face upward. Then tilt
the motor in the table as shown & pull upward
and outward to remove.
2. Once the primer has dried spread 680 Loc-tite
Retaining Compound onto the shaft. The
retaining compound is very important; it fills in
small inconsistencies in the shaft and creates a
better bond between the shaft and the sprocket.
Drive Motor Removal and
Installation
Use manufacturer-recommended tools whenever
possible.
Table 12-6
Required Tools
Socket/Combination Wrench
12-10
Compact Track Loader
12. Undercarriage Disassembly and Assembly
Note: During disassembly, cap all hoses and fittings to
prevent fluid loss and contamination of the system fluids.
Drive Motor Removal
Top Large
Angled Small
Figure 12-43
3. Remove the four bolts that secure the drive
motor to the drive table using a thin wall socket.
Straight Small
Bottom Large
Fittings
on top
Figure 12-41
1. Locate four drive motor hoses in back of drive
motor.
“T” marking
Plug
Figure 12-44
4. Remove drive motor by turning motor with the
hydraulic hose fittings facing upward and
angle the motor out of the table weldment and
pull in upward motion.
Figure 12-42
Drive Motor Installation
2. Mark the top (T) and bottom (B) large hoses to
ensure proper re-installation. For ease of
removal, remove hoses in this order: angled
small, top large, straight small, bottom large. It
is important to cap fittings and plug drive
hoses to ensure hydraulic systems is free from
debris.
1. Position the drive motor so the hydraulic fittings
enter in the correct location. Install the drive
motor bolts. Clean and inspect the drive motor
shaft.
2. Re-install all hoses and fitting in the same order
instructions direct in removal.
3. Re-install drive sprocket as outlined above.
12-11
13. Lift Arm
Disassembly and Assembly
Chapter Overview
Lift Arm Disassembly and
Assembly Procedures
This chapter provides disassembly and assembly
procedures for the loader assembly.
Disassembly and assembly procedures are provided
for the following loader components.
Personal Safety
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in
machine damage, injury or death.
Do not attempt to perform any type of repair or
maintenance on a Compact Track Loader until you have
read and fully understood the information in this manual.
•
Lift Cylinders
•
Tilt Cylinders
•
Pressure Release Valve
•
Lift Arm Bushings
Note: Procedures are provided for only those loader
components listed above. However, information for
removal and installation of other loader components can
be obtained from the machine specific parts manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation
techniques before operating any Compact Track Loader.
Prior to performing any type of service work on a Compact
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
Lift Cylinder/Tilt Cylinder
Removal and Installation
Machine Preparation
The tools required for lift cylinder and tilt cylinder
removal and installation are listed in Table 13-1. Use
manufacturer-recommended tools whenever
possible.
Accidental machine starting can cause injury or death to
personnel working on a Compact Track Loader.
As a precaution, disconnect the battery cables from the
battery terminals, tape the battery clamps and remove the
key from the ignition switch prior to performing any service
work on a Compact Track Loader.
Table 13-1
Required Tools
Combination Wrench
Socket Wrench
Place a “Do Not Operate” tag prominently on the machine
to inform personnel that the machine is being worked on.
Lift Cylinder/Tilt Cylinder Removal
Note: The procedures for removing the lift cylinders and
tilt cylinders are very similar, as a result only the lift
cylinder procedure is described below.
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
13-1
Compact Track Loader
13. Loader Disassembly and Assembly
5. Disconnect and cap the hose on the rear end of
the cylinder.
Collect and contain liquids in a suitable
container. Dispose of all liquids according to local
regulations and mandates.
Note: During disassembly, cap all hoses and fittings to
prevent fluid loss and contamination of the system fluids.
Disconnect
Hose
1. To remove lift cylinders raise the lift arms and
support them with the lift arm brace as described
in Ch 16 of this manual.
Note: When removing tilt cylinder(s), lower the loader
arms onto a mechanical support with the arms resting
about 6 inches off the ground.
2. Turn the ignition switch to the OFF position and
remove the key to avoid accidental start.
Figure 13-3
6. Disconnect and cap the hose on the forward end
of the cylinder.
Zip tie
Remove
Bolt
Figure 13-1
3. Remove the zip tie that secures the hydraulic
hose to the lift cylinder.
4. Release hydraulic pressure by performing step 3
on page 13-6 of this chapter.
Figure 13-4
7. Remove the forward pin assembly bolt.
Lift
Cylinder
Disconnect
Hose
Figure 13-5
8. Support the cylinder from the underside then
remove the forward pin assembly.
Figure 13-2
13-2
Compact Track Loader
13. Loader Disassembly and Assembly
Remove
bolt and
then pin
End gland
Figure 13-6
Figure 13-7
9. Remove the bolt and pin from the loader tower.
1. Secure the cylinder into a vice and remove the
end gland by turning counter clockwise with
channel lock pliers. Be sure to have a container
to catch draining hydraulic fluid.
10. Again support the cylinder from the underside
then remove the lift cylinder from the machine.
Lift Cylinder/Tilt Cylinder Installation
1. To install the lift/tilt cylinder, reverse the removal
procedure.
2. Add removable locktite to all fittings.
3. Add grease to loader pin zerks to ensure
lubrication of bushings.
Lift Cylinder/Tilt Cylinder
Seals Removal
Figure 13-8
Table 13-2
2. Remove the rod from cylinder by pulling
outward using both hands as shown.
Required Tools
Channel Lock Pliers
Bench Vice
Blade Type Screwdriver
Socket
Rubber Mallet
Lift Cylinder / Tilt Cylinder Seal Removal
Note: The procedures for removing seals on the lift
cylinders and tilt cylinders are similar, only the lift cylinder
procedure is described below.
Figure 13-9
3. Secure the rod in the bench vice as shown.
13-3
Compact Track Loader
13. Loader Disassembly and Assembly
O-rings
Figure 13-13
7. Remove the three o-rings located on the outside
of the end gland with a small blade type
screwdriver paying close attention to the order
they are removed to aid during installation of
new seals.
Figure 13-10
4. Remove the nut from the rod end using the
correct size socket.
Piston
O-ring
Rod seal
Wiper
Figure 13-14
Figure 13-11
8. Remove the shaft wiper and then the rod seal
from the inside of the end gland with a small
blade type screwdriver. Pay attention to seal
orientation upon removal to aid during
installation of new seals.
5. Remove the piston and the o-ring off the rod by
sliding them upward and off.
End gland
Figure 13-12
6. Remove the end gland by sliding upward and off
the rod.
13-4
Compact Track Loader
13. Loader Disassembly and Assembly
11. To remove cylinder bushings, place cylinder in
vice and find a socket the same diameter as the
bushing. Remove the bushing with a rubber
mallet and the socket. You may need to use a
punch tool to complete the removal of the
bushing.
Back-up ring
12. Thoroughly clean and dry all parts prior to
installation of new seals to prevent
contamination of hydraulic oil when cylinders are
reassembled and installed.
Lift Cylinder/Tilt Cylinder Seal Kit Install
Note: The procedures for installing the seal kits on the lift
cylinders and tilt cylinders are similar, only the lift cylinder
procedure is described below.
Figure 13-15
9. Remove the back-up ring on the inside of the
end gland with a small blade type screwdriver.
Lift Cylinder Seal Kit: P/N 2010-552
Tilt Cylinder Seal Kit: P/N 2010-548
1. Reverse the cylinder seal removal procedure to
install seal kits on both the lift and tilt cylinders.
2. Make sure your work area is clean and that all
tools are clean before beginning seal install.
Lubricate all seals with new hydraulic oil prior to
install.
Piston seal
Socket
Wear ring
Piston
Wiper
Figure 13-16
10. Remove piston seal and wear ring from piston
using a blade type screwdriver.
Figure 13-18
3. Use a rubber mallet and a socket or section of
pipe with the same outside diameter as the seal
to drive into place.
4. Reverse steps 1-6 of the seal removal
procedure to reassemble the cylinder.
5. Add removable locktite to the nut and torque to
75 ft. lbs.
6. Torque the cap gland to 100 ft. lbs.
Figure 13-17
13-5
Compact Track Loader
13. Loader Disassembly and Assembly
2. Turn the engine start switch to the OFF position
and remove the key to avoid accidental start.
Lift Arm Bushing Removal and
Installation
The tools required for lift arm and lift arm bushing
removal and installation are listed in Table 13-3. Use
manufacturer-recommended tools whenever
possible.
Table 13-3
Required Tools
Socket
Dead Blow Hammer
Combination Wrench
Crescent Wrench
Mechanical Support
Lifting Device
Pry Bar
Figure 13-21
3. Remove the bolts from each side of the lift arm
that secure the pins to the chassis.
Lift Arm Bushing Placement
Upper
Friction
Point
Lower
Friction
Point
Bushings
Figure 13-22
4. Remove the pins from each side of the chassis.
Figure 13-19
Upper Friction Points:
Note: Each worn bushing will be removed one at a
time.
Figure 13-23
5. Raise the lifting device until arm has cleared the
chassis and the hydraulic hoses. Use a pry bar
to guide the lift arm upward if necessary.
Figure 13-20
6. Inspect the bushings for wear according to the
procedure in page 16-6, step 3. If it is
determined that replacement is needed,
continue onto step 7 of this procedure.
1. Lower the lift arm to the chassis stops. Then
attach suitable lifting device to them as shown,
to secure them during the procedure.
13-6
Pry bar
Compact Track Loader
13. Loader Disassembly and Assembly
Figure 13-24
7. Compress a replacement bushing to fit the hole
size and start the insertion with a dead blow
hammer as shown. As you drive the new
bushings into the lift arm, the old bushings will
be forced out of the opposite side of the lift arm.
Figure 13-26
12. With an assistant, lower lifting device to drop lift
arm back into position to re-install pins. A pry
bar may be used to aid in aligning chassis and
lift arm pin holes.
Do not use fingers to align pin holes.
Figure 13-25
8. Complete the insertion of the first bushing with a
socket and hammer until the bushing is flush
with the surface of the lift arm.
9. Repeat Step 8 to install the second
bushing. This action will force the remaining
worn bushing out and drive the first replacement
bushing to its permanent position.
Figure 13-27
13. Insert the pin into the chassis and through the lift
arm.
10. Clean and remove any debris, then apply
anti-seize to the inside of the bushings.
11. Perform steps 7-10 on opposite side of lift arm to
remove remaining bushings.
Figure 13-28
14. Install bolt and nut to secure pin to chassis.
15. Perform steps 12-13 for opposite side of lift arm.
13-7
Compact Track Loader
13. Loader Disassembly and Assembly
Figure 13-29
Figure 13-32
16. Add grease to the zerks located on each of the
lift pins to lubricate them.
2. Remove bolt from pins that secure the tilt
cylinder to the quick attach.
Lower Friction Points:
Note: Each worn bushing will be removed one at a
time.
Figure 13-33
3. Remove pin from the cylinder and quick attach.
Figure 13-30
Bolt
Figure 13-31
Figure 13-34
1. Lower lift arms onto a mechanical support,
with quick attach resting about 1 ft. off the
ground. Then attach a lifting device to secure
the lift arm in position.
4. Remove bolt from pins that secure the quick
attach to the lift arm.
13-8
Compact Track Loader
13. Loader Disassembly and Assembly
9. Complete insertion of the bushing with a socket
and the hammer until the bushing is flush with
the surface of the lift arm. This action will force
the worn bushing out the opposite side of the lift
arm for removal.
10. Repeat steps 7-9 for opposite side of lower lift
arm.
11. Clean and remove any debris, then apply
anti-seize to the inside of the bushings
12. Reverse steps 2-6 to install the pins and bolts.
Figure 13-35
5. Remove pin.
6. Perform steps 2-5 on opposite side of quick
attach.
7. Inspect the lower lift arm bushings for wear
according to the procedure in page 16-6, step 3.
If it is determined that replacement is needed,
continue onto step 8 of this procedure.
Figure 13-38
13. Add grease to the zerks located on each of the
lift pins and lubricate them.
Quick-Coupler Block /
Pressure Release Valve
Removal and Installation
The tools required for quick coupler block removal
and installation are listed in Table 13-4. Use
manufacturer-recommended tools whenever
possible.
Figure 13-36
8. Compress a replacement bushing to fit the hole
size and start the insertion with a dead blow
hammer.
Table 13-4
Required Tools
Combination Wrench
Socket Wrench
Quick Coupler Block Removal
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and the machine has been allowed to cool
thoroughly.
Figure 13-37
13-9
Compact Track Loader
13. Loader Disassembly and Assembly
Collect and contain liquids in a suitable
container. Dispose of all liquids according to local
regulations and mandates.
Note: During disassembly, cap all hoses and fittings to
prevent fluid loss and contamination of the system fluids.
Remove
Bolts
1. Lower the lift arms to the ground.
2. Turn the engine start switch to the OFF position
and remove the key to avoid accidental start.
Figure 13-41
5. Remove the four bolts that secure the quick
coupler block to the loader frame and remove
the block.
Quick Coupler Block / Pressure Release
Valve Installation
Figure 13-39
Install
Bolts
3. Press the button on top of the quick coupler
block to release hydraulic pressure.
Figure 13-42
Disconnect
Tubes
1. Install the four bolts that secure the quick
coupler block to the loader frame.
Figure 13-40
Reconnect
Tubes
4. Disconnect and cap all three hydraulic tubes.
Figure 13-43
2. Reconnect all three hydraulic tubes.
13-10
14. Quick Attach
Disassembly and Assembly
Chapter Overview
Quick Attach Disassembly and
Assembly Procedures
This chapter provides disassembly and assembly
procedures for the quick attach assembly.
Disassembly and assembly procedures are provided
for the following quick attach components.
Personal Safety
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in
machine damage, injury or death.
•
Latch Mechanism
•
Quick Attach Assembly
Note: Procedures are provided for only those quick attach
components listed above. However, information for
removal and installation of other quick attach components
can be obtained from the machine specific parts manual.
Do not attempt to perform any type of repair or
maintenance on a Compact Track Loader until you have
read and fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation
techniques before operating any Compact Track Loader.
Latch Mechanism Removal
and Installation
Prior to performing any type of service work on a
Compact Track Loader, read and understand
Chapter 1 (Product Safety) for personal safety
information.
The tools required for latch mechanism removal and
installation are listed in Table 14-1. Use
manufacturer recommended tools whenever
possible.
Machine Preparation
Table 14-1
Accidental machine starting can cause injury or
death to personnel working on a Compact Track
Loader.
Required Tools
Socket/Combination Wrench
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to
performing any service work on a Compact Track
Loader.
Latch Mechanism Assembly Removal
1. Remove any attachments and place support
blocks beneath the quick attach. Then tilt the
quick attach assembly forward and lower the lift
arms until the quick attach assembly rests
securely on the blocks (approximately 6 inches
off the ground).
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is
being worked on.
Figure 14-1
14-1
Compact Track Loader
14. Quick Attach Disassembly and Assembly
2. Turn the engine start switch to the OFF position.
Figure 14-4
6. Disassemble as necessary and replace worn
components to ensure proper function.
Figure 14-2
Latch Mechanism Installation
3. Remove the bolt securing the latch mechanism
to the quick attach spring block using an allen
wrench.
1. Latch installation is the reverse of the removal
procedure.
2. Add removable lock tite to allen bolt threads.
Quick Attach Assembly
Removal and Installation
The tools required for quick attach assembly
removal and installation is listed in Table 14-2. Use
manufacturer-recommended tools whenever
possible.
Table 14-2
Required Tools
Combination Wrench
Figure 14-3
Quick Attach Assembly Removal
4. Remove the bolt and nut using to two wrenches.
5. Slide the latch mechanism out for parts
inspection.
1. Remove any attachments and place support
blocks beneath the quick attach. Then tilt the
quick attach assembly forward and lower the lift
arms until the quick attach assembly rests
securely on the blocks (approximately 6 inches
or 15.24 cm off the ground).
2. Turn the engine start switch to the OFF position.
14-2
Compact Track Loader
14. Quick Attach Disassembly and Assembly
Remove
Remove
Pin
Insert
Pin
Install
Figure 14-5
Figure 14-7
3. Remove the bolt and push out the pin that
secures each end of the quick attach assembly
to the tilt cylinders.
2. Insert the pin and install the bolt that secures
each end of the quick attach assembly to the
loader frame.
Install
Insert
Pin
Remove
Pin
Remove
Figure 14-6
Figure 14-8
4. Remove the bolt and push out the pin that
secures each end of the quick attach assembly
to the loader frame.
3. Insert the pin and install the bolt that secures
each end of the quick attach assembly to the tilt
cylinders.
5. The quick attach assembly is now free and
ready to be moved by a forklift.
Quick Attach Assembly Installation
1. With a forklift, move the quick attach assembly
in position to be secured to the loader frame and
tilt cylinders.
14-3
15. Troubleshooting
Chapter Overview
Preliminary Inspection
This chapter contains basic troubleshooting procedures for the Compact Track Loader.
A simple visual inspection and operational check
can identify many problems without the need for extensive troubleshooting. If these checks indicate a
problem that requires further analysis, proceed to
Troubleshooting in this section.
Additional troubleshooting aids are provided in
Chapter 3. System Diagrams and in those chapters
containing disassembly and assembly procedures
for the appropriate component or assembly.
Visual Inspection
Prior to troubleshooting, perform a visual inspection
of the machine. Look for missing, loose or worn
parts. Perform the following visual checks.
Personal Safety
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in machine damage, injury or death.
Do not attempt to perform any type of repair or maintenance on a Compact Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for instructions regarding proper machine operation techniques
before operating any Compact Track Loader.
Prior to performing any type of service work on a
Compact Track Loader, read and understand Chapter 1 (Product Safety) for personal safety information.
Machine Preparation
Accidental machine starting can cause injury or
death to personnel working on a Compact Track
Loader.
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to performing any service work on a Compact Track Loader.
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is being worked on.
15-1
•
Track tension
•
Fluid levels
•
Fan belt tension and condition
•
Hoses (no visible sign of wear)
•
Fittings (no leaks)
•
Battery cables
•
Fuse box (fuses in place and operational)
•
Controls (for neutral)
Compact Track Loader
15. Troubleshooting
Problem 4
Troubleshooting
Loader operates but tracks will not move.
This section identifies selected problems and suggests probable causes.
Probable cause
1. Leak in feed line to pilot control.
2. Pilot control malfunctioning.
Problem 1
Machine will not crank over.
Problem 5
Probable cause
1. Auxiliary hydraulic switch activated.
2. Weak or dead battery.
3. Battery cables loose or corroded.
4. Ignition fuse blown.
5. Main starter fuse blown.
6. Starter relay malfunctioning.
7. Bad ignition switch.
8. Bad starter.
9. Poor wire connections at key, relay, or starter.
Tracks operate but loader will not operate.
Problem 2
Problem 6
Machine cranks but will not start.
Auxiliary flow does not work. Loader works.
Probable cause
1. Injection pump fuse blown.
2. Main power fuse B blown.
3. Main power relay B not activating.
4. Poor wire connection at injection pump or fuse.
5. Glow plugs not heating. (Will see black smoke.)
a) Main glow plug fuse blown.
b) Glow plug relay not activating.
c) Poor wire connections at ignition switch, relay,
or glow plug strip.
d) Failed glow plugs.
e) Bad ignition switch.
Probable cause
1. Auxiliary hydraulic fuse blown.
2. Faulty ground wire.
a) Clean ground connections on left rear side of
hydraulic tank.
3. Auxiliary hydraulic direction switch failure.
4. Poor wire connections at fuse, direction switch, or
pin connector P17.
5. Auxiliary hydraulic pilot generation spool stuck.
6. Bad or not fully connected Quick-Coupler
Problem 3
Probable cause
1. Auxiliary direction switch faulty.
2. Poor wire connections at mode switch or direction
switch.
Probable cause
1. Auxiliary direction switch activated sending oil over
relief.
2. Check to see if auxiliary flow works. (If auxiliary
flow works, skip to number 5).
3. Main auxiliary relief malfunction.
4. Auxiliary pump bad.
5. Leak in feed line to loader control pilot.
6. Loader control pilot malfunctioning.
Problem 7
Auxiliary hydraulic part-time thumb switch operates but
full-time flow direction switch will not operate.
Machine starts but hydraulics will not operate.
Probable cause
1. Lap bar must be in down position, operator must be
seated in seat, and front door (if installed) must be
closed.
2. Safety fuse blown.
3. Faulty operator presence switch.
a) Test continuity through seat, lap bar, and door
switch. Adjust or replace as necessary. Lap bar
and door switch are magnetic switches and
should be adjusted to approximately 1/16 inch
(.16 cm) away from steel pickup bracket.
4. Poor ground (check ground wires on bottom left rear
side of hydraulic reservoir).
5. Safety relay is not activating.
6. Faulty safety solenoid or safety solenoid spool.
7. Poor wire connections on fuse, relay, or safety solenoid.
8. Low charge pressure.
15-2
Compact Track Loader
15. Troubleshooting
Problem 8
Problem 13
Auxiliary hydraulic full-time direction switch operates but
part-time thumb switch will not operate.
Loader will not float; labors engine and has down pressure
when detented into float.
Probable cause
1. Auxiliary hydraulic thumb switch malfunction.
2. Poor wire connections at direction switch, thumb
switch, or pin connector P17.
Probable cause
1. Engine RPM too low.
a) Float must be operated at a minimum of half
throttle.
2. Low charge pressure.
3. Pilot control malfunction.
4. Loader valve malfunction.
Problem 9
Auxiliary hydraulics will only flow one way.
Probable cause
1. Auxiliary hydraulic relay 1 or 2 failure.
2. Auxiliary hydraulic pilot generation coil faulty.
3. Auxiliary hydraulic pilot generation spool faulty.
4. Poor wire connections at relay, pilot generation solenoid, pin connector P16 or P21.
5. Loader valve malfunction.
Problem 14
Hot oil light illuminates; hydraulic system operating hot.
Probable cause
1. Auxiliary hydraulic switch activated sending oil over
relief.
2. Low oil level.
3. Debris plugging oil cooler limiting airflow.
4. Broken fan blades.
5. Loose fan belt.
6. Improper attachment.
a) Attachment must be rated at a minimum of 10
gallons per minute (37.8 lpm) and 3000 psi
(20,680 kPa).
b) Attachment hose size must be a minimum of 3/8
inch (.95 cm).
7. Faulty hot oil sending unit.
a) Hot oil light should illuminate at 225°F
(107.2 °C).
8. Faulty quick coupler.
9. Cooler bypass relief.
a) Cooler bypass relief should open at 100 psi
(689.5 kPa).
Problem 10
No power to numerous auxiliary functions or accessories
in ON or RUN position.
Probable cause
1. Main power relay A or B fuse blown.
2. Main relay A or B faulty.
3. Ignition switch malfunction.
4. Poor wire connections at ignition switch, fuse, or relay.
Problem 11
Battery will not charge and/or battery goes dead.
Probable cause
1. Alternator fuse blown.
2. Alternator diode defective or inserted backwards.
3. Poor wire connections at battery, alternator, diode,
or fuse.
4. Excessive draw in off position.
a) Fuel gauge and hour meter should draw only
0.01 amps in off position.
5. Bad battery.
6. Bad alternator.
Problem 15
Track makes popping noise.
Probable cause
1. Track too loose. (Refer to track adjustment section.)
2. Worn or stuck drive teeth. Outer roller should pivot
as lug comes into sprocket.
3. Loose or worn sprocket.
4. Worn track lugs.
Problem 12
Loader control will not lock in float position.
Probable cause
1. Float magnet fuse blown.
2. Poor wire connections at fuse, float detent magnet,
or pin connector P18.
3. Faulty float detent magnet.
15-3
16. Maintenance
Chapter Overview
Lift Arm Brace
This chapter contains maintenance requirements
and procedures for the following Compact Track
Loader components.
The lift arm brace is intended to keep service
personnel safe when it is necessary to work on a
machine with the lift arms in the raised position. It is
not safe to rely on the hydraulic system to hold the
lift arms in the raised position just as it is not safe to
crawl under a machine support only by one jack.
The lift arm brace is used support the weight of the
lift arms much mechanical supports bear the vehicle
weights.
• Engine oil
• Air cleaner
• Hydraulic fluid and filter
• Fuse box
• Fuel filter
• Grease fittings
• Track tension
• Lift Arm Brace
• Lift arm bushings
To install the lift arm brace:
Maintenance Schedule
1. Park the machine on level ground in a safe area
for performing service work.
Maintenance schedule is listed in Table 16-1.
2. Remove any attachments that may be
fastened to the quick attach.
Table 16-1
Item
Frequency
Lubricant
Hydraulic Fluid
1000 hrs
Mobile DTE10 8 gal/30 l
Excel Series
Hydraulic Filter
Engine Oil
250 hrs
250 hrs
Engine Filter
Fuel Filter
Primary Air
Filter
250 hrs
500 hrs
Check daily, clean and reuse as needed
up to 5 times; change at least once per
year
Every 3 cleanings
of primary filter
10 hrs
Lithium Grease
As needed
Secondary Air
Filter
Grease Fittings
Track Tension
3. Have an assistant remove the retaining pins that
secure the lift arm brace and remove it from the
machine.
Capacity
4. Make sure bystanders are clear of the lift arms,
and then raise them to the upper limit.
HD Diesel En- 4 qt/3.79 l
gine Oil, or
equivalent
5. Have an assistant install the brace around the
cylinder shaft as shown and reinstall the pins to
secure it to the cylinder as shown in Figure 16-1.
6. Lower the lift arms slowly until the come to rest
on the brace.
7. It is now safe to shut the engine off and exit the
machine.
To remove the lift arm brace:
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.
NOTICE
When replacing engine coolant, use Terex Long Life
50/50 Antifreeze/Coolant or equivalent antifreeze with
the proper SCA (Supplemental Cooling Additive)
1. Start the machine and raise the lift arms until
they are clear of the brace.
2. Once clear, have an assistant remove the brace
for the cylinder and stow it on the machine with
the pins.
3. Once the brace has been stowed and the
assistant is clear of the lift arms, lower the arms
to the ground and shut the engine off to
complete the procedure.
16-1
Compact Track Loader
16. Maintenance
2. Remove drain plug from bottom of the engine.
3. Drain oil into suitable container.
4. Remove engine oil filter, making sure the gasket
is also removed.
5. Apply a light coat of fresh oil to the new filter
gasket, then install new filter.
6. Tighten filter to specifications on filter label or
box.
7. Refill the engine to capacity with engine oil, as
specified.
Braced position
with pins
Engine Oil Specifications
Due to the variations in the quality and performance
of commercially available oils, Terex Heavy Duty
Diesel Engine Oil – 10W30 is recommended. If
Terex lubricants are not available, use a substitute
meeting the following qualifications:
Figure 16-1
Stowed position
with pins
- API CH-4 multi-grade engine oil
Hydraulic Fluid and Filter
The hydraulic fluid should be changed every 500
service hours, and the hydraulic filter should be
changed every 250 hours. Hydrostatic components
require extremely clean oil for long service life.
Figure 16-2
Engine Oil
Hydraulic Fluid and Filter Change
Procedures
Regular oil changes are necessary to maintain a
strong running engine. A normal oil change interval
of 250 hours or every six months is recommended.
This recommendation has been made to help
ensure proper lubrication during operation and to
prolong engine life under typical operating
conditions. Oil Change Procedures
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Allow the machine to cool thoroughly and relax all
hydraulic circuits before performing this procedure.
NOTICE
1. Run the engine for a few minutes to warm the
engine oil.
Extreme care must be taken when changing the hydraulic
fluid. Before starting the procedure, make sure the
machine is in a clean working environment. Precautions
should be taken to prevent any debris from entering the
hydrostatic system.
Collect and contain liquids in a suitable
container. Dispose of all liquids according to local
regulations and mandates.
Oil
Filter
Oil Drain Plug
Figure 16-3
16-2
Compact Track Loader
16. Maintenance
4. Remove the filter element and replace it. Install
as found upon removal.
5. Fill with manufacturer-approved hydraulic fluid.
Fuel Filter
The fuel filter should be changed every 500 service
hours, or as needed. A plugged fuel filter can cause
loss of engine power, rough running, or no start.
Hydraulic Fluid
Drain Plug
Collect and contain liquids in a suitable
container. Dispose of all liquids according to local
regulations and mandates.
Figure 16-4
1. Locate and remove the hydraulic fluid drain plug
and drain the fluid into a suitable container.
Fuel Filter Change Procedures
Filter
Assembly
Figure 16-5
Figure 16-7
2. Clean the area around the filter assembly, which
is located on the top of the hydraulic reservoir.
1. Clean the outside of the filter thoroughly.
2. Remove the retaining bolt (top of assembly)
securing the filter to the head, then removes.
3. Pour diesel fuel into the new filter until it is full.
4. Install the new filter by reversing step 2.
Fuel Specifications
In North America, diesel fuel distilled from crude oil
and identified as NO. 1-D or No. 2-D in “ASTM
D975” generally meets the proper specifications.
Filter
Element
Air Cleaner
The air cleaner is one of the most important
maintenance items on the machine. A poorly
maintained air cleaner can seriously shorten the life
of the engine.
Figure 16-6
3. Remove the retaining bolts and cover, and then
remove the cover to access the filter.
16-3
Compact Track Loader
16. Maintenance
Air Filter Change Procedures
Track Tension
NOTICE
Proper track tension is very important for optimum
performance and long track life. Tracks that are run
too loose can cause misfeeding and ratcheting
possibly causing damage to the track. During the
first 50 hours of operation, the tracks will “break in”
and will most likely require adjustment.
When working in dusty conditions, the air cleaner
elements should be checked and changed more frequently
than when working under normal conditions.
NOTICE
Do not clean the primary air cleaner element by bumping
and tapping. This could damage the seals. Do not use
elements with damaged pleat gaskets or seals.
Track Tension Adjustment Procedures
1. Open the hood, release the latches on either
side of the air cleaner, and then remove the
cover.
Jam
Nut
Primary
Element
Track
Tensioner
Figure 16-10
1. Locate the jam nut on the track tensioner and
clean the threads thoroughly before proceeding.
2. Loosen the jam nut.
Figure 16-8
2. Remove the primary element. The primary
element can be cleaned and reused up to five
times, but it should be changed at least once a
year.
Secondary
Element
Figure 16-11
3. After loosening the jam nut, turn the track
tensioner until the track tension is within
specifications.
4. Once proper tension is achieved, retighten the
jam nut
Figure 16-9
3. Remove the secondary element. The secondary
element is not serviceable or washable. It should
be replaced with every three cleanings of the
primary element.
16-4
Compact Track Loader
16. Maintenance
Checking for Proper Track Adjustment
Fuse Box
1. Drive the machine forward five feet to remove
slack from the lower and rearward portions of
the track.
Figure 16-14
The fuse box is located on the left side of the engine
compartment. The machine should never be
operated with the fuse box cover removed.
Figure 16-12
2. Lay a straightedge along the top of the track
between the sprocket and the front idler wheel.
3. Using a rope or wire, put 50 pounds (23.68 kg)
of down force on the track at the midpoint of the
straightedge.
Grease Fittings
Figure 16-15
The locations of the grease fittings for the left side of
the machine are shown above. An identical set of
fittings is located on the right side of the machine.
These fitting should be lubricated at least after every
10 hours of operation using Terex Multi Purpose
EP Lithium Grease, or other high-quality,
low-temperature grease.
Figure 16-13
4. Using a ruler, measure the distance between the
straightedge and track. The track should not
deflect more than 0.75 inch (1.9 cm) between
the top of the track and the straightedge.
5. If the track deflects more than 0.75 inch (1.9
cm), tighten the track.
16-5
Compact Track Loader
16. Maintenance
Lift Arm Bushings
Quick Attach Wear Inspection
Daily inspection can be carried out by
performing the following steps:
1. Lower the lift arm until it makes contact with the
chassis stops. Rotate the bucket against the
ground repeatedly. Have an assistant look for
independent movement between the bucket and
the lift arm. Any movement should be readily
noticeable by the attendant. If movement is
detected, bushing will need further inspection.
2. Rotate the bucket downward to approximately
45° from level. Then lower the lift arm until the
bucket contacts the ground repeatedly. Have an
assistant look for independent movement
between the:
•
Lift arms & chassis
•
Lift arms & lift cylinder
•
Lift cylinder & chassis
Any movement will be readily noticeable by the
attendant. If movement is detected, bushings will
need further inspection as shown in the following
step.
3. Refer to Chapter 13 of Lift Arm Bushing
Removal and Installation procedure to access
bushings for measurement inspection.
Note: Inspect the bushing for wear and replace as
necessary. Maximum recommended wear on the
bushing is 50% as shown in figure 16-16.
Lift Arm Bushings
.063”
Service
Limit
New bushing
Max recommended
wear: 50%
Figure 16-16
16-6
17. Hydraulic Pressure
Check & Adjustment
Chapter Overview
Hydraulic Pressure
Adjustment Procedures
This chapter provides a overview of checking and
setting pressures. It is important to contact the
manufacturer for assistance before beginning these
procedures.
Adjustment and test procedures are provided for the
following transmission and drive components.
Personal Safety
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in machine damage, injury or death.
•
Charge Pressure Check & Adjustment
•
Drive-Pressure Relief Valve Adjustment
•
Auxiliary Valve Pressure Check & Adjustment
Do not attempt to perform any type of repair or maintenance on a Compact Track Loader until you have read and
fully understood the information in this manual.
Charge Pressure Check
Refer to the Operation and Maintenance manual for instructions regarding proper machine operation techniques
before operating any Compact Track Loader.
The service tools required for the charge pressure
check are listed in Table 0-1. Use manufacturerrecommended tools whenever possible.
Prior to performing any type of service work on a
Compact Track Loader, read and understand Chapter 1 (Product Safety) for personal safety information.
Table 0-1
Required Tools
Pressure Gauge
Combination Wrench
Socket Wrench
Machine Preparation
Accidental machine starting can cause injury or
death to personnel working on a Compact Track
Loader.
Note: The fuel tank SHOULD NOT be removed to perform this procedure.
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to performing any service work on a Compact Track Loader.
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is being worked on.
Figure 0-1
1. Remove the floor pan.
17-1
Compact Track Loader
17. Hydraulic Pressure Check & Adjustment
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and has been allowed to cool thoroughly.
Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates.
Attach
Gauge
Note: During disassembly, plug all hoses and tubes to
prevent fluid loss and contamination of the system fluids.
Figure 0-2
2. Attach the gauge to the pilot control manifold
test port. Located under the fuel tank, you will
not need to remove the fuel tank.
3. Start the engine.
4. Check the pressure with the engine at wide
open throttle. Make sure the engine is properly
warmed up before running wide open.
5. Turn the engine start switch to the OFF position.
Figure 0-3
6. Remove the gauge from the pilot control manifold test port.
1. Remove belly pan and locate the charge pressure relief valves on the left side of the tandem
pump.
7. Install the floor pan
Charge Pressure Relief Valve Adjustment
The service tools required for charge pressure relief
valve adjustment are listed in Table 0-2. Use manufacturer-recommended tools whenever possible.
Remove
Hose
Table 0-2
Required Tools
Combination Wrench
Socket Wrench
Figure 0-4
2. Remove the hose coupling from the tandem
pump T-adapter to allow access to the front charge
pressure relief valve locking screw.
Note: In the following procedure, some components are
shown detached from the machine to facilitate the description. However, the charge pressure check is normally performed from under the machine with only the center skid
plate removed.
17-2
Compact Track Loader
17. Hydraulic Pressure Check & Adjustment
9. Connect the hose coupling on the tandem pump
T-adapter.
Remove
Cap
10. Check the charge pressure.
11. Install the belly pan.
Drive-Pressure Relief Valve Adjustment
The service tools required for drive-pressure relief
valve adjustment are listed in Table 0-3. Use manufacturer-recommended tools whenever possible.
Table 0-3
Figure 0-5
Required Tools
3. Unscrew and remove the charge pressure relief
valve locking screw. The valve piston and o-ring will
remain attached to the locking screw when the locking screw is removed.
Combination Wrench
Socket Wrench
Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and has been allowed to cool thoroughly.
Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates.
Spring,
Spring
Collar and
Shims
Locking
Screw,
Valve Piston
and O-ring
Note: During disassembly, plug all hoses and tubes to
prevent fluid loss and contamination of the system fluids.
Figure 0-6
1. Remove the seat. Refer to Chapter 6. Seat Removal.
4. Extract the spring, spring collar and shims from
the charge pressure relief valve cavity. The front and
rear charge pressure relief valves are identical.
2. Remove the fuel tank. Refer to Chapter 6. Fuel
tank Removal.
5. Adjust the charge pressure by adding or removing shims. Contact Manufacturer.
3. Remove belly pan.
6. Insert the spring, spring collar and shims in the
charge pressure relief valve cavity.
7. Install the charge pressure relief valve locking
screw (with valve piston and o-ring attached).
8.
Repeat procedure on remaining charge pressure relief valve. The charge pressure relief
valves must have the same number of shims.
17-3
Compact Track Loader
17. Hydraulic Pressure Check & Adjustment
6. Extract the high-pressure relief valve collar,
valve spring, spring loading nut and pressure
spring from the valve cavity.
7. Adjust the drive pressure by turning the spring
loading nut. Turning Clockwise will increase
pressure. Never adjust by more than a quarter
turn before checking pressure.
Drive-Pressure Relief
Valves (Reverse)
Drive-Pressure Relief
Valves (Forward)
8. Insert the high-pressure relief valve collar, valve
spring, spring loading nut and pressure spring in
the valve cavity.
9. Replace the high-pressure relief valve locking
screw and o-ring.
Figure 0-7
4. Locate the drive-pressure relief valves.
Auxiliary Pressure Check & Adjustment
Remove
Locking
Screw
The service tools required for the auxiliary pressure
check and adjustment are listed in Table 0-4. Use
manufacturer-recommended tools whenever possible.
Table 0-4
Required Tools
Pressure Gauge
Allen Wrench
Figure 0-8
5. Unscrew and remove the necessary drivepressure relief valve locking screw. The drivepressure relief valve o-ring will remain attached
to the locking screw when the locking screw is
removed.
Figure 10
1. Insert the hydraulic gauge into one of the attachment quick couplers.
Figure 0-9
17-4
Compact Track Loader
17. Hydraulic Pressure Check & Adjustment
Figure 12
2. Engage the continuous flow switch located on
the right side of the dash panel. Make sure it is
in the direction that sends flow to the gage.
Jam Nut
Adjustment
Screw
Figure 13
Loosen the jam nut and turn the adjustment screw in
with an allen wrench to increase pressure and turn
screw out to decrease pressure. Tighten jam nut
when after adjustment has been made.
17-5
Terex Construction Americas
8800 Rostin Road
Southaven, MS 38671
(888)-201-6008
(662)-393-1800
www.terex.com
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