Service Manual Rubber Track Loader PT-70/80 Part Number: 2046-310 Printed (4-10)
Table of Contents 1. Product Safety Chapter Overview . . . . . . . . . . . . . . . . . . . . . 1-1 Safety Messages . . . . . . . . . . . . . . . . . . . . . 1-1 Information Messages . . . . . . . . . . . . . . . . . 1-1 Basic Precautions . . . . . . . . . . . . . . . . . . . . . 1-1 Safety Labels . . . . . . . . . . . . . . . . . . . . . . . 1-1 Protective Equipment . . . . . . . . . . . . . . . . 1-1 Entering and Exiting . . . . . . . . . . . . . . . . . 1-2 Lifting . . . . . . . . . . . . . . . . . . . .
Rubber Track Loader Table of Contents 6. Operator Enclosure Chapter Overview . . . . . . . . . . . . . . . . . . . . . Personal Safety . . . . . . . . . . . . . . . . . . . . . . Machine Preparation . . . . . . . . . . . . . . . . . . . Removal & Installation . . . . . . . . . . . . . . . . . Door Gas Spring . . . . . . . . . . . . . . . . . . . . Removal Procedure . . . . . . . . . . . . . . . . Installation Procedure . . . . . . . . . . . . . . Pillar Switch Panels . . . . . . . . . . . . . . . . . .
Rubber Track Loader Table of Contents 12. Engine Chapter Overview . . . . . . . . . . . . . . . . . . . . . Personal Safety . . . . . . . . . . . . . . . . . . . . . . Removal & Installation . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal Procedure . . . . . . . . . . . . . . . . Installation Procedure . . . . . . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . Removal Procedure . . . . . . . . . . . . . . . .
1. Product Safety Chapter Overview This chapter contains product safety information for the Terex PT-70/80 Rubber Track Loaders. Read and understand all product safety information before attempting to service any Rubber Track Loader. Safety Alert Symbol This symbol means: Attention! Be alert! Your safety is involved! The safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Rubber Track Loader 1. Product Safety Entering and Exiting Pressurized Items Always use steps and handholds when entering or exiting a Rubber Track Loader. Clean any mud or debris from steps or work platforms before using them. Always face the machine when using steps and handholds. When it is not possible to use the designed entry/exit system, utilize ladders, scaffolds, or work platforms to safely gain access to the machine. 1.
Rubber Track Loader 1. Product Safety 8. Be prepared to stop an engine if it has been recently overhauled or the fuel system has been recently serviced. If the engine has not been assembled correctly, or if the fuel settings are not correct, the engine can possibly overspeed and cause bodily injury, death or property damage. Be prepared to shut off the fuel and air supply to the engine in order to stop the engine.
Rubber Track Loader 1. Product Safety Safety Label Examples Attachments Only use attachments that are recommended by Terex. Examples of the labels and decals displayed on the machine are shown on this page. Make sure that all necessary guards and protective equipment are in place and functioning prior to operating any attachment. WARNING Wear protective glasses and protective equipment as required by conditions or as recommended in the attachment’s operation manual.
Rubber Track Loader 1. Product Safety WARNING Improper operation or maintenance can result in serious injury or death. WARNING Crush Hazard Rollover can crush and result in serious injury or death. Read and understand the operator’s manual and all safety signs prior to operating or maintaining the machine. WARNING DANGER Explosion/Burn Hazard Will cause death, burns or blindness due to ignition of explosive gasses or contact with corrosive acid.
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2. Technical Specifications & Service Tools PT-70 Specifications Engine Oil Cooler - - Model: Perkins 804C-33T Displacement: 3.3 liter Gross horsepower: 71 hp (53 kW) Torque: 173 lb-ft. (234 Nm) Idle rpm: 1000 (low idle), 2600 (high idle) Average water /thermostat temperature: 190°F, 87.8°C Critical Torque Specs Transmission - - Model: Cat A22VG45 tandem (Rexroth) - Drive Pumps - - Displacement: 2.7459 in3/rev (45 cc/rev) Relief pressure: 5500 psi (380 bar) Flow: 30.
Rubber Track Loader 2. Technical Specifications & Service Tools PT-80 Specifications Engine Oil Cooler - - Model: Perkins 804D-33T Displacement: 3.3 liter Gross horsepower:80 hp (60 kW) Torque: 186 lb-ft. (253 Nm) Idle rpm: 1200 (low idle), 2600 (high idle) Average water /thermostat temperature: 190°F, 87.8°C Transmission - Critical Torque Specs - Model: Cat A22VG tandem (Rexroth) - Drive Pumps - Displacement: 2.349 in3/rev (38.5cc/rev) Relief pressure: 5500 psi (380 bar) Flow: 26.
3. Circuit Diagrams Chapter Overview Hydraulic Charge Circuit This chapter contains diagrams for the following PT70/80 circuits: hydraulic charge circuit, hydraulic auxiliary circuit, hydraulic drive circuit, loader valve, hydraulic pilot generation (solenoid) block and electrical attachment outlet. It also contains hose routing information for the control configurations for the drive and lift arm pilot controls.
Rubber Track Loader 3. Circuit Diagrams Hydraulic Auxiliary Circuit Figure 3-2 PT-70/80 Hydraulic Auxiliary Circuit OIL COOLER TO ATTACHMENT CASE DRAIN Q/C TO TANK TO BUCKET CYL. CHECK VALVE (80 PSI / 552 kPa) FLOW TO TANK LOADER CONTROL TO LIFT ARM CYL. TO AUXILIARY Q/C TO LIFT ARM CYL. LIFT ARM VALVE TO TANK LOAD SENSE AUXILIARY PUMP CHARGE PUMP INLET AUXILIARY PUMP INLET PILOT GEN.
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Rubber Track Loader 3. Circuit Diagrams Hydraulic Pilot Generation Block Figure 3-5 PT-70/80 Hyd.
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4. Maintenance Chapter Overview Lift Arm Brace This chapter provides information on general maintenance procedures for the PT-70/80. If there is an issue that requires troubleshooting, refer to Chapter 18, Troubleshooting. The lift arm brace (A) is intended to keep service personnel safe when it is necessary to work on a machine with the lift arms in the raised position.
Rubber Track Loader 4. Maintenance C B A 4-4 4-3 Tilt-Up Cab The ROPS/FOPS approved cab (A) tilts up to allow easier access while performing maintenance. It features a gas spring assist and a brace mechanism to hold it in place while tilted. To tilt the cab: 1. Remove any attachments that may be fastened to the machine. 4-5 2. (Optional) Raise the lift arms and secure them with the lift arm brace. (See page 4-1.
Rubber Track Loader 4. Maintenance Grease Fitting Locations A. B. C. D. E. F. G. H. Lower Bucket Cylinder Pivot (2) Upper Bucket Cylinder Pivot (2) Front Lift Cylinder Pivot (2) Lift Arm Pivot (2) Rear Lift Cylinder Pivot (2) Rear Axle Pivot (2) Front Axle Pivot (2) Lower Bucket Pivot (2) 4-6 D E C B A H G F Grease Fittings The PT-70/80 are equipped with grease fittings at pivot points throughout the machine.
Rubber Track Loader 4. Maintenance Track Tension Straight-Edge Proper track tension must be maintained for optimal performance and track/undercarriage life. Running a track that is too loose may cause the track to misfeed possibly causing damage to the track and or undercarriage components. Running a track that is too tight may cause track stretch, premature bearing failure, or other preventable damage to the machine. As a rule, a track should only be tightened to the point where there is no visible sag.
Rubber Track Loader 4. Maintenance Steel Pin (.088”) F New Roller Normal Wear 35% life C E D J I H G 4-10 K A B Note: You may need to pry or lift the track upwards with a hoist above the drive sprocket to provide clearance for removal. Drive Sprocket Rollers Terex rubber track loaders utilize rollers on the drive sprockets to drive the track. These rollers help minimize friction between the track and the drive sprocket to prolong track life.
Rubber Track Loader 4. Maintenance Track Removal/Installation Tracks may need to be removed periodically to inspect undercarriage components or for replacement if worn or damaged. This section covers the procedure to remove and install a track on PT-70/ 80 machines. Tools required: • Socket/impact wrench • Ratchet strap • Heavy duty hydraulic jack • Combination wrench • Long pry bar(s) • Terex approved jack stands (2) • Spray lubricant • Shop vac or Pressure washer Cavity 4-12 Track Removal 1.
Rubber Track Loader 4. Maintenance 4-19 4-16 6. Remove the outer scraper plate from the suspen sion rail. (fig. 4-17) 7. Remove the bolts securing the inner wheel to the hub, then remove the wheel. (fig. 4-18, 4-19) 8. Use a pry bar to peel the track over the inner wheel(s) toward the outside of the machine. (fig. 4-20) 9. Once the track is off of the front wheel(s), pull the rear of the track clear of the suspension. (fig.
Rubber Track Loader 4. Maintenance Track Installation 1. Slide the track over the drive sprocket at the rear of the machine. (fig. 4-23, 4-24) 2. Slide the front of the track into position for installa tion. (fig. 4-25) 3. Lubricate the inner front wheel(s) and the inside of the front portion of the track with a spray lubricant. (fig. 4-26) 4. Attach a ratchet strap to the upper front portion of the track and the other end to one of the tow hooks on the front of the machine. (fig. 4-27) 4-25 5.
Rubber Track Loader 4. Maintenance 9. Once the track is in position over the idler wheels, install the inner idler wheel onto the hub and secure it in place with the mounting bolts. Torque them to 90 +/- 10 Lb. Ft. (122 Nm) (fig. 4-29, 4-30, 4-31) Note: You may need to use a bar to keep the wheel from spinning as you torque the mounting bolts to spec. (fig. 4-31) 10. Install the scraper onto the suspension rail and tighten the bolts to secure it in place. (fig. 4-32) 4-31 11.
Rubber Track Loader 4. Maintenance Air Cleaner The PT-70/80 are equipped with two air filter elements to remove contaminants from the air used for combustion. Regular inspection and replacement is necessary to ensure proper performance and to prolong engine life. A To remove and inspect your air cleaner elements: 1. Turn the engine off. 2. Open the hood at the rear of the machine to gain access to the engine compartment. 3.
Rubber Track Loader 4. Maintenance Fuel Filter The fuel filter removes contaminants from the fuel as it enters the engine for combustion. Over time the filter can become plugged and cause the engine to lose power, run roughly or fail to start. The fuel filter should be changed every 500 hours or more often if needed to prevent these conditions from occurring. To change the fuel filter: 1.
Rubber Track Loader 4. Maintenance Accessory Belt Tension Drive belts typically stretch and wear during their service life. The fan and A/C belts should be checked for tension, condition and presence daily prior to operating your machine. To check fan or A/C belt tension: 1. With the engine cold and off, remove the key from the ignition to avoid accidental start. 2. Lift the hood at the rear of the machine and check to make sure the fan and A/C belts are present and in good condition.
Rubber Track Loader 4. Maintenance Fan Belt Removal & Installation Pry-bar To remove the fan belt: 1. Follow steps 1 and 2 of the belt adjustment proce dure. 2. Once loose, pivot the alternator towards the engine to increase slack. Bolt 3. Then, remove the three bolts securing the fan cage (half) to the fan shroud. Remove that portion of the cage. (fig. 4-45, 4-46) 4. Slip the belt off of the engine pulleys and work it around the fan until it is clear of the blades. 4-44 To install the fan belt: 1.
Rubber Track Loader 4. Maintenance Engine Oil/Filter Change Regular oil changes are necessary to maintain a strong running engine. Terex recommends a normal oil change interval of 250 hours or every six months. This recommendation has been made to help ensure proper lubrication during operation and to prolong engine life under typical operating conditions. To change the oil and filter: 1. Start and run the engine for a few minutes to warm the oil. Then turn the engine off before proceeding. 4-47 2.
Rubber Track Loader 4. Maintenance 4-51 10. Remove the oil filler cap and fill the engine crankcase with Terex 10W-30 Heavy Duty Engine Oil (capacity: 9 qt./8.5l including filter). (fig. 4-51) Low 11. Install the oil filler cap. Full 12. Perform a visual inspection to make sure the drain plug, filter and oil filler cap are in place and tight. 13. Start the engine and watch the oil pressure gauge located in the lap bar instrument display.
Rubber Track Loader 4. Maintenance Hydraulic Fluid/Filter Change Hydrostatic components require extremely clean oil in order to have a long service life. Use extreme caution when changing the hydraulic oil. Introducing dirt or debris could be detrimental to the hydraulic system. Terex recommends service intervals of 500 hours for hydraulic fluid and 250 hours for hydraulic fluid filters. To change the hydraulic fluid: 1.
Rubber Track Loader 4. Maintenance Radiator/Oil Cooler The Radiator and Oil Cooler must be kept clean to ensure proper operation. Engine and hydraulic system overheating, damage and even failure can result if the radiator/oil cooler is not kept clean. A pressure washer or compressed air nozzle work well to blow debris clear of the fins in the oil cooler and radiator.
Rubber Track Loader 4. Maintenance 4-62 4-63 Case Drain Filter Fuse Panel The PT machines are also equipped with a filter in the auxiliary circuit case drain line. It protects the main hydraulic system in the event of catastrophic failure in an attachment. This filter is designed to last the life of the vehicle. The only instance where this filter should be replaced is if an attachment equipped with a case drain has a drive motor failure during use. (fig.
Rubber Track Loader 4. Maintenance Maintenance Item Grease fittings Service required Lubricate Fluid levels Check Daily Fan-A/C belt tension Check Daily Adjust tension as necessary. Fan-A/C belt condition Inspect Daily Replace as a pair if worn or damaged. Water separator Drain Daily Track condition Inspect Daily Replace if severely damaged. Track tension Inspect Daily Adjust tension as necessary. Air cleaners Inspect Daily Replace if damaged or heavily soiled.
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5. Machine Controls and Instrumentation Chapter Overview Instrumentation This chapter contains an overview of the machine controls and instrumentation. For further information regarding machine controls, instrumentation or operation, refer to the operation and maintenance manual for the PT-70/80. Included here are illustrations of the following controls and instrumentation components and a description of their functions.
Rubber Track Loader 5. Machine Controls and Instrumentation Switches The various switches (Figure 5-3, 5-4, 5-5) are positioned to provide good access and visibility. The standard and optional switches are listed below.
6. Operator Enclosure Chapter Overview Removal and Installation This chapter provides information on the assembly and disassembly of the operator enclosure assembly. If there is an issue that requires troubleshooting, refer to Chapter 18, Troubleshooting. Removal and installation procedures are provided for the following operator enclosure components. Personal Safety Improper or incomplete maintenance/repair of a Rubber Track Loader can be dangerous and may result in ma-chine damage, injury or death.
Rubber Track Loader 6. Operator Enclosure Pillar Switch Panels Removal Required Tools Open or Box end Wrenches 6-6 6-3 1. Remove the screws/bolts securing the pillar switch panel to the cab enclosure. (fig. 6-3) 6-7 4. Pivot the panel further backward to expose the connectors on the lower switches and disconnect them. You may then remove the panel. (fig. 6-6, 6-7) 6-4 2.
Rubber Track Loader 6. Operator Enclosure Side Panels/Gauges Removal Required Tools Phillips Type Screwdriver Combination/Socket Wrenches 6-12 4. Remove the screws securing the rear side panel section to the cab enclosure. (fig. 6-12) 6-9 1. Remove the screws securing the forward side panel to the operator enclosure. (fig. 6-9) 6-13 5. Disconnect any switches from the harness (unbolt the heater control if removing left side) then remove the panel from the machine (fig. 6-13) 6-10 2.
Rubber Track Loader 6. Operator Enclosure Seat Removal Required Tools Combination/Socket Wrench 6-18 5. Disconnect the harness and then remove the seat from the machine. (fig. 6-18) 6-15 Installation 1. To install the seat, reverse the removal procedure. 1. Remove the bolts (2) securing the cab to the chassis. They are located inside the cab in the upper front corners of the foot well. (fig. 6-15) Rear Interior Panel Removal Required Tools 2.
7. Chassis and Fuel Tank Chapter Overview Removal and Installation This chapter provides information on the assembly and disassembly of the chassis. If there is an issue that requires troubleshooting, refer to Chapter 18, Troubleshooting. Removal and installation procedures are provided for the following chassis components. Personal Safety Improper or incomplete maintenance/repair of a Rubber Track Loader can be dangerous and may result in ma-chine damage, injury or death.
Rubber Track Loader 7. Chassis and Fuel Tank Fuel Tank Removal Remove Screws Required Tools Screwdriver Combination/Socket Wrench 1. Raise and support the lift arms as described on page 4-1 of this manual. 2. Tilt and support the operator enclosure (cab) as described on page 4-2 of this manual. (optional) 7-2 5. Remove the screws securing the fuel sending unit to the tank. (fig. 7-2) 7-5 3. Loosen the hose clamps securing the vent hoses to the left rear tank end. (fig. 7-5) 7-3 6.
Rubber Track Loader 7. Chassis and Fuel Tank 7-8 6. Loosen the hose clamp securing the main fuel line to the tank outlet in the front right corner of the machine. (fig. 7-8) 7-11 9. Remove the bolts (3) securing the fuel tank to the front mounting plate. (fig. 7-11) 7-12 7-9 7. Disconnect this line and drain the fuel into a suitable catch container. (fig. 7-9) 10. Now that the tank is loose and empty, loosen the hose clamp and disconnect the filler tube from the right rear end of the tank. (fig.
Rubber Track Loader 7. Chassis & Fuel Tank Footwell Bolts Removal Required Tools Screwdriver Combination/Socket Wrench 1. Raise and support the lift arms as described on page 4-1 of this manual. (optional) 2. Tilt and support the operator enclosure (cab) as described on page 4-2 of this manual. 7-16 5. Remove the bolts (4) securing the footwell assembly to the chassis. (fig. 7-16) 7-14 3. Remove the bolts (4) securing the foot pedal cover to the pedal, then remove the cover. (fig.
Rubber Track Loader 7. Chassis & Fuel Tank Foot Throttle Assembly Hood Assembly Removal Removal Required Tools Screwdriver Combination/Socket Wrench Required Tools Screwdriver Combination/Socket Wrench Note: The foot throttle assembly may be removed with the footwell still installed in the machine. 1. Perform steps 3 and 4 of the footwell removal procedure on page 7-4. Bolts 7-19 Pry Off 7-18 2. Remove the bolts (2) and associated hardware securing the foot throttle assembly to the footwell. (fig.
Rubber Track Loader 7. Chassis & Fuel Tank 7-23 3. Have an assistant help you to remove the hood assembly from the machine. (fig. 7-23) 7-24 4. Carefully set the hood assembly aside. (fig. 7-24) Installation 1. To install the hood assembly, reverse the removal procedure.
8. Radiator and Oil Cooler Chapter Overview Removal and Installation This chapter provides information on the disassembly and assembly of the radiator/oil cooler and associated components. If there is an issue that requires troubleshooting, refer to chapter 18, Troubleshooting. Removal and installation procedures are provided for the following radiator/oil cooler components.
Rubber Track Loader 8. Radiator and Oil Cooler Fan & Fan Shroud Removal Required Tools Combination Wrench Socket Wrench 8-2 8-5 8-3 1. Remove the bolts (2) securing the fuel pump/filter assembly to the radiator support and lay it aside over the bumper to allow clearance to remove the shroud and fan. (fig. 8-5) 2. Remove bolts (5) securing the fan guard halves to the fan shroud. (fig. 8-2, 8-3) 8-6 8-4 2. Remove the bolts (6) securing the radiator and shroud to the radiator support. (fig. 8-6) 3.
Rubber Track Loader 8. Radiator and Oil Cooler Radiator/Oil Cooler Removal Personal injury can result from exposure to hot fluids and components. Allow the machine to cool thoroughly before attempting any type of service on the cooling or hydraulic systems. Cooling system conditioner contains alkali. Avoid contact with skin and eyes. 8-8 Note: Collect and contain liquids in suitable containers. Dispose of all liquids according to local regulations and mandates.
Rubber Track Loader 8. Radiator and Oil Cooler 8-16 8-13 4. Remove the bolts (6) securing the outer shroud to the chassis, then remove the shroud. (fig. 8-13) 8-17 8-14 7. Loosen the clamps securing the upper and lower coolant hoses to the radiator, then disconnect the hoses from the radiator. (fig. 8-16, 8-17) 5. Remove the upper hydraulic cooler hose. Cap or plug the hose upon removal. (fig. 8-14) 8-18 8-15 6. Loosen and disconnect the lower hydraulic line from the cooler.
9. Hydraulic Reservoir Chapter Overview Removal and Installation This chapter provides removal and installation procedures for the hydraulic reservoir. Removal and installation procedures are provided for the following hydraulic components. • • Personal Safety Improper or incomplete maintenance/repair of a Rubber Track Loader can be dangerous and may result in machine damage, injury or death.
Rubber Track Loader 9. Hydraulic Reservoir 1. Remove the center and rear belly pans from the machine. 2. Drain the hydraulic fluid. Refer to page 4-16 for the hydraulic fluid and filter change procedure. 3. Remove the engine as described on page 12-5 of this manual. Disconnect 4. Remove the auxiliary and drive pumps (for inspection, repair, or replacement) according to the procedures in section 11 of this manual. 9-4 6.
Rubber Track Loader 9. Hydraulic Reservoir 9-7 9-10 9. Gently move the hard lines out of the way to allow for reservoir removal then zip tie them to the motor mount to keep them secure. (fig. 9-7) 9-8 10. Disconnect the bucket cylinder hoses from the hard lines in the upper right portion of the engine compartment. Remove all line clamps. (fig. 9-8) 9-11 12. Disconnect the bucket cylinder hard lines from the lift arm control valve and then remove them from the machine. (fig.
Rubber Track Loader 9. Hydraulic Reservoir 9-16 9-13 14. Disconnect the main oil cooler line from the fitting at the filter. (fig. 9-13) 16. Remove the clamps securing the auxiliary hydraulic lines to the chassis. (fig. 9-16) Disconnect 9-17 9-14 9-18 9-15 17. Disconnect the auxiliary hydraulic lines from the lift arm control valve and the hoses leading to the quick coupler lines on the lift arm. (fig. 9-17, 9-18) 15.
Rubber Track Loader 9. Hydraulic Reservoir 9-19 9-22 fuel lines 20. Remove the auxiliary hydraulic tubes from the machine. 9-20 18. Slide the two fuel lines through the chassis opening and into the engine compartment so that the aux. hyd. tubes can be removed. (fig. 9-19, 9-20) 9-23 21. Disconnect the lower portions of the cab support gas springs from the chassis. (fig. 9-23) 9-21 19. Disconnect the fuel sender from the main harness at the connector.
Rubber Track Loader 9. Hydraulic Reservoir 9-28 9-25 23. Remove the lower hose restraints to allow the hoses to be pulled through the chassis. (fig. 9-25) 26. Remove the bolts securing the metal tank restraint straps, them remove them from the machine. (fig. 9-28) 9-26 9-29 24. Pull the hoses up through the chassis opening and lay them aside as shown (both sides). (fig. 9-26) 27.
Rubber Track Loader 9. Hydraulic Reservoir 29. Make sure there is nothing that would visibly prevent the reservoir from being removed or is still attached to other components within the machine, then proceed. Reservoir Pry-bar 9-31 30. Use a long pry bar to pry the tank upward and rearward from the front as shown. (fig. 9-31) Note: You may need to pry the tank upwards within the chassis from the rear if it isn’t already to prepare the tank to be moved in step 30. 9-34 31.
Rubber Track Loader 9. Hydraulic Reservoir Suction Screen Suction screen Removal Required Tools Small Pry Bar (hose removal if necessary) Socket Wrench & Extension Combination Wrenches (to remove lines) Note: The suction screen may be removed with the reservoir (tank) still in the machine. If this is necessary, remove the center belly pan and tilt and support the cab to gain access, then follow the procedure described below to remove the suction screen. 1.
10. Lift-Arm/Drive Controls Chapter Overview Removal and Installation This chapter provides removal and installation procedures for the lift-arm and drive control components. Removal and installation procedures are provided for the following lift-arm/drive control components. • • • Personal Safety Improper or incomplete maintenance/repair of a Rubber Track Loader can be dangerous and may result in machine damage, injury or death.
Rubber Track Loader 10. Lift-Arm/Drive Controls 1. Relax all hydraulic actuators to relieve pressure in the hydraulic system prior to service. 2. Turn the ignition switch to the OFF position, remove the key and disconnect the battery to avoid accidental start. Remove (optional) 3. Perform the interior side panel removal procedure that addresses the joystick you plan to remove in chapter 6 of this manual. 10-3 5. Remove the bolts (3) securing the joystick mounting bracket to the cab from the outside.
Rubber Track Loader 10. Lift-Arm/Drive Controls Lift Arm Float Magnet Removal Required Tools Fittings Socket Wrench Combination/Open End Wrench Allen Wrench 1. Perform steps 3, 4 and 11 of the lift arm joystick control removal process. 10-7 9. Remove the fittings on the back of the joystick (lift arm control joystick only). (fig. 10-7) 10-10 2. Remove the allen bolt from the underside of the magnet. (fig. 10-10) 10-8 10. Remove the bolts and nuts securing the joystick to the mounting bracket. (fig.
Rubber Track Loader 10. Lift-Arm/Drive Controls Lift Arm Control Valve Removal Required Tools Socket Wrench Combination/Open End Wrench Screwdriver (hose clamps) 1. Perform the footwell removal procedure on page 74 of this manual. 10-15 2. Drain the hydraulic system as described on page 4-16 of this manual. 10-16 10-12 3. Label all lines and hoses as necessary to aid in reassembly. (fig. 10-12) 5. Disconnect all lines and hoses from the valve to allow for removal.
11. Hydraulic Pumps/Motors Chapter Overview Removal and Installation This chapter provides removal and installation procedures for the hydraulic pumps and motors. Removal and installation procedures are provided for the following hydraulic components. • Charge Pump • Auxiliary Pump • Tandem (Drive) Pump • Drive Motor Personal Safety Improper or incomplete maintenance/repair of a Rubber Track Loader can be dangerous and may result in machine damage, injury or death.
Rubber Track Loader 11. Hydraulic Pumps/Motors 1. Lower the lift arms to the ground and relax the bucket tilt/curl cylinders to relieve pressure within the hydraulic system. 2. Turn the ignition switch to the OFF position and remove the key to avoid accidental start. 3. Drain the hydraulic fluid. Refer to page 4-16 for the hydraulic fluid and filter change procedure. 4. Raise the hood at the rear of the machine. Upper Hose 11-3 8. Remove the charge pump from the engine. (fig.
Rubber Track Loader 11. Hydraulic Pumps/Motors Auxiliary Pump Removal Required Tools Combination Wrench Socket Wrench & Extension Pry bar Allen socket 11-6 4. Loosen the clamp securing the hose onto the barbed fitting on the right side of the pump, then disconnect it. (fig. 11-6) 11-4 1. Loosen the bolts securing the spilt flange clamp to the upper front port on the aux. pump. (fig. 11-4) Weldment 2. Remove the clamp and lay the hose aside. 11-7 5.
Rubber Track Loader 11. Hydraulic Pumps/Motors Tandem (Drive) Pump Removal Required Tools Screwdriver Combination/Open End Wrenches Personal injury can result from exposure to hot fluids and components. Allow the machine to cool thoroughly before attempting any type of service on the cooling or hydraulic systems. 11-9 Note: Collect and contain liquids in a suitable container. Dispose of all fluids according to local regulations and mandates. 7. Use a pry-bar to pry the inlet weldment out of the hoses.
Rubber Track Loader 11. Hydraulic Pumps/Motors Top & Bottom Drive Pump Hoses To Oil Cooler (return) TOP BTM BTM BTM BTM To Drive Motor (RT) From Charge Filter BTM To Drive Motor (LT) FRONT RIGHT LEFT REAR • View is from the top. • The pump is to be perceived as transparent. • Ports are labeled top or bottom as they are on the pump. 11-13 11-16 3. Support the pump with a hoist or floor jack to prevent it from falling as the mounting bolts are removed. (fig.
Rubber Track Loader 11. Hydraulic Pumps/Motors Drive Motor Removal Required Tools Combination/Socket Wrench Impact Wrench 3-Jaw Puller Snap Ring Pliers Hammer/Mallet 1. Remove the track from the undercarriage by performing the track removal procedure on page 4-6 of this manual. Remove Bolts 11-21 4. Remove the bearing support plate from the undercarriage. (fig. 11-21) 11-19 2. Remove the three bolts securing the outer bearing support plate to the drive table. (fig. 11-19) 11-22 5.
Rubber Track Loader 11. Hydraulic Pumps/Motors 11-27 11-24 7. Remove the snap ring securing the bearing assembly to the outer sprocket shaft. (fig. 11-24) 10. Remove the sprocket assembly from the undercarriage. (fig. 11-27) 11-28 11-25 8. Use a jaw style puller and an impact wrench to remove the bearing assembly from the sprocket shaft. (fig. 11-25) 11. Remove the bolts securing the drive motor to the drive table. (fig. 11-28) 11-29 11-26 9. Remove the bolts securing the sprocket to the drive motor.
Rubber Track Loader 11. Hydraulic Pumps/Motors 11-30 13. Note the orientation of the hoses as they are connected to the drive motor. Label them to ensure correct installation and proper orientation during reassembly. (fig. 11-30) 11-31 14. Disconnect the hoses from the drive motor making sure to cap and plug all openings to avoid contamination. Remove the drive motor from the undercarriage. (fig. 11-31) Installation 1. To install the drive motor into the undercarriage, reverse the removal procedure.
12. Engine Chapter Overview Removal and Installation This chapter provides procedures for the removal and installation of the engine and associated components. Removal and installation procedures are provided for the following engine related components. • • • • Personal Safety Improper or incomplete maintenance/repair of a Rubber Track Loader can be dangerous and may result in machine damage, injury or death.
Rubber Track Loader 12. Engine Exhaust System Removal Required Tools Pry Bar(s) Combination/Socket Wrench Rubber Mallot Penetrating Lubricant 12-3 The exhaust system is very hot at operating temperature. Make sure the machine is off and cool before attempting to service the exhaust system. 4. Remove the two tension (L) rods by twisting and maneuvering them out of the chassis mounting holes. (fig. 12-3) 12-6 12-4 1.
Rubber Track Loader 12. Engine Spring 12-8 12-11 4. Remove the tension springs that secure the middle pipe section to the head (upper) pipe and muffler inlet (lower) pipe. (fig. 12-8) 7. Remove the inlet pipe from the muffler. It may be necessary to use levers to force the inlet pipe section out of the muffler. (fig. 12-11) Note: Use caution not to damage the pipe or connection point during removal. 12-9 5. Remove the upper and middle pipe sections from the machine. (fig. 12-9) 12-12 8.
Rubber Track Loader 12. Engine Air Cleaner Removal Required Tools Combination Wrenches Socket Wrench & Extension 12-14 10. You may now remove the tail pipes by sliding them forward within the chassis, then out. (fig, 12-14). Installation 12-15 1. To install the exhaust system, reverse the removal procedure. 1. Remove the cover and the filter elements from the air cleaner assembly. (fig. 12-15) 12-16 2. Loosen the clamp securing the intake hose to the air cleaner housing. (fig. 12-16) 12-17 3.
Rubber Track Loader 12. Engine Engine Removal Required Tools Combination/Socket Wrenches Angle Iron or Similar (approx. 43” / 109cm long) Tie Down or Ratchet Strap Forklift/Engine Hoist Pry Bar 12-18 4. Remove the air cleaner housing from the machine. (fig. 12-18) 1. Perform the battery, air cleaner, and charge pump, removal procedures in sections 11 and 12 of this manual prior to starting this procedure. Installation 2. Remove the hood assembly as described on page 7-5 of this manual. 1.
Rubber Track Loader 12. Engine Ballstud Bolts Cable 12-24 12-21 8. Disconnect the throttle cable from the engine. Note: Once loose, you may want to pull the throttle cable forward through the chassis to make sure it is clear of the engine during removal. Engine 11. Disconnect the case drain filter and bracket from the engine adapter plate and lay it aside. It is situated beneath the drive pump. (fig. 12-24) Bolts Wire Harness Restraint Restraint 12-25 12-22 Rear Axle 12.
Rubber Track Loader 12. Engine 12-27 12-31 14. Lay the angle iron across the fenders (or fuel tank if still in place) and attach one or two tie down straps to serve as a sling to hold the hydraulic pumps up in position during engine removal. (fig. 12-27) Note: The rear cab window is directly over the lift point of the engine. It is important to use an engine lifting device that is low in profile and can reach forward between the engine and chassis (as shown in fig.
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13. Undercarriage Chapter Overview Removal and Installation This chapter provides removal and installation procedures for the undercarriages. Removal and installation procedures are provided for the following undercarriage components. • Idler Wheels (Removal and installation) • Bogie Wheels (Removal and installation) • Hub Assembly Service Procedures Note: For track removal and installation procedures, refer to pages 4-6 through 4-9 of this manual.
Rubber Track Loader 13. Undercarriage 3. Clean the threads on the turnbuckle thoroughly using a stiff bristle brush. 13-2 13-6 7. Remove the outer scraper plate from the suspension rail. (fig. 13-6) 13-3 13-7 4. Loosen the lock nut on the turnbuckle and spin it to the end of the threaded shaft to allow clearance when the drive table is lowered. (fig. 13-2) 5. Rotate the turnbuckle and lower the drive table as far as it will go. (fig. 13-3) 13-8 13-4 8.
Rubber Track Loader 13. Undercarriage 10” & 15” Wheels (PT-70) 4. Repeat as necessary to remove the idler and bogie wheels throughout the undercarriages. Note: The 15” idler and 10” bogie wheels may be removed from the PT-70 and PT-80 undercarriages without removing the tracks. Installation Removal Required Tools Socket/impact wrench Heavy duty hydraulic jack Combination wrench ASV approved jack stands (2) Shop vac or Pressure washer 1.
Rubber Track Loader 13. Undercarriage Bogie Wheel (PT-80 only) Removal & Service Procedure Required Tools Combination/Socket Wrenches (including Allen) Press & Various Press Tooling Torque Wrench Bench Vise 13-12 4. The inner and or outer bogie wheels may now be removed with an impact wrench and allen socket as shown in (fig. 13-12). If necessary, clamp one wheel in a vise to keep the axle from spinning while you remove the bolts.
Rubber Track Loader 13. Undercarriage Sealing Surfaces Face Seal Halves 13-14 Rubber Seals 13-17 6. Once the wheels have been removed, use a press to push the axle and far side bearing out of the hub as shown. (fig. 13-16, 13-17) 7. If it is necessary to remove the other bearing for replacement, press it out as well. If not, you may leave this bearing in the hub during cleaning.
Rubber Track Loader 13. Undercarriage 10. Disassemble and clean the face seals and their rubber outer seals thoroughly, then wipe them dry to ensure a good seal when assembled. 13-23A 13-20 11. Once the seals and hub have been thoroughly cleaned and dried, reinstall the hub portion of the face seal into the hub as shown. Make sure to work the rubber seal down into place within the hub (until it seats) to ensure a good seal. (fig. 13-20) 13-23B 13.
Rubber Track Loader 13. Undercarriage 13-26 13-30 17. Apply red (high strength) thread locking compound to the wheel retaining bolt as shown. (fig. 13-26) 21. Remove the allen plug from the center of the hub assembly and fill it with 2 ounces of Terex 10W-30 Heavy Duty Engine Oil. Then reinstall the plug. (fig. 13-29, 13-30) 22. Repeat this procedure on the other half of the bogie assembly if necessary prior to installing the two halves back onto the undercarriage. 13-27 18.
Rubber Track Loader 13. Undercarriage Hub Tool Kits PT-80: 0403-339 13-32 Idler Hub Service Procedure PT-80 Note: If you are removing the outer or rear hub assemblies you will be able to remove the hub assembly once step three is complete. Required Tools Socket Wrench & Sockets (including Allen) Press & Tool Kit (PT-80: 0403-339) Snap Ring Pliers 1. Remove the hub assemblies from the undercarriages as required first by following steps 1-7 of the track removal procedure on page 4-6.
Rubber Track Loader 13. Undercarriage Part #: 0403-337 Rear race 13-36 Part #: 0403-333 13-39 5. Remove the bearing out of the front of the hub as shown. (fig. 13-36) 7. If bearings are to be replaced, press the rear bearing race out of the assembly from the front of the hub with tools 0403-337 and 0403-333. (fig. 13-39) Center seal Front race Part #: 0403-336 13-37 13-40 Part #: 0403-337 Part #: 0403-334 8. Press the bearing sleeve out of the rear bearing using tool 0403-336. (fig.
Rubber Track Loader 13. Undercarriage Note: Take care not to drop the metal face seal halves. The sealing surfaces are surface ground and have an extremely fine finish. If scratched or disfigured, the seal will not function as intended. Note: Now is a good time to inspect the components for damage or wear. If the bearings do not roll smoothly when rotated, replace them. If the seals appear worn or damaged, replace them. If the wheels are worn or damaged, replace them.
Rubber Track Loader 13. Undercarriage Part #: 0403-335 13-48 13-51 16. Once the seals are in place, wipe the mating surfaces of the face seals with a clean shop cloth and alcohol in a circular motion ending in a gentle sweep from the inside to the outside of the face until clear of the face.This will ensure a clean mating surface and a good seal. (fig. 13-47, 13-48) 19.
Rubber Track Loader 13. Undercarriage Part #: 0403-330 13-54 13-57 22. Press the outer bearing race into the hub with tool # 0403-330 until it seats. (fig. 13-54) 26. Remove the allen plug in the center portion of the hub. (fig. 13-57) Part #: 0403-333 13-55 13-58 23. Pack the bearing with Terex Multi-Purpose EP Lithium Grease and then install it onto the bearing sleeve using tool 0403-333. (fig. 13-55) 27. Add 2 oz.
14. Lift-Arm Components Chapter Overview Removal and Installation This chapter provides removal and installation procedures for the lift-arm components. Removal and installation procedures are provided for the following lift-arm components. • • • Personal Safety Improper or incomplete maintenance/repair of a Rubber Track Loader can be dangerous and may result in machine damage, injury or death.
Rubber Track Loader 14. Lift-Arm Components 14-4 14-1 1. Rest the lift arms on an Terex approved jack stand to provide clearance for lift cylinder removal. (fig. 14-1) 4. Remove the bolts securing the front and rear lift arm cylinder pivot pins to the lift arm and lift arm tower. (fig. 14-4) 14-5 5. Remove the grease fitting from the pivot pins to allow the installation of the pin removal tool. (fig. 14-5) 14-2 2. Disconnect the inlet and outlet hoses from the cylinder. (fig. 14-2) 14-6 6.
Rubber Track Loader 14. Lift-Arm Components Bucket/Tilt Cylinder Removal Required Tools Socket Wrench Combination/Open End Wrench Hammer Punch (brass) 14-7 7. Remove the cylinder from the machine for service or inspection. (fig. 14-7) Note: At this time the pivot bushings and pivot pins are easily accessible for replacement. Inspect them for visible wear or damage and replace them as necessary . 14-8 1. Raise the lift arms and support them with the lift arm brace as described on page 4-1. (fig.
Rubber Track Loader 14. Lift-Arm Components 14-13 14-10 4. Remove the bolt securing the lower pin to the quick attach. (fig. 14-10) 7. Use a pry bar to slide the lower pin out of the cylinder end allowing it to be removed. (fig. 14-13) 14-11 14-14 5. Remove the bolt securing the upper pin to the lift arm weldment. (fig. 14-11) Disconnect 8. Use a pry bar to pry the lower cylinder eyelet out of the upper Q/A mount as shown. (fig. 14-14) 14-12 6.
Rubber Track Loader 14. Lift-Arm Components Quick Coupler Block PRV Removal Required Tools Combination Wrench 14-16 10. Remove the pin from the cylinder while supporting the cylinder. (fig. 14-16) 14-18 1. With the machine off and cool and with all hydraulic actuators relaxed, loosen the pressure release valve on the top of the auxiliary quick coupler block. (fig. 14-18) 14-17 11. Remove the cylinder from the machine. (fig. 14-17) Installation 1.
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15. Quick Attach Chapter Overview Removal and Installation This chapter provides removal and installation procedures for the quick attach and associated components. Removal and installation procedures are provided for the following quick attach components. • • Personal Safety Improper or incomplete maintenance/repair of a Rubber Track Loader can be dangerous and may result in machine damage, injury or death.
Rubber Track Loader 15. Quick Attach Upper guard 15-5 15-2 5. Remove the pivot link from the quick attach. (fig. 15-5) 2. Remove the bolts (3) securing the upper guard to the quick attach weldment. (fig. 15-2) Upper guard 15-6 6. Slide the locking pin assembly out of the quick attach. (fig. 15-6) 15-3 3. Remove the upper guard from the quick attach. (fig. 15-3) 15-7 Note: At this time the locking pin assembly components are easily accessible for replacement.
Rubber Track Loader 15. Quick Attach Pivot Pin (quick attach) Removal Required Tools Combination/Open End/Socket Wrenches Terex Approved Jack Stand (or equivalent) Hammer Punch (brass) 15-8 1. Rest the lift arms on an Terex approved jack stand to provide clearance for quick attach disassembly. (fig. 15-8) Remove bolt & nut Drive out 15-9 2. Remove the bolt securing the pivot pin to the quick attach weldment, then drive the pin out with a hammer and brass drift punch. (fig.
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NOTICE 16. Hydraulic Component Service Procedures Disassembly of hydraulic components should only be performed by factory trained personnel experienced in the disassembly and repair of hydraulic components. Components should not be serviced during the warranty period without written instruction from the Terex service department. Component disassembly during this period may void the manufacturer’s warranty.
Rubber Track Loader 16. Hydraulic Component Service Cylinder Tube Weldment 16-2 16-5 4. Use an open end or pipe wrench to turn and remove the end gland. (figure 16-2) 7. With the piston and rod removed from the cylinder, inspect the cylinder bore for scratches or other damage. If any are present that are deep enough to catch with your fingernail, the cylinder tube weldment should be replaced. (figure 16-5) End Gland Rod 16-3 16-6 5.
Rubber Track Loader 16. Hydraulic Component Service 16-8 16-11 13. Remove the tandem seals from the end gland paying close attention to the order of removal to aid during installation of the new seals. (fig. 16-11) 16-9 11. Remove the seals and piston ring taking care not to scratch the piston. Also, pay close attention to seal and ring orientation and position to aid when installing new parts. (figures 16-8, 16-9) 16-12 14. Remove the inner seal from the end gland.
Rubber Track Loader 16. Hydraulic Component Service 4. Remove each valve section and inspect the seals for damage, replace if necessary. (figure 16-15) Lift Arm Control Valve Disassembly Required Tools Socket Wrench Combination Wrench Screwdriver (blade type) Low Profile Needle Nose Pliers O-ring 1. With machine off and cool and with hydraulic actuators relaxed, remove the lift arm control valve according to the procedure on page 10-4. 16-16 2. Place the valve on a bench in a clean work area. 16-17 5.
Rubber Track Loader 16. Hydraulic Component Service 16-22 16-19 8. Remove the spring from the spool. (fig. 16-22) Note: Figure 16-19 displays the assembly order of the spool and associated components. Spool Load Check Spool Spring Cap 16-20 Note: The lift arm and bucket control spools are each equipped with a unique load check spool. The load check spools provide bucket positioning (self-Leveling). The components can be seen above in figure 16-20. 16-23 9.
Rubber Track Loader 16. Hydraulic Component Service Assembly Drive Motor (brake portion) 1. Install new seals and components in place of the originals as necessary paying close attention to location and orientation to ensure proper function. Disassembly 2. Thoroughly clean all components to prevent system contamination. 3. Reassemble components by reversing the disassembly process.
Rubber Track Loader 16. Hydraulic Component Service Shims Seal Bolts 16-27 Spring 16-30 4. Remove the brake spring and shims. Make sure to note the order of assembly to ensure correct reassembly. (fig. 16-27) 9. Inspect the seal for any damage. (fig. 16-30) 10. Remove the allen bolts securing the upper casting to the drive motor. (fig. 16-30) 16-28 16-31 5. Insert an air nozzle into the port closest to the rear of the pump as shown. (fig. 16-28) 11.
Rubber Track Loader 16. Hydraulic Component Service Drive Motor (motor portion) Disassembly Required Tools Allen Wrench/Socket Snap Ring Pliers Screwdriver (blade type) (seal removal if needed) Surfaces 16-36 3. Lift and remove the piston block to expose the sealing surfaces. Inspect these surfaces to ensure there is no scratching or abrasion that may affect operation. (fig. 16-36) 16-33 Surfaces 1. Mark the casing across the parting lines as shown to ensure correct reassembly of the drive motor. (fig.
Rubber Track Loader 16. Hydraulic Component Service Drive Pump (Drive Relief Valves) Disassembly & Adjustment Required Tools Allen Wrench/Socket Combination/Socket wrench 1. With machine off and cool and with hydraulic actuators relaxed, remove the drive pump from the machine by following the procedure in section 11. 16-39 Ring Groove Ring 16-42 16-40 6. Once the snap rings and retainers are removed, slide the piston assemblies out one at a time and inspect them for damage. (fig.
Rubber Track Loader 16. Hydraulic Component Service Drive Pump Disassembly Required Tools Combination/Socket wrench Allen Wrench/Socket Rubber Mallot Screwdriver (blade type) Snap RIng Pliers 16-45 4. Flip the valve over, then tighten the nut to increase the pressure setting (CW) or loosen it to decrease the pressure setting (CCW). Assembly & Test 1. Retighten the locking set screw and reinstall by reversing the disassembly procedure.
Rubber Track Loader 16. Hydraulic Component Service Bearings Swash Plate 16-49 16-52 3. Remove the valve plate and inspect it for damage or wear, specifically, scratches that can be felt with a fingernail. (fig. 16-49) Surfaces Barrel Face 16-53 5. Remove the swash plate along with the bearings and inspect them for any damage or scratching that could affect operation. (fig. 16-52, 16-53) 16-50 Slipper Faces 16-54 16-51 4.
Rubber Track Loader 16. Hydraulic Component Service Drive Pump Assembly Required Tools Combination/Socket wrench Allen Wrench/Socket Rubber Mallot Screwdriver (blade type) Snap RIng Pliers 16-55 7. Using a rubber mallot, gently tap the shaft and bearing out of the casing for inspection or replacement. (fig. 16-55) 16-56 1. Using a rubber mallot, gently tap the shaft and bearing into the casing until seated. (fig. 16-56) 16-57 2.
Rubber Track Loader 16. Hydraulic Component Service 16-58 16-61 4. Flip the assembly over and lay it on a table, then remove the pivot caps from both sides as shown. (fig. 16-58) Note: Behind each cap is a pivot that aligns with the two small pivot wires attached to the swash plate. Remove these from their cavities while installing the swash plate. 7. Once the pivots are installed, check to make sure both of them are properly mated with the pins.
Rubber Track Loader 16. Hydraulic Component Service Auxiliary Pump Disassembly Required Tools Allen Wrench/Socket Snap Ring Pliers O-ring 1. With machine off and cool and with hydraulic actuators relaxed, remove the drive pump from the machine by following the procedure in section 11. 16-67 5. Lift the cover off to expose the pump components and the o-ring seal. Inspect the o-ring for damage, replace if necessary. (fig. 16-67) 16-64 Inspect Face 2.
Rubber Track Loader 16. Hydraulic Component Service Inspect Faces 16-70 8. Remove the piston/barrel assembly and inspect the slipper faces for scratches or any other damage that can be felt with a fingernail. (fig. 16-70) Assembly 1. To reassemble, reverse the disassembly procedure.
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17. Hydraulic Pressure/Flow Test & Troubleshooting Chapter Overview Hydraulic Pressure/Flow Test & Troubleshooting Procedures This chapter provides hydraulic pressure and flow check, adjustment and troubleshooting procedures. Test and troubleshooting procedures are provided for the following Hydraulic system components. Personal Safety Improper or incomplete maintenance/repair of a Rubber Track Loader can be dangerous and may result in machine damage, injury or death.
Rubber Track Loader 17. Hydraulic Pressure & Flow 1. Attach the gauge to test port A. (fig. 17-1) Route the gauge so that you or an assistant can read it during testing. Charge Relief 2. Make sure any bystanders are clear of moving components, then start the engine. 3. Allow the engine to warm up to operating temperature, then with the engine at idle, check the charge pressure. Record your reading. It should read 475 +/- 30 psi (3275 kPa) at this test port.
Rubber Track Loader 17. Hydraulic Pressure & Flow 6. If necessary, adjust the relief settings on the auxiliary standby or high pressure valves. (figure 17-7) To adjust: a) Remove the cap covering the affected relief valve. Auxiliary Pressure Check Required Tools Pressure Gauges 0-1000 p.s.i. (0-6895 kPa) & 0-6000 p.s.i. (0-41370 kPa) Auxiliary pressure is used to drive flow style attachments.
Rubber Track Loader 17. Hydraulic Pressure & Flow Lift Arm Pressure Check Drive Pressure Check Required Tools Pressure Gauge 0-6000 p.s.i. (0-41370 kPa) Required Tools Pressure Gauge 0-6000 p.s.i. (0-41370 kPa) Lift arm pressure is used to lift loads or “break-out”. Low lift arm pressure can produce a weak lift arm function while high lift arm pressure can damage lift arm and hydraulic components. Note: Make sure auxiliary circuit pressures are set correctly prior to testing this function.
Rubber Track Loader 17. Hydraulic Pressure & Flow Check your readings against that stated below. If your readings differ, relief replacement and or component repair may be required. Posi-Power Pressure Check Posi-power is a function of the tandem drive pump assembly. The posi-power control reads charge flow (which is directly related to engine rpm) and adjusts drive pump flow to maximize torque and prevent engine stall during high load conditions.
Rubber Track Loader 17. Hydraulic Pressure & Flow 6. If your reading is low, remove the cap and loosen the jam nut on the posi-power adjustment screw and turn it counter clockwise until it stops then retighten the jam nut. (figure 17-11) Auxiliary Flow Test The PT-70/80 is equipped with both high and low flow auxiliary circuits. If an auxiliary flow problem is suspected, the following procedures should be performed.
Rubber Track Loader 17. Hydraulic Pressure & Flow Note: The charts pictured give the acceptable ranges for fluid flow when loaded to the levels indicated. The low flow values are to be understood as acceptable if within 1 gpm (3.8 lpm) of the specified value. The high flow values are acceptable if within 2 gpm (7.6 lpm) of the specified value. (Oil at operating temperature) To test flow: 1. Attach a flow meter to the quick couplers of the circuit to be tested. (high or low flow) 2.
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18. Troubleshooting Chapter Overview Visual Inspection This chapter contains basic troubleshooting procedures for PT-70/80 Rubber Track Loaders. Prior to troubleshooting, walk around the machine and perform an overall visual inspection. Look for missing, loose, worn or broken parts.
Rubber Track Loader 18. Troubleshooting Problem 2: Machine cranks, but will not start. Possible causes 1. Fuel tank empty, fuel filter plugged or fuel line restricted. 2. Battery discharged (engine rotates slowly). 3. Injection pump fuse blown. 4. Power relay (B) fuse blown (40 amp). 5. Faulty power relay (B). 6. Loose, broken or disconnected wiring at injection pump, fuel pump or fuse. 7. Glow plugs not pre-heating (look for black smoke). a) Main glow plug fuse blown. b) Glow plug relay malfunctioning.
Rubber Track Loader 18. Troubleshooting Problem 9: Lift arm control joystick will not lock into float position. Possible causes Engine/Machine Troubleshooting 1. Float magnet fuse blown. 2. Loose, broken, or disconnected wiring at fuse, float detent magnet, or pin connector P8. 3. Faulty float detent magnet. Problem 10: Lift arms will not float, engine labors and lift arms create down pressure when float is engaged. Possible causes 1. 2. 3. 4. Engine RPM too low. Low charge pressure.
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19. Lubricant & Fuel Specifications Chapter Overview Fuel Specifications When replacing or replenishing the fluids and lubricants in an Terex Rubber Track Loader, use Terex products. This ensures that the new fluids and lubricants match those originally installed when the machine left the Terex factory. Terex products were developed for, tested and approved by Terex to assure optimum life and performance in all Terex Rubber Track Loaders, when used as recommended.
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Terex Construction Americas 8800 Rostin Road Southaven, MS 38671 (888)-201-6008 (662)-393-1800 www.terex.
