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PT-30Part Number: 2010-513

Printed (1-11)

Service Manual

Compact Track Loader

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i

Table of Contents

1. Product Safety

Chapter Overview ................................................... 1-1

Basic Precautions ................................................... 1-1Safety Labels ..................................................... 1-1Personal Protective Equipment .......................... 1-1Entering and Exiting ........................................... 1-2Lifting ................................................................. 1-2Hot Fluids and Components .............................. 1-2Corrosion Inhibitor ............................................. 1-2Batteries ............................................................ 1-2Pressurized Items .............................................. 1-2

Repair ..................................................................... 1-3Attachments ............................................................ 1-4Machine Labels and Decals .................................... 1-4

Product ID Number ............................................ 1-4Safety Label Examples ...................................... 1-4

2. Technical SpecificationsChapter Overview ................................................... 2-1PT-30 Specifications ............................................... 2-1

3. System Diagrams

Chapter Overview ................................................... 3-1Filtering and Cooling System .................................. 3-1

Auxiliary Circuit System .......................................... 3-2Drive Loop System .................................................. 3-3

4. Machine Controls and Instrumentation

Chapter Overview ................................................... 4-1Machine Controls .................................................... 4-1

Loader Control ................................................... 4-1Drive Control ...................................................... 4-1Throttle .............................................................. 4-1

Instrumentation ....................................................... 4-1Switches .................................................................. 4-2

5. Operator Enclosure Disassemblyand Assembly

Chapter Overview ................................................... 5-1Personal Safety ....................................................... 5-1Machine Preparation ............................................... 5-1Operator Enclosure Disassembly and AssemblyProcedures .............................................................. 5-1Light Bar Removal and Installation .......................... 5-1

Light Bar Removal ............................................. 5-1Light Bar Installation .......................................... 5-2

Ignition Switch Removal and Installation ................. 5-2Ignition Switch Removal .................................... 5-2Ignition Switch Installation ................................. 5-3

Gauge Removal and Installation ............................. 5-4Gauge Removal ................................................. 5-4Gauge Installation .............................................. 5-4

Lap Bar Gas Assist Spring Removaland Installation ........................................................ 5-5

Lap Bar Gas Assist Spring Removal .................. 5-5Lap Bar Gas Assist Spring Installation ............... 5-5

6. Chassis Disassembly and Assembly

Chapter Overview ................................................... 6-1

Personal Safety ....................................................... 6-1Machine Preparation ............................................... 6-1Chassis Disassembly and AssemblyProcedures.............................................................. 6-1Seat Removal and Installation ................................ 6-1

Seat Removal .................................................... 6-1Seat Installation ................................................. 6-2

Fuel Sending Unit Removal and Installation ........... 6-2Fuel Sending Unit Removal ............................... 6-3Fuel Sending Unit Installation ............................ 6-3

Fuel Tank Removal and Installation ....................... 6-4Fuel Tank Removal ........................................... 6-4Fuel Tank Installation......................................... 6-6

7. Radiator/Oil Cooler Disassembly

and AssemblyChapter Overview ................................................... 7-1Personal Safety ....................................................... 7-1Machine Preparation ............................................... 7-1Radiator/Oil Cooler Disassembly and AssemblyProcedures.............................................................. 7-1Fan Guard Removal and Installation ....................... 7-1

Fan Guard Removal .......................................... 7-2Fan Guard Installation ....................................... 7-2

Fan and Fan Shroud Removal and Installation ....... 7-2Fan and Fan Shroud Removal ........................... 7-2Fan and Fan Shroud Installation ........................ 7-3

Radiator/Cooler Removal and Installation ............... 7-4Radiator/Cooler Removal .................................. 7-4

Radiator/Cooler Installation ............................... 7-6Radiator/Oil Cooler Adjustment Procedures .......... 7-7

Fan Shroud Adjustment ..................................... 7-7Fan Guard Adjustment....................................... 7-8

8. Hydraulic Reservoir Disassemblyand Assembly

Chapter Overview ................................................... 8-1Personal Safety ....................................................... 8-1Machine Preparation ............................................... 8-1Hydraulic Reservoir Disassembly and AssemblyProcedures.............................................................. 8-1Filter Element Removal and Installation .................. 8-1Filter Assembly Removal and Installation ............... 8-1

Filter Assembly Removal ................................... 8-2Filter Assembly Installation ................................ 8-3

Access Cover Assembly Removal and Installation . 8-4Access Cover Assembly Removal ..................... 8-4Access Cover Assembly Installation .................. 8-4

Reservoir Gauge Removal and Installation ............. 8-5Reservoir Gauge Removal ................................ 8-5Reservoir Gauge Installation ............................. 8-6

Suction Screen Removal and Installation ............... 8-6Suction Screen Removal ................................... 8-6Suction Screen Installation ................................ 8-7

Hydraulic Reservoir Cleaning Procedures ............. 8-7

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Compact Track LoaderTable of Contents

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9. Loader/Transmission Controls Disassemblyand Assembly

Chapter Overview ................................................... 9-1Personal Safety ....................................................... 9-1Machine Preparation ............................................... 9-1Loader/Transmission Controls Disassembly and

Assembly Procedures ............................................. 9-1

Loader Control Joystick/Drive Control JoystickRemoval and Installation ......................................... 9-1

Loader Control Joystick/Drive Control JoystickRemoval ............................................................ 9-2Loader Control Joystick/Drive Control JoystickInstallation.......................................................... 9-3

Loader Float Magnet Removal and Installation ....... 9-3Loader Float Magnet Removal........................... 9-3Loader Float Magnet Installation ........................ 9-4

Loader Valve Removal and Installation .................. 9-4Loader Valve Removal ...................................... 9-4Loader Valve Installation ................................... 9-6

10. Transmission and Drive Disassemblyand Assembly

Chapter Overview ................................................. 10-1Personal Safety ..................................................... 10-1Machine Preparation ............................................. 10-1Transmission and Drive Disassemblyand Assembly Procedures .................................... 10-1Brake Cylinder Removal and Installation .............. 10-1Drive Motor Removal and Installation ................... 10-1

Auxiliary Gear Pump Removal and Installation ..... 10-2Auxiliary Gear Pump Removal ......................... 10-2Auxiliary Gear Pump Installation ...................... 10-3

Tandem Pump Removal and Installation .............. 10-4Tandem Pump Removal .................................. 10-4Tandem Pump Installation ............................... 10-5

Pump Drive Coupler Removal and Installation ...... 10-6

Pump Drive Coupler Removal ......................... 10-6Pump Drive Coupler Installation ...................... 10-7

11. Engine Components Disassembly and As-sembly

Chapter Overview ................................................. 11-1Personal Safety ..................................................... 11-1Machine Preparation ............................................. 11-1Engine Components Disassembly and

Assembly Procedures ........................................... 11-1Primary Air Filter Removal and Installation ........... 11-1Safety Air Filter Removal and Installation ............. 11-1Engine Oil Filter Removal and Installation ............ 11-1Fuel Filter Removal and Installation ..................... 11-1Muffler Removal and Installation .......................... 11-2

Muffler Removal ............................................... 11-2Muffler Installation ............................................ 11-2

Exhaust Pipe Removal and Installation ................. 11-3Exhaust Pipe Removal .................................... 11-3Exhaust Pipe Installation ................................. 11-4

Battery Removal and Installation........................... 11-5Battery Removal .............................................. 11-5Battery Installation ........................................... 11-6

Bleeding the Fuel System.11-7

12. Undercarriage Disassembly and Assembly

Chapter Overview ................................................. 12-1Personal Safety ..................................................... 12-1Machine Preparation ............................................. 12-1Undercarriage Disassembly and AssemblyProcedures............................................................ 12-1Wheel Removal and Installation ........................... 12-1

Wheel Removal ............................................... 12-2Wheel Installation ............................................ 12-3

Track Removal and Installation ............................. 12-3Track Removal ............................................... 12-3Track Installation ............................................ 12-3

Sprocket Bearing Plate Removal and Installation . 12-6Sprocket Bearing Plate Removal ................... 12-7Sprocket Bearing Plate Installation ................ 12-8

Sprocket Roller Removal and Installation ............. 12-8Sprocket Roller Removal ............................... 12-8Sprocket Roller Installation ............................ 12-9

Sprocket Removal and Installation ........................ 12-9Sprocket Removal ......................................... 12-9Sprocket Installation .................................... 12-10

Drive Motor Removal and Installation ................ 12-10

Drive Motor Removal.................................. 12-11Drive Motor Installation............................... 12-11

13. Loader Disassembly and Assembly

Chapter Overview ................................................. 13-1Personal Safety ..................................................... 13-1Machine Preparation ............................................. 13-1Loader Disassembly and Assembly Procedures .. 13-1Lift Cylinder/Tilt Cylinder Removaland Installation ...................................................... 13-1

Lift Cylinder/Tilt Cylinder Removal ................... 13-1Lift Cylinder/Tilt Cylinder Installation ................ 13-3

Lift Cylinder/Tilt Cylinder Seal Kit Removaland Installation ...................................................... 13-3

Seal Kit Removal ............................................ 13-3Seal Kit Installation ......................................... 13-5Lift Arm Bushing Removal and Installation ........... 13-6

Upper Friction Points ....................................... 13-6Lower Friction Points ....................................... 13-8

Low-Flow Relief Valve Removal and Installation .. 13-9Low Flow Relief Valve Removal ...................... 13-9Low Flow Relief Valve Installation ................. 13-10

14. Quick Attach Disassembly and Assembly

Chapter Overview ................................................. 14-1Personal Safety ..................................................... 14-1Machine Preparation ............................................. 14-1Quick Attach Disassembly and AssemblyProcedures............................................................ 14-1

Latch Pin Assembly Removal and Installation ...... 14-1Latch Pin Assembly Removal .......................... 14-1Latch Pin Assembly Installation ....................... 14-2

Quick Attach Assembly Removal and Installation . 14-2Quick Attach Assembly Removal ..................... 14-2Quick Attach Assembly Installation .................. 14-3

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Compact Track LoaderTable of Contents

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15. Troubleshoot ing

Chapter Overview ................................................. 15-1Personal Safety ..................................................... 15-1Machine Preparation ............................................. 15-1

Visual Inspection .............................................. 15-1Troubleshooting .................................................... 15-2

16. MaintenanceChapter Overview ................................................. 16-1Maintenance Schedule .......................................... 16-1Engine Oil ............................................................. 16-1

Oil Change Procedures ................................... 16-1Engine Oil Specifications ................................. 16-1

Hydraulic Fluid and Filter ...................................... 16-2Hydraulic Fluid and Filter ChangeProcedures ...................................................... 16-2

Fuel Filter .............................................................. 16-3Fuel Filter Change Procedures ........................ 16-3Fuel Specifications ........................................... 16-3

Air Cleaner ............................................................ 16-3Air Filter Change Procedures........................... 16-3

Track Tension ....................................................... 16-4Track Tension Adjustment Procedures ............ 16-4Checking for Proper Track Adjustment ............ 16-4

Fuse Box ............................................................... 16-5Grease Fittings ...................................................... 16-5Lift Arm Bushings .................................................. 16-6

17. Hydraulic Pressure Check & AdjustmentChapter Overview ................................................. 17-1Personal Safety ..................................................... 17-1Machine Preparation ............................................. 17-1Charge Pressure check. 17-1Charge Pressure Adjustment17-2Drive Pressure Adjustment17-3

Auxiliary Pressure Check & Adjustment..17-4

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Chapter Overview

This chapter contains product safety information for theTerex PT-30 Compact Track Loaders. Read and under-

stand all product safety information before attempting

to service any Compact Track Loader.

Safety Alert Symbol

This symbol means: Attention! Be

alert! Your safety is involved!

The safety alert symbol is used to alert you to potential

personal injury hazards. Obey all safety messages

that follow this symbol to avoid possible injury or

death.

This symbol is used as an attention-getting device

throughout this manual as well as on decals and labels

fixed to the machinery to assist in potential hazard

recognition and prevention.

Property or equipment damage warnings in this publi-

cation are identified by the signal word "NOTICE".

The word Note is used throughout this manual to

draw your attention to specific topics or to supplement

the information provided in that section.

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 usecaution when performing service tasks. Familiarize

yourself with the affected system(s) and components

before attempting any type of maintenance or service.

It is not possible to anticipate every potential haz-

ard. The safety messages included in this docu-

ment and displayed on the machine are not all-

inclusive. They are intended to make you aware of

potential risks and encourage a safe approach to

performing service work. If you use a tool, proce-

dure, work method or operating technique that is

not specifically recommended by Terex, you must

satisfy yourself that it is safe for you and others.

You must also ensure that the machine will not be

damaged or be made unsafe by the operation,

lubrication, maintenance or repair procedures that

you choose.

Basic Precautions

Safety LabelsSafety labels have been included and are displayed in

various places throughout the machine to serve as

warnings of potentially dangerous conditions. Readand understand all "Safety" labels on any Compact

Track Loader before attempting to operate, maintain or

repair it. Replace any damaged, illegible or missing

labels immediately, prior to service.

Personal Protective EquipmentPersonal 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 equipmentnecessary to ensure your safety and the safety of oth-

ers around you as you work.

1. Product Safety

1-1

NOTICE Indicates a hazardous situation which,

if not avoided, could result in property or equip-ment damage.

NOTICE

Improper or incomplete maintenance/repair of a

Compact Track Loader can be dangerous and

may result in machine damage, injury or death.

Do not attempt to perform any type of repair or main-

tenance on a Compact Track Loader until you have

read and fully understood both this manual and the

machine specific operation and maintenance manual.

Refer to the Operation and Maintenance manual for

instructions regarding proper machine operation and

maintenance techniques before operating or servicing

any Compact Track Loader.

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Entering and ExitingAlways use steps and handholds when entering or

exiting a Compact Track Loader. Clean any mud or

debris from steps or work platforms before using them.

Always face the machine when using steps and hand-

holds. When it is not possible to use the designed

entry/exit system, utilize ladders, scaffolds, or work

platforms to safely gain access to the machine.

LiftingUse 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 posi-

tioned correctly and equipped with a spring latch.

Lifting eyes are not to be side loaded during a lifting

operation.

Hot Fluids and Components

Stay clear of hot components and system fluids of theengine, exhaust, radiator/oil cooler and hydraulic

lines/tubes. Also, use caution when removing fill caps,

breathers and plugs on the machine. Hold a rag over

the cap or plug to prevent being sprayed or splashed

by liquids under pressure. Be especially careful if the

machine has been operated recently, fluids may still be

hot. To ensure your safety, allow the machine to cool

before attempting any service procedure that involves

hot fluids or components.

Corrosion Inhibitor

Corrosion inhibitor contains alkali. Avoid contact witheyes. 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.

BatteriesDo not smoke when inspecting the battery electrolyte

level. Never disconnect any charging unit circuit or bat-

tery circuit cable from the battery when the charging

unit is operating. A spark can cause an explosion from

the flammable vapor mixture of hydrogen and oxygenthat 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.

Pressurized Items1. Do not use hands or any other body part to check

for fluid leaks in the hydraulic system. Always use

a solid material like wood or metal to check for this

type of leak. Leaking fluid under pressure can pen-

etrate body tissue. Fluid penetration can cause

serious injury and even death. If fluid is injected

into your skin, get treatment immediately. Seektreatment from a doctor that is familiar with this

type of injury.

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.

3. Lower the lift arms before performing any work on

the machine. If this cannot be done, make surethey 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 clean-

ing, wear a protective face shield, protective cloth-

ing, and protective shoes. The recommended max-

imum air pressure for cleaning purposes is 30 psi

(205 kPa). When using a pressure washer, keep in

mind that nozzle pressures are typically very high.

Generally, pressures are well above 2000 psi

(13,790 kPa). Follow all recommended practices

provided by the pressure washer manufacturer.

1-2


1. Product Safety

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Repair

1. Disconnect the battery and discharge any capaci-

tor before beginning work on a machine. Attach a

Do Not Operate tag in the cab to alert any opera-

tor that service is in progress.

2. If possible, make all repairs with the machine

parked on a level, hard surface. Use blocks to pre-

vent the machine from rolling while working on or

under the machine.

3. Do not work on or under any machine that is sup-

ported only by a hydraulic jack or hoist. Always

use some sort of mechanical support to ensure

that the machine will not fall.

4. Make sure the work 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

engines exhaust is properly vented.

5. Be sure all protective devices including guards and

shields are properly installed and functioning cor-

rectly before beginning any service task. If a guard

or shield must be removed to perform the repair

work, use extra caution.

6. Always use the appropriate tools for the work to be

performed. Tools should be in good condition and

you should understand how to use them properly

before performing any service work.

7. When replacing fasteners, use parts of equivalentgrade and size. Do not use a lesser quality fasten-

er if replacements are necessary.

8. Be prepared to stop an engine if it has been re-

cently overhauled or the fuel system has been

recently serviced. If the engine has not been

assembled correctly, or if the fuel settings are not

correct, the engine can possibly overspeed and

cause bodily injury, death or property damage. Be

prepared to shut off the fuel and air supply to the

engine in order to stop the engine.

9. Be careful when removing cover plates. Gradually

back off the last two bolts or nuts located on oppo-

site sides of the cover. Then, pry the cover loose

to relieve any spring or other pressure before

removing the last two nuts or bolts completely.

10. Repairs requiring welding should be performed

only by personnel adequately trained and knowl-

edgeable in welding procedures and with the guid-

ance of appropriate reference information.

Determine the type of metal being welded and

select the correct welding procedure and fillermaterial to provide a weld that is as strong or

stronger than the original weld.

11. Take precautions to avoid damaging wiring during

removal and installation operations. Carefully route

wires so that they will not contact sharp corners,

objects or hot surfaces during operation.

12. When performing service that requires the lift arms

to be in the raised position, always utilize the lift

arm brace located on the rear of the loader tower.

13. Relieve hydraulic system pressure by relaxing allhydraulic 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 exces-

sive heat, vibration or unwanted contact between

parts during operation. Shields that protect

exhaust components from oil spray in event of a

line, tube or seal failure must be correctly installed.

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


1. Product Safety

Accidental machine starting can cause injury

or even death to personnel working on a

Compact Track Loader.

As a precaution, disconnect the battery cables from

the battery terminals, tape the battery clamps and

remove the key from the ignition switch prior to per-forming any service work on a Compact Track Loader.

Place a Do Not Operate tag prominently on the

machine to inform personnel that the machine is

being serviced.

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Attachments

Only use attachments that are recommended by Terex.

Make sure that all necessary guards and protective

equipment are in place and functioning prior to operat-ing any attachment.

Wear protective glasses and protective equipment as

required by conditions or as recommended in the

attachments operation manual.

Ensure that all personnel are far enough away from

the work area so they will not be struck by flying ob-

jects.

Stay clear of the cutting edges, pinching surfaces or

crushing surfaces of the attachment while performing

any attachment maintenance, testing or adjustments.

Machine Labels and Decals

Labels and decals placed on the machine provide

safety information and operating instructions.

Familiarize yourself with the location and significance

of these labels to ensure your safety.

Product Identification Number

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

the dealer about parts, service, warranty or

accessories. No warranty claims will be

processed unless the PIN is provided.

Safety

Label

WARNING

Crush Hazard

Death or serious injury can result

from contact with moving lift arm or

attachment.

Keep clear of lift arms and

attachments.

1-4


1. Product Safety

1-1

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.

WARNING

Fall Hazard

Serious injury or death can r esult

from falling.

Use the provided access system when

entering or exiting the machine.

Entanglement Hazard

Rotating parts can cause personal injury.

Keep away from fan and belt while the

engine is running. Stop engine before

servicing.2030-600

WARNING

WARNING

Crush Hazard

Death or serious injury can result

from contact with moving lift arm or

attachment. Install lift arm brace prior to servicing.

NOTICE

Fire Hazard

Flammable debris can collect near hot

components and lead to a fire.

Read Operators manual

Keep engine, exhaust and chassis

areas free of debris.

Burn Hazard

Hot fluid under pressure can scald.

Allow the machine to cool thoroughly

before opening.

2030-595

WARNING

WARNING

CRUSH HAZARD

Contact with moving machine can

result in death or serious injury.

Keep clear of moving machine.

2030-593

WARNING

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1-5


1. Product Safety

WARNING

Fasten Seat Belt

Crush Hazard

Rollover can crush and result in serious injury or death.

Do not use the bucket/attachment as a work platform.

Fall Hazard

Falling can result in serious injury or death .

WARNING

WARNING

Read Operators ManualRead and understand the operators manualand all safety signs prior to operating or

maintaining the machine.

WARNING WARNING

Improper operation or maintenance can re-

sult in serious injury or death.

No Riders

Fall HazardFalling from a machine can result in serious

injury or death.

Carry loads low. Load unload and turn onlevel ground. Travel on inclines with heaviest

end of machine uphill.

Rollover/Ejection HazardSerious injury or death can result.

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 surgi-

cally removed within a few hours by a

doctor familiar with this type of injury

or gangrene will result.

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1-6

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PT-30 Specifications

Engine- 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: 190F,

87.8C

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

Drive Motors- Model: Rexroth Sauer Danfoss

- Displacement: 19.215 in3/rev (314.9 cc/rev)

Pilot Controls (Joysticks)- Model: Rexroth 4TH6

Auxiliary Pump- Make: Rexroth

- Type: Gear

- Displacement: 0.87 in3/rev (14.3 cc/rev)

- Max Flow: 10 gpm (37.9 lpm) @ 2800 rpm

- Relief pressure: 3000 psi (20,684 kPa)- Cooling/filtering: Oil is filtered and cooled at all

times. In auxiliary mode, the oil is filtered after the

attachment to protect the machine if the attach-

ment motor fails or contaminants are introduced

from the quick couplers.

Lift Arm Control Valve- Make: Husco

- Relief Pressure: 3000 psi (20,684 kPa)

- Pilot pressure required to move spools: 180-220psi

(1241-1517 kPa)

Oil Cooler- Operating pressure: 250 psi (1724 kPa)

- Bypass relief pressure: 80 psi (551.6 kPa)

- Hot oil sending unit: 225F (107.2C)

- Avg. oil operating temp. 50-60F (10-16C) above

ambient. (extreme application 80F , 27C above

ambient.)

Critical Torque Specs- Transmission Mounting Bolts

-- 80 ft-lb (108 Nm). w/Blue Loctite

- Drive Sprocket Drive Teeth Bolts

-- 62 ft-lb (84 Nm). -Dry

- Bogie Wheel Retaining Nuts

-- 110 ft-lb (149 Nm). - Dry

- Drive Sprocket Retaining Bolt

(Serial # 00101-05000)

-- 60 ft-lb (81 Nm). w/Blue Loctite

- Drive Sprocket Retaining Castle Nut

(Serial # 05001-Current)

-- 270 ft-lb (366 Nm)

Service ToolsListed below are common service tools which are iden-

tified and utilized in the service procedures described

in this manual. Use tools recommended by Terex

whenever possible to reduce risk of injury and or

machine damage during service.

Heavy Duty Hydraulic Jack (5-ton rating)

Test Gauge Kit (P/N: 0402-935)

Long Pry Bar(s)

2. Technical Specifications

& Service Tools

2-1

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Chapter Overview

This chapter contains diagrams for the followingCompact Track Loader systems.

Filtering and cooling system

Auxiliary circuit system

Drive loop system

Figure 3-1 PT-30 Filtering and Cooling System

Filtering and Cooling System

The filtering and cooling system (Figure 3-1) containsthe following major components.

Hydraulic reservoir

Radiator/oil cooler

Loader valve

Auxiliary gear pump

Pilot control manifold

3. Circuit Diagrams

3-1

100psi (689.5 kPa)

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Auxiliary Circuit SystemThe auxiliary circuit system (Figure 3-2) contains the

following major components.

Loader valve


Auxiliary gear pump

Loader control joystick

Figure 3-2 PT-30 Auxiliary Circuit System

3-2


3. Circuit Diagrams

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Drive Loop SystemThe drive loop system (Figure 3-3) contains the fol-

lowing major components.

Tandem pump

Drive motors


Drive control joystick

Figure 3-3 PT-30 Drive Loop System

3-3


3. Circuit Diagrams

DRIVE MOTOR

DRIVE MOTOR

CHARGE PRESSURE

TEST PORT

DRIVE CONTROL

TANK

CASE DRAIN

BRAKE

TANDEM PUMP (WITH DRIVE

AND CHARGE PRESSURE

RELIEF VALVES.)

CASE DRAIN

TO IMPLEMENT

VALVE

Drive ReliefsCharge Reliefs

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Chapter OverviewThis chapter contains an overview of the machine con-

trols and instrumentation. For further information

regarding machine controls, instrumentation or opera-

tion, refer to the operation and maintenance manual

for your particular machine. Included here are illustra-

tions of the following controls and instrumentation com-

ponents and a description of their functions.

Machine Controls

Instrument Location and Function

Switch Location and Function

Machine Controls (fig. 4-1)

There are three primary machine controls: loader con-trol (1), drive control (2) and throttle (3).

Loader ControlThe 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 ControlThe drive control (2) is also a pilot operated joystick. It

allows the operator to change the direction and speed

of the machine.

ThrottleThe hand throttle (3) controls engine rpm.

InstrumentationThe Instruments (Figure 4-2) are positioned in the

overhead dash panel for ease of access and visibility

when seated inside the operator enclosure.

Instruments include the following components.

(1) Fuel Gauge

(2) Tachometer (optional)

(3) Engine Coolant Temp. Gauge (optional)

(4) Hour Meter

(5) Warning Indicator Display

Engine Oil Pressure Warning Light

Engine Temperature Warning Light

Hydraulic Oil Temperature Warning Light

Battery Voltage Warning Light

If the engine temperature, engine oil pressure or hydraulic oil

temperature lights illuminate or should the eng. coolant temp.

gauge read excessive temperatures during normal machine

operation, shut the machine down immediately (in a safe

location). Diagnose the problem and make any necessary

repairs before resuming normal operation.

If the battery low-voltage light should illuminate during opera-

tion, drive the machine to a suitable location and shut the

engine off. Diagnose the problem and make any needed

repairs before resuming operation.

The glow plug operation light illuminates only when the

key switch is turned to engine pre-heat, showing nor-

mal operation.

4. Machine Controls and

Instrumentation

4-1

1

3

4-1

2

4-2

1 5 4

NOTICE

NOTICE

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PT-30 Switches

The various switches (Figure 4-3) are positioned to

provide good access and visibility. The standard and

optional switches are listed below.

(1) Work lights

(2) Heater fan (optional)(3) Front wiper (optional)

(4) Beacon light (optional)

(5) Ignition, glow plug (pre-heat)

(6) Auxiliary hydraulics

4-2


4. Machine Controls and Instrumentation

4-3

1 2 3 4 5 6

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5-1

5. Operator EnclosureDisassembly and Assembly

Chapter OverviewThis chapter provides disassembly and assemblyprocedures for the operator enclosure assembly.

Personal SafetyImproper or incomplete maintenance/repair of a CompactTrack 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 andfully understood the information in this manual.

Refer to the Operation and Maintenance manual for in-structions regarding proper machine operation techniquesbefore operating any Compact Track Loader.

Prior to performing any type of service work on aCompact Track Loader, read and understand Chap-ter 1 (Product Safety) for personal safety informa-tion.

Machine PreparationAccidental machine starting can cause injury ordeath to personnel working on a Compact TrackLoader.

As a precaution, disconnect the battery cables fromthe battery terminals, tape the battery clamps andremove the key from the ignition switch prior to per-forming any service work on a Compact Track Load-er.

Place a Do Not Operate tag prominently on themachine to inform personnel that the machine is be-ing worked on.

Operator EnclosureDisassembly and AssemblyProceduresDisassembly and assembly procedures are providedfor the following operator enclosure components.

Light Bar

Ignition Switch

Gauges

Lap Bar Gas Assist Spring

Note: Procedures are provided for only those operatorenclosure components listed above. However, informationfor removal and installation of other operator enclosurecomponents can be obtained from the machine specificparts manual.

Light Bar Removal andInstallationThe tools required for light bar console removal andinstallation are listed in Table 5-1. Use manufacturerrecommended tools whenever possible.

Table 5-1

Required Tools

Combination Wrench

Light Bar Removal

Figure 5-1

1. Loosen the two cap screws that attach the lightbar to the cab frame.

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Compact Track Loader5. Operator Enclosure Disassembly and Assembly

5-2

Figure 5-2

2. Carefully lower the light bar with the wire har-ness attached.

Figure 5-3

3. View of light bar interior components. Interiorcomponents are now accessible for servicing.

Figure 5-4

4. View of dome light. If removal is required, simply

insert a lever (blade-type screw driver) at oppo-site end of switch in pry-pocket, and gently prythe light assembly out of the light bar.

Light Bar Installation

Figure 5-5

1. Carefully position the light bar, without pinchingthe wiring harness against the cab roof.

Figure 5-6

2. Secure the light bar to the cab roof with the twocapscrews

Ignition Switch Removal andInstallationThe tools required for ignition switch removal andinstallation are listed in Table 5-2. Use manufactur-er-recommended tools whenever possible.

Table 5-2

Required Tools

Combination Wrench

Ignition Switch Removal

1. Lower the light bar. Refer to Chapter 5.Light BarRemovalprocedure.

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5-3

Figure 5-7

2. Remove the nut that secures the ignition switchto the dash panel.

Figure 5-8

3. Pull the ignition switch out from the rear of thedash panel.

Figure 5-9

4. Unplug the ignition switch connector.

Ignition Switch Installation

Figure 5-10

1. Insert the ignition switch from the rear of thedash panel.

Figure 5-11

2. Install the nut that secures the ignition switch tothe dash panel.

Figure 5-12

3. Plug in the ignition switch connector.

Remove Nut

Install Nut

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5-4

4. Install the light bar. Refer to Chapter 5.Light BarInstallationprocedure.

Gauge Removal and Installa-tionThe tools required for gauge removal and installationare listed in Table 5-3. Use manufacturer-recommended tools whenever possible.

Table 5-3

Required Tools

Combination wrench

Gauge Removal

1. Lower the light bar. Refer to Chapter 5.Light Bar

Removalprocedure.

Figure 5-13

2. Disconnect the connector from the gauge.

Figure 5-14

3. Remove the two nuts that secure the gauge tothe retaining bracket.

Figure 5-15

4. Pull the gauge out from the front of the dashpanel.

Gauge Installation

Figure 5-16

1. Insert the gauge from the front of the dash pan-el.

Figure 5-17

2. Install the two nuts that secure the gauge to theretaining bracket.

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5-5

Figure 5-18

3. Reconnect the gauge connector.

4. Install the light bar. Refer to Chapter 5.Light BarInstallationprocedure.

Lap Bar Gas Assist SpringRemoval and InstallationThe tools required for gas assist spring removal andinstallation are listed in Table 5-4. Use manufactur-er-recommended tools whenever possible.

Table 5-4

Required Tools

Screwdriver

Lap Bar Gas Assist Spring Removal

Raise Lap Bar(Shown in Down

Position)

Gas Assist

Spring

Figure 5-19

1. Put the lap bar in the UP position to relieve ten-sion on the lap bar gas assist spring.

Remove

Retaining Clip

Figure 5-20

2. Using a small screwdriver, remove the retainingclip from each end of the gas assist spring.

Figure 5-21

3. Remove the gas assist spring by pulling bothends out from the ball joints.

Lap Bar Gas Assist Spring Installation

Gas Assist

Spring Location

Raise Lap Bar(Shown in Down

Position)

Figure 5-22

1. Put the lap bar in the UP position to minimizetension on the lap bar gas assist spring duringinstallation.

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5-6

Install Ends onBall Joints

Figure 5-23

2. Install the ends of the lap bar gas assist springonto the ball joints.

Insert

Retaining Clip

Figure 5-24

3. Slide the retaining clip on to each end of the gasassist spring.

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6-1

6. ChassisDisassembly and Assembly

Chapter OverviewThis chapter provides disassembly and assemblyprocedures for the chassis assembly.





Machine PreparationAccidental machine starting can cause injury ordeath to personnel working on a Compact Track

Loader.As a precaution, disconnect the battery cables fromthe battery terminals, tape the battery clamps andremove the key from the ignition switch prior to per-forming any service work on a Compact Track Load-er.


Chassis Disassembly andAssembly ProceduresDisassembly and assembly procedures are providedfor the following chassis components.

Seat

Fuel Sending Unit

Fuel Sending Unit Hose

In-Tank Weight

Fuel Tank

Note: Procedures are provided for only those chassiscomponents listed above. However, information for re-moval and installation of other chassis components can beobtained from the exploded view illustration provided inthe machine specific parts manual.

Seat Removal and InstallationThe tools required for seat removal and installationare listed in Table 6-1. Use manufacturer-recommended tools whenever possible.

Table 6-1

Required Tools

Socket Wrench

Seat Removal

Remove Seat Bolts

Figure 6-1

1. Remove the four bolts that fasten the seatmounts to the frame.

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Compact Track Loader6. Chassis Disassembly and Assembly

6-2

UnplugConnector

Figure 6-2

2. Tilt the seat forward and reach behind the seatto unplug the seat switch wiring harness.

Figure 6-3

3. Remove the seat. Be careful not to scratch thecontrol panel or sides of the cab.

Seat Installation

Figure 6-4

1. With the seat mounts attached, place the seat inthe cab. Be careful not to scratch the controlpanel or sides of the cab.

Plug in the Connector

Figure 6-5

2. Tilt the seat forward and reach behind the seatto plug in the seat switch connector

Note:The machine will not operate unless the seat switchconnector is plugged in.

insert Seat Bolts

Figure 6-6

3. Position the seat so the holes in the seat mountsare aligned with the holes in the frame. Insertthe four seat mount bolts and washers.

Fuel Sending Unit Removaland Installation

The tools required for fuel sending unit removal andinstallation are listed in Table 6-2. Use manufactur-er-recommended tools whenever possible.

Table 6-2

Required Tools

Screwdriver

Combination Wrench

Socket Wrench

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6-3

Fuel Sending Unit Removal

1. Remove the seat. Refer to Chapter 6.Seat Re-movalprocedure.

2. Pump fuel from the tank until there is no fuelremaining above the sending unit.

Collect and contain li quids in a suitable contain-er. Dispose of all liquids according to local regula-tions and mandates.

FuelSending

Unit

Figure 6-7

3. Remove the hoses and wires from the fuel send-ing unit, then remove the screws that fasten theunit to the tank. Mark the wires and hoses.

Note: If the fuel sending unit wires are crossed, the fuelgauge will not work. If the hoses are crossed, the enginewill not run.

Figure 6-8

4. Remove the fuel sending unit. Be careful not todamage the float mechanism when pulling itthrough the opening in the fuel tank.

Figure 6-9

5. The fuel pickup line will also come out with thefuel sending unit.

Fuel Sending Unit Installation

Figure 6-10

1. Insert the fuel pickup line into the fuel tank open-ing. The pickup line is attached to the fuel send-ing unit.

Note: The weight on the end of the fuel pickup line mustrest on the bottom of the tank for proper operation.

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6-4

Figure 6-11

2. Insert the fuel sending unit float mechanism intothe fuel tank opening. Be careful not to damagethe float when pushing it through the opening.

Note: Make sure that the wire on the sending unit is notbent and the fuel pickup line does not interfere with themovement of the float.

FuelSending

Unit

Figure 6-12

3. Connect the hoses and wires to the fuel sendingunit, then install the screws that fasten the unitto the tank.

Note: Be careful not to cross the wires or hoses. If thefuel sending unit wires are crossed, the fuel gauge will notwork. If the hoses are crossed, the engine will not run.

4. Install the seat. Refer to Chapter 6.Seat Instal-lationprocedure.

Fuel Tank Removal andInstallationThe tools required for fuel tank removal and installa-tion are listed in Table 6-3. Use manufacturer-recommended tools whenever possible.

Table 6-3

Required Tools

Screwdriver

Combination Wrench

Socket Wrench

Fuel Tank Removal

1. Remove the seat. Refer to Chapter 6.Seat Re-movalprocedure.

Figure 6-13

2. View of fuel tank with seat removed.

3. Pump all fuel from the fuel tank.

Collect and contain liquids in a suitable contain-er. Dispose of all liquids according to local regula-tions and mandates.

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6-5

Remove Floor

Pan Bolts

Figure 6-14

4. Remove the four bolts that hold the floor pan tothe frame.

Figure 6-15

5. Remove the floor pan.

FuelSending

Unit

Figure 6-16

6. Remove the hoses and wires from the fuel send-ing unit.

RemoveFiller Piece

Figure 6-17

7. Remove the steel filler piece behind the fueltank.

Remove

Bolt

Figure 6-18

8. Remove the bolt that fastens the fuel tank to theframe.

Disconnect

Vent Hose

Figure 6-19

9. Disconnect the Compact vent hose from the fueltank.

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6-6

Remove

Filler Hose

Figure 6-20

10. Remove the Compact filler hose from the backend or the tank.

Figure 6-21

11. Remove the tank carefully from the machine.

Fuel Tank Installation

Figure 6-22

1. Place the fuel tank in the machine in approx-imately its normal position.

Attach

Filler Hose

Figure 6-23

2. Attach the filler hose to the rear of the tank.

Connect

Vent Hose

Figure 6-24

3. Connect the vent hose to the fuel tank.

InsertBolt and

Washer

Figure 6-25

4. Insert the bolt and washer that connect the fueltank to the frame.

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6-7

Insert

Filler Piece

Figure 6-26

5. Insert the steel filler piece behind the fuel tank.

Fuel

SendingUnit

Figure 6-27

6. Attach the hoses and wiring to the fuel sendingunit.

Figure 6-28

7. Replace the floor pan.

Install Floor Pan

Bolts and Washers

Figure 6-29

8. Install the four floor pan bolts and washers.

9. Install the seat. Refer to Chapter 6.Seat Instal-lationprocedure.

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7-1

7. Radiator/Oil CoolerDisassembly and Assembly

Chapter OverviewThis chapter provides disassembly and assemblyprocedures for the radiator/oil cooler assembly. Ad-

justment procedures are also included for selectedradiator/oil cooler components.







Place a Do Not Operate tag prominently on themachine to inform personnel that the machine is be-

ing worked on.

Radiator/Oil CoolerDisassembly and AssemblyProceduresDisassembly and assembly procedures are providedfor the following radiator/oil cooler components.

Fan Guard

Fan Shroud

Fan

Multi-Wing Fan

Radiator/Cooler

Note:Procedures are provided for only those radiator/oilcooler components listed above. However, information forremoval and installation of other radiator/oil cooler compo-nents can be obtained from the machine specific partsmanual.

Note:Refer to Figure 3-1 for an overview of the filteringand cooling system.

Fan Guard Removal and In-stallationThe tools required for fan guard removal and instal-lation are listed in Table 7-1. Use manufacturer-recommended tools whenever possible.

Table 7-1

Required Tools

Combination Wrench

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Compact Track Loader7. Radiator/Oil Cooler Disassembly and Assembly

7-2

Fan Guard Removal

Figure 7-1

1. Remove the capscrews that secure the fanguard to the fan guard mounts.

2. Remove the fan guard from the engine com-partment.

Fan Guard Installation

1. Position the fan guard over the fan and againstthe fan shroud.

Figure 7-2

2. Install the capscrews that secure the fan guard

to the fan guard mounts.

Fan and Fan Shroud Removaland InstallationThe tools required for fan and fan shroud removaland installation are listed in Table 7-2. Use manufac-turer-recommended tools whenever possible.

Table 7-2

Required Tools

Combination Wrench

Socket Wrench

Fan and Fan Shroud Removal

Hot fluids can cause burns. Allow the machineto cool thoroughl y prior to proceeding.

Figure 7-3

1. Remove the upper hose from the oil cooler sec-tion. Cap the hose and fitting.

2. Remove the fan guard. Refer to Chapter 7. FanGuard Removal.

RemoveHose

FanGuardMount

FanGuard

FanGuardMount

Fan

Guard

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7-3

Figure 7-4

3. Remove the three bolts from each side of thefan shroud that secure the shroud to the radia-tor/cooler.

Figure 7-5

4. With the shroud pulled back, reach between theradiator/cooler and the fan and remove the fourbolts that secure the fan to the engine.

Figure 7-6

5. Remove the fan from the engine compartment.

Figure 7-7

6. Remove the shroud from the engine compart-ment.

Fan and Fan Shroud Installation

Figure 7-8

1. Place the fan shroud in the engine compartment.

Figure 7-9

2. Place the fan in the engine compartment.

RemoveBolts

RemoveBolts

FanShroud

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7-4

Figure 7-10

3. Holding the fan in position between the radia-tor/cooler and the fan shroud, install the fourbolts that secure the fan to the fan drive motor.

Figure 7-11

4. Pull the shroud over the fan and install the threebolts on each side of the fan shroud that securethe shroud to the radiator/cooler.

5. Install the fan guard. Refer to Chapter 7. FanGuard Installation.

Figure 7-12

6. Install the upper hose on the oil cooler section.

Radiator/Cooler Removal andInstallationThe tools required for radiator/cooler removal andinstallation are listed in Table 7-3. Use manufactur-er-recommended tools whenever possible.

Table 7-3

Required Tools

Combination Wrench

Socket Wrench

Screwdriver

Radiator/Cooler Removal

Hot oil can cause personal injury. Make sure the

oil is coo l before removing any components or lines.

Remove the oil filler cap only when the engine isstopped and has been allowed to cool thoroughly.

Personal injury can result from hot coolant,steam and alkali.

At operat ing temperature, engine coolant is hot andunder pressure. The radiator and hoses contain hotcoolant and steam. Allow the machine to cool tho-roughly prior to performing service or repair proce-dures to avoid burns.

Remove the filler cap slowly to relieve pressure onlywhen the engine is stopped and the machine has beenallowed to cool thoroughly.

Cooling system conditioner contains alkali. Avoidcontact with skin and eyes.

Collect and contain l iquids in a suitable contain-er. Dispose of all liquids according to local regula-tions and mandates.

1. Remove fan and shroud. Refer to Chapter 7.

2. Drain the hydraulic fluid. Refer to Chapter 16.Hydraulic Fluid and Filter Change.

InstallBolts

InstallBolts

InstallHose

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7-5

Figure 7-13

3. Remove the bolts from the lower engine com-partment screen.

Figure 7-14

4. Remove the lower engine compartment screenand drain the coolant using the petcock on thebottom of the radiator.

Figure 7-15

5. Remove the lower hose from the oil cooler sec-tion. Cap the hose and fitting.

Figure 7-16

6. Remove the upper hose from the oil cooler sec-tion. Cap the hose and fitting.

Figure 7-17

7. Remove the upper hose from the radiator sec-tion. Cap the hose and fitting.

Figure 7-18

8. Remove the lower hose from the radiator sec-tion. Cap the hose and fitting.

RemoveHose

DrainCoolant

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7-6

Figure 7-19

9. Remove the three mounting bolts on each sideof the radiator/cooler.

Figure 7-20

10. Remove the radiator/cooler from the enginecompartment.

Radiator/Cooler Installation

Figure 7-21

1. Position the radiator/cooler in the engine com-partment.

Figure 7-22

2. With the radiator/cooler in position, install thethree mounting bolts on each side of the radia-tor/cooler.

Figure 7-23

3. Remove the hose and fitting caps and install thelower hose on the radiator section.

Figure 7-24

4. Remove the hose and fitting caps and install theupper hose on the radiator section.

InstallBolts

RemoveBolts

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7-7

Figure 7-25

5. Remove the hose and fitting caps and install theupper hose on the oil cooler section.

Figure 7-26

6. Remove the hose and fitting caps and install thelower hose on the oil cooler section.

Figure 7-27

7. Position the lower engine compartment screenand secure with the mounting bolts.

8. Fill the radiator with coolant and the hydraulicreservoir with oil.

Radiator/Oil Cooler

Adjustment ProceduresAdjustment procedures are provided for the follow-ing radiator/oil cooler components.

Fan Shroud

Fan Guard

Fan Shroud Adjustment

The tools required for fan shroud adjustment arelisted in Table 7-4. Use manufacturer-recommendedtools whenever possible.

Table 7-4

Tool Name

Combination Wrench

Figure 7-28

1. The fan shroud can adjusted upward or down-ward. To adjust, loosen the bolts on each side ofthe shroud and move the shroud in the desireddirection. Tighten the bolts when finished.

LoosenBolts

to Adjust

InstallHose

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7-8

Fan Guard Adjustment

The tools required for fan guard adjustment arelisted in Table 7-5. Use manufacturer-recommendedtools whenever possible.

Table 7-5

Tool Name

Combination Wrench

Figure 7-29

1. The fan guard can adjust forward or rearward.To adjust, loosen the capscrews that fasten thefan guard to the fan guard mounts. Tighten thecapscrews when finished.

LoosenCapscrews

to Adjust

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8-1

8. Hydraulic ReservoirDisassembly and Assembly

Chapter OverviewThis chapter provides disassembly and assemblyprocedures for the hydraulic reservoir assembly.Cleaning procedures are also included for the hy-draulic reservoir.







Place a Do Not Operate tag prominently on themachine to inform personnel that the machine is be-

ing worked on.

Hydraulic ReservoirDisassembly and AssemblyProceduresDisassembly and assembly procedures are providedfor the following hydraulic reservoir components.

Filter Element

Filter Assembly

Filler Cap Assembly

Access Cover Assembly

Reservoir Gauge

Suction Screen

Note: Procedures are provided for only those hydraulicreservoir components listed above. However, informationfor removal and installation of other hydraulic reservoircomponents can be obtained from the Compact TrackLoader Parts List manual.

Note:Refer to Figure 3-1 for an overview of the filteringand cooling system.

Filter Element Removal andInstallationRefer to Chapter 16. Maintenance Hydraulic Fluidand Filterfor removal and installation of the filter.

Filter Assembly Removal andInstallationThe tools required for filter assembly removal and

installation are listed in Table 8-1. Use manufactur-er-recommended tools whenever possible.

Table 8-1

Required Tools

Combination/Socket Wrenches

Needle Nose Pliers

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Compact Track Loader8. Hydraulic ReservoirDisassembly and Assembly

8-2

Filter Assembly Removal

Hot oil can cause personal injury. Make sure theoil is coo l before removing any components or lines.

Remove the oil filler cap only when the engine is

stopped and the machine has been allowed to coolthoroughly

Note: During disassembly, cap all hoses and fittings toprevent fluid loss and contamination of the system fluids.

Figure 8-1

1. Remove the screws securing the cover to thefilter assembly.

Figure 8-2

2. Remove the cap from the filter assembly asshown.

Figure 8-3

3. Remove the filter from the reservoir as shown.

Figure 8-4

4. Disconnect the hose from the filter assembly.

Figure 8-5

5. Remove the bolts securing the filter head as-sembly to the reservoir.

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8-3

Figure 8-6

6. Remove the filter head and gasket from the re-servoir.

Filter Assembly Installation

Figure 8-7

1. Place the filter assembly gasket in position ontop of the reservoir. Replace if damaged.

Figure 8-8

2. Position the filter head onto the gasket with themounting holes aligned, install bolts.

Figure 8-9

3. Reconnect the hose to the filter head and se-cure.

Figure 8-10

4. Reinstall the filter and filter tube into the reser-voir as shown.

Figure 8-11

5. Install the cap onto the filter head as shown.

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8-4

Figure 8-12

6. Install the cap bolts and tighten to secure.

Access Cover Removal and

InstallationThe tools required for access cover removal andinstallation are listed in Table 8-2. Use manufactur-er-recommended tools whenever possible.

Table 8-2

Required Tools

Combination Wrench

Access Cover Assembly Removal


Remove the oil filler cap only when the engine isstopped and the machine has been allowed to coolthoroughly

Figure 8-13

1. Slightly loosen the access cover bolt to separatethe upper cap from the oval-shaped clampingdisk on the underside of the assembly. This willallow the assembly to be removed. Do not re-move the bolt entirely or the oval-shaped clampwill fall into the reservoir.

Figure 8-14

2. Remove the access cover assembly from thereservoir.

Access Cover Assembly Installation

Figure 8-15

1. Insert the access cover assembly with theclamping disk extending completely through the

opening in the top of the reservoir and into thetank.

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8-5

Figure 8-16

2. Tighten the access cover bolt.

Reservoir Gauge Removal and

InstallationThe tools required for reservoir gauge removal andinstallation are listed in Table 8-3. Use manufactur-er-recommended tools whenever possible.

Table 8-3

Required Tools

Combination Wrenches

Reservoir Gauge Removal



Collect and contain liqu ids in a suitable contain-er. Dispose of all liquids according to local regula-tions and mandates.

Note: During disassembly, cap all hoses and fittings toprevent fluid loss and contamination of the system fluids.


2. Remove the filter assembly. Refer to Chapter 8.Filter Assembly Removal.

Figure 8-17

3. View of hydraulic reservoir with filter assemblyremoved.

Figure 8-18

4. Reach inside the reservoir and remove the twonuts that fasten the reservoir gauge to the reser-voir.

Figure 8-19

5. Pull the reservoir gauge and the two mountingbolts/washers off the reservoir. DO NOT mis-place the Compact washers or the reservoir willleak.

Remove Re-servoir Gaugewith Mounting

Bolts/Washers

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8-6

Reservoir Gauge Installation

Figure 8-20

1. Install the reservoir gauge in the reservoir usingthe two mounting bolts/washers.

Figure 8-2113

2. Reach inside the reservoir and install the twonuts that secure the reservoir gauge to the re-servoir.

3. Install the filter assembly. Refer to Chapter 8.Filter Assembly Installation.

4. Add manufacturer-approved hydraulic fluid.

Suction Screen Removal andInstallationThe tools required for suction screen removal andinstallation are listed in Table 8-4. Use manufactur-er-recommended tools whenever possible.

Table 8-4

Required Tools

Combination Wrench

Suction Screen Removal



stopped and the machine has been allowed to coolthoroughly

Collect and con tain liquids in a suitable contain-er. Dispose of all liquids according to local regula-tions and mandates.

Note: It is normally not necessary to replace the suctionscreen unless there has been a catastrophic failure andthere is debris in the reservoir.


2. Remove the access cover assembly. Refer toChapter 8.Access Cover Assembly Removal.

Figure 8-22

3. With a magnet centered in an absorbent rag,thoroughly clean the interior of the reservoir toprevent any debris from entering the systemwhen you remove the suction filter.

Insert Reser-voir Gauge

with Mounting

Bolts/Washers

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8-7

Figure 8-23

4. Reach inside the reservoir and unscrew the suc-tion screen. Remove the suction screen from thereservoir.

Suction Screen Installation

Figure 8-24

1. Insert the suction screen in the reservoir throughthe access cover opening.

2. Reach inside the reservoir and screw the suctionscreen into the bottom of the reservoir.

3. Install the access cover assembly. Refer toChapter 8.Access Cover Assembly Installation.


Hydraulic Reservoir CleaningProceduresCleaning procedures are provided for the followinghydraulic reservoir components.

Hydraulic Reservoir

Hydraulic Reservoir Cleaning

The tools required for hydraulic reservoir cleaningare listed in Table 8-5. Use manufacturer-recommended tools whenever possible.

Table 8-5

Tool Name

Combination Wrench



Collect and con tain liquids in a suitable contain-er. Dispose of all liquids according to local regula-tions and mandates.

1. Drain the hydraulic fluid. Refer to Chapter 16.

Hydraulic Fluid and Filter Change.

2. Remove the access cover assembly. Refer toChapter 8.Access Cover Assembly Removal.

3. Thoroughly wipe out the interior of the hydraulicreservoir with a magnet and a clean rag.

4. Install the access cover assembly. Refer toChapter 8.Access Cover Assembly Installation.


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Chapter OverviewThis chapter provides disassembly and assembly pro-

cedures for the loader and transmission controls.

Personal SafetyImproper 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 regard-

ing proper machine operation techniques before operating

any Compact Track Loader.

Prior to performing any type of service work on a Compact

Track Loader, read and understand Chapter 1 (Product

Safety) for personal safety information.

Machine PreparationAccidental machine starting can cause injury or death to per-

sonnel working on a Compact Track Loader.

As a precaution, disconnect the battery cables from the bat-

tery terminals, tape the battery clamps and remove the key

from the ignition switch prior to per-forming any service work

on a Compact Track Loader.

Place a Do Not Operate tag prominently on the machine to

inform personnel that the machine is be-ing worked on.

Loader/Transmission Controls

Disassembly and AssemblyProceduresDisassembly and assembly procedures are provided

for the following loader/transmission control compo-

nents.

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 ofother loader/transmission control components can be

obtained from the Compact Track Loader Parts List

manual.

Note: Refer to Figure 3-2 for an overview of the auxil-

iary circuit system and Figure 3-3 for an overview of

the drive loop system.

Loader Control Joystick/Drive

Control Joystick Removal and

Installation

There are two joysticks that control the operation of the

machine: a drive control joystick and a loader control

joystick.

Drive Control Joystick Operation The left-hand

joystick controls the speed and direction of the ma-

chine. The further the joystick is pushed, the faster the

machine travels. The joystick operates on hy-draulic

charge pressure. When the joystick is moved, oil is

sent to the hydrostatic transmission. The transmission

then delivers oil, in the correct amount, to the drivemotors.

9. Loader/Transmission Controls

Disassembly and Assembly

9-1

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Loader Control Joystick Operation The right-hand

joystick controls the loader arm and the at-tachment tilt

cylinder. It allows the operator to raise, lower and pivot

the attachment. The joystick operates on hydraulic

charge pressure.

The loader control also has a float position, which is

activated by moving the joystick completely forward

until it is held in detent. The joystick is held in the for-

ward float position by an electromagnet.

The tools required for loader/drive control joystick

removal and installation are listed in Table 9 1. Use

manufacturer recommended tools whenever possible.

Table 9-1

Loader Control Joystick/Drive Control

Joystick Removal

Note: The procedures for removing both joystick con-

trols are nearly identical, as a result, only the right con-

trol joystick procedure is described below.

Note: During disassembly, cap and plug all hoses and

fittings to prevent fluid loss and contamination of the

system fluids.

1. Remove the seat from the machine according to

the procedure in chapter 6, seat removal.

2. Lower the lift arms to the ground.

3. Turn the ignition switch to the OFF position.

4. Relax all hydraulic circuits.

Figure 9-1

5. Remove the various screws holding the plastic

side consoles to the cab enclosure as shown.

Figure 9-2

6. Pivot the panel away from the joystick, then lift and

remove it from the machine.

Figure 9-3

7. Remove the three nuts securing the joystick mount

to the cab enclosure from the outside of themachine.

9-2



Combination/Socket Wrenches

Screwdriver (phillips)

Required Tools

Relax all hydraulic circuits/controls and make

sure the oil is cool before disconnecting anycomponent or line from the system.

Pressurized and or hot hydraulic fluid can cause per-

sonal injury.

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Figure 9-4

8. Pull the joystick away from the cab wall as shown.

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 andplug the openings to prevent spills.

Figure 9-6

10. Disconnect the electrical connections shown to

free the joystick from the machine, then remove.

11. Reverse the removal procedure to reinstall the joy

stick. Take care to ensure all connections are to

the appropriate ports on the joystick and that they

are tight and leak free.

Note: If it is neccessary to remove the left joystick on a

machine equipped with a heater, you must disconnect

the heater lines at the heater unit in order to remove

the side panel. Cap and plug hoses and ports to mini-

mize coolant loss.

Loader Float Magnet Removal and

Installation

The tools required for loader float magnet removal and

installation are listed in Table 9-2. Use manufacturer

recommended tools whenever possible.

Table 9-2

Loader Float Magnet Removal

Figure 9-7

1. Remove the zip tie securing the lower portion of

the joystick boot to the joystick as shown.

Figure 9-8

2. Lift the boot to expose the magnet and joystick

mounting bolts. Remove the joystick mounting

bolts to allow the joystick to be moved upward

within the bracket.

9-3



Allen (hex) Wrenches


Screwdriver

Required Tools

Remove

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Figure 9-9

3. Use an allen (hex) wrench to remove the bolt

securing the magnet to the joystick.

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.

Loader Valve Removal and

Installation

The tools required for loader valve removal and in-stal-

lation are listed in Table 9 3. Use manufacturer-recom-

mended tools whenever possible.

Table 9-3

Loader Valve Removal

Note: During disassembly, cap all hoses and fittings to

prevent fluid loss and contamination of the system flu-

ids.

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




Required Tools

Hot oil can cause personal injury. Lower all

attach-ments and make sure the oil is cool

before removing any components or lines.


stopped and the filler cap is cool enough to touch

with your hands.

Collect and contain liquids in a suitable con-

tainer. Dispose of all liquids according to local

regulations and mandates.

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Figure 9-11

5. Disconnect the gas springs, then press the spring

latches inward as shown to remove the hood.

Figure 9-12

6. Carefully remove the hood from the machine and

set it aside.

Figure 9-13

7. Remove the bolts securing the rear valance panelto the chassis to allow for removal.

Figure 9-14

8. Carefully remove the rear valance from the

machine to allow access to the loader valve.

Figure 9-15

9. Locate the loader valve on the side of the

hydraulic reservoir.

Figure 9-16

10. Disconnect the tubes from the top and bottom ofthe loader valve. Cap and plug all openings to pre-

vent fluid loss.

9-5



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Figure 9-17

11. Disconnect the tubes from the side of the loader

valve. Cap and plug all openings to prevent fluid

loss.

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.

Figure 9-19

13. Remove the nuts securing the valve to the reser

voir as shown.

Figure 9-20

14. Remove the valve from the machine.

15. Installation is the reverse of the removal proce-

dure.

16. Once all components have been reinstalled and

are secure, add manufacturer approved hydraulic

fluid until full mark is reached on the level gauge.

Note: To eliminate trapped air from the system, acti-

vate all hydralic circuits and run machine through its

paces including moving the lift arms up and down, curl-

ing and tilting the Q/A, driving forward and in reverse,

and activating the auxiliary circuit. Then, check

hydraulic fluid level and add as required to reach full

mark.

9-6



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10-1

10. Transmission and DriveDisassembly and Assembly

Chapter OverviewThis chapter provides disassembly and assemblyprocedures for the transmission and drive assembly.








Transmission and DriveDisassembly and AssemblyProceduresDisassembly and assembly procedures are providedfor the following transmission and drive components.

Drive Motors

Auxiliary Gear Pump

Tandem Pump

Pump Drive Coupler

Note:Procedures are provided for only those transmissionand drive components listed above. However, informationfor removal and installation of other transmission and drivecomponents can be obtained from the machine specificparts manual.

Note:Refer to Figure 3-2 for an overview of the auxiliarycircuit system and Figure 3-3 for an overview of the driveloop system.

Drive Motor Removal and In-stallationRefer to Chapter 12. Undercarriage Disassemblyand Assembly Drive Motor Removal and Installa-tion for removal and installation of the drive motors.

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Compact Track Loader10. Transmiss ion and Drive Disassembly and Assembly

10-2

Auxiliary Gear Pump Removaland InstallationThe tools required for auxiliary gear pump removaland installation are listed in Table 10-1. Use manu-facturer-recommended tools whenever possible.

Table 10-1

Required Tools

Screwdriver

Combination Wrench

Socket Wrench

Auxi liary Gear Pump Removal

Hot oil can cause personal injury. Make sure theoil is coo l before removing

Documents

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