Terex PT100 Forestry Service & Repair Manual
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Terex PT100 Forestry Service & Repair Manual

Terex PT100 Forestry Service & Repair Manual

Compact track loaders
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Download this manual See also: Operation & Maintenance Manual
8/17/2016
Language:
English
Geographic Region:
All
Serial Number Range:
SN All
PT100 Forestry
Service Repair Manual
This manual is complements of
TrackLoaderParts.com
The world's best source for Terex parts.
Track Loader Parts
6543 Chupp Road
Atlanta, Georgia 30058
USA
(800)616-8156

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Summary of Contents for Terex PT100 Forestry

  • Page 1 8/17/2016 Language: English Geographic Region: Serial Number Range: SN All PT100 Forestry Service Repair Manual This manual is complements of TrackLoaderParts.com The world's best source for Terex parts. Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 (800)616-8156...

  • Page 2: Table Of Contents

    Table of Contents 1. Product Safety Ignition Switch Removal and Installation ....5-2 Ignition Switch Removal ........5-2 Chapter Overview ........... 1-1 Ignition Switch Installation ......... 5-3 Basic Precautions ........... 1-1 Gauge Removal and Installation ......5-4 Safety Labels…..........1-1 Gauge Removal ..........
  • Page 3 Rubber Track Loader Table of Contents 9. Hydrostatic & Aux. Pump Disassembly Cab Filtration ............11-22 and Assembly Fan Cleaning ............11-22 Maintenance Schedule ........11-23 Chapter Overview ........... 9-1 Personal Safety ............9-1 Machine Preparation ..........9-1 12. Lubricant & Fuel Specifications Hydrostatic &...

  • Page 4: Product Safety

    This chapter contains product safety information for the Loader may be unfamiliar with many of the systems on Terex PT-100 Forestry Compact Track Loaders. Read the machine. This makes it especially important to use and understand all product safety information before caution when performing service tasks.

  • Page 5: Entering And Exiting

    Compact Track Loader 1. Product Safety Entering and Exiting Pressurized Items Always use steps and handholds when entering or 1. Do not use hands or any other body part to check exiting a Compact Track Loader. Clean any mud or for fluid leaks in the hydraulic system.

  • Page 6: Repair

    Terex jack stands objects or hot surfaces during operation. work well to support the machine while performing maintenance or repair work.

  • Page 7: Attachments

    1. Product Safety Attachments Safety Label Examples Examples of the labels and decals displayed on the Only use attachments that are recommended by Terex. machine are shown on this page. Make sure that all necessary guards and protective WARNING WARNING equipment are in place and functioning prior to operat- ing any attachment.
  • Page 8 Compact Track Loader 1. Product Safety DANGER WARNING WARNING WARNING WARNING WARNING Explosion/Burn Hazard Will cause death, burns or Fall Hazard Burn Hazard blindness due to ignition of Crush Hazard Falling can result in serious injury or death ot surfaces can Contact with h Rollover can crush and result in serious injury or death.

  • Page 10: Technical Specifications

    2. Technical Specifications PT-100 Forestry Specifications Engine Loader Valve − − Make: Husco Model: Perkins 1104C-44T (Turbo) − − Type: Load Sense Displacement: 4.4 liter − Gross horsepower: 99.9 hp (74.5 kW) Cooler − Torque: 304 lb-ft. (412 Nm) − Operating pressure: 150 psi (1034 kPa) −...

  • Page 12: Circuit Diagrams

    3. Circuit Diagrams Chapter Overview Hydraulic Charge Circuit This chapter contains diagrams for the following PT- 100 Forestry circuits: hydraulic charge circuit, hydraulic auxiliary circuit, hydraulic drive circuit, loader valve, hydraulic pilot generation (solenoid) block and electri- cal attachment outlet. Figure 3-1 PT-100 Forestry Hydraulic Charge Circuit...

  • Page 13: Hydraulic Auxiliary Circuit

    Compact Track Loader 3. Circuit Diagrams Hydraulic Auxiliary Circuit Figure 3-2 PT-100 Forestry Hydraulic Auxiliary Circuit...

  • Page 14: Hydraulic Drive Circuit

    Compact Track Loader 3. Circuit Diagrams Hydraulic Drive Circuit Figure 3-3 PT-100 Forestry Hydraulic Drive Circuit...

  • Page 15: Lift Arm Control Valve

    Compact Track Loader 3. Circuit Diagrams Lift Arm Control Valve Figure 3-4 PT-100 Forestry Lift Arm Control Valve...
  • Page 16 Compact Track Loader 3. Circuit Diagrams Hydraulic Pilot Generation Block Figure 3-5 PT-100 Forestry Pilot Generation Block...

  • Page 17: Electrical Attachment Outlet

    Compact Track Loader 3. Circuit Diagrams Electric Attachment Outlet Figure 3-6 PT-100 Forestry Electric Attachment Outlet...

  • Page 18: Machine Controls And Instrumentation

    4. Machine Controls and Instrumentation Chapter Overview Instrumentation This chapter contains an overview of the machine con- The Instruments (Figure 4-2) are positioned in the trols and instrumentation. For further information overhead dash panel for ease of access and visibility regarding machine controls, instrumentation or opera- when seated inside the operator enclosure.

  • Page 19: Switches

    Compact Track Loader 4. Machine Controls and Instrumentation Switches The various switches (Figure 4-3) are positioned to provide good access and visibility. The standard and optional switches are listed below. (1) Lights (front and rear) (2) Reversible Fan (cooler cleanout)) (3) Wiper (4) Beacon (optional) (5) Ignition, glow plug (pre-heat)

  • Page 20: Operator Enclosure Disassembly

    5. Operator Enclosure Disassembly and Assembly Chapter Overview Operator Enclosure Disassembly and Assembly This chapter provides disassembly and assembly procedures for the operator enclosure assembly. Procedures Disassembly and assembly procedures are provided Personal Safety for the following operator enclosure components. Improper or incomplete maintenance/repair of a Compact •...

  • Page 21: Gauge Panel Installation

    Compact Track Loader 5. Operator Enclosure Disassembly and Assembly Gauge Panel Installation Figure 5-2 2. Carefully lower the gauge panel with the wire Figure 5-5 harness attached. 1. Carefully position the gauge panel, without pinching the wiring harness against the cab. Figure 5-3 3.

  • Page 22: Ignition Switch Installation

    Compact Track Loader 5. Operator Enclosure Disassembly and Assembly Ignition Switch Installation Remove Nut Figure 5-7 Figure 5-10 2. Remove the nut that secures the ignition switch 1. Insert the ignition switch from the rear of the to the gauge panel. dash panel.

  • Page 23: Gauge Removal And Installation

    Compact Track Loader 5. Operator Enclosure Disassembly and Assembly 4. Install the gauge panel. Refer to Chapter 5. Gauge Panel Installation procedure. Gauge Removal and Installa- tion The tools required for gauge removal and installation are listed in Table 5-3. Use manufacturer- recommended tools whenever possible.

  • Page 24: Head Light Removal And Installation

    Compact Track Loader 5. Operator Enclosure Disassembly and Assembly Figure 5-18 Figure 5-20 3. Reconnect the gauge connector. 2. To remove light, push the light inward and re- move grommet. Then reach through opening and pull light out. 4. Install the gauge panel. Refer to Chapter 5. Gauge Panel Installation procedure.
  • Page 25 Compact Track Loader 5. Operator Enclosure Disassembly and Assembly Figure 5-23 Figure 5-26 2. Install rubber grommet around head light. 5. Install light cover and secure in place to complete this procedure. Figure 5-24 3. Install head light by inserting one edge of the grommet.

  • Page 26: Fuel Tank Disassembly And Assembly

    6. Fuel Tank Disassembly and Assembly Chapter Overview Disassembly and Assembly Procedures This chapter provides disassembly and assembly procedures for the chassis assembly. Disassembly and assembly procedures are provided for the following chassis components. Personal Safety • Fuel Sending Unit Improper or incomplete maintenance/repair of a Compact •...

  • Page 27: Fuel Sending Unit Installation

    Compact Track Loader 6. Chassis Disassembly and Assembly 3. Disconnect the wires to the fuel sending unit on the right side tank. (fig. 6-3) Fuel drain Note: If the fuel sending unit wires are crossed, the fuel plug gauge will not work. Figure 6-1 2.

  • Page 28: Fuel Tank Installation

    Compact Track Loader 6. Chassis Disassembly and Assembly 4. Disconnect the wires to the fuel sending unit on Remove Exhaust the right side tank. (fig. 6-8) Pipe Sending Unit Wires Figure 6-5 3. Loosen up the cross over tube on both ends, where it enters each fuel tank.

  • Page 30: Radiator/Oil Cooler Disassembly

    7. Radiator/Oil Cooler Disassembly and Assembly Chapter Overview Radiator/Oil Cooler Disassembly and Assembly This chapter provides disassembly and assembly procedures for the radiator/oil cooler assembly. Procedures Disassembly and assembly procedures are provided Personal Safety for the following radiator/oil cooler components. Improper or incomplete maintenance/repair of a Compact •...

  • Page 31: Fan Guard Removal

    Compact Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Fan Guard Removal Fan Removal The tools required for radiator/cooler removal and installations are listed below. Use manufacturer- recommended tools whenever possible. Required Tools Combination Wrench Socket Wrench Screwdriver 1. Remove the fan guard as described above. (fig. 7-1) Figure 7-1 1.

  • Page 32: Radiator/Cooler Removal

    Compact Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Radiator/Cooler Removal Hot oil can cause personal injury. Make sure the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped and has been allowed to cool thoroughly. Personal injury can result from hot coolant, steam and alkali.
  • Page 33 Compact Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Figure 7-8 Figure 7-10 5. Remove rear engine skid plate from the ma- 7. Remove the two lower hydraulic oil cooler hos- chine. This will give you access to the lower ra- es.

  • Page 34: Radiator/Cooler Installation

    Compact Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Disconnect Figure 7-14 Figure 7-12 9. Lift the radiator/cooler straight upward to remove 2. To disconnect blue air line from air filter hosing it. It may be necessary to move the fan shroud and the supply line to fan, press the yellow part out of the way for the radiator/cooler to clear.

  • Page 35: Reversible Fan Compressor And Control Box Installation

    Compact Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Figure 7-17 5. To remove the compressor: Remove the mounting screws securing the compressor the screen, then remove. To remove the control box: Remove the mounting screws securing the con- trol box to the screen, then remove. Reversible Fan Compressor and Control Box Installation 1.

  • Page 36: Loader/Transmission Controls Disassembly

    8. Loader/Transmission Controls Disassembly and Assembly Chapter Overview Loader/Transmission Controls Disassembly and Assembly This chapter provides disassembly and assembly procedures for the loader/transmission controls as- Procedures sembly. Disassembly and assembly procedures are provided for the following loader/transmission control compo- Personal Safety nents.

  • Page 37: Joystick Installation

    Compact Track Loader 8. Loader/Transmission Controls Disassembly and Assembly Hot oil can cause personal injury. Lower any attachments and make sure the oil is cool before re- moving any components or lines. 1. Raise the lift arms and cab according to Tilt-Up Canopy procedure on page 11-5 of this manual.

  • Page 38: Loader Float Magnet Removal And Installation

    Compact Track Loader 8. Loader/Transmission Controls Disassembly and Assembly Loader Float Magnet Removal and Installation The tools required for loader float magnet removal and installations are listed in Table 8-1. Use manu- facturer-recommended tools whenever possible. Remove Screw Table 8-1 Required Tools Screwdriver Open End Wrench...
  • Page 39 Compact Track Loader 8. Loader/Transmission Controls Disassembly and Assembly Install Screw Loader Float Magnet Figure 8-13 Figure 8-14 2. The loader float magnet is held in place by an Allen screw at the bottom of the magnet. Install this screw. (fig. 8-13) 3.

  • Page 40: Chapter Overview

    9. Hydrostatic and Aux. Pump Disassembly and Assembly Chapter Overview Hydrostatic and Hydraulic Pump Disassembly and As- This chapter provides disassembly and assembly procedures for the hydrostatic and auxiliary pump. sembly Procedures Disassembly and assembly procedures are provided Personal Safety for the following transmission and drive components.
  • Page 41 Compact Track Loader 9. Transmission and Drive Disassembly and Assembly Collect and contain liquids in a suitable contain- er. Dispose of all liquids according to local regula- tions and mandates. Note: During disassembly, cap all hoses and fittings to prevent fluid loss and contamination of the system fluids. 1.

  • Page 42: Auxiliary Pump Removal

    Compact Track Loader 9. Transmission and Drive Disassembly and Assembly Auxiliary Pump Removal Remove split flange Figure 9-8 1. Disconnect all hoses from auxiliary pump. Figure 9-6 (fig. 9-8) Pump support bolt Figure 9-9 2. Loosen (remove) the pump support bolt. You Figure 9-7 must first loosen the jam nut near the engine in or- 8.

  • Page 43: Auxiliary Pump Installation

    Compact Track Loader 9. Transmission and Drive Disassembly and Assembly Auxiliary Pump Installation 1. To install auxiliary pump, reverse the removal procedure. Tandem Pump Removal The tools required for tandem pump removal and installation are listed in Table 9-2. Use manufactur- Support pump prior er-recommended tools whenever possible.

  • Page 44: Tandem Pump Installation

    Compact Track Loader 9. Transmission and Drive Disassembly and Assembly Tandem Pump Installation Hydraulic Reservoir Cleaning The tools required for hydraulic reservoir cleaning are listed in Table 9-3. Use manufacturer- recommended tools whenever possible. Table 9-3 Tool Name Combination Wrench Hot oil can cause personal injury.
  • Page 45 Compact Track Loader 9. Transmission and Drive Disassembly and Assembly Figure 9-16 5. Thoroughly wipe out the interior of the hydraulic reservoir with a magnet and a clean rag. 6. Install the access cover assembly. 7. Add manufacturer-approved hydraulic fluid.

  • Page 46: Undercarriage Disassembly And Assembly

    10. Undercarriage Disassembly and Assembly Chapter Overview Undercarriage Disassembly and Assembly Procedures This chapter provides disassembly and assembly procedures for the undercarriage assemblies. Disassembly and assembly procedures are provided for the following undercarriage components. Personal Safety • Drive Sprocket Improper or incomplete maintenance/repair of a Compact •...
  • Page 47 Compact Track Loader 10. Undercarriage Disassembly and Assembly Figure 10-21 Figure 10-18 Figure 10-22 Figure 10-19 2. Remove the soft plug from the end of bearing 2. Pry the bearing plate off and remove. (fig. 10-20, flange and remove the snap ring on the shaft. 10-21) The plug may be either metal or rubber depending on the manufacture date of the...

  • Page 48: Sprocket Installation

    Compact Track Loader 10. Undercarriage Disassembly and Assembly Figure 10-23 Figure 10-26 4. Using a puller, remove the bearing and bearing housing from the shaft. (fig. 10-23, 10-24) Sprocket Installation 1. To install sprocket, reverse the removal procedure. Drive Motor Removal 1.

  • Page 49: Drive Motor Installation

    Compact Track Loader 10. Undercarriage Disassembly and Assembly Figure 10-28 Figure 10-31 3. Pull the drive motor free from the drive table housing. Drive Motor Installation 2. To install drive motor, reverse the removal procedure. Wheel Replacement 1. Remove the bolts which fasten the wheel tube to the frame rail, there are two on the inside and two on the outside.

  • Page 50: Wheel Installation

    Compact Track Loader 10. Undercarriage Disassembly and Assembly Shown in the "flipped" position Figure 10-33 Figure 10-35 3. Unbolt the wheels from the tube and replace (the 1. Flip both the inside and outside keeper plates on center wheel is split for easy removal and the end 14"...

  • Page 52: 11. Maintenance

    11. Maintenance Chapter Overview Air Cleaner This chapter provides information on general mainte- Your PT-100 Forestry compact track loader is nance procedures for the PT-100 Forestry. If there is equipped with two air filter elements to remove con- an issue that requires troubleshooting, refer to Chapter taminants from the air your engine uses for combus- 13, Troubleshooting.
  • Page 53 Do not clean air filter elements while engine warranty is in effect. During the warranty period, Terex recommends replacing air filter elements instead of cleaning them. Heavy- Note: The primary element may be cleaned and reused up...

  • Page 54: Grease Fittings

    "break-in" and will most likely require adjustment. work in mud, gravel, debris and various other abrasive To check track tension: materials during operation. Terex recommends a daily 1. Drive the machine forward 5 feet ( 1.5 m) to inspection of the undercarriage assemblies and clean- remove any slack from the lower and rearward ing if necessary.

  • Page 55: Drive Sprocket Rollers

    Repeat on the other side of the machine if necessary. Drive Sprocket Rollers Terex compact track loaders utilize rollers on the drive sprockets to drive the track. These rollers help mini- mize friction between the track and the drive sprocket to prolong track life.

  • Page 56: Tilt-Up Canopy

    8. Perform the track tension adjustment procedure on page 11-4 to complete the procedure. Note: Terex recommends replacing external rollers as a set to simplify inspection and maintain proper sprocket function. Note: Internal pins should be inspected when replacing rollers.

  • Page 57: Jacking Procedure

    11-3,11-4) 5. Once in place, jack the machine upward making sure it remains stable until it has reached sufficient height to install an Terex jack stand beneath the machine. 6. Slide the jack stand into place making sure it is...

  • Page 58: Lift Arm Brace

    Compact Track Loader 11. Maintenance Lift Arm Brace The lift arm brace (A) is intended to keep service per- sonnel safe when it is necessary to work on a machine with the lift arms in the raised position. It is not safe to rely on the hydraulic system to hold the lift arms in the raised position just as it is not safe to crawl under a machine supported only by a jack.

  • Page 59: Track Removal

    Required Tools Socket/Impact Wrench Ratchet Strap Heavy Duty Hydraulic Jack Combination wrench 11-6 Long Pry Bar(s) Terex Approved Jack Stands (2) Spray Lubricant Hammer Punch Port-A-Power Track Installation Tool (P/N: 0703-138) To remove the tracks: (see page 11-4 for steps 5-8) 1.
  • Page 60 Compact Track Loader 11. Maintenance 14. Once the track has been pulled clear of the front idler wheels it should easily clear the rest of the undercarriage. Remove the track from the machine. (fig. 11-11) To install the tracks: 1. Lift the top portion of the track over the drive table and sprocket towards the undercarriage then slide the rest of the track up to the undercarriage.
  • Page 61 Compact Track Loader 11. Maintenance 4. Lubricate the front and rear most idler wheels with a spray lubricant. You may also want to lubricate the inside of the track drive lugs to make installa- tion easier. (fig. 11-14) 5. Install the half moon and lever portion of the instal- lation tool with the supplied bolt and nut.

  • Page 62: Engine Oil & Filter

    Regular oil changes are necessary to maintain a back to its operating position using a port-a-power. strong running engine.Terex recommends a normal oil You may have to reposition the port-a-power sev- change interval of 250 hours or every six months. This eral times to accomplish this.
  • Page 63 11-24 to 50 +/- 10 lb ft (68 +/- 13 Nm) 10. Remove the oil filler cap and fill the engine crankcase with Terex 10W-30 Heavy Duty Engine Oil (capacity: 8.5 U.S. quarts or 8.44 liters including filter). (fig. 11-24) 11.

  • Page 64: Engine Oil Specifications

    Compact Track Loader 11. Maintenance Engine Oil Specifications Use Terex 10W-30 Heavy Duty Engine Oil for most conditions (if available). In the event of an alternate working environment, the following chart may be used as a guide to oil viscosity grades (see below).

  • Page 65: Hydraulic Fluid & Filter

    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.

  • Page 66: Fuel Filter

    Compact Track Loader 11. 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.

  • Page 67: Water Separator

    Compact Track Loader 11. Maintenance Water Separator The water separator removes water from the fuel sup- ply as the engine runs. It collects the water in a bowl equipped with a drain valve. Drain the bowl daily to maintain proper function. To drain the water separator: 1.
  • Page 68 Compact Track Loader 11. Maintenance Drive Belts the alternator or A/C pump against the belt(s) to increase belt tension to the appropriate level, then Drive belts typically stretch and wear during their serv- tighten bolts to specification. (fig. 11-38, 11-39) ice life.
  • Page 69 Compact Track Loader 11. Maintenance To remove the fan or A/C belt: 1. Follow steps 1 and 2 of the belt adjustment proce- dure on page 11-17. 2. Once loose, pivot the alternator or A/C pump towards the engine to increase the slack in the belts.

  • Page 70: Radiator/Oil Cooler Cleaning

    Compact Track Loader 11. Maintenance Radiator/Oil Cooler The radiator and oil cooler must be clean to ensure proper operation. Engine and hydraulic system over- heating, damage and even failure can result if the radi- ator/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.

  • Page 71: Extreme Conditions

    Test Requirements Recommendations: Required Tools 1. Air flow test the radiator. terex has available an Anemometer (Terex Part #: 0403-112) Anemometer, Terex part # 0403-112, which allows you to see the volume of air through the cooling package.
  • Page 72 T. 17.4 pulleys, cooling fan and radiator/cooler will result. Note: Even the simplest aftermarket screening and guarding can affect the airflow through the radiator. To ensure proper performance, use only the original guarding and screening tested and approved by Terex. 11-21...

  • Page 73: Cab Filtration

    Compact Track Loader 11. Maintenance Cab Filtration Fan Cleaning The cab is equipped with two air filters, one on each The heater/AC unit is equipped with two fans that cir- side of the cab enclosure. They should be inspected culate air through the unit. They must be cleaned daily daily and cleaned/replaced as necessary.

  • Page 74: Maintenance Schedule

    Compact Track Loader 11. Maintenance Maintenance Schedule Maintenance Service Service Interval Notes Item required Capacity Grease fittings Lubricate Daily Grease often. Adjust levels as Fluid levels Check Daily necessary. Fan-A/C belt Adjust tension as Check Daily tension necessary. Fan-A/C belt Replace as a pair if Inspect Daily...

  • Page 76: Lubricant & Fuel Specifications Specifications

    Diesel fuel is distilled from crude oil, identified as No. cants in the PT-100 Forestry Compact Track Loader, 1-D or No. 2-D in “ASTM D975”, EN590 generally use Terex products. This ensures that the new fluids meet machine requirements. and lubricants match those originally installed when the machine left theTerex factory.

  • Page 78: 13. Troubleshooting

    13. Troubleshooting Chapter Overview Preliminary Checkout This chapter contains basic troubleshooting proce- A simple visual inspection and operational check dures for the Compact Track Loader. can identify many problems without the need for ex- tensive troubleshooting. If these checks indicate a Additional troubleshooting aids are provided in problem that requires further analysis, proceed to Chapter 3.
  • Page 79 Compact Track Loader 13. Troubleshooting Faulty safety solenoid or safety solenoid spool. Troubleshooting Poor wire connections on fuse, relay, or safety sole- This section identifies selected problems and sug- noid. gests probable causes. Low charge pressure. Problem 4 Lift arms operate but tracks will not move. Problem 1 Probable cause Machine will not crank over.
  • Page 80 Compact Track Loader 13. Troubleshooting Problem 8 Problem 12 Battery will not charge and/or battery goes dead. Hot coolant light illuminates; engine operating hot. Probable cause Probable cause Alternator fuse blown. 1. Low coolant level. Alternator diode bad. 2. Debris plugging radiator, limiting airflow. Alternator resistor behind fuse panel bad.

  • Page 82: Hydraulic Pressure (Check & Adjustment)

    14. Hydraulic Pressure Chapter Overview Hydraulic Pressure Check & This chapter provides hydraulic pressure check, Troubleshooting Procedures adjustment and troubleshooting procedures. Test and troubleshooting procedures are provided for the following Hydraulic system components. Personal Safety • Charge Pressure Check & Adjustment Improper or incomplete maintenance/repair of a •...
  • Page 83 Compact Track Loader 14. Hydraulic Pressure 1. Attach the gauge to test port A. (fig. 14-1) Route the gauge so that you or an assistant can read it during testing. 2. Make sure any bystanders are clear of moving components, then start the engine. Test Port (B) 3.
  • Page 84 Compact Track Loader 14. Hydraulic Pressure Auxiliary Pressure Check Auxiliary pressure is used to drive flow style attach- ments. Low auxiliary pressure can produce poor per- formance in attachments while high pressure can cause component damage/failure in the machine or the Test Port (C) attachment being utilized.

  • Page 85: Lift Arm Pressure Check

    Compact Track Loader 14. Hydraulic Pressure High flow auxiliary troubleshooting: Lift Arm Pressure Check Required Tools 4. If both high and low flow readings are low, adjust Pressure Gauge 0-6000 p.s.i. (41,370 kPa) the high pressure relief setting at the pump. (see step 3).
  • Page 86 Compact Track Loader 14. Hydraulic Pressure Drive Pressure Check Check your readings against that stated below. If your readings differ, relief replacement and or component repair may be required. Required Tools Pressure Gauge 0-6000 p.s.i. (41,370 kPa) Pressures should read: •...
  • Page 87 Compact Track Loader 14. Hydraulic Pressure Posi-Power Pressure Check 6. If your reading is low, remove the cap and loosen Posi-power is a function of the tandem drive pump the jam nut on the posi-power adjustment screw assembly. The posi-power control reads charge flow and turn it counter clockwise until it stops then (which is directly related to engine rpm) and adjusts retighten the jam nut.

  • Page 88: Hydraulic Cylinder & Loader Valve

    15. Hydraulic Cylinder & Loader Valve Chapter Overview Disassembly & Assembly This chapter provides information on inspection, disas- Disassembly and assembly procedures are provided sembly, assembly and resealing hydraulic cylinders. for the following components: • Hydraulic Cylinders • Loader Valve Personal Safety Improper or incomplete maintenance/repair of a Note: Procedures are provided for only those hydraulic com-...
  • Page 89 Compact Track Loader 15. Hydraulic Cylinder & Loader Valve Cylinder Tube Weldment 15-2 15-5 4. Use a open end or pipe wrench to turn and 7. With the piston and rod removed from the cylinder, remove the end gland. (fig. 15-2) inspect the cylinder bore for scratches or other damage.

  • Page 90: Hydraulic Cylinder Assembly

    Compact Track Loader 15. Hydraulic Cylinder & Loader Valve 15-8 15-11 15-12 15-9 14. Remove the inner seal from the end glad. Pay 11. Remove the seals and piston ring taking care not to scratch the piston. Also, pay close attention to attention to the seal orientation upon removal to aid during installation of the new seal.

  • Page 91: Loader Valve Disassembly

    Compact Track Loader 15. Hydraulic Cylinder & Loader Valve Loader Valve Disassembly 4. Remove each valve section and inspect the seals for damage, replace if necessary. (fig. 15-15) Required Tools Note: Make sure not to lose springs or disks when removing Socket Wrench sections.
  • Page 93 Terex Construction Americas 8800 Rostin Road Southaven, MS 38671 (888)-201-6008 (662)-393-1800 www.terex.com...

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