ASV PT60 Service & Repair Manual
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ASV PT60 Service & Repair Manual

ASV PT60 Service & Repair Manual

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See also: Operation & Maintenance Manual
8/17/2016
Language:
English
Geographic Region:
All
Serial Number Range:
SN 00101-03704
PT60
Service Repair Manual
This manual is complements of
TrackLoaderParts.com
The world's best source for ASV parts.
Track Loader Parts
6543 Chupp Road
Atlanta, Georgia 30058
USA
(800)616-8156

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  • Page 1 8/17/2016 Language: English Geographic Region: Serial Number Range: SN 00101-03704 PT60 Service Repair Manual This manual is complements of TrackLoaderParts.com The world's best source for ASV parts. Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 (800)616-8156...
  • Page 2 Table of Contents 1. Product Safety 5. Operator Enclosure Disassembly and Assembly Chapter Overview ...........1-1 Safety Messages.............1-1 Chapter Overview ...........5-1 Information Messages..........1-1 Personal Safety............5-1 Basic Precautions ...........1-1 Machine Preparation ..........5-1 Safety Signs............1-1 Preliminary Checkout ..........5-1 Protective Equipment.........1-2 Operator Enclosure Disassembly and Assembly Mounting and Dismounting ........1-2 Procedures..............5-1 Lifting ..............1-2...
  • Page 3 Rubber Track Loader Table of Contents Preliminary Checkout ..........11-1 8. Hydraulic Reservoir Disassembly Undercarriage Disassembly and Assembly and Assembly Procedures............11-1 Chapter Overview ...........8-1 Center Wheel Removal and Installation ....11-1 Personal Safety............8-1 Wheel Removal ..........11-2 Machine Preparation ..........8-1 End Wheel Removal and Installation ....11-3 Preliminary Checkout ..........8-1 End Wheel Removal ........11-3 Hydraulic Reservoir Disassembly and Assembly...
  • Page 4 Rubber Track Loader Table of Contents 14. Hydraulic Pressure Check & Adjustment Chapter Overview ..........14-1 Personal Safety.............14-1 Machine Preparation ..........14-1 Hydraulic Pressure Adjustment Procedures..12-1 Charge Pressure check……………………………. 14-1 Charge Pressure Adjustment………………………14-2 Auxiliary Pressure Check & Adjustment…………..14-2 15. Troubleshooting Chapter Overview ..........15-1 Personal Safety.............15-1 Machine Preparation ..........15-1 Preliminary Checkout ..........15-1...

  • Page 6: Chapter Overview

    1. Product Safety Chapter Overview Note: This label is used to provide important additional This chapter contains product safety information for information, comments, explanations or amplification of the PT-50/60 Rubber Track Loaders. Read this the accompanying subject matter. chapter and understand all safety messages and information messages before attempting to service The person servicing the Rubber Track Loader may the machine.

  • Page 7: Protective Equipment

    Rubber Track Loader 1. Product Safety Protective Equipment Batteries Always wear a hard hat, protective glasses, protec- Do not smoke when inspecting the battery electro- tive shoes and other protective equipment as re- lyte level. Never disconnect any charging unit circuit quired by job conditions when working around this or battery circuit cable from the battery when the product.

  • Page 8: Repair

    Rubber Track Loader 1. Product Safety 9. Be careful when removing cover plates. Gradu- Repair ally back off the last two bolts or nuts located at ! WARNING ! opposite ends of the cover or device. Then, pry the cover loose to relieve any spring or other Accidental machine starting can cause injury or death pressure before removing the last two nuts or to personnel working on the machine.

  • Page 9: Asbestos Information

    Rubber Track Loader 1. Product Safety Ensure that all personnel are far enough away from the work area so they will not be struck by flying ob- ! WARNING ! jects. When replacement parts are required for this product, Stay clear of the cutting edges, pinching surfaces or use only genuine manufacturer’s replacement parts or crushing surfaces of the attachment while perform- parts with equivalent specifications including, but not...

  • Page 10: Machine Label And Decal Examples

    Rubber Track Loader 1. Product Safety Machine Label and Decal Examples Examples of the labels and decals placed on the machine are shown on this page.

  • Page 12: Engine

    2. Technical Specifications Loader Valve PT-50 Specifications − Model: Husko − Relief pressure: 3000 psi (20,684 kPa) Engine − Pilot pressure required to move spools: 180- − Model: Perkins 404C-22 220 psi (1241-1517 kPa) − Displacement: 2.2 liter − Gross horsepower: 50 hp, 37.3 kW Cooler −...

  • Page 13: Pt-60 Specifications

    Rubber Track Loader 2. Technical Specifications PT-60 Specifications Cooler − Burst pressure: 400 psi (2757 kPa) Engine − Operating pressure: 250 psi (1724 kPa) − Model: Perkins 404C-22T − Bypass relief pressure: 80 psi (689 kPa) − Displacement: 2.2 liter −...

  • Page 14: Filtering And Cooling System

    3. System Diagrams Chapter Overview Filtering and Cooling System This chapter contains diagrams for the following The filtering and cooling system (Figure 3-1) contains PT-50/60 systems. the following major components. • Filtering and cooling system • Hydraulic reservoir • Auxiliary circuit system •...
  • Page 15 Rubber Track Loader 3. System Diagrams Auxiliary Circuit System The auxiliary circuit system (fig. 3-2) contains the following major components. • Loader valve • Pilot control manifold • Auxiliary gear pump • Loader control joystick Figure 3-2 PT-50/60 Auxiliary Circuit System 3-002 Self leveling (optional)
  • Page 16 Rubber Track Loader 3. System Diagrams Drive Loop System The drive loop system (fig. 3-3) contains the following major components. • Drive motors • Pilot control manifold • Drive control joystick • Tandem pump Figure 3-3 PT-50/60 Drive Loop System 3-003 Input Portion (joystick) tank...
  • Page 17 Rubber Track Loader 3. System Diagrams Electrical Attachment Outlet Figure 3-4 PT-50/60 Electrical Attachment Outlet...

  • Page 18: Chapter Overview

    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

    Rubber 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) Heater Fan (optional) (3) Wiper (optional) (4) Beacon (optional) (5) Ignition, glow plug (pre-heat) (6) Auxiliary Hydraulics...

  • Page 20: Chapter Overview

    5. Operator Enclosure Disassembly and Assembly Operator Enclosure Chapter Overview Disassembly and Assembly This chapter provides disassembly and assembly Procedures procedures for the operator enclosure assembly. Disassembly and assembly procedures are provided for the following operator enclosure components. Personal Safety •...

  • Page 21: Light Bar Installation

    Rubber Track Loader 5. Operator Enclosure Disassembly and Assembly Light Bar Installation Figure 5-2 5-002 2. Carefully lower the light bar with the wire har- Figure 5-5 5-005 ness attached. 1. Carefully position the light bar, without pinching the wiring harness against the cab roof. Figure 5-3 5-003 3.

  • Page 22: Ignition Switch Installation

    Rubber Track Loader 5. Operator Enclosure Disassembly and Assembly Ignition Switch Installation Remove Nut Figure 5-7 5-007 Figure 5-10 5-010 2. Remove the nut that secures the ignition switch 1. Insert the ignition switch from the rear of the to the dash panel. dash panel.

  • Page 23: Gauge Removal And Installation

    Rubber Track Loader 5. Operator Enclosure Disassembly and Assembly 4. Install the light bar. Refer to Chapter 5. Light Bar 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: Lap Bar Gas Assist Spring Removal And Installation

    Rubber Track Loader 5. Operator Enclosure Disassembly and Assembly Remove Retaining Clip Figure 5-18 5-018 Figure 5-20 5-020 3. Reconnect the gauge connector. 2. Using a small screwdriver, remove the retaining clip from each end of the gas assist spring. 4.
  • Page 25 Rubber Track Loader 5. Operator Enclosure Disassembly and Assembly Install Ends on Ball Joints Figure 5-23 5-023 2. Install the ends of the lap bar gas assist spring onto the ball joints. Insert Retaining Clip Figure 5-24 5-024 3. Slide the retaining clip on to each end of the gas assist spring.

  • Page 26: Chapter Overview

    6. Seat & Fuel Sender Disas- sembly and Assembly Chapter Overview Chassis Disassembly and Assembly Procedures This chapter provides disassembly and assembly procedures for the chassis assembly. Disassembly and assembly procedures are provided for the following chassis components. Personal Safety •...

  • Page 27: Seat Installation

    Rubber Track Loader 6. Chassis Disassembly and Assembly Unplug Connector Plug in the Connector Figure 6-2 6-002 Figure 6-5 6-002 2. Tilt the seat forward and reach behind the seat to unplug the seat switch wiring harness. 2. Tilt the seat forward and reach behind the seat to plug in the seat switch connector Note: The machine will not operate unless the seat switch connector is plugged in.

  • Page 28: Fuel Sending Unit Removal

    Rubber Track Loader 6. Chassis Disassembly and Assembly 4. Remove the fuel-sending unit. Be careful not to Fuel Sending Unit Removal damage the float mechanism when pulling it 1. Remove the seat. Refer to Chapter 6. Seat Re- through the opening in the fuel tank. moval procedure.
  • Page 29 Rubber Track Loader 6. Chassis Disassembly and Assembly Note: Make sure that the wire on the sending unit is not bent and the fuel pickup line does not interfere with the movement of the float. 3. Connect the hoses and wires to the fuel-sending unit, and then install the screws that fasten the unit to the tank.

  • Page 30: Chapter Overview

    7. Radiator/Oil Cooler Disassembly and Assembly Chapter Overview Preliminary Checkout This chapter provides disassembly and assembly If troubleshooting is required prior to disassembly or procedures for the radiator/oil cooler assembly. Ad- assembly, refer to Chapter 15. Troubleshooting. justment procedures are also included for selected radiator/oil cooler components.

  • Page 31: Fan Guard Removal

    Rubber Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Fan Guard Removal Radiator/Cooler Removal and Installation The tools required for radiator/cooler removal and installations are listed in Table 7-2. Use manufac- turer-recommended tools whenever possible. Table 7-2 Required Tools Combination Wrench Socket Wrench Screwdriver Radiator/Cooler Removal...
  • Page 32 Rubber Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Figure 7-5 7-011 Figure 7-2 7-008 5. Remove the upper hose from the radiator sec- tion. Cap the hose and fitting. 2. Drain the coolant using the petcock on the bot- tom of the radiator.

  • Page 33: Radiator/Cooler Installation

    Rubber Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly 7. Remove the three mounting bolts on each side of the radiator/cooler. Install Bolts Figure 7-10 7-003 Figure 7-8 7-013 2. With the radiator/cooler in position, install the three mounting bolts on each side of the radia- 8.
  • Page 34 Rubber Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly 4. Remove the hose and fitting caps and install the upper hose on the radiator section. Install Hose Figure 7-13 7-002 5. Remove the hose and fitting caps and install the upper hose on the oil cooler section.

  • Page 36: Chapter Overview

    8. Hydraulic Reservoir Disassembly and Assembly Chapter Overview Hydraulic Reservoir Disassembly and Assembly This chapter provides disassembly and assembly procedures for the hydraulic reservoir assembly. Procedures Cleaning procedures are also included for the hydraulic reservoir. Disassembly and assembly procedures are provided for the following hydraulic reservoir components.

  • Page 37: Access Cover Removal And Installation

    Rubber Track Loader 8. Hydraulic Reservoir Disassembly and Assembly 3. Remove the filter manifold assembly. Reverse Filter Manifold Assembly Removal steps for installation. ! WARNING ! Access Cover Removal and Hot oil can cause personal injury. Make sure the oil is cool before removing any components or lines.

  • Page 38: Access Cover Assembly Installation

    Rubber Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Reservoir Gauge Removal and Installation The tools required for reservoir gauge removal and installation are listed in Table 8-3. Use manufacturer-recommended tools whenever possible. Table 8-3 Required Tools Combination Wrench Figure 8-4 8-013 2.

  • Page 39: Reservoir Gauge Installation

    Rubber Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Reservoir Gauge Installation Insert Reservoir Gauge with Mounting Bolts/Washers Figure 8-7 8-016 3. View of hydraulic reservoir with filter assembly Figure 8-10 8-018 removed. 1. Install the reservoir gauge in the reservoir using the two mounting bolts/washers.

  • Page 40: Suction Screen Removal

    Rubber Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Suction Screen Removal ! WARNING ! Hot oil can cause personal injury. Make sure the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped and the machine has been allowed to cool thoroughly.

  • Page 41: Hydraulic Reservoir Cleaning Procedures

    Rubber Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Hydraulic Reservoir Cleaning Procedures Cleaning procedures are provided for the following hydraulic reservoir components. • Hydraulic Reservoir Hydraulic Reservoir Cleaning The tools required for hydraulic reservoir cleaning are listed in Table 8-5. Use manufacturer- recommended tools whenever possible.

  • Page 42: Personal Safety

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

  • Page 43: Joystick Removal

    Rubber Track Loader 9. Loader/Transmission Controls Loader Control Joystick Operation – The right-hand joystick controls the loader arm and the at-tachment tilt cylinder. It allows the operator to raise, lower and pivot the attachment. The joystick operates on hydraulic charge pressure. The loader control also has a float position, which is activated by moving the joystick completely forward until it is held in detent.

  • Page 44: Loader Float Magnet Removal And Installation

    Rubber Track Loader 9. Loader/Transmission Controls Note: If it is neccessary to remove the left joystick on a machine equipped with a heater, you must disconnect the (cool) heater lines at the heater unit in order to remove the side panel. Cap and plug hoses and ports to minimize coolant loss.

  • Page 45: Loader Valve Removal And Installation

    Rubber Track Loader 9. Loader/Transmission Controls 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 Required Tools Combination Wrenches Loader Valve Removal Figure 9-9 9-009 !WARNING!
  • Page 46 Rubber Track Loader 9. Loader/Transmission Controls Figure 9-11 9-011 Figure 9-14 9-014 5. Disconnect the gas springs, then remove the bolts 8. Carefully remove the rear valance from the securing the hood as shown to allow for removal. machine to allow access to the loader valve. Loader Valve Figure 9-12 9-012...

  • Page 47: Self Level Valve Removal And Installation

    Rubber Track Loader 9. Loader/Transmission Controls Disconnect Figure 9-18 9-018 11. Disconnect the hoses from the rear and side of the loader valve. Cap and plug all openings to prevent Figure 9-19 9-019 fluid loss. Self Level Valve Removal and Installation The tools required for loader valve removal and instal- lation are listed in Table 9-4.

  • Page 48: Personal Safety

    10. 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 49 Rubber Track Loader 10. Transmission and Drive Disassembly and Assembly Remove the oil filler cap only when the engine is stopped and the machine has been allowed to cool thoroughly. NOTICE Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates.

  • Page 50: Tandem Pump Removal And Installation

    Rubber Track Loader 10. Transmission and Drive Disassembly and Assembly Tandem Pump Removal and Installation Remove Split The tools required for tandem pump removal and Flange installation are listed in Table 10-2. Use manufac- turer-recommended tools whenever possible. Remove Table 10-2 Tube and Fitting Required Tools...

  • Page 51: Tandem Pump Installation

    Rubber Track Loader 10. Transmission and Drive Disassembly and Assembly 8. Disconnect all hoses and tubes from the tandem Tandem Pump Installation pump. Cap/plug the hoses and tubes. Pump Drive Coupler Flywheel Gear Pump Remove Mounting Bolt Plate Figure 10-10 10-010 Figure 10-7 10-008...

  • Page 52: Pump Drive Coupler Removal And Installation

    Rubber Track Loader 10. Transmission and Drive Disassembly and Assembly 5. Remove the seat. Refer to Chapter 6. Seat Re- moval. 4. Install the access cover and seat. Refer to Chapter 6. Seat Installation. 6. Remove the auxiliary gear pump. Refer to Chap- ter 10.

  • Page 53: Pump Drive Coupler Installation

    Rubber Track Loader 10. Transmission and Drive Disassembly and Assembly Pump Drive Coupler Installation Tandem Pump Drive Shaft Pump Drive Coupler Figure 10-15 10-012 1. Slide the pump drive coupler all the way onto the tandem pump drive shaft. Tighten Locking Screw Pump...

  • Page 54: Personal Safety

    11. Undercarriage Disassembly and Assembly Chapter Overview Preliminary Checkout This chapter provides disassembly and assembly If troubleshooting is required prior to disassembly or procedures for the undercarriage assemblies. assembly, refer to Chapter 15. Troubleshooting. Personal Safety Undercarriage Disassembly and Assembly Procedures ! WARNING ! Disassembly and assembly procedures are provided Improper operation, lubrication, maintenance or repair...

  • Page 55: Wheel Removal

    Rubber Track Loader 11. Undercarriage Disassembly and Assembly Wheel Removal 1. Locate the wheel cap snap ring. Figure 11-4 11-008 Using a socket, remove the nut that fastens the wheel to the shaft. Remove the wheel with the wheel extractor. Figure 11-1 11-005 Inside Wheel...
  • Page 56 11-014 Figure 11-7 11-011 4. Slide the track outward as you pull on the wheel to 1. Raise and support the machine on ASV jackstands remove the wheel. in the front and rear as shown. Installation 1. To install the end wheels, reverse the removal pro- cedure.

  • Page 57: End Wheel Removal

    Table 11-4 Required Tools Required Tools Combination/Socket Wrench Socket/impact wrench Heavy duty hydraulic jack Combination wrench ASV approved jack stands (2) Retaining Ring Bolt Removal 1. Perform the end wheel removal procedure located on page 11-3 of this chapter. Drive...

  • Page 58: Bearing Removal

    Rubber Track Loader 11. Undercarriage Disassembly and Assembly Outboard Bearing Removal and Installation The tools required to remove and install the outboard bearing assembly are listed in table 11-5. Use manu- facturer recommended tools whenever possible. Table 11-5 Required Tools Combination/socket wrench Snap ring pliers Puller...

  • Page 59: Drive Sprocket Removal And Installation

    Rubber Track Loader 11. Undercarriage Disassembly and Assembly Drive Sprocket Removal and Drive Motor Removal and Installation Installation The tools required to remove and install the drive The tools required to remove and install the drive sprocket assembly are listed in table 11-6. Use manu- motor are listed in table 11-7.
  • Page 60 Rubber Track Loader 11. Undercarriage Disassembly and Assembly Hub Tool Kits 11-23 PT-50/60: 0403-552 Idler Hub Service Procedure PT-50/60 Required Tools Socket Wrench & Sockets (including Allen) Press & Tool Kit (0403-552) Snap Ring Pliers 1. Remove the hub assemblies from the undercar- Part #: 0403-550 riages as required first by performing the track removal procedure on page 11-4.
  • Page 61 Rubber Track Loader 11. Undercarriage Disassembly and Assembly Part #: 0403-550 Part #: 0403-546 11-27 11-30 5. Remove the bearing out of the front of the hub as shown as well as the metal face seal half and rub- ber ring from the rear of the hub. (fig. 11-27) Part #: 0403-550 Part #: 0403-548 11-31...
  • Page 62 Rubber Track Loader 11. Undercarriage Disassembly and Assembly 8. Thoroughly clean all parts with parts cleaning solu- tion and gently blow them clean with air if neces- sary, then wipe dry. 9. Disassemble and clean the face seals and their rubber outer seals thoroughly, then wipe them dry to ensure a good seal when assembled.
  • Page 63 19. Install the bearing (cleaned, dried and repacked the bottom with tool #: 0403-551 and set it onto with ASV Multi-Purpose EP Lithium Grease) onto the press for center seal installation. (fig. 11-40) the bearing sleeve as shown. Press into the assembly until seated against the race.
  • Page 64 21. Remove the allen plug in the center portion of the hub. (fig. 11-45) 11-46 22. Add 1 oz. of ASV 10W-30 Heavy Duty Engine Oil to the hub as shown, then reinstall the plug and tighten. (fig. 11-46) 23. The hub assembly is now ready to be reinstalled.

  • Page 66: Assembly Procedure

    12. Loader Disassembly and Assembly Chapter Overview Loader Disassembly and Assembly Procedures This chapter provides disassembly and assembly procedures for the loader assembly. Disassembly and assembly procedures are provided for the following loader components. Personal Safety • Lift Cylinders ! WARNING ! •...
  • Page 67 Rubber Track Loader 12. Loader Disassembly and Assembly NOTICE Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates. Lift Cylinder Note: During disassembly, cap all hoses and fittings to Remove prevent fluid loss and contamination of the system fluids. Hose 1.

  • Page 68: Lift Cylinder/Tilt Cylinder Installation

    Rubber Track Loader 12. Loader Disassembly and Assembly Quick-Coupler Block / Pressure Release Valve Remove Removal and Installation The tools required for low-flow relief valve removal and installation are listed in Table 12-2. Use manufacturer-recommended tools whenever possible. Table 12-2 Required Tools Combination Wrench Figure 12-6...
  • Page 69 Rubber Track Loader 12. Loader Disassembly and Assembly Quick Coupler Block / Pressure Release Valve Installation Install Bolts Figure 12-8 12-008 3. Press the button on top of the valve to release Figure 12-11 12-009 hydraulic pressure. 1. Install the four bolts that secure the low-flow relief valve to the loader frame.

  • Page 70: Maintenance Schedule

    Engine Oil Specifications NOTICE Due to the significant variations in the quality and When replacing engine coolant, use ASV Long Life 50/50 performance of commercially available oils, ASV Antifreeze/Coolant, Caterpillar Extended Life Coolant or Heavy Duty Diesel Engine Oil – 10W30 is recom- equivalent antifreeze with the proper SCA (Supplemental mended.

  • Page 71: Hydraulic Fluid And Filter

    Rubber Track Loader 13. Maintenance Hydraulic Fluid and Filter The hydraulic fluid should be changed every 500 service hours, and the hydraulic filter should be changed every 250 hours. Hydrostatic components require extremely clean oil for long service life. Hydraulic Fluid and Filter Change Procedures ! WARNING ! Hot oil can cause personal injury.

  • Page 72: Fuel/Water Separator

    Rubber Track Loader 13. Maintenance 2. Remove the bolt on the top of the assembly, Fuel-Water Separator then slide the filter and retainer down and off of the assembly. 3. Install the new filter by reversing step 2. 4. Bleed the fuel system according to the proce- dure at the end of this chapter.

  • Page 73: Track Tension

    Rubber Track Loader 13. Maintenance Safety Element Figure 16-7 16-011 Figure 16-9 16-007 3. Remove the safety element. The safety element 3. After loosening the jam nut, turn the track ten- is not serviceable or washable. It should be re- sioner until the track tension is within specifica- placed with every three cleanings of the primary tions.

  • Page 74: Fuse Box

    An identical set of fittings is located on the right side of the machine. These fitting should be lubricated at least after every Fuse Box 10 hours of operation using ASV Multi Purpose EP Lithium Grease. Figure 16-12 16-012 The fuse box is located on the left side of the engine compartment.

  • Page 75: Bleeding The Fuel System

    Rubber Track Loader 13. Maintenance Bleeding the Fuel System The tools required for bleeding the fuel system are listed below. Use manufacturer-recommended tools whenever possible. Table 16-1 Required Tools Combination Wrench If the machine has been run out of fuel, it may be necessary to bleed the fuel system.

  • Page 76: Hydraulic Pressure Adjustment Procedures

    14. Hydraulic Pressure Check & Adjustment Chapter Overview Hydraulic Pressure This chapter provides an overview of checking and Adjustment Procedures setting pressures. It is important to contact the manufacturer for assistance before beginning these Adjustment and test procedures are provided for the procedures.

  • Page 77: Auxiliary Pressure Check & Adjustment

    All Surface Loader 14. Hydraulic Pressure Check & Adjustment Attach Gauge Figure 14-3 14-110 Figure 14-2 14-102 Insert the hydraulic gauge into one of the attachment quick couplers. 1. Attach the gauge to the charge pressure test port, located next to the fuel filter. 2.
  • Page 78 All Surface Loader 14. Hydraulic Pressure Check & Adjustment Jam Nut Adjustment Screw Figure 14-5 14-113 4. To adjust the auxiliary pressure, loosen the jam nut and turn the adjustment screw in with an al- len wrench to increase pressure and turn screw out to decrease pressure.

  • Page 80: Visual Inspection

    15. Troubleshooting Chapter Overview Preliminary Checkout This chapter contains basic troubleshooting proce- A simple visual inspection and operational check dures for the Rubber 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 81 Rubber Track Loader 15. Troubleshooting Problem 4 Troubleshooting Loader operates but tracks will not move. This section identifies selected problems and sug- Probable cause gests probable causes. Leak in feed line to pilot control. Pilot control malfunctioning. Problem 1 Low pilot pressure. Machine will not crank over.
  • Page 82 Rubber Track Loader 15. Troubleshooting Problem 10 Problem 13 No power to numerous auxiliary functions or accessories Loader will not float; labors engine and has down pressure in ON or RUN position. when detented into float. Probable cause Probable cause Main power relay A or B fuse blown.
  • Page 83 Terex Construction Americas 8800 Rostin Road Southaven, MS 38671 (888)-201-6008 (662)-393-1800 www.terex.com...

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