Terex PT-100G Forestry Service Manual
  1. Manuals
  2. Brands
  3. Terex Manuals
  4. Compact Loader
  5. PT100G Forestry
  6. Service manual
Terex PT-100G Forestry Service Manual

Terex PT-100G Forestry Service Manual

Compact track loader
Hide thumbs Also See for PT-100G Forestry:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Operation & Maintenance Manual
Service Manual
Compact Track Loader
PT-100G
PT-100G Forestry
Part Number: 2076-286
Printed (8-10)

Advertisement

Table of Contents
loading

Related Manuals for Terex PT-100G Forestry

Summary of Contents for Terex PT-100G Forestry

  • Page 1 Service Manual Compact Track Loader PT-100G PT-100G Forestry Part Number: 2076-286 Printed (8-10)
  • Page 2  ...

  • Page 3: Table Of Contents

    Table of Contents 1. Product Safety Planetary Oil Change ....4-4 Chapter Overview ..... 1-1 Drive Sprocket Rollers .
  • Page 4 Compact Track Loader Table of Contents 7. Chassis and Fuel Tank 10. Lift Arm/Drive Controls Chapter Overview ..... 7-1 Chapter Overview .....10-1 Personal Safety .
  • Page 5 Compact Track Loader Table of Contents 13. Undercarriage 16. Hydraulic Component Service Chapter Overview ..... 13-1 Chapter Overview ..... 16-1 Personal Safety .
  • Page 6  ...

  • Page 7: Product Safety

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

  • Page 8: 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 9: Repair

    Always use some sort of mechanical support to ensure A proper ground is essential to protect the that the machine will not fall. Terex jack stands machine from damage when welding. Improper work well to support the machine while performing grounding can cause damage to mechanical, maintenance or repair work.

  • Page 10: Attachments

    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 equipment are in place and functioning prior to operat-...
  • Page 11 Compact Track Loader 1. Product Safety DANGER WARNING WARNING WARNING WARNING DANGER Improper operation or maintenance Explosion/Burn Hazard Crush Hazard can result in serious injury or death. Will cause death, burns or Rollover can crush and result in blindness due to ignition of serious injury or death.
  • Page 12  ...

  • Page 13: Technical Specifications

    Listed below are common service tools which are iden- Gear reduction: 18:47:1 tified and utilized in the service procedures described in this manual. Use tools recommended by Terex Controls (Joysticks) whenever possible to reduce risk of injury and or machine damage during service.
  • Page 14  ...

  • Page 15: Circuit Diagrams

    100G circuits: hydraulic charge circuit, hydraulic auxil- iary circuit, hydraulic control circuit, hydraulic drive cir- cuit, lift arm control valve, hydraulic solenoid blocks and electrical attachment outlet. Figure 3-1 PT-100G Hydraulic Charge Circuit OIL COOLER TANK CHECK VALVE (80 PSI / 552 kPa)

  • Page 16: Hydraulic Auxiliary Circuit

    Compact Track Loader 3. Circuit Diagrams Hydraulic Auxiliary Circuit Figure 3-2 PT-100G Hydraulic Auxiliary Circuit TO HIGH FLOW AUX. Q/C FROM ATTACHMENT CASE DRAIN Q/C TO LOW FLOW AUX. Q/C LIFT ARM VALVE LOAD SENSE AUXILIARY PUMP AUXILIARY PUMP INLET...

  • Page 17: Hydraulic Control Circuit

    Compact Track Loader 3. Circuit Diagrams Hydraulic Control Circuit Figure 3-3 PT-100G Hydraulic Control Circuit TO BUCKET CYL. TO POWER Q/A. TO LIFT ARM CYL. CHARGE PRESSURE TEST PORT (400 / 2758 kPa) TANK LIFT ARM CONTROL VALVE...

  • Page 18: Hydraulic Drive Circuit

    Compact Track Loader 3. Circuit Diagrams Hydraulic Drive Circuit Figure 3-4 PT-100G Hydraulic Drive Circuit CHARGE PRESSURE DRIVE PRESSURE RELIEF RELIEF VALVES (4) (400 / 2758 kPa) (5500 PSI / 37920 kPa) DRIVE MOTOR DRIVE PUMP DRIVE MOTOR CASE DRAIN...

  • Page 19: Lift Arm Control Valve

    Compact Track Loader 3. Circuit Diagrams Lift Arm Control Valve Figure 3-5 PT-100G Lift Arm Control Valve ELIEF ALVE ETTINGS 3989 PSI 3989 PSI 4206 PSI (27500 kPa) (27500 kPa) (29000 kPa) 3989 PSI 4496 PSI (27500 kPa) (31000 kPa)

  • Page 20: Hydraulic Solenoid Blocks

    Compact Track Loader 3. Circuit Diagrams Hydraulic Solenoid Blocks Figure 3-6 PT-100G Hyd. Solenoid blocks...

  • Page 21: Electrical Attachment Outlet

    Compact Track Loader 3. Circuit Diagrams Electrical Attachment Outlet Figure 3-7 PT-100G Electrical Attachment Outlet...

  • Page 23: Maintenance

    This chapter provides information on general The lift arm brace (fig. 4-1, item A) is intended to keep maintenance procedures for the PT-100G. If there is an service personnel safe when it is necessary to work on issue that requires troubleshooting, refer to Chapter a machine with the lift arms in the raised position.

  • Page 24: Tilt-Up Cab

    Hold the brace upwards and lower the cab until height to install a Terex jack stand beneath the the locking channel is clear of the shoulder bolt machine. (fig. 4-4) then release the brace.

  • Page 25: Grease Fittings

    Undercarriages The undercarriage assemblies in Compact Track Loaders typically operate in harsh working conditions. They work in mud, gravel, debris and various other abrasive materials during operation. Terex recommends a daily inspection of the undercarriage assemblies and cleaning if necessary.

  • Page 26: Track Tension

    Compact Track Loader 4. Maintenance To adjust track tension: (fig. 4-9) Track Tension (PT-100G) 1. Loosen the lock nut (A) on the turnbuckle (B) Proper track tension must be maintained for optimal and adjust by turning the turn buckle itself until performance and track/undercarriage life.

  • Page 27: Drive Sprocket Rollers

    5. Repeat this process as required throughout the sprocket. Drive Sprocket Rollers Terex compact track loaders utilize rollers on the drive 6. Reinstall the sprocket by reversing steps 2-3. sprockets to drive the track. These rollers help minimize friction between the track and the drive 7.

  • Page 28: Track Removal

    • Ratchet strap • Heavy duty hydraulic jack • Combination wrench • Long pry bar(s) • Terex approved jack stands (2) 4-12 • Spray lubricant • Shop vac or pressure washer 1. Break up and remove any foreign material from the...
  • Page 29 Compact Track Loader 4. Maintenance 4-19 4-16 6. Remove the outer scraper plate from the suspension rail. (fig. 4-17) 7. Remove the bolts securing the inner wheel to the hub, then remove the wheel. (fig. 4-18, 4-19) 8. Use a pry bar to peel the track over the inner wheel(s) toward the outside of the machine.

  • Page 30: Track Installation

    Compact Track Loader 4. Maintenance Track Installation 1. Slide the track over the drive sprocket at the rear of the machine (fig. 4-23, 4-24). 2. Slide the front of the track into position for installation (fig. 4-25). 3. Lubricate the inner front wheel and the inside of the front portion of the track with a spray lubricant (fig.
  • Page 31 Compact Track Loader 4. Maintenance 9. Once the track is in position over the idler wheels, install the inner idler wheel onto the hub and secure it in place with the mounting bolts. Torque them to 90 +/- 10 Lb. Ft. (122 Nm) (fig.

  • Page 32: Air Cleaner

    (.3175cm) diameter nozzle at least 2" (5.1 cm) warranty is in effect. During the warranty period, away . Terex recommends replacing air filter elements Water: 40 P.S.I. (276 kPa) max. without nozzle. instead of cleaning them. Heavy-duty air filter 2. Soak the filter in a non-sudsing detergent solution...

  • Page 33: Fuel Filter

    Compact Track Loader 4. Maintenance 4-38 4-39 Fuel Filter The fuel filter removes contaminants from the fuel as it enters the engine for combustion. Over time the filter Insert ratchet 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 34: Engine Oil/Filter Change

    4. Maintenance Engine Oil/Filter Change Regular oil changes are necessary to maintain a strong running engine. Terex recommends a normal oil change interval of 250 hours or every six months. This recommendation has been made to help ensure proper lubrication during operation and to prolong engine life under typical operating conditions.

  • Page 35: Engine Oil Specifications

    16. Re-install the belly pan. its tube (fig. 4-44, item A). Engine Oil Specifications Terex recommends using Terex 10W-30 Heavy Duty Engine Oil for most conditions. In the event of an alternate working environment, the following chart may be used as a guide to oil viscosity grades.

  • Page 36: Hydraulic Fluid/Filter Change

    Use extreme caution when changing the hydraulic oil. Introducing dirt or debris could be detrimental to the hydraulic system. Terex recommends service intervals of 1000 hours for hydraulic fluid and 250 hours for hydraulic fluid filters. To change the hydraulic fluid: 1.

  • Page 37: Radiator/Oil Cooler Cleaning

    Compact Track Loader 4. Maintenance Radiator/Oil Cooler Cleaning The Radiator and Oil Cooler must be kept clean to ensure proper operation. Engine and hydraulic system overheating, damage and even failure can result if the radiator/oil cooler is not kept clean. A pressure washer or compressed air nozzle work well to blow debris clear of the fins in the oil cooler and radiator.

  • Page 38: Case Drain Filter

    Compact Track Loader 4. Maintenance 4-51 4-52 (fig. 4-51) Case Drain Filter (fig. 4-52) The PT machines are also equipped with a filter in the Fuse Panel The electrical systems in the PT machines are auxiliary circuit case drain line (A). It protects the main equipped with fuses that protect the electrical hydraulic system in the event of catastrophic failure in components from damage.
  • Page 39 Compact Track Loader 4. Maintenance 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 condition...
  • Page 40  ...

  • Page 41: Machine Controls And Instrumentation

    Instruments include the follow- tion, refer to the operation and maintenance manual ing components. for the PT-100G. Included here are illustrations of the (7) Display following controls and instrumentation components and • Oil Pressure Gauge a description of their functions.

  • Page 42: Switches

    Compact Track Loader 5. Machine Controls and Instrumentation Switches The various switches (Figure 5-3, 5-4) are positioned to provide good access and visi- bility. The standard and optional switches are listed below. 1. Fan Speed Switch (optional) 2. A/C Activation Switch (optional 3.

  • Page 43: Operator Enclosure

    However, exploded understood the information in this manual. Refer to the parts diagrams exist in the PT-100G Parts manuals to Operation and Maintenance manual for instructions serve as visual aids in the removal or installation of regarding proper machine operation techniques before other operator enclosure components.

  • Page 44: Removal Procedure

    Compact Track Loader 6. Operator Enclosure Dash Pod Covers Removal Required Tools Phillips Screwdriver 2. Remove the retaining clip from each of the gas springs using a small screwdriver (6-2). 1. Remove the fasteners securing the dash pod covers to the pod base (fig. 6-4). 3.

  • Page 45: Installation Procedure

    Compact Track Loader 6. Operator Enclosure Side Panels Removal Power Outlet Required Tools Phillips Type Screwdriver 4. If removing the left side panel, disconnect the 12v power outlet, then remove the panel from the machine (fig. 6-9). Installation 1. To install the side panels, reverse the removal procedure.

  • Page 46: Installation Procedure

    Compact Track Loader 6. Operator Enclosure Seat Headliner Removal Removal Required Tools Required Tools Combination/Socket Wrench Phillips/Blade Type Screwdrivers 1. Raise and secure the cab as described on page 1. Remove the finishing caps with a blade type 4-2 of this manual. screwdriver to gain access to screws as shown (fig.

  • Page 47: Chassis And Fuel Tank

    However, exploded parts diagrams Do not attempt to perform any type of repair or maintenance exist in the PT-100G Parts manual to serve as visual aids in on a Compact Track Loader until you have read and fully the assembly and disassembly of other chassis components.

  • Page 48: Fuel Tank

    Compact Track Loader 7. Chassis and Fuel Tank Fuel Tank Removal Remove Screws Required Tools Screwdriver Combination/Socket Wrench 1. Raise and support the lift arms as described on page 4-1 of this manual. 2. Tilt and support the operator enclosure (cab) as described on page 4-2 of this manual.

  • Page 49: Installation Procedure

    Compact Track Loader 7. Chassis and Fuel Tank Main fuel gas line location 7-10 9. Lift and remove the tank from the machine (fig. 7-10). Installation 1. To install the fuel tank, reverse the removal procedure. Footwell Removal Required Tools Screwdriver Combination/Socket Wrench 7.

  • Page 50: Installation Procedure

    Compact Track Loader 7. Chassis & Fuel Tank 7-12 4. Remove the bolts (4) that secure the foot pedal cover to the pedal, then remove the cover and the throttle boot (fig. 7-12). 7-15 7. Remove the footwell from the chassis as shown (fig.

  • Page 51: Removal Procedure

    Compact Track Loader 7. Chassis & Fuel Tank Note: Record the order of assembly during removal to ensure proper operation when re-installed. 3. Remove the foot throttle from the machine. Installation 1. To install the foot throttle assembly, reverse the removal procedure.
  • Page 52  ...

  • Page 53: Radiator And Oil Cooler

    However, exploded parts damage, injury or death. diagrams exist in the PT-100G Parts manuals to serve as visual aids in the assembly and disassembly of other system Do not attempt to perform any type of repair or maintenance components.

  • Page 54: Installation Procedure

    Compact Track Loader 8. Radiator and Oil Cooler 2. Remove the bolts (6) securing the radiator and shroud to the radiator support (fig. 8-4). 3. Push the shroud forward to allow access to the fan 2. Remove the fan guard from the machine by sliding mounting bolts.

  • Page 55: Radiator/Oil Cooler/Fan Shroud

    Compact Track Loader 8. Radiator and Oil Cooler Radiator/Oil Cooler/Fan Shroud Removal Personal injury can result from exposure to hot fluids and components. Allow the machine to cool thoroughly before attempting any type of service on the cooling or hydraulic systems. Cooling system conditioner contains alkali.

  • Page 56: Installation

    Compact Track Loader 8. Radiator and Oil Cooler 8-11 8-14 9. Tilt the fan shroud rearward and remove it from the machine (fig. 8-14). Installation 1. To install the radiator/oil cooler, reverse the removal procedure. 8-12 7. Loosen the clamps securing the upper and lower coolant hoses to the radiator, then disconnect the hoses from the radiator.

  • Page 57: Hydraulic Reservoir

    However, exploded parts diagrams exist in the PT-100G Parts manuals to serve as visual aids in Do not attempt to perform any type of repair or maintenance the removal and installation of other system components.
  • Page 58 Compact Track Loader 9. Hydraulic Reservoir Keep steady Bracket Bolt 5. Remove bracket that secures the wire harness to 8. Using one wrench, keep the pilot tube steady to the right side of chassis (fig. 9-1). Move the ensure it does not twist, with another wrench harness up and away from the tank.
  • Page 59 Compact Track Loader 9. Hydraulic Reservoir Springs Hoses 9-10 14. Remove both the auxiliary inlet and return 11. Disconnect the exhaust springs (6) on either side of the middle exhaust pipe. Remove the lower and hoses from the right front of the hydraulic tank (fig.
  • Page 60 Compact Track Loader 9. Hydraulic Reservoir Tubes 9-15 9-13 17. Disconnect the pilot and case drain tubes from the Fuel Hose clamp hydraulic tank. Disconnect the other ends of tubes; bolt pilot tube from the loader valve and the case drain from the 10 micron hydraulic filter.

  • Page 61: Removal Procedure

    Compact Track Loader Loader 9. Hydraulic reservoir 22. Carefully remove hydraulic tank from chassis by 1. If the tank is still in the machine, drain the lifting up and sliding it towards the back of the hydraulic fluid as described on page 4-14 of this machine (fig 9-17).
  • Page 62  ...

  • Page 63: 10. Lift-Arm/Drive Controls

    However, exploded parts diagrams exist in the PT-100G Parts manuals to serve as Do not attempt to perform any type of repair or maintenance visual aids in the assembly and disassembly of other system on a Compact Track Loader until you have read and fully components.
  • Page 64 Compact Track Loader 10. Lift-Arm/Drive Controls 1. Relax all hydraulic actuators to relieve pressure in the hydraulic system prior to service. 2. Turn the ignition switch to the OFF position, remove the key and disconnect the battery to avoid accidental start. 3.

  • Page 65: Removal Procedure

    Compact Track Loader 10. Lift-Arm/Drive Controls Lift Arm Control Valve Removal Required Tools Socket Wrench Combination/Open End Wrench NOTICE Cap and plug all fittings and tubes to prevent fluid loss and or contamination during service work. 10-9 5. Remove the carriage bolts (3) securing the loader valve to the chassis, then remove the valve.
  • Page 66  ...

  • Page 67: 11. Hydraulic Pumps/Motors

    However, exploded parts diagrams Do not attempt to perform any type of repair or maintenance exist in the PT-100G Parts manuals to serve as visual aids in on a Compact Track Loader until you have read and fully understood the information in this manual.

  • Page 68: Auxiliary Pump

    Compact Track Loader 11. Hydraulic Pumps/Motors Auxiliary Pump Upper Removal bolt Required Tools Outlet hose Screwdriver Combination Wrench Socket Wrench 1. Raise and support lift arms as described on page 4-1of this manual. 2. Turn the ignition switch to the OFF position and remove the key to avoid accidental start.

  • Page 69: Tandem Drive Pump

    Compact Track Loader 11. Hydraulic Pumps/Motors Tandem (Drive) Pump Removal Required Tools Screwdriver Combination/Open End Wrenches Personal injury can result from exposure to hot fluids and components. Allow the machine to 11-4 cool thoroughly before attempting any type of 8. Disconnect hose clamp from case drain hose and service on the cooling or hydraulic systems.
  • Page 70 Compact Track Loader 11. Hydraulic Pumps/Motors Charge pressure 11-12 11-9 hose 7. Attach a lifting device to elevate and secure the 4. Remove the charge pressure hose from the rear tandem pump as it is disconnected from the adapter on the hydraulic filter to allow access to engine.

  • Page 71: Drive Motor

    Compact Track Loader 11. Hydraulic Pumps/Motors Note: Label the drive hoses, drive motor and drive table to ensure correct installation and proper orientation during reassembly. 11-15 10. Slide the pump forward and lift out of the machine utilizing the lifting device (11-15). Installation 1.
  • Page 72 Compact Track Loader 11. Hydraulic Pumps/Motors 11-19 5. Remove the drive motor by sliding it away from the chassis and then out of the drive table (fig. 11-19). Installation 1. To install the drive motor into the undercarriage, reverse the removal procedure. 11-6...

  • Page 73: 12. Engine

    However, exploded Do not attempt to perform any type of repair or maintenance parts diagrams exist in the PT-100G parts manuals to serve on a Compact Track Loader until you have read and fully as visual aids in the assembly and disassembly of other understood the information in this manual.

  • Page 74: Installation Procedure

    Compact Track Loader 12. Engine 12-5 3. Remove the nuts securing the head-pipe to the turbo, then pull it away from the studs (fig. 12-5). 12-3 4. Remove the battery from the tower compartment (fig. 12-3). Spring Installation 1. To install the battery, reverse the removal procedure.
  • Page 75 Compact Track Loader 12. Engine Note: Use caution when striking the pipes with a mallet. The pipes are easily damaged and may be disfigured by the blows. 12-8 Note: Thoroughly coat all clamped exhaust pipe joints with a penetrating lubricant prior to attempting to remove the pipe sections from the muffler.

  • Page 76: Air Cleaner

    Compact Track Loader 12. Engine 2. Locate and open left tower engine air filter access. Then, pull the yellow slide lock on the air cleaner Air Cleaner housing outward as shown. Next, turn the cover Removal approximately 1/8 turn CCW and pull to remove (fig.

  • Page 77: Removal Procedure

    Compact Track Loader 12. Engine Engine Removal Required Tools Bolts Combination/Socket Wrenches Tie Down or Ratchet Strap Forklift/Engine Hoist Pry Bar 1. Perform the battery, air cleaner, and charge pump, removal procedures in sections 11 and 12 of this manual prior to starting this procedure. 2.
  • Page 78 Compact Track Loader 12. Engine Fuel line return Bolt ECU wire 12-22 12-25 harness 8. Separate the return fuel line connector plug 11. Disconnect the ECU wire harness connector from located behind the oil dipstick on the ride side of the ECU (computer), located behind the oil dip the engine (fig.

  • Page 79: Installation Procedure

    Compact Track Loader 12. Engine 12-31 Note: The rear cab window is directly over the lift point 12-28 of the engine. It is important to use an engine lifting 14. Remove the intake tube from the top of the engine device that is low in profile and can reach forward by loosening the hose clamp on the left side and between the engine and chassis (as shown in fig.
  • Page 80  ...

  • Page 81: 13. Undercarriage

    Note: For drive sprocket removal and roller inspection and listed above. However, exploded parts diagrams exist in the replacement, refer to page 4-5 of this manual. PT-100G parts manuals to serve as visual aids in the removal and installation of other system components. Personal Safety...

  • Page 82: Removal & Service Procedure

    Compact Track Loader 13. Undercarriage Bogie Wheel Removal & Service Procedure Required Tools Combination/Socket Wrenches (including Allen) Press & Various Press Tooling Torque Wrench Bench Vise 1. Perform steps 1-5 of the 15” idler wheel removal procedure on page 4-6 to loosen the track and provide clearance for bogie wheel removal.
  • Page 83 Compact Track Loader 13. Undercarriage Sealing Surfaces Face Seal Halves 13-6 Rubber Seals 13-9 6. Once the wheels have been removed, use a press to push the axle and far side bearing out of the hub as shown (fig. 13-8, 13-9). 7.
  • Page 84 Compact Track Loader 13. Undercarriage 10. Disassemble and clean the face seals and their rubber outer seals thoroughly, then wipe them dry to ensure a good seal when assembled. 13-15A 13-15B 13. Once the seals are in place, wipe the mating 13-12 surfaces of the face seals with a clean shop cloth and alcohol in a circular motion ending in a gentle...
  • Page 85 Compact Track Loader 13. Undercarriage 13-18 17. Apply red (high strength) thread locking compound 13-22 to the wheel retaining bolt as shown (fig. 13-18). 21. Remove the allen plug from the center of the hub assembly and fill it with 2 ounces of 10W-30 API CH-4 engine oil.

  • Page 86: Idler Hub

    Compact Track Loader 13. Undercarriage 0403-339 Hub Tool Kits 13-24 Note: If you are removing the outer or rear hub assemblies you will be able to remove the hub Idler Hub assembly once step three is complete. Service Procedure Required Tools Press &...
  • Page 87 Compact Track Loader 13. Undercarriage Part #: 0403-337 Rear race Part #: 0403-333 13-28 13-31 5. Remove the bearing out of the front of the hub as 7. If bearings are to be replaced, press the rear bear- shown (fig. 13-28). ing race out of the assembly from the front of the hub with tools 0403-337 and 0403-333 (fig.
  • Page 88 Compact Track Loader 13. Undercarriage Note: Take care not to drop the metal face seal halves. The sealing surfaces are surface ground and have an extremely fine finish. If scratched or disfigured, the seal will not function as intended. Note: Now is a good time to inspect the components for damage or wear.
  • Page 89 Compact Track Loader 13. Undercarriage Part #: 0403-335 13-40 13-43 16. Once the seals are in place, wipe the mating 19. Flip the hub over, support the bearing sleeve from surfaces of the face seals with a clean shop cloth the bottom with tool 0403-335 and set it onto the and alcohol in a circular motion ending in a gentle press for center seal installation (fig.
  • Page 90 Part #: 0403-333 13-47 13-50 23. Pack the bearing with Terex Multi-Purpose EP 27. Add 2 oz. of 10W-30 (API CH-4) engine oil to the Lithium Grease and then install it onto the bearing hub as shown, then reinstall the plug and tighten sleeve using tool 0403-333 (fig.

  • Page 91: Front And Rear Axles

    4. Remove the four bolts that secure the drive hose guides located on both the right and left sides of the chassis (fig. 13-54). 1. Suspend machine from the ground as described in jacking procedure on page 4-2 using Terex approved jack stands. 13-52 13-55 2.
  • Page 92 Compact Track Loader 13. Undercarriage 13-57 7. Lowerand remove front and rear axles (fig. 13-57). Note: Supprt the axles at the ends while lowering to keep them steady on the lifting device as they are lowered. Installation 1. To install rear and front axles, reverse the removal procedure.

  • Page 93: 14. Lift-Arm Components

    However, exploded parts diagrams exist Do not attempt to perform any type of repair or maintenance in the PT-100G Parts manual to serve as visual aids in the on a Compact Track Loader until you have read and fully assembly and disassembly of other system components.
  • Page 94 4. Remove the bolts securing the front and rear lift 14-1 arm cylinder pivot pins to the lift arm and lift arm 1. Rest the lift arms on an Terex approved jack stand tower. (fig. 14-4) to provide clearance for lift cylinder removal. (fig.

  • Page 95: Bucket/Tilt Cylinder

    Track Loader Compact 14. Lift-Arm Components Bucket/Tilt Cylinder Removal Required Tools Socket Wrench Combination/Open End Wrench Hammer Punch (brass) 14-7 7. Remove the cylinder from the machine for service or inspection. (fig. 14-7) Note: At this time the pivot bushings and pivot pins are easily accessible for replacement.
  • Page 96 Track Loader Compact 14. Lift-Arm Components 14-10 14-13 7. Use a pry bar to slide the lower pin out of the cylin- 4. Remove the bolt securing the lower pin to the der end allowing it to be removed. (fig. 14-13) quick attach.
  • Page 97 Track Loader Compact 14. Lift-Arm Components Quick Coupler Block PRV Removal Required Tools Combination Wrench 14-16 10. Remove the pin from the cylinder while supporting the cylinder. (fig. 14-16) 14-18 1. With the machine off and cool and with all hydraulic actuators relaxed, loosen the pressure release valve on the top of the auxiliary quick cou- pler block.

  • Page 99: 15. Quick Attach

    However, exploded parts diagrams exist in the PT-100G Parts manual to serve as visual aids in Do not attempt to perform any type of repair or maintenance the assembly and disassembly of other system components.
  • Page 100 Track Loader Compact 15. Quick Attach Upper guard 15-5 5. Remove the pivot link from the quick attach. 15-2 (fig. 15-5) 2. Remove the bolts (3) securing the upper guard to the quick attach weldment. (fig. 15-2) Upper guard 15-6 6.

  • Page 101: Removal Procedure

    Combination/Open End/Socket Wrenches Terex Approved Jack Stand (or equivalent) Hammer Punch (brass) 15-8 1. Rest the lift arms on an Terex approved jack stand to provide clearance for quick attach disassembly. (fig. 15-8) Remove bolt & nut Drive out 15-9 2.
  • Page 102  ...

  • Page 103: Hydraulic Component Service

    However, exploded parts diagrams exist in the on a Compact Track Loader until you have read and fully PT-100G parts manual to serve as visual aids in the assem- understood the information in this manual. Refer to the bly and disassembly of other system components.
  • Page 104 Compact Track Loader 16. Hydraulic Component Service Cylinder Tube Weldment 16-2 16-5 4. Use an open end or pipe wrench to turn and 7. With the piston and rod removed from the cylinder, remove the end gland. (fig. 16-2) inspect the cylinder bore for scratches or other damage.
  • Page 105 Compact Track Loader 16. Hydraulic Component Service 16-8 16-11 13. Remove the tandem seals from the end gland pay- ing close attention to the order of removal to aid during installation of the new seals. (fig. 16-11) 16-9 11. Remove the seals and piston rings taking care not 16-12 to scratch the piston.

  • Page 106: Lift Arm Control Valve

    Compact Track Loader 16. Hydraulic Component Service Lift Arm Control Valve O-rings Disassembly Required Tools Socket Wrench Combination Wrench Screwdriver (blade type) Allen Wrench Note: All valve shown can be done with valve in machine. 1. With machine off and cool and with hydraulic actu- ators relaxed, drain hydraulic oil according to the 16-16 cover...
  • Page 107 Compact Track Loader 16. Hydraulic Component Service 16-19 16-23 O-rings 10. Remove solenoid block from valve, inspect the o- rings for damage, replace if necessary. (fig. 16-23) 16-20 7. To remove solenoids, unplug wiring harness from solenoids, then remove fastener and clamp as shown.

  • Page 108: Drive Pump (Drive Relief Valves)

    Compact Track Loader 16. Hydraulic Component Service Drive Pump (Drive Relief Valves) Removal & Adjustment Required Tools Allen Wrench/Socket Combination/Socket wrench 1. Make sure the machine isoff and cool and with hydraulic actuators are relaxed. 16-28 4. Flip the valve over, then tighten the nut to increase the pressure setting (CW) or loosen it to decrease the pressure setting (CCW) (fig.

  • Page 109: Auxiliary Pump

    Compact Track Loader 16. Hydraulic Component Service 3. Inspect o-rings for proper shape and condition. Replace if necessary. (fig. 16-33) 16-31 4. Remove spool from drive pump. Inspect spool and 16-34 o-ring for damage, replace if necessary. (fig. 16- 4. Remove the Allen bolts securing the cover onto the pump.
  • Page 110 Compact Track Loader 16. Hydraulic Component Service Inspect Face 16-37 7. Inspect the barrel face for scratches or any other damage that can be felt with a fingernail. (fig. 16-37) Inspect Faces 16-38 8. Remove the piston/barrel assembly and inspect the slipper faces for scratches or any other dam- age that can be felt with a fingernail.

  • Page 111: Chapter Overview

    If contamination is suspected, contact for general pressure checks and troubleshooting. the Terex service department at 1-800-346-4367. 17-1...
  • Page 112 Compact Track Loader 17. Hydraulic Pressure & Flow 1. Attach the gauge to test port A. (fig. 17-1) Route the gauge so that you or an assistant can read it Charge Relief Charge Orifice during testing. 2. Make sure any bystanders are clear of moving components, then start the engine.
  • Page 113 Compact Track Loader 17. Hydraulic Pressure & Flow 6. If necessary, adjust the relief settings on the auxil- iary standby or high pressure valves. (figure 17-7) Auxiliary Pressure Check Required Tools a) Remove the cap covering the affected relief To adjust: Pressure Gauges 0-1000 p.s.i.

  • Page 114: Lift Arm Pressure Check

    Compact Track Loader 17. Hydraulic Pressure & Flow Lift Arm Pressure Check Drive Pressure Check Required Tools Required Tools Pressure Gauge 0-6000 p.s.i. (0-41370 kPa) Pressure Gauge 0-6000 p.s.i. (0-41370 kPa) Lift arm pressure is used to lift loads or “break-out”. Low lift arm pressure can produce a weak lift arm func- NOTICE tion while high lift arm pressure can damage lift arm...
  • Page 115 Compact Track Loader 17. Hydraulic Pressure & Flow Check your readings against that stated below. If your readings differ, relief replacement and or component repair may be required. 5100 PSI (35160kPa) the relief is reached in Pressures should read: attempted forward or reverse motion. •...
  • Page 116  ...

  • Page 117: 18. Troubleshooting

    18. Troubleshooting Chapter Overview Visual Inspection This chapter contains general and control system Prior to troubleshooting, walk around the machine and troubleshooting guides and information for the PT- perform an overall visual inspection. Look for missing, 100G Compact Track Loaders. loose, worn or broken parts.
  • Page 118 • Control system troubleshooting guide (pg. 18-4) • Perkins Engine Service Tool • PT-100G Service Tool (chapter 19) • Control system troubleshooting guide (pg. 18-4) Problem 7: Problem 3: Multiple switches/electrical accessories are not Possible causes Machine starts, but hydraulics will not operate.

  • Page 119: Engine/Machine Troubleshooting

    Compact Track Loader 18. Troubleshooting Problem 9: Engine/Machine Troubleshooting When a problem occurs that effects engine perform- Hydraulic oil temperature elevated; hydraulic sys- ance or function, it is important to determine whether Possible causes tem overheating. or not the problem lies with the machine itself, or with 1.
  • Page 120 Compact Track Loader 18. Troubleshooting Control System Troubleshooting Propel Propel Display reads: Fault results in: Possible causes: Solution Invalid propel mode Propel disabled Valid propel mode not selected. Select valid Select valid mode and cycle power by turning the selection mode (Accomplished through the display in config key off then back on menu) and cycle power by turning the key off then...
  • Page 121 Compact Track Loader 18. Troubleshooting Propel (continued) Right Forward Threshold Propel automatically limited to default threshold Threshold needs to be calibrated Perform threshold calibration procedure not calibrated parameters If threshold < 4000, limit to 4000, If > 6000, limit to 6000 Right Reverse Threshold Propel automatically limited to default threshold Threshold needs to be calibrated...
  • Page 122 Compact Track Loader 18. Troubleshooting Propel (continued) Right Fwd Solenoid Machine stops immediately and returns to neutral. Faulty connections or wires to or from right fwd Restore connections, replace faulty compoents, open circuit Forward propel is disabled and reverse propel is solenoid, faulty solenoid.
  • Page 123 Compact Track Loader 18. Troubleshooting Bucket Bucket Display reads: Fault results in: Possible causes: Solution: Invalid propel mode Bucket control disabled Valid propel mode not selected Select valid propel mode selection Loader Speed selection Automatically sets speed to 100% Loader speed set above 100% Select valid speed above upper limit Loader Speed selection...
  • Page 124 Compact Track Loader 18. Troubleshooting High Flow Auxiliary High Flow Auxiliary Display reads: Fault results in: Possible causes Solution: GPM selection Automatically sets GPM to 45 GPM selection greater than 45 GPM Select valid GPM value above upper limit GPM selection Automatically sets GPM to 30 GPM selection less than 30 GPM Select valid GPM value...
  • Page 125 Compact Track Loader 18. Troubleshooting Low Flow Auxiliary Low Flow Auxiliary Display reads: Fault results in: Possible causes: Solution: Low Flow Rocker voltage Low flow variable disabled Faulty joystick Replace joystick, then cycle power by turning the above upper limit key off then back on Low Flow Rocker voltage Faulty joystick...
  • Page 126 Compact Track Loader 18. Troubleshooting Quick Attach Quick Attach Display reads: Fault results in: Possible causes: Solution: Invalid Keypad Installed Quick attach output de-energized CE keypad installed in US machine or vice versa. Install correct keypad for your machine, then cycle power Loss of communications Quick attach output de-energized...

  • Page 127: Service Tool

    19. Service Tool Chapter Overview This chapter contains information on how to download and use the service tool for the PT-100G Compact Track Loaders. Personal Safety Improper or incomplete maintenance/repair of a Compact Track Loader can be dangerous and may result in machine damage, injury or death.
  • Page 128 Compact Track Loader 19. Service Tool 3. Select: PLUS+1 GUIDE 4. Select: PLUS+1 GUIDE Downloads 5. Select: PLUS+1 GUIDE Service Tool Software & License 6. Select: .exe file 7. Select: Save 19-2...
  • Page 129 Compact Track Loader 19. Service Tool 8. At this point, you will need to select a location on your laptop to save the file. Once you have found a suitable location, click save. 9. Navigate to the folder where you saved the file. 10.

  • Page 130: Connecting The Service Tool

    1. Connect your laptop to the port on your machine located within the fuse panel (to the upper right of the oper- ator’s seat) with the cable purchased from your Terex dealer for use with the service tool. 2. With your service tool application running on your laptop, open the .P1D file (available under “service tools”...
  • Page 131 Compact Track Loader 19. Service Tool The diagnostic navigator for the service tool is shown Diagnostic Navigator in figure 1. You can see the different systems and components that are accessible with this tool. Enable Screens The enable screen for Ground Drive is shown here, press play accessed by clicking on the item in the Diagnostic Navigator.
  • Page 132 Compact Track Loader 19. Service Tool The control screen for ISO is shown here, accessed Control Screens by clicking on the item in the Diagnostic Navigator. The control screens show the sequence of events that take place when a command is given. The numerical values of the signals sent between components are displayed in the white boxes (fig.
  • Page 133 Compact Track Loader 19. Service Tool The parameter screens display current settings pro- Parameter Upload grammed into the onboard computers when the upload button is pressed. upload parameters These values affect operating characteristics and should be changed only when following the calibration procedure for the particular function (see chapter 00).
  • Page 134 Compact Track Loader 19. Service Tool If a value needs to be changed, it is done on this Parameter Download screen in the “edit value” column . Change the value according to the appropriate cali- download parameters bration procedure, then select it by clicking the down- load box to the left of the row (check mark).
  • Page 135 To download the update: 1. Visit: constructionsupport.terex.com to download the latest version of the software for your machine. 2. With the machine connected to the laptop, ignition key in the “on”...
  • Page 136  ...

  • Page 137: Lubricant & Fuel Specification

    When replacing or replenishing the fluids and lubri- Diesel fuel, distilled from crude oil, identified as No. 1- cants in an Terex Compact Track Loader, use Terex D or No. 2-D in “ASTM D975” and “EN 590” generally products. This ensures that the new fluids and lubri- meet machine requirements.
  • Page 138  ...

  • Page 139: Service Aids & Supplements

    21. Service Aids & Supplements General Torque Specifications Inch Fasteners Metric Fasteners Thread Size Standard Torque Thread Size Standard Torque 1/4" 9 +/- 2 lb ft 12 +/- 3 Nm 5/16" 18 +/- 4 lb ft 28 +/- 7 Nm 3/8"...
  • Page 140  ...
  • Page 141  ...
  • Page 142 Terex Construction Americas 8800 Rostin Road Southaven, MS 38671 (888)-201-6008 (662)-393-1800 www.terex.com...

This manual is also suitable for:

Pt100g

Table of Contents