To obtain the wiring diagram for the Terex PT-30 overhead bar, refer to the "ASV Posi-Track PT-30 Track Loader Service Repair Manual." This manual contains wiring diagrams and other technical details for the PT-30, including the overhead bar.

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Summary of Contents for Terex PT-30

Page 1 Service Manual Compact Track Loader PT-30 Part Number: 2010-513 Printed (1-11)
Page 2 ...
Page 3 ...
Page 4: Table Of Contents
7. Radiator/Oil Cooler Disassembly 2. Technical Specifications and Assembly Chapter Overview ........... 2-1 Chapter Overview ........... 7-1 PT-30 Specifications ..........2-1 Personal Safety ............7-1 Machine Preparation ..........7-1 Radiator/Oil Cooler Disassembly and Assembly 3. System Diagrams Procedures .............. 7-1 Fan Guard Removal and Installation .......
Page 5 Compact Track Loader Table of Contents 9. Loader/Transmission Controls Disassembly 12. Undercarriage Disassembly and Assembly and Assembly Chapter Overview ..........12-1 Personal Safety ............. 12-1 Chapter Overview ........... 9-1 Machine Preparation ..........12-1 Personal Safety ............9-1 Undercarriage Disassembly and Assembly Machine Preparation ..........
Page 6 Compact Track Loader Table of Contents 15. Troubleshooting Chapter Overview ..........15-1 Personal Safety ............. 15-1 Machine Preparation ..........15-1 Visual Inspection ..........15-1 Troubleshooting ............ 15-2 16. Maintenance Chapter Overview ..........16-1 Maintenance Schedule .......... 16-1 Engine Oil ............. 16-1 Oil Change Procedures ........
Page 7 ...
Page 8: Product Safety
Loader may be unfamiliar with many of the systems on This chapter contains product safety information for the the machine. This makes it especially important to use Terex PT-30 Compact Track Loaders. Read and under- caution when performing service tasks. Familiarize stand all product safety information before attempting yourself with the affected system(s) and components to service any Compact Track Loader.
Page 9: 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 10: Repair
Compact Track Loader 1. Product Safety Repair 8. Be prepared to stop an engine if it has been re- cently overhauled or the fuel system has been recently serviced. If the engine has not been Accidental machine starting can cause injury assembled correctly, or if the fuel settings are not or even death to personnel working on a Compact Track Loader.
Page 11: Attachments
No warranty claims will be processed unless the PIN is provided. WARNING Attachments Only use attachments that are recommended by Terex. Crush Hazard Death or serious injury can result Keep clear of lift arms and Make sure that all necessary guards and protective from contact with moving lift arm or attachments.
Page 12 Compact Track Loader 1. Product Safety WARNING WARNING Fall Hazard Crush Hazard Falling can result in serious injury or death Rollover can crush and result in serious injury or death. Do not use the bucket/attachment as a work platform. Fasten Seat Belt WARNING WARNING WARNING...
Page 14: Technical Specifications
Listed below are common service tools which are iden- tified and utilized in the service procedures described Model: Rexroth Sauer Danfoss in this manual. Use tools recommended by Terex Displacement: 19.215 in3/rev (314.9 cc/rev) whenever possible to reduce risk of injury and or machine damage during service.
Page 15 ...
Page 16: Chapter Overview
• Filtering and cooling system • Hydraulic reservoir • Auxiliary circuit system • Radiator/oil cooler • Drive loop system • Loader valve • Auxiliary gear pump • Pilot control manifold Figure 3-1 PT-30 Filtering and Cooling System 100psi (689.5 kPa)
Page 17: Auxiliary Circuit System
Compact Track Loader 3. Circuit Diagrams Auxiliary Circuit System The auxiliary circuit system (Figure 3-2) contains the following major components. • Loader valve • Pilot control manifold • Auxiliary gear pump • Loader control joystick Figure 3-2 PT-30 Auxiliary Circuit System...
Page 18: Drive Loop System
• Tandem pump • Drive motors • Pilot control manifold • Drive control joystick Figure 3-3 PT-30 Drive Loop System TANDEM PUMP (WITH DRIVE AND CHARGE PRESSURE RELIEF VALVES.) TO IMPLEMENT VALVE BRAKE DRIVE MOTOR TANK Charge Reliefs...
Page 19 ...
Page 20: 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 21: Pt-30 Switches
Compact Track Loader 4. Machine Controls and Instrumentation PT-30 Switches The various switches (Figure 4-3) are positioned to provide good access and visibility. The standard and optional switches are listed below. (1) Work lights (2) Heater fan (optional) (3) Front wiper (optional)
Page 22: 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 23: Light Bar Installation
Compact Track Loader 5. Operator Enclosure Disassembly and Assembly Light Bar Installation Figure 5-2 2. Carefully lower the light bar with the wire har- Figure 5-5 ness attached. 1. Carefully position the light bar, without pinching the wiring harness against the cab roof. Figure 5-3 3.
Page 24: 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 dash panel. dash panel.
Page 25: Gauge Removal And Installation
Compact 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 26: Lap Bar Gas Assist Spring Removal And Installation
Compact Track Loader 5. Operator Enclosure Disassembly and Assembly Remove Retaining Clip Figure 5-18 Figure 5-20 3. Reconnect the gauge connector. 2. Using a small screwdriver, remove the retaining clip from each end of the gas assist spring. 4. Install the light bar. Refer to Chapter 5. Light Bar Installation procedure.
Page 27 Compact Track Loader 5. Operator Enclosure Disassembly and Assembly Install Ends on Ball Joints Figure 5-23 2. Install the ends of the lap bar gas assist spring onto the ball joints. Insert Retaining Clip Figure 5-24 3. Slide the retaining clip on to each end of the gas assist spring.
Page 28: Chassis Disassembly And Assembly
6. Chassis Disassembly 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 • Seat Improper or incomplete maintenance/repair of a Compact •...
Page 29: Seat Installation
Compact Track Loader 6. Chassis Disassembly and Assembly Unplug Connector Plug in the Connector Figure 6-2 Figure 6-5 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 30: Fuel Sending Unit Installation
Compact Track Loader 6. Chassis Disassembly and Assembly Fuel Sending Unit Removal 1. Remove the seat. Refer to Chapter 6. Seat Re- moval procedure. 2. Pump fuel from the tank until there is no fuel remaining above the sending unit. Collect and contain liquids in a suitable contain- er.
Page 31: Fuel Tank Removal And Installation
Compact Track Loader 6. Chassis Disassembly and Assembly Fuel Tank Removal and Installation The tools required for fuel tank removal and installa- tion are listed in Table 6-3. Use manufacturer- recommended tools whenever possible. Table 6-3 Required Tools Screwdriver Combination Wrench Socket Wrench Figure 6-11 2.
Page 32 Compact Track Loader 6. Chassis Disassembly and Assembly Remove Floor Pan Bolts Remove Filler Piece Figure 6-14 Figure 6-17 4. Remove the four bolts that hold the floor pan to 7. Remove the steel filler piece behind the fuel the frame. tank.
Page 33: Fuel Tank Installation
Compact Track Loader 6. Chassis Disassembly and Assembly Attach Remove Filler Hose Filler Hose Figure 6-20 Figure 6-23 10. Remove the Compact filler hose from the back 2. Attach the filler hose to the rear of the tank. end or the tank. Connect Vent Hose Figure 6-24...
Page 34 Compact Track Loader 6. Chassis Disassembly and Assembly Install Floor Pan Bolts and Washers Insert Filler Piece Figure 6-29 Figure 6-26 8. Install the four floor pan bolts and washers. 5. Insert the steel filler piece behind the fuel tank. 9.
Page 35 ...
Page 36: 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. Ad- Procedures justment procedures are also included for selected radiator/oil cooler components. Disassembly and assembly procedures are provided for the following radiator/oil cooler components.
Page 37: Fan Guard Removal
Compact Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Fan Guard Removal Fan and Fan Shroud Removal and Installation The tools required for fan and fan shroud removal and installation are listed in Table 7-2. Use manufac- turer-recommended tools whenever possible. Table 7-2 Required Tools Guard...
Page 38: Fan And Fan Shroud Installation
Compact Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Remove Bolts Figure 7-7 Figure 7-4 6. Remove the shroud from the engine compart- 3. Remove the three bolts from each side of the ment. fan shroud that secure the shroud to the radia- tor/cooler.
Page 39: Radiator/Cooler Removal And Installation
Compact Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Radiator/Cooler Removal and Installation The tools required for radiator/cooler removal and installation are listed in Table 7-3. Use manufactur- er-recommended tools whenever possible. Table 7-3 Required Tools Install Combination Wrench Bolts Socket Wrench Screwdriver Figure 7-10...
Page 40 Compact Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Remove Hose Figure 7-13 Figure 7-16 3. Remove the bolts from the lower engine com- 6. Remove the upper hose from the oil cooler sec- partment screen. tion. Cap the hose and fitting. Drain Coolant Figure 7-14...
Page 41: Radiator/Cooler Installation
Compact Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Install Remove Bolts Bolts Figure 7-19 Figure 7-22 9. Remove the three mounting bolts on each side 2. With the radiator/cooler in position, install the of the radiator/cooler. three mounting bolts on each side of the radia- tor/cooler.
Page 42: Radiator/Oil Cooler Adjustment Procedures
Compact Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly 8. Fill the radiator with coolant and the hydraulic reservoir with oil. Install Hose Radiator/Oil Cooler Adjustment Procedures Adjustment procedures are provided for the follow- ing radiator/oil cooler components. • Fan Shroud •...
Page 43: Fan Guard Adjustment
Compact Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Fan Guard Adjustment The tools required for fan guard adjustment are listed in Table 7-5. Use manufacturer-recommended tools whenever possible. Table 7-5 Tool Name Combination Wrench Loosen Capscrews to Adjust Figure 7-29 1.
Page 44: Hydraulic Reservoir Disassembly
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 hy- draulic reservoir. Disassembly and assembly procedures are provided for the following hydraulic reservoir components.
Page 45: Filter Assembly Removal
Compact Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Filter Assembly 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 the machine has been allowed to cool thoroughly Note: During disassembly, cap all hoses and fittings to...
Page 46: Filter Assembly Installation
Compact Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Figure 8-6 Figure 8-9 6. Remove the filter head and gasket from the re- 3. Reconnect the hose to the filter head and se- servoir. cure. Filter Assembly Installation Figure 8-10 Figure 8-7 4.
Page 47: Access Cover Assembly Removal
Compact Track Loader 8. Hydraulic Reservoir Disassembly and Assembly 1. Slightly loosen the access cover bolt to separate the upper cap from the oval-shaped clamping disk on the underside of the assembly. This will allow the assembly to be removed. Do not re- move the bolt entirely or the oval-shaped clamp will fall into the reservoir.
Page 48: Reservoir Gauge Removal And Installation
Compact Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Figure 8-16 Figure 8-17 2. Tighten the access cover bolt. 3. View of hydraulic reservoir with filter assembly removed. Reservoir Gauge Removal and Installation The tools required for reservoir gauge removal and installation are listed in Table 8-3.
Page 49: Reservoir Gauge Installation
Compact Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Reservoir Gauge Installation Suction Screen 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 Insert Reser- stopped and the machine has been allowed to cool voir Gauge...
Page 50: Suction Screen Installation
Compact 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 51 ...
Page 52: Loader/Transmission Controls Disassembly
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- Improper or incomplete maintenance/repair of a Compact nents.
Page 53: Loader Control Joystick/Drive Control Joystick Removal
Compact 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 54: Installation
Compact 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 heater lines at the heater unit in order to remove the side panel. Cap and plug hoses and ports to mini- mize coolant loss.
Page 55: Loader Valve Removal And Installation
Compact 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 Hot oil can cause personal injury.
Page 56 Compact Track Loader 9. Loader/Transmission Controls Figure 9-11 Figure 9-14 5. Disconnect the gas springs, then press the spring 8. Carefully remove the rear valance from the latches inward as shown to remove the hood. machine to allow access to the loader valve. Figure 9-12 Figure 9-15 6.
Page 57 Compact Track Loader 9. Loader/Transmission Controls Figure 9-17 Figure 9-20 11. Disconnect the tubes from the side of the loader 14. Remove the valve from the machine. valve. Cap and plug all openings to prevent fluid loss. 15. Installation is the reverse of the removal proce- dure.
Page 58: Transmission And Drive Disassembly
10. Transmission and Drive Disassembly and Assembly Chapter Overview Transmission and Drive Disassembly and Assembly This chapter provides disassembly and assembly procedures for the transmission and drive assembly. Procedures Disassembly and assembly procedures are provided Personal Safety for the following transmission and drive components. Improper or incomplete maintenance/repair of a Compact •...
Page 59: Auxiliary Gear Pump Removal And Installation
Compact Track Loader 10. Transmission and Drive Disassembly and Assembly Auxiliary Gear Pump Removal and Installation The tools required for auxiliary gear pump removal and installation are listed in Table 10-1. Use manu- facturer-recommended tools whenever possible. Table 10-1 Auxiliary Gear Required Tools Pump...
Page 60: Auxiliary Gear Pump Installation
Compact Track Loader 10. Transmission and Drive Disassembly and Assembly Note: It is not necessary to separate the lower manifold tube from the gear pump: this can be done after the pump is removed, if necessary. Remove Bolt Auxiliary Gear Pump Installation Tandem Pump Auxiliary...
Page 61: Tandem Pump Removal And Installation
Compact Track Loader 10. Transmission and Drive Disassembly and Assembly Tandem Pump Removal and Installation Install The tools required for tandem pump removal and Bolt installation are listed in Table 10-2. Use manufactur- er-recommended tools whenever possible. Table 10-2 Required Tools Screwdriver Combination Wrench Socket Wrench...
Page 62: Tandem Pump Installation
Compact Track Loader 10. Transmission and Drive Disassembly and Assembly Pump Drive Coupler Remove Pump Hoses and Mounting Tubes Plate Figure 10-11 Figure 10-14 8. Remove all hoses and tubes from the tandem 11. Remove the tandem pump (with pump drive pump.
Page 63: Pump Drive Coupler Removal And Installation
Compact Track Loader 10. Transmission and Drive Disassembly and Assembly 5. Install the auxiliary gear pump. Refer to Chapter 10. Auxiliary Gear Pump Installation. Install Bolt 6. Install the fuel tank. Refer to Chapter 6. Fuel Tank Installation. 7. Install the seat. Refer to Chapter 6. Seat Instal- lation.
Page 64: Pump Drive Coupler Installation
Compact Track Loader 10. Transmission and Drive Disassembly and Assembly Pump Drive Coupler Installation 5. Remove the seat. Refer to Chapter 6. Seat Re- moval. Tandem Pump Drive Shaft 6. Remove the fuel tank. Refer to Chapter 6. Fuel Tank Removal. 7.
Page 65 ...
Page 66: Engine Components Disassembly And As
11. Engine Components Disassembly and Assembly Chapter Overview Engine Components Disassembly and Assembly This chapter provides disassembly and assembly procedures for the engine components. Procedures Disassembly and assembly procedures are provided Personal Safety for the following engine components. Improper or incomplete maintenance/repair of a Compact •...
Page 67: Muffler Removal And Installation
Compact Track Loader 11. Engine Components Disassembly and Assembly Muffler Removal and Installation Remove Bolts The tools required for muffler removal and installa- tion are listed in Table 11-1. Use manufacturer- recommended tools whenever possible. Table 11-1 Required Tools Socket/Combination Wrenches Pry Bar Penetrating Lubricant Rubber Mallet/Plastic Hammer...
Page 68: Exhaust Pipe Removal And Installation
Compact Track Loader 11. Engine Components Disassembly and Assembly Tighten Nuts Install Bolts Figure 11-5 Figure 11-7 2. From the underside, install the four muffler 4. Install the muffler clamp and secure in place. mounting bolts and washers/shims as found upon disassembly.
Page 69: Exhaust Pipe Installation
Compact Track Loader 11. Engine Components Disassembly and Assembly Exhaust Pipe Installation Remove Bolts Figure 11-9 2. Remove the four bolts that secure the exhaust Figure 11-12 pipe to the exhaust manifold. 5. Carefully slide the curved pipe into the muffler inlet.
Page 70: Battery Removal And Installation
Compact Track Loader 11. Engine Components Disassembly and Assembly Battery Removal Install Negative Positive Bolts Terminal Terminal Figure 11-14 7. With the exhaust pipe gasket in place, install the Figure 11-16 remaining bolts that secure the exhaust pipe to the exhaust manifold. 1.
Page 71: Battery Installation
Compact Track Loader 11. Engine Components Disassembly and Assembly 1. Place the battery in position in the engine com- partment. Remove Capscrews Install Capscrews Figure 11-19 4. Remove the two capscrews from the battery holdown bracket and remove the bracket. Figure 11-22 2.
Page 72: Bleeding The Fuel System
Compact Track Loader 11. Engine Components Disassembly and Assembly 4. Connect the battery cable to the negative battery terminal. Bleeding the Fuel System The tools required for muffler removal and installa- tion are listed in Table 11-1. Use manufacturer- recommended tools whenever possible. Table 11-4 Required Tools Combination Wrench...
Page 73 ...
Page 74: Undercarriage Disassembly And Assembly
12. Undercarriage Disassembly and Assembly Chapter Overview Undercarriage Disassembly and Assembly Procedures This chapter provides disassembly and assembly procedures for the following undercarriage Disassembly and assembly procedures are provided assemblies. for the following undercarriage components. • Track • Wheels (also see track procedure) •...
Page 75 Compact Track Loader 12. Undercarriage Disassembly and Assembly Rear Front Idler Idler Bogie Wheels Wheels Wheels Figure 12-4 Figure 12-1 Remove the nut that fastens the wheel to the 1. Loosen up the track tensioner as described in shaft with the correct size socket. the track removal procedure on page 12-3, steps 1-4.
Page 76: Wheel Installation
Note: Refer to bearing illustration on figure 12-9 of this up and placed on jack stands sturdy enough to support the chapter to ensure proper installation of each style of weight of the machine. Terex approved jack stands are bearing. recommended.
Page 77 Compact Track Loader 12. Undercarriage Disassembly and Assembly NOTE: Bearings Tapered Roller Bearing Ball Bearing Figure 12-11 2. Remove the nut from the bolt that fastens the In the illustration above, the rear wheel is shown track tensioner to the drive sprocket assembly. with a tapered roller style bearing while the center wheel is shown with a ball type bearing.
Page 78: Track Installation
Track Installation To remove the tracks, the machine must be jacked up and placed on jack stands sturdy enough to support the weight of the machine. Terex approved jack stands are recommended. Figure 12-14 5. Locate the wheel marked “A” in fig. 12-14.
Page 79: Sprocket Bearing Plate Removal And Installation
Compact Track Loader 12. Undercarriage Disassembly and Assembly Figure 12-22 Figure 12-19 6. Install the remaining wheels making sure the 3. Install the front wheel. Refer to Chapter 12. bearing, washer, wheel nuts, wheel caps, and Wheel Installation pg 12-3. snap-rings are properly installed.
Page 80: Sprocket Bearing Plate Removal
Compact Track Loader 12. Undercarriage Disassembly and Assembly Table 12-3 Required Tools Socket Wrench Combination Wrench Bearing Puller Tool Torque Wrench Sprocket Bearing Plate Removal 1. Remove the track. Refer to Chapter 12. Track Removal. Figure 12-26 5. Remove the four bolts that secure the bearing Castle nut assembly to the bearing plate, remove the bearing plate.
Page 81: Sprocket Roller Removal And Installation
Compact Track Loader 12. Undercarriage Disassembly and Assembly 2. Align the grease hole of the bearing flange with zerk and the grease track on the bearing as shown in figure 12-28. 3. Ensure that the concave side of the washer is contacting the sprocket.
Page 82: Sprocket Roller Installation
Compact Track Loader 12. Undercarriage Disassembly and Assembly Sprocket Removal and Installation The tools required for sprocket removal and installation are listed in table 12-5 below. Use manufacturer-recommended tools whenever possible. Sprocket Removal Table 12-5 Required Tools Socket Wrench Impact Driver Figure 12-32B Sprocket Puller Sprocket Roller Installation...
Page 83: Sprocket Installation
Compact Track Loader 12. Undercarriage Disassembly and Assembly 3. Operate the puller by tightening the push bolt with a wrench until the sprocket is pulled off the drive motor shaft as shown in figure 12-36. Re- move sprocket and inspect sprocket rollers for wear.
Page 84: Drive Motor Removal
Compact Track Loader 12. Undercarriage Disassembly and Assembly Note: During disassembly, cap all hoses and fittings to prevent fluid loss and contamination of the system fluids. Drive Motor Removal Top Large Angled Small Figure 12-43 3. Remove the four bolts that secure the drive motor to the drive table using a thin wall socket.
Page 86: Chapter Overview
13. Lift Arm Disassembly and Assembly Chapter Overview Lift Arm 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 Improper or incomplete maintenance/repair of a Compact •...
Page 87 Compact Track Loader 13. Loader Disassembly and Assembly 5. Disconnect and cap the hose on the rear end of Collect and contain liquids in a suitable the cylinder. container. Dispose of all liquids according to local regulations and mandates. Note: During disassembly, cap all hoses and fittings to prevent fluid loss and contamination of the system fluids.
Page 88: Lift Cylinder/Tilt Cylinder Installation
Compact Track Loader 13. Loader Disassembly and Assembly Remove bolt and then pin End gland Figure 13-6 Figure 13-7 9. Remove the bolt and pin from the loader tower. 1. Secure the cylinder into a vice and remove the end gland by turning counter clockwise with 10.
Page 89 Compact Track Loader 13. Loader Disassembly and Assembly O-rings Figure 13-13 7. Remove the three o-rings located on the outside of the end gland with a small blade type screwdriver paying close attention to the order Figure 13-10 they are removed to aid during installation of 4.
Page 90 Compact Track Loader 13. Loader Disassembly and Assembly To remove cylinder bushings, place cylinder in vice and find a socket the same diameter as the bushing. Remove the bushing with a rubber mallet and the socket. You may need to use a Back-up ring punch tool to complete the removal of the bushing.
Page 91: Lift Arm Bushing Removal And Installation
Compact Track Loader 13. Loader Disassembly and Assembly 2. Turn the engine start switch to the OFF position Lift Arm Bushing Removal and and remove the key to avoid accidental start. Installation The tools required for lift arm and lift arm bushing removal and installation are listed in Table 13-3.
Page 92 Compact Track Loader 13. Loader Disassembly and Assembly Figure 13-24 7. Compress a replacement bushing to fit the hole size and start the insertion with a dead blow Figure 13-26 hammer as shown. As you drive the new 12. With an assistant, lower lifting device to drop lift bushings into the lift arm, the old bushings will arm back into position to re-install pins.
Page 93: Lower Friction Points
Compact Track Loader 13. Loader Disassembly and Assembly Figure 13-32 Figure 13-29 16. Add grease to the zerks located on each of the 2. Remove bolt from pins that secure the tilt cylinder to the quick attach. lift pins to lubricate them. Lower Friction Points: Note: Each worn bushing will be removed one at a time.
Page 94: Removal And Installation
Compact Track Loader 13. Loader Disassembly and Assembly 9. Complete insertion of the bushing with a socket and the hammer until the bushing is flush with the surface of the lift arm. This action will force the worn bushing out the opposite side of the lift arm for removal.
Page 95 Compact Track Loader 13. Loader Disassembly and Assembly Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates. Note: During disassembly, cap all hoses and fittings to Remove prevent fluid loss and contamination of the system fluids. Bolts 1.
Page 96: Quick Attach Disassembly And Assembly
14. Quick Attach Disassembly and Assembly Chapter Overview Quick Attach Disassembly and Assembly Procedures This chapter provides disassembly and assembly procedures for the quick attach assembly. Disassembly and assembly procedures are provided for the following quick attach components. Personal Safety •...
Page 97: Quick Attach Assembly Removal And Installation
Compact Track Loader 14. Quick Attach Disassembly and Assembly 2. Turn the engine start switch to the OFF position. Figure 14-4 6. Disassemble as necessary and replace worn components to ensure proper function. Figure 14-2 Latch Mechanism Installation 3. Remove the bolt securing the latch mechanism 1.
Page 98: Quick Attach Assembly Installation
Compact Track Loader 14. Quick Attach Disassembly and Assembly Remove Remove Insert Install Figure 14-5 Figure 14-7 3. Remove the bolt and push out the pin that 2. Insert the pin and install the bolt that secures secures each end of the quick attach assembly each end of the quick attach assembly to the to the tilt cylinders.
Page 100: 15. Troubleshooting
15. Troubleshooting Chapter Overview Preliminary Inspection 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 101: Troubleshooting
Compact 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 Machine will not crank over. Problem 5 Tracks operate but loader will not operate.
Page 102 Compact Track Loader 15. Troubleshooting Problem 8 Problem 13 Auxiliary hydraulic full-time direction switch operates but Loader will not float; labors engine and has down pressure part-time thumb switch will not operate. when detented into float. Probable cause Probable cause Auxiliary hydraulic thumb switch malfunction.
Page 103 ...
Page 104: 16. Maintenance
NOTICE arms in the raised position unless the lift arm brace has been correctly installed. When replacing engine coolant, use Terex Long Life 1. Start the machine and raise the lift arms until 50/50 Antifreeze/Coolant or equivalent antifreeze with the proper SCA (Supplemental Cooling Additive) they are clear of the brace.
Page 105: Engine Oil
Due to the variations in the quality and performance Figure 16-1 of commercially available oils, Terex Heavy Duty Diesel Engine Oil – 10W30 is recommended. If Terex lubricants are not available, use a substitute meeting the following qualifications: Stowed position - API CH-4 multi-grade engine oil...
Page 106: Fuel Filter
Compact Track Loader 16. Maintenance 4. Remove the filter element and replace it. Install as found upon removal. 5. Fill with manufacturer-approved hydraulic fluid. Fuel Filter The fuel filter should be changed every 500 service hours, or as needed. A plugged fuel filter can cause Hydraulic Fluid loss of engine power, rough running, or no start.
Page 107: Air Filter Change Procedures
Compact Track Loader 16. Maintenance Air Filter Change Procedures Track Tension NOTICE Proper track tension is very important for optimum performance and long track life. Tracks that are run When working in dusty conditions, the air cleaner too loose can cause misfeeding and ratcheting elements should be checked and changed more frequently possibly causing damage to the track.
Page 108: Checking For Proper Track Adjustment
Figure 16-13 These fitting should be lubricated at least after every 10 hours of operation using Terex Multi Purpose 4. Using a ruler, measure the distance between the EP Lithium Grease, or other high-quality, straightedge and track.
Page 109: Lift Arm Bushings
Compact Track Loader 16. Maintenance Lift Arm Bushings Quick Attach Wear Inspection Daily inspection can be carried out by performing the following steps: 1. Lower the lift arm until it makes contact with the chassis stops. Rotate the bucket against the ground repeatedly.
Page 110: Hydraulic Pressure Check & Adjustment
17. Hydraulic Pressure Check & Adjustment Chapter Overview Hydraulic Pressure This chapter provides a overview of checking and setting pressures. It is important to contact the Adjustment Procedures manufacturer for assistance before beginning these procedures. Adjustment and test procedures are provided for the following transmission and drive components.
Page 111 Compact Track Loader 17. Hydraulic Pressure Check & Adjustment 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. Collect and contain liquids in a suitable contain- er.
Page 112 Compact Track Loader 17. Hydraulic Pressure Check & Adjustment 9. Connect the hose coupling on the tandem pump T-adapter. Remove 10. Check the charge pressure. 11. Install the belly pan. Drive-Pressure Relief Valve Adjustment The service tools required for drive-pressure relief valve adjustment are listed in Table 0-3.
Page 113: Auxiliary Pressure Check & Adjustment
Compact Track Loader 17. Hydraulic Pressure Check & Adjustment 6. Extract the high-pressure relief valve collar, valve spring, spring loading nut and pressure spring from the valve cavity. 7. Adjust the drive pressure by turning the spring loading nut. Turning Clockwise will increase pressure.
Page 114 Compact Track Loader 17. Hydraulic Pressure Check & Adjustment Figure 12 2. Engage the continuous flow switch located on the right side of the dash panel. Make sure it is in the direction that sends flow to the gage. Jam Nut Adjustment Screw Figure 13...
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Page 116 Terex Construction Americas 8800 Rostin Road Southaven, MS 38671 (888)-201-6008 (662)-393-1800 www.terex.com...

Terex PT-30 Service Manual

1 Product Safety

2 Technical Specifications

3 System Diagrams

4 Machine Controls and Instrumentation

5 Operator Enclosure Disassembly

6 Chassis Disassembly and Assembly Procedures

7 Radiator/Oil Cooler Disassembly

8 Hydraulic Reservoir Disassembly

9 Loader/Transmission Controls Disassembly

10 Transmission and Drive Disassembly

11 Engine Components Disassembly and as

12 Undercarriage Disassembly and Assembly

13 Loader Disassembly and Assembly

14 Quick Attach Disassembly and Assembly

15 Troubleshooting

16 Maintenance

17 Hydraulic Pressure Check & Adjustment

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Troubleshooting

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Summary of Contents for Terex PT-30

Table of Contents