ASV PT-70 Service Manual Download

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Service Manual

PT-70/PT-80
Rubber Track Loader

• Safety Overview

• Technical Specifications

• Circuit Diagrams

• Maintenance

• Controls & Instrumentation

• Component Removal & Installation

• Hydraulic Component Service

• Hydraulic Pressure & Flow Check & Adjustment

• Troubleshooting

ASVPT003

Part Number: 2046-159

Printed (1-08)

Summary of Contents for PT-70

Page 1: ...fety Overview Technical Specifications Circuit Diagrams Maintenance Controls Instrumentation Component Removal Installation Hydraulic Component Service Hydraulic Pressure Flow Check Adjustment Troubleshooting ASVPT003 Part Number 2046 159 Printed 1 08 ...

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Page 3: ...PT 70 PT 80 Service Manual Printed 1 08 ...

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Page 5: ...2 Cycle times 2 2 Service Tools 2 2 3 Circuit Diagrams Chapter Overview 3 1 Hydraulic Charge Circuit 3 1 Hydraulic Auxiliary Circuit 3 2 Hydraulic Drive Circuit 3 3 Lift Arm Control Valve 3 4 Hydraulic Pilot Generation Solenoid Block 3 5 Electrical Attachment Outlet 3 6 Drive Control line routing 3 7 Lift Arm Control line routing 3 8 4 Maintenance Chapter Overview 4 1 Personal Safety 4 1 Lift Arm ...

Page 6: ...5 Hood Assembly 7 5 Removal Procedure 7 5 Installation Procedure 7 6 8 Radiator and Oil Cooler Chapter Overview 8 1 Personal Safety 8 1 Machine Preparation 8 1 Removal Installation 8 1 Fan Guard 8 1 Removal Procedure 8 1 Installation Procedure 8 2 Fan Shroud 8 2 Removal Procedure 8 2 Installation Procedure 8 3 Radiator Oil Cooler 8 3 Removal 8 3 Installation 8 4 9 Hydraulic Reservoir Chapter Overv...

Page 7: ...tion Procedure 15 3 16 Hydraulic Component Service Chapter Overview 16 1 Personal Safety 16 1 Disassembly Assembly 16 1 Hydraulic Cylinder 16 1 Disassembly Procedure 16 1 Assembly Procedure 16 3 Lift Arm Control Valve 16 4 Disassembly Procedure 16 4 Assembly Procedure 16 6 Drive Motor brake portion 16 6 Disassembly Procedure 16 6 Assembly Procedure 16 7 Drive Motor motor portion 16 8 Disassembly P...

Page 8: ...IV ...

Page 9: ...ing a Rubber Track Loader may be unfamiliar with many of the systems on the machine This makes it especially important to use caution when performing service tasks Familiarize yourself with the affected system s and components before attempting any type of maintenance or service It is not possible to anticipate every potential haz ard The safety messages included in this docu ment and displayed on...

Page 10: ...h with large amounts of water for at least 15 minutes Call Physician Keep out of reach of children Batteries Do not smoke when inspecting the battery electrolyte level Never disconnect any charging unit circuit or bat tery circuit cable from the battery when the charging unit is operating A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from t...

Page 11: ...the engine can possibly overspeed and cause bodily injury death or property damage Be prepared to shut off the fuel and air supply to the engine in order to stop the engine 9 Be careful when removing cover plates Gradually back off the last two bolts or nuts located on oppo site sides of the cover Then pry the cover loose to relieve any spring or other pressure before removing the last two nuts or...

Page 12: ... the high efficiency particulate air filter HEPA filter can also be used 2 Use exhaust ventilation on permanent machining jobs 3 Wear an approved respirator if there is no other way to control the dust 4 Comply with applicable rules and regulations for the work place In the USA use Occupational Safety and Health Administration requirements These OSHA requirements can be found in 29 CFR 1910 1001 5...

Page 13: ...ghly clean these areas as often as necessary to avoid combustion Failure to do so could result in fire that may cause machine damage personal injury or even death 2 Speed if equipped To engage Press the button located on the front of the right joystick control To disengage Press the button a sec ond time 2045 468 DANGER Operating Position Never operate the machine with any part of your body protru...

Page 14: ...1 6 ...

Page 15: ...taminants are introduced from the quick couplers Lift Arm Control Valve Make Rexroth Type Load Sense Oil Cooler Operating pressure 150 psi 1034 kPa Bypass relief pressure 80 psi 689 kPa Hot oil sending unit 225 F 107 2 C Avg oil operating temp 50 60 F above ambient High flow application 80 F above ambient Critical Torque Specs Transmission Mounting Bolts 85 ft lb w Blue Loctite Drive Sprocket Driv...

Page 16: ...taminants are introduced from the quick couplers Lift Arm Control Valve Make Rexroth Type Load Sense Oil Cooler Operating pressure 150 psi 1034 kPa Bypass relief pressure 80 psi 689 kPa Hot oil sending unit 225 F 107 2 C Avg oil operating temp 50 60 F above ambient High flow application 80 F above ambient Critical Torque Specs Transmission Mounting Bolts 85 ft lb w Blue Loctite Drive Sprocket Driv...

Page 17: ...ment outlet It also contains hose routing information for the control configurations for the drive and lift arm pilot controls Figure 3 1 PT 70 80 Hydraulic Charge Circuit Hydraulic Charge Circuit 3 Circuit Diagrams 3 1 OIL COOLER TANK INLET CHARGE PUMP FLOW PILOT GEN BLOCK CHARGE PRESSURE TEST PORT 475 30 PSI TO HYD Q A OPTIONAL PT 70 TANK 5 MICRON FILTER TANK CHECK VALVE 15 PSI CHECK VALVE 0 PSI...

Page 18: ...ack Loader 3 Circuit Diagrams OIL COOLER TO TANK TO ATTACHMENT CASE DRAIN Q C LOAD SENSE TO LIFT ARM CYL TO AUXILIARY Q C TO TANK FLOW AUXILIARY PUMP LOADER CONTROL LIFT ARM VALVE PILOT GEN BLOCK TO LIFT ARM CYL TO TANK CHARGE PUMP INLET TO BUCKET CYL CHECK VALVE 80 PSI AUXILIARY PUMP INLET ...

Page 19: ...igure 3 3 PT 70 80 Hydraulic Drive Circuit 3 3 Rubber Track Loader 3 Circuit Diagrams DRIVE MOTOR DRIVE MOTOR DRIVE PUMP DRIVE CONTROL TO COOLER TANK CASE DRAIN BRAKE 2 SPEED SHIFT PT 80 DRIVE PRESSURE RELIEF VALVES 4 5500 PSI ...

Page 20: ...ontrol Valve Figure 3 4 PT 70 80 Lift Arm Control Valve 3 4 Rubber Track Loader 3 Circuit Diagrams RELIEF VALVE SETTINGS B3 3307 PSI B2 3147 PSI B1 3640 PSI A3 3307 PSI A2 3669 PSI A1 Anti Cavitation Check Valve ...

Page 21: ...Hydraulic Pilot Generation Block Figure 3 5 PT 70 80 Hyd Pilot Generation Block 3 5 Rubber Track Loader 3 Circuit Diagrams ...

Page 22: ...Electrical Attachment Outlet Figure 3 6 PT 70 80 Electrical Attachment Outlet 3 6 Rubber Track Loader 3 Circuit Diagrams ...

Page 23: ...Drive Control line routing Figure 3 7 PT 70 80 Standard Drive Control 3 7 Rubber Track Loader 3 Circuit Diagrams ...

Page 24: ...Lift Arm Control line routing Figure 3 8 PT 70 80 Lift Arm Control 3 8 Rubber Track Loader 3 Circuit Diagrams ...

Page 25: ...only by a jack The lift arm brace is used to support the weight of the lift arms much like jack stands are used to mechanically support vehicle weight To install the lift arm brace 1 Park the machine on level ground in a safe area for performing service work 2 Remove any attachments that may be fastened to the quick attach 3 Have an assistant remove the retaining pins B securing the lift arm brace...

Page 26: ...he ground to perform maintenance Exercise caution when jacking the machine Always use a jack that is capable of lifting the machine and support its weight with ASV approved jack stands while suspend ed Never work on or under a machine supported only by a jack To safely jack your machine 1 Remove any attachments that may be fastened to the machine and raise the lift arms 2 Install the lift arm brac...

Page 27: ...l should be cleaned from the undercar riages more often to minimize component wear A pressure washer works well for cleaning materials from the undercarriages At times when a pressure washer is not available use a bar shovel or similar device to remove foreign materials When cleaning pay particular attention to the drive tables sprockets and the front and rear wheels where debris is likely to accu...

Page 28: ...the machine forward 5 feet to remove belt slack from the lower and rearward portions of the track 2 Lay a straight edge along the top of the track bridging the drive sprocket and front idler wheel 3 Apply 90 lbs of down force to the the track by either placing weight on top or hanging it using rope or wire midway between the drive sprocket and front idler 4 Measure from the bottom of the straight ...

Page 29: ... remove the bearing assembly J from the shaft 6 Remove the sprocket mounting bolts C then remove the sprocket Note You may need to pry or lift the track upwards with a hoist above the drive sprocket to provide clear ance for removal 7 Remove one bolt F holding the steel pins D and rollers E in place Install the new rollers over the pins then slide the bolt back through the sprocket and pins and se...

Page 30: ...els The track removal procedure is identical with this exception fig 4 11 Track Removal 1 Break up and remove any foreign material from the cavity between the suspension rail and the drive table support fig 4 12 Note A shop vac or pressure washer will work well to remove material from this cavity 2 Clean the threads on the turnbuckle thoroughly using a stiff bristle brush 3 Loosen the lock nut on ...

Page 31: ...ub then remove the wheel PT 80 only 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 fig 4 20 9 Once the track is off of the front wheel s pull the rear of the track clear of the suspension fig 4 21 4 22 4 7 Rubber Track Loader 4 Maintenance 4 16 4 17 4 18 4 19 4 20 4 21 4 22 ...

Page 32: ...pward slightly and in position to slide over the inner idler wheel s at the front fig 4 27 6 Pull all of the slack forward and make sure the track drive lugs are properly meshed with the sprocket to provide as much slack as possible for installation 7 If you have an assistant have them pull the track forward while you push inward on the track Work the track over the wheel s and into place 8 If you...

Page 33: ...spinning as you torque the mounting bolts to spec fig 4 31 10 Install the scraper onto the suspension rail and tighten the bolts to secure it in place PT 80 only fig 4 32 11 Install the outer idler wheel and secure it in place with the mounting bolts Torque them to 90 10 Lb Ft fig 4 33 4 34 12 Perform the track tension adjustment and check procedures on page 4 4 to complete installation 4 9 Rubber...

Page 34: ...h to remove the cover then remove the cover The primary element B should be exposed 5 Remove the primary element and inspect it If it appears damaged in any way replace it If the ele ment is heavily soiled replace it If it appears to be in good condition clean if necessary and re install 6 Once the primary element has been removed the secondary element C should be visible Remove and inspect it If ...

Page 35: ...eaning them Heavy duty air filter manufactur ers will not warrant the air filter once it has been cleaned Fuel Filter The fuel filter removes contaminants from the fuel as it enters the engine for combustion Over time the filter can become plugged and cause the engine to lose power run roughly or fail to start The fuel filter should be changed every 500 hours or more often if needed to prevent the...

Page 36: ...ure the distance from the bottom of the straight edge to the top surface of each belt deflection Fan belt deflection should meas ure 3 8 7 16 A C if properly tensioned 5 If the belts are loose or tight adjust tension until correct To adjust fan or A C belt tension 1 Make sure the engine is cold off and the key has been removed from the ignition to avoid accidental start 2 Lift the hood at the rear...

Page 37: ...of the removal procedure 2 Perform the belt tension check and adjustment procedures on page 4 12 to complete the installation A C Belt Removal Installation To remove the A C belt 1 Follow steps 1 and 2 of the belt adjustment proce dure 2 Once loose pivot the A C pump towards the engine to increase slack 3 Slip the belt off of the pulleys and remove it from the machine To install the A C belt 1 Rev...

Page 38: ...plug in reusable condition fig 4 48 5 Remove the engine oil filter by hand or with strap if necessary fig 4 49 6 Once the filter has been removed check to make sure the rubber gasket has come off of the filter head with the old filter If it is not on the old filter check the filter head If it is still on the filter head remove it prior to installing the new filter fig 4 50 If the old filter gasket...

Page 39: ...V 10W 30 Heavy Duty Engine Oil for most conditions In the event of an alter nate working environment the following chart may be used as a guide to oil viscosity grades You may also use a quality engine oil substitute meet ing the following minimum specification API CH 4 multigrade engine oil Oil Level Check To check the oil level 1 Park the machine on level ground 2 Open the hood to gain access to...

Page 40: ...nt of fresh hydraulic oil onto the filter gasket surface and then threading them onto their respective filter heads Tighten filters by hand as instructed by the label located on the filter or filter box 8 Install the hydraulic system drain plug and tighten 9 Remove the hydraulic reservoir filler cap black and fill the hydraulic system with ASV Premium All Season MV Hydraulic Oil or equivalent unti...

Page 41: ...r oil cooler 1 Make sure the engine is off and cool 2 Using compressed air or a pressure washer thor oughly clean radiator oil cooler as shown Note Make sure water nozzle is at least 12 8 for air from the cooler and that the spray is directed straight through the cooler or the cooling fins may be damaged bent over which will decrease cooling performance Engine Periodic cleaning of the chassis area...

Page 42: ...fuse panel behind the access cover on the lower right side of the cab interior fig 4 63 In the event of an electrical malfunction the most logi cal place to start is at the fuse panel Check the fuse related to the problem you are having and inspect it If the fuse appears black and burned it needs to be replaced Replace fuses with the correct amperage replacement fuse only Replacing a fuse with one...

Page 43: ...ners Inspect Daily Replace if damaged or heavily soiled Radiator oil cooler Inspect Daily Clean often as necessary Undercarriages Inspect Daily Clean often as necessary Engine compartment Inspect Daily Clean often as necessary Drive sprocket rollers Inspect 50 hr Replace if damaged or worn 35 min Engine oil and filter Replace 250 hr or 6 Mo 9 qt Hydraulic filter Replace 250 hr Hydraulic oil Replac...

Page 44: ...4 20 ...

Page 45: ...Instrumentation The Instruments Figure 5 2 are positioned in the lap bar for good visibility and when seated inside the oper ator enclosure Instruments include the following com ponents 1 Engine Temperature Gauge 2 Multi Gauge Oil Pressure Gauge Hyd Oil Temperature Gauge Fuel Gauge Voltmeter 3 Tachometer 4 Indicator Light Display High Range Indicator Low Range Indicator Glow Plug Operation Indicat...

Page 46: ...an dard and optional switches are listed below 1 Ignition 2 Hour Meter 3 Beacon optional 4 Wiper optional 5 Heater Fan optional 6 Parking Brake 7 Headlight 8 Bucket Pos 9 Hight Flow Aux 10 Low Flow Aux 11 Hyd Q A 5 2 Rubber Track Loader 5 Machine Controls and Instrumentation 5 3 5 4 5 5 1 2 3 4 5 9 10 11 6 7 8 ...

Page 47: ...amps and remove the key from the ignition switch prior to performing any service work on a Rubber Track Loader Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Removal and Installation Removal and installation procedures are provided for the following operator enclosure components Cab Door Gas Spring MP 1 MP 2 Forward Pillar Switch Pane...

Page 48: ...hem from the switch fig 6 5 4 Pivot the panel further backward to expose the connectors on the lower switches and disconnect them You may then remove the panel fig 6 6 6 7 Note The connectors on the harness are labeled as are the switches in the panel Use these labels to properly identify match up and reconnect the harness to the switches during installation Note At this point in the disassembly p...

Page 49: ...te At this point in the disassembly procedure the gauges may be replaced if necessary 3 If gauges must be removed remove the nuts securing the backing plate to the gauge fig 6 12 4 The gauge may now be removed for repair or replacement fig 6 13 6 14 Installation 1 To reinstall the gauges and cluster reverse the removal procedure 6 3 Rubber Track Loader 6 Operator Enclosure 6 9 6 10 6 11 6 12 6 13 ...

Page 50: ...s securing the rear side panel section to the cab enclosure fig 6 18 5 Disconnect any switches from the harness unbolt the heater control if removing left side then remove the panel from the machine fig 6 19 6 If gauges need to be removed remove the nuts securing the bracket to the back of the gauge then remove the bracket and gauge from the opposite sides of the panel fig 6 20 Side Panels Gauges ...

Page 51: ...artially to expose the seat switch harness located behind the seat fig 6 23 5 Disconnect the harness and then remove the seat from the machine fig 6 24 Seat Installation 1 To install the seat reverse the removal procedure Interior Side Panel LT MP 2 Removal 1 Remove the mounting screws 5 and washers securing the panel to the chassis fig 6 25 2 Remove the cup holder mounting screws 4 and remove the...

Page 52: ...e the fuse panel access cover fig 6 28 2 Remove the mounting screws 6 and washers securing the panel to the chassis fig 6 29 3 Disconnect the ignition switch hour meter and any other switches from the cab harness fig 6 30 4 Remove the panel by lifting and twisting it over the joystick and clear of the lap bar fig 6 31 Installation 1 To re install the right interior side panel reverse the removal p...

Page 53: ...terior panels from the cab to access the gas spring 2 Put the lap bar in the raised position to relieve ten sion on the lap bar gas spring fig 6 34 3 Using a small screwdriver remove the retaining clip from each end of the gas spring fig 6 35 4 Remove the gas spring by pulling both ends off of the ball joints Installation 1 Reverse the removal procedure to reinstall the lap bar gas spring 6 7 Rubb...

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Page 55: ...from the ignition switch prior to performing any service work on a Rubber Track Loader Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Removal and Installation Removal and installation procedures are provided for the following chassis components Fuel Sending Unit Fuel Tank Footwell Foot Throttle Assembly Hood Assembly Note Procedures a...

Page 56: ...ms 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 optional 3 Loosen the hose clamps securing the vent hoses to the left rear tank end fig 7 5 4 Disconnect and plug the hoses fig 7 6 5 Remove the bolts securing the forward belly pan and remove it from the machine fig 7 7 7 2 Rubber Track Loader 7 Chassis and Fuel Tank 7 ...

Page 57: ... regulations and mandates 8 Remove the bolts securing the fuel tank to the fenders fig 7 10 9 Remove the bolts 3 securing the fuel tank to the front mounting plate fig 7 11 10 Now that the tank is loose and empty loosen the hose clamp and disconnect the filler tube from the right rear end of the tank fig 7 12 11 Lift and remove the tank from the machine fig 7 13 Installation 1 To install the fuel ...

Page 58: ...emove the cover fig 7 14 4 Pry the throttle cable off of the ball stud on the foot pedal fig 7 15 5 Remove the bolts 4 securing the footwell assem bly to the chassis fig 7 16 6 Remove the footwell from the chassis as shown fig 7 17 Installation 1 To install the footwell reverse the removal proce dure 7 4 Rubber Track Loader 7 Chassis Fuel Tank 7 14 Screwdriver Combination Socket Wrench Required To...

Page 59: ...l 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 Hood Assembly Removal 1 Remove the bolts 4 securing the fluid filler tray and hoses to the hood assembly fig 7 19 7 20 2 Remove the bolts 6 that secure the hood to the chassis fig 7 21 7 22 7 5 Rubber Track Loader 7 Chassis Fu...

Page 60: ...to remove the hood assembly from the machine fig 7 23 4 Carefully set the hood assembly aside fig 7 24 Installation 1 To install the hood assembly reverse the removal procedure 7 6 Rubber Track Loader 7 Chassis Fuel Tank 7 23 7 24 ...

Page 61: ... remove the key from the ignition switch prior to performing any service work on a Rubber Track Loader Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Prior to performing any type of service work on a Rubber Track Loader read and understand Chapter 1 Product Safety for personal safety information Removal and Installation Removal and in...

Page 62: ... Remove the bolts 2 securing the fuel pump filter assembly to the radiator support and lay it aside over the bumper to allow clearance to remove the shroud and fan fig 8 5 2 Remove the bolts 6 securing the radiator and shroud to the radiator support fig 8 6 3 Push the shroud forward to allow access the fan mounting bolts fig 8 7 8 2 Rubber Track Loader 8 Radiator and Oil Cooler 8 2 8 3 Required To...

Page 63: ...Cooling system conditioner contains alkali Avoid con tact with skin and eyes NOTICE Collect and contain liquids in suitable containers Dispose of all liquids according to local regulations and mandates 1 Perform the fan guard and fan shroud removal pro cedures 2 Remove the bolts securing the rear belly plates to the chassis and remove them fig 8 11 3 Attach a piece of 3 8 fuel line to the drain va...

Page 64: ...ler Cap and plug the line and cooler opening upon disassembly fig 8 15 7 Loosen the clamps securing the upper and lower coolant hoses to the radiator then disconnect the hoses from the radiator fig 8 16 8 17 8 Tilt the radiator rearward and then remove it from the machine fig 8 18 Installation 1 To install the radiator oil cooler reverse the removal procedure 8 4 Rubber Track Loader 8 Radiator and...

Page 65: ...n Prior to performing any type of service work on a Rubber Track Loader read and understand Chapter 1 Product Safety for personal safety information Removal and Installation Removal and installation procedures are provided for the following hydraulic components Hydraulic Reservoir tank Suction Screen Note Procedures are provided for only those hydraulic com ponents listed above However exploded pa...

Page 66: ...nual 5 Disconnect the hoses and lines attached to the two upright portions of the tank fig 9 1 9 2 9 3 6 Remove the clamps securing the quick attach hard lines and the test port line that run from the pilot generation block down the left side of the machine to the engine compartment fig 9 4 7 Disconnect the quick attach hoses from the hard lines if equipped fig 9 5 8 Disconnect the quick attach an...

Page 67: ...ngine compartment Remove all line clamps fig 9 8 11 Disconnect the lift cylinder hoses from the hard lines to allow the bucket cylinder lines to be removed fig 9 9 12 Disconnect the bucket cylinder hard lines from the lift arm control valve and then remove them from the machine fig 9 10 9 11 13 Remove the hose retainer or move it aside as shown fig 9 12 9 3 Rubber Track Loader 9 Hydraulic Reservoi...

Page 68: ...t from the machine fig 9 14 9 15 16 Remove the clamps securing the auxiliary hydraulic lines to the chassis fig 9 16 17 Disconnect the auxiliary hydraulic lines from the lift arm control valve and the hoses leading to the quick coupler lines on the lift arm fig 9 17 9 18 9 4 Rubber Track Loader 9 Hydraulic Reservoir 9 13 9 14 Disconnect 9 15 9 17 9 16 9 18 ...

Page 69: ...tubes to be removed 20 Remove the auxiliary hydraulic tubes from the machine 21 Disconnect the lower portions of the cab support gas springs from the chassis fig 9 23 22 Label then disconnect any control hoses coming from the joysticks that are still attached to compo nents to allow them to be pulled up through the chassis opening for clearance fig 9 24 Note Refer to the individual hydraulic compo...

Page 70: ...hown fig 9 27 26 Remove the bolts securing the metal tank restraint straps them remove them from the machine fig 9 28 27 Slide the quick attach and test port tubes forward so that they do not interfere with the reservoir tank moving upwards in the chassis fig 9 29 28 Slide the various control hoses to the side of the reservoir tank so that they do not interfere with the tank moving upwards in the ...

Page 71: ...n step 30 31 Once the tank is over the axle mounts lift and remove it from the chassis as shown fig 9 32 9 33 9 34 Installation 1 To install the hydraulic reservoir reverse the removal procedure Note The only service issue warranting the removal of the reservoir is hydraulic system contamination Upon installation the tank must be clean and free of any dirt or debris that may contaminate the hydrau...

Page 72: ...own in fig 9 36 and 9 37 5 The suction screen is now accessible for inspec tion or replacement Note If removal is necessary thread the suction screen off of the flange weldment and remove Installation 1 To install the suction screen reverse the removal procedure Note It is important to inspect the screen for pieces of metal or other debris that may have been generated by a worn or defective compon...

Page 73: ...der read and understand Chapter 1 Product Safety for personal safety information Removal and Installation Removal and installation procedures are provided for the following lift arm drive control components Pilot Control Joystick Lift Arm Float Magnet Lift Arm Control loader Valve Note Procedures are provided for only those lift arm drive control components listed above However exploded parts diag...

Page 74: ...e The float magnet is now exposed as well as the mounting bolts securing the joystick to the bracket figure 10 2 5 Label each of the hoses during the removal process to aid in reassembly 6 Remove the bolts 3 securing the joystick mount ing bracket to the cab from the outside fig 10 3 optional 7 Label the hydraulic hoses to aid in reassembly see page 3 7 or 3 8 for routing and identification 8 Disc...

Page 75: ...orm steps 3 4 and 11 of the lift arm joystick control removal process 2 Remove the allen bolt from the underside of the magnet fig 10 10 3 Disconnect the magnet harness connector from the machine 4 Lift the joystick within the bracket slightly then pull the magnet harness and connector through the bracket past the joystick to remove it fig 10 11 Installation 1 To install the float magnet reverse t...

Page 76: ...provide additional clear ance for line removal fig 10 13 10 14 5 Disconnect all lines and hoses from the valve to allow for removal figure 10 15 10 16 6 Remove the carriage bolts 3 securing the loader valve to the chassis Then remove the valve Note The bolts have a square shank that mates with a square hole in the chassis to keep them from rotat ing upon removal Installation 1 To install the lift ...

Page 77: ...k Loader read and understand Chapter 1 Product Safety for personal safety information The hydraulic system fluid should be changed follow ing any hydraulic component service according to the procedure described on page 4 16 Removal and Installation Removal and installation procedures are provided for the following hydraulic components Charge Pump Auxiliary Pump Tandem Drive Pump Drive Motor Note P...

Page 78: ...pump fig 11 1 7 Remove the upper and lower 12 point bolts secur ing the charge pump to the engine fig 11 2 8 Remove the charge pump from the engine fig 11 3 Installation 1 To install the charge pump reverse the removal procedure Note The front bearing on the charge pump uses engine oil for lubrication It must be kept extremely clean Make sure to shield it as well as the opening to the engine from ...

Page 79: ... fitting on the right side of the pump then disconnect it fig 11 6 5 Loosen the clamps securing the hoses to the inlet weldment attached to the bottom of the pump fig 11 7 6 Loosen and remove the split flange clamp securing the inlet weldment to the bottom of the pump simi larly to the one previously removed on the top of the pump fig 11 8 11 3 Rubber Track Loader 11 Hydraulic Pumps Motors 11 4 11...

Page 80: ...any type of service on the cooling or hydraulic systems NOTICE Collect and contain liquids in a suitable container Dispose of all fluids according to local regulations and mandates During disassembly plug and cap hoses and fittings to prevent fluid loss and or contamination 1 Perform the auxiliary pump removal procedure on page 11 3 of this manual 2 Label and disconnect all hoses from the tandem d...

Page 81: ...to secure the bolts in position 11 13 To Oil Cooler return To Drive Motor LT To Drive Motor RT From Charge Filter BTM BTM BTM BTM TOP BTM Top Bottom Drive Pump Hoses View is from the top The pump is to be perceived as transparent Ports are labeled top or bottom as they are on the pump REAR FRONT RIGHT LEFT 11 14 TOP BTM TOP BTM REAR FRONT RIGHT LEFT Top Bottom Control Hoses E C F D View is from th...

Page 82: ...plate to the bearing assembly fig 11 20 4 Remove the bearing support plate from the under carriage fig 11 21 5 Use a hammer to tap around the circumference of the bearing cap which releases the outward pres sure holding it in place fig 11 22 6 Remove the bearing cap from the assembly fig 11 23 Rubber Track Loader 11 Hydraulic Pumps Motors 11 6 Required Tools Combination Socket Wrench Impact Wrench...

Page 83: ...curing the drive motor to the drive table fig 11 28 12 Lift the drive motor straight upward until it clears the drive table then forward to expose the hydraulic hoses for removal fig 11 29 Note There are two large bolts near the front of the drive motor support securing it to the lower drive table from the inside near the chassis Remove these bolts prior to lifting the motor to provide additional ...

Page 84: ...carriage fig 11 31 Installation 1 To install the drive motor into the undercarriage reverse the removal procedure Note During the removal of the bearing cap the bulged or domed area is beaten inward When rein stalling the cap flip it around so that the domed area is toward the outside of the machine Then tap the center of the cap with a ball peen hammer or similar device to reset the cap Do this g...

Page 85: ...r to performing any type of service work on a Rubber Track Loader read and understand Chapter 1 Product Safety for personal safety information Removal and Installation Removal and installation procedures are provided for the following engine related components Battery Exhaust Air Cleaner Engine Note Procedures are provided for only those engine associ ated components listed above However exploded ...

Page 86: ... system is very hot at operating tem perature Make sure the machine is off and cool before attempting to service the exhaust system 1 Perform the radiator oil cooler removal procedure on page 8 3 to provide access to the exhaust sys tem components 2 Remove the bolts securing the rear belly pan and remove it from the machine fig 12 6 3 Remove the nuts securing the head pipe to the turbo then pull i...

Page 87: ...sier 7 Remove the inlet pipe from the muffler It may be necessary to use levers to force the inlet pipe sec tion out of the muffler fig 12 11 Note Use caution not to damage the pipe or connec tion point during removal 8 Remove the tail pipes from the muffler If neces sary tap the pipes lightly with a rubber mallot or dead blow hammer to loosen the joints fig 12 12 Note Use caution when striking th...

Page 88: ...eaner Removal 1 Remove the cover and the filter elements from the air cleaner assembly fig 12 15 2 Loosen the clamp securing the intake hose to the air cleaner housing fig 12 16 3 Remove the bolts and nuts securing the air cleaner housing to the chassis fig 12 17 12 4 Rubber Track Loader 12 Engine 12 14 Required Tools Combination Wrenches Socket Wrench Extension 12 15 12 16 12 17 ...

Page 89: ...f this manual 3 Raise and support the operator enclosure cab as described on page 4 2 of this manual 4 Perform steps 2 7 of the exhaust removal proce dure on page 12 2 of this manual 5 Remove the center belly pan from the machine 6 Remove the front motor mount bolts 2 from the machine fig 12 19 7 Remove the rear motor mount bolts 2 from the machine fig 12 20 12 5 Rubber Track Loader 12 Engine 12 1...

Page 90: ...he upper right hand portion of the engine compart ment when viewed from the rear fig 12 23 11 Disconnect the case drain filter and bracket from the engine adapter plate and lay it aside It is situ ated beneath the drive pump fig 12 24 12 Remove the two bolts securing the drive pump to the engine adapter plate fig 12 25 13 Loosen and disconnect the fuel lines 2 from the engine fig 12 26 12 6 Rubber...

Page 91: ... as shown in fig 12 30 or the rear window could be damaged fig 12 31 18 Slide the engine rearward to clear the forward motor mounts then up and out between the radia tor supports fig 12 32 Installation 1 To install the engine reverse the removal proce dure Note When reinstalling the engine lightly grease the rubber motor mount surfaces to allow the engine to slide onto them without snagging or dis...

Page 92: ...12 8 ...

Page 93: ...e tag prominently on the ma chine to inform personnel that the machine is being worked on Prior to performing any type of service work on a Rubber Track Loader read and understand Chapter 1 Product Safety for personal safety information Removal and Installation Removal and installation procedures are provided for the following undercarriage components Idler Wheels Removal and installation Bogie Wh...

Page 94: ...ig 13 4 13 5 7 Remove the outer scraper plate from the suspen sion rail fig 13 6 8 Remove the bolts securing the inner wheel to the hub then remove the wheel fig 13 7 13 8 9 Repeat this procedure as necessary to remove the 15 idler wheels throughout the undercarriage Note To remove the 10 bogie wheels on the PT 80 undercarriages refer to page 13 3 of this manual Installation 1 To install the 15 id...

Page 95: ...es Installation 1 To install the idler wheels on the PT 70 reverse the removal procedure Torque the 15 wheel mounting bolts upon installation to 90 10 Lb Ft Torque the 10 wheel mounting bolts upon installation to 37 5 Lb Ft Bogie Wheel PT 80 only Removal Service Procedure 1 Perform steps 1 5 of the 15 idler wheel removal procedure on page 13 1 to loosen the track and provide clearance for bogie wh...

Page 96: ...wheel bearings During wheel removal replacement it is nec essary to remove inspect and clean all components prior to reassembly to ensure proper function 5 Remove both wheels from the hub fig 13 17 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 Also tak...

Page 97: ...ess to push the axle and far side bearing out of the hub as shown fig 13 20 13 21 7 If it is necessary to remove the other bearing for replacement press it out as well If not you may leave this bearing in the hub during cleaning 8 Clean all parts including wheels thoroughly with parts cleaning solution and dry them prior to reassembly Wipe the inner hub surfaces to remove any solvent or oil residu...

Page 98: ...od seal fig 13 25 13 Once the seals are in place wipe the mating sur faces of the face seals with a clean shop cloth and alcohol in a circular motion ending in a gentle sweep from the inside to the outside of the face until clear of the face This will ensure a clean mat ing surface and a good seal fig 13 26 13 27 14 Apply a very thin coating of fresh 10W30 engine oil onto the seal faces faces only...

Page 99: ... 2 ounces of ASV 10W 30 Heavy Duty Engine Oil Then reinstall the plug fig 13 33 13 34 22 Repeat this procedure on the other half of the bogie assembly if necessary prior to installing the two halves back onto the undercarriage 23 Place the rubber rods back into position on the square shaft then tape them in place to keep them secure while installing the bogie assemblies around them fig 13 35 24 Re...

Page 100: ...13 36 13 37 Note If you are removing the outer or rear hub assemblies you will be able to remove the hub assem bly once step three is complete 4 Using a press and tool 0403 336 press the bearing sleeve out of the hub assembly fig 13 38 13 39 13 8 Rubber Track Loader 13 Undercarriage 13 36 13 37 Axle 13 38 13 39 Required Tools Socket Wrench Sockets including Allen Press Tool Kit PT 70 0403 475 or P...

Page 101: ...nt of the hub with tools 0403 337 and 0403 333 fig 13 43 8 Press the bearing sleeve out of the rear bearing using tool 0403 336 fig 13 44 9 Remove the face seals and retaining ring from the bearing sleeve for cleaning and or replacement fig 13 45 Note There is no retaining ring on PT 70 machines 13 9 Rubber Track Loader 13 Undercarriage 13 40 13 41 Center seal Front race 13 42 Center seal Front ra...

Page 102: ...hen wipe them dry to ensure a good seal when assembled 12 Once components are clean and dry install half of the rear face seal into the bearing sleeve Make sure to work the rubber seal down into place within the seal recess until it seats to ensure a good seal fig 13 46 13 Install the other half of the rear face seal into the retaining ring Make sure to work the rubber seal down into place within ...

Page 103: ...led into the hub with tool 0403 336 until seated fig 13 54 19 Flip the hub over support the bearing sleeve from the bottom with tool 0403 335 and set it onto the press for center seal installation fig 13 55 20 Install the center seal into the hub Work the lip around the bearing sleeve with your fingers prior to pressing it into place fig 13 56 21 Install the race into the hub as shown above the se...

Page 104: ...len plug in the center portion of the hub fig 13 61 27 Add 2 oz 1 oz PT 70 of ASV 10W 30 Heavy Duty Engine Oil to the hub as shown then reinstall the plug and tighten fig 13 62 28 The hub assembly is now ready to be reinstalled To install it onto the machine reverse steps 1 3 on page 13 8 of this procedure Make sure to read the note below step 3 prior to reinstalling fig 13 63 29 Repeat this proce...

Page 105: ...Track Loader read and understand Chapter 1 Product Safety for personal safety information The hydraulic system fluid should be changed follow ing any hydraulic component service according to the procedure described on page 4 16 Removal and Installation Removal and installation procedures are provided for the following lift arm components Lift Cylinder Bucket Tilt Cylinder Quick Coupler Block PRV N...

Page 106: ...he hoses and fittings to prevent fluid loss and or sys tem contamination fig 14 3 4 Remove the bolts securing the front and rear lift arm cylinder pivot pins to the lift arm and lift arm tower fig 14 4 5 Remove the grease fitting from the pivot pins to allow the installation of the pin removal tool fig 14 5 6 Thread the removal tool into each pin then use the slide hammer to extract them fig 14 6 ...

Page 107: ...al procedure Bucket Tilt Cylinder Removal 1 Raise the lift arms and support them with the lift arm brace as described on page 4 1 fig 14 8 2 Place a suitable catch container beneath the cylin der fittings then disconnect the inlet and outlet hoses from the cylinders fig 14 9 3 Cap and plug the hoses and fittings to prevent fluid loss and or system contamination 14 3 Rubber Track Loader 14 Lift Arm...

Page 108: ...t to be removed fig 14 13 8 Use a pry bar to pry the lower cylinder eyelet out of the upper Q A mount as shown fig 14 14 9 Use a hammer and a brass punch to tap the upper pin most of the way out of the lift arm weldment fig 14 15 Note Make sure to support the cylinder have an assistant support it if necessary while removing the upper pin to prevent it from falling and being damaged or from causing...

Page 109: ... 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 fig 14 18 2 Once loose remove the valve from the block by twisting it counter clock wise until free fig 14 19 Installation 1 To install the Q C PRV reverse the removal proce dure 14 5 Rubber Track Loader 14 Lift Arm Components 14 16 14 17 14 18 ...

Page 110: ...14 6 ...

Page 111: ...t Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Prior to performing any type of service work on a Rubber Track Loader read and understand Chapter 1 Product Safety for personal safety information Removal and Installation Removal and installation procedures are provided for the following quick attach components Quick Attach locking Pin Assemblies Qui...

Page 112: ...the locking pin assembly out of the quick attach fig 15 6 Note At this time the locking pin assembly compo nents are easily accessible for replacement Inspect them for visible wear or damage and replace them as necessary Pay attention to the quantity and position s of each component to aid during reassembly fig 15 7 Installation 1 To install the quick attach locking pin assembly reverse the remova...

Page 113: ...re are four pivot pins that connect the quick attach to the lift arm and cylinders All four pins are removed in a similar manner Installation 1 To install the quick attach pivot pins reverse the removal procedure 2 Repeat this process as necessary to remove and replace worn or damaged quick attach pins 15 3 Rubber Track Loader 15 Quick Attach 15 8 15 9 Required Tools Combination Open End Socket Wr...

Page 114: ...15 4 ...

Page 115: ...g any hydraulic component service according to the procedure described on page 4 16 Disassembly Assembly Disassembly and assembly procedures are provided for the following components Hydraulic Cylinders Lift Arm Control Valve Drive motor Drive Pump Auxiliary Pump Note Procedures are provided for only those components listed above However exploded parts diagrams exist in the PT 70 PT 80 parts manua...

Page 116: ...l leakage and impaired func tion Defective components must be repaired or replaced 7 With the piston and rod removed from the cylinder inspect the cylinder bore for scratches or other damage If any are present that are deep enough to catch with your fingernail the cylinder tube weldment should be replaced figure 16 5 8 Remove the nut from the rod end figure 16 6 9 Support the piston loosely from t...

Page 117: ... Remove the end gland outer seal from the end gland figure 16 10 16 Thoroughly clean all parts to prevent contamina tion of hydraulic oil when reinstalled Assembly 1 Install new seals and components in place of the originals paying close attention to orientation and location to ensure proper operation 2 Lubricate the piston ring and seals with fresh hydraulic oil prior to assembly to avoid damage ...

Page 118: ...ch valve section and inspect the seals for damage replace if necessary figure 16 15 5 Remove the inlet port assemblies and inspect the seals for damage replace if necessary figure 16 16 16 17 6 Once the inlet port covers have been removed from both sides of a spool the spool may be removed fig 16 18 16 4 Rubber Track Loader 16 Hydraulic Component Service Required Tools Socket Wrench Combination Wr...

Page 119: ...hold the spool in place in a vice without damaging the spool and remove the end cap with an allen wrench fig 16 21 8 Remove the spring from the spool fig 16 22 9 Remove the load check spool with a low profile needle nose pliers fig 16 23 Note There is a passageway in the load check spool that must be kept clear to ensure proper operation It leads from the small hole in the side of the spool to the...

Page 120: ...actu ators relaxed remove the drive motor from the undercarriage by following the procedure in sec tion 13 2 Remove all but four of the allen bolts on opposite sides of the cover holding the rear cover onto the drive motor then back the remaining four out evenly to release the light spring pressure against the cover fig 16 25 3 Remove the rear cover to expose the brake assembly fig 16 26 16 6 Rubb...

Page 121: ...tly slide out 8 Remove the piston from the motor Inspect the seal for any damage fig 16 29 9 Inspect the seal for any damage fig 16 30 10 Remove the allen bolts securing the upper casting to the drive motor fig 16 30 11 Remove the upper casting from the drive motor to expose the clutch discs fig 16 31 12 Inspect the discs for discoloration blueing or for signs of excessive wear fig 16 32 Note If a...

Page 122: ...ching or abrasion that may affect operation fig 16 36 4 Inspect the surfaces of the cam ring and the piston rollers for imperfections Any damage found indi cates a need for component replacement fig 16 37 5 Using a snap ring pliers remove the snap and retaining rings on both sides of the piston block to allow for removal and inspection of the block pis tons piston rings and rollers fig 16 38 16 8 ...

Page 123: ... ly clean all parts then reassemble the motor by reversing the disassembly procedure Drive Pump Drive Relief Valves Disassembly Adjustment 1 With machine off and cool and with hydraulic actu ators relaxed remove the drive pump from the machine by following the procedure in section 11 2 Remove the drive pressure relief valves as shown in fig 16 42 and 16 43 3 If adjustment is needed see drive press...

Page 124: ...ease see the posi power relief valve adjustment pro cedure in section 17 of this manual 1 Remove the valve from the drive pump as shown in figure 16 46 Installation 1 To install reverse the removal procedure Drive Pump Disassembly Note The drive pump is a tandem design where two pumps share one housing The disassembly and assembly procedures are identical for both pumps 1 Remove the allen bolts se...

Page 125: ...aft as an assembly then inspect 5 Remove the swash plate along with the bearings and inspect them for any damage or scratching that could affect operation fig 16 52 16 53 6 Remove the snap ring holding the shaft seal and bearing into the casing then remove the seal fig 16 54 Note If you are repairing the existing pump you will need to replace the outer seal as it will be destroyed upon removal 16 ...

Page 126: ...asing until seated fig 16 56 2 Replace the seal with a new one and install taking care not to damage it upon installation fig 16 57 3 Install the snap ring that secures the shaft bear ing and seal in place fig 16 57 16 12 Rubber Track Loader 16 Hydraulic Component Service 16 55 16 56 Required Tools Combination Socket wrench Allen Wrench Socket Rubber Mallot Screwdriver blade type Snap RIng Pliers ...

Page 127: ...60 7 Once the pivots are installed check to make sure both of them are properly mated with the pins Using a blade type screwdriver turn the pivots slightly to the right or left The swash plate should move with the pivot as each one is turned If it does not move repeat step 6 then recheck Once correct reinstall the caps to secure them in place fig 16 61 8 Reassemble the piston and barrel portion of...

Page 128: ... onto the pump fig 16 66 5 Lift the cover off to expose the pump components and the o ring seal Inspect the o ring for damage replace if necessary fig 16 67 6 Inspect the valve plate face both sides for scratches or any other damage that can be felt with a fingernail fig 16 68 7 Inspect the barrel face for scratches or any other damage that can be felt with a fingernail fig 16 69 16 14 Rubber Trac...

Page 129: ...inspect the slipper faces for scratches or any other dam age that can be felt with a fingernail fig 16 70 Assembly 1 To reassemble reverse the disassembly proce dure 16 15 Rubber Track Loader 16 Hydraulic Component Service 16 70 Inspect Faces ...

Page 130: ...16 16 ...

Page 131: ...he filters are to be expected but If there is significant metallic debris found in either filter certain components of your hydraulic system may be contaminated To inspect for contamination label the hydraulic filters by location and remove them Cut them apart approx halfway between the top and bottom of the filter and inspect them for debris If contamination is suspected contact the ASV service d...

Page 132: ...is necessary 4 If necessary adjust the charge relief pressure To adjust a Tilt the cab as described on page 4 2 of this manual to access the pump b Locate the charge relief valve on the top of the drive pump fig 17 2 c Remove the relief valve from the top of the pump as shown in figure 17 3 d Add shims to increase the pressure setting or remove shims to decrease the setting until within specificat...

Page 133: ...hen activate the low or high flow auxiliary hydraulics with no auxiliary attachment fastened to the quick couplers This action will send oil over relief and you will read the actual pressures required to acti vate the relief valve for each circuit Do this for both the high and low flow circuits in both direc tions Record the pressure readings Check your readings against those stated below If your ...

Page 134: ...es used during this process are clean and free of contaminants that may potentially cause damage to the hydraulic pump and or system components Drive pressure is used to turn the drive motors that power your tracks Low pressure can cause decreased drive motor performance resulting in sluggish maneu vering decreased speed and or uneven forward or reverse motion 1 Remove the plug from the port you w...

Page 135: ...ch is directly related to engine rpm and adjusts drive pump flow to maximize torque and prevent engine stall during high load conditions This procedure should only be performed if you suspect that the Posi Power relief valve is faulty In performing this procedure you risk contaminating your hydraulic system if your equipment and work ing environment is not clean Make certain all couplers fittings ...

Page 136: ... and low flow auxiliary circuits If an auxiliary flow problem is suspected the following procedures should be per formed Note If an auxiliary circuit problem is suspected per form all pressure test and adjustment procedures as necessary prior to attempting the perform the flow test procedure Most issues will be solved with the pres sure test and adjustment procedures but if a problem still persist...

Page 137: ... To correct 1 Turn the adjustment screw on the pilot generation block pressure reducing valve clockwise to increase the flow within the low flow circuit until correct see page 3 5 view D item 5 to locate Problem 5 Low flow readings are higher than specified High flow is within specification To correct 1 Turn the adjustment screw on the pilot generation block pressure reducing valve counter clockwi...

Page 138: ...17 8 ...

Page 139: ...t tension and condition Hoses no visible sign of wear Fittings no apparent leaks Battery cables Fuse panel fuses in place and operational Controls for neutral A simple visual inspection and operational check can identify many problems without the need for extensive troubleshooting However if these checks indicate a problem that requires further analysis proceed to Troubleshooting General Troublesh...

Page 140: ...wire to DA control solenoid 3 Drive control joystick pilot control malfunction 4 Low charge pressure 5 Parking brake switch in on position 6 Faulty parking brake switch Problem 5 Tracks are operational but lift arms will not move Possible causes 1 Continuous hydraulic flow switch activated sending oil over relief lift arms work but move slowly If auxiliary flow hydraulics work check for a Leak in ...

Page 141: ...determine whether or not the problem lies with the machine itself or with the engine A machine problem should be repaired by an ASV dealer while an engine specific problem should only be repaired by a representative of the engine manufacturer Making this determination will ensure timely and appropriate service to help minimize down time Problem Hard starting check for 1 12V power to glow plugs Wit...

Page 142: ...18 4 ...

Page 143: ... gallon P N 0402 840 6 gallons Engine Anti freeze Coolant ASV Long Life 50 50 Antifreeze Coolant Capacity 3 125 U S gallons P N 0300 766 1 gallon P N 0402 841 6 gallons Hydraulic Oil ASV Premium All Season MV Hydraulic Oil Capacity 20 U S gallons including filters P N 0400 253 5 gallons P N 0402 833 55 gallons Grease general use ASV Multi Purpose EP Lithium Grease P N 0300 769 1 tube P N 0402 844 ...

Page 144: ...19 2 ...

Page 145: ...t 7 16 50 11 lb ft 1 2 75 15 lb ft 9 16 120 22 lb ft 5 8 160 30 lb ft 3 4 275 37 lb ft 7 8 460 60 lb ft 1 660 75 lb ft 1 1 8 960 110 lb ft 1 1 4 1320 150 lb ft 1 3 8 1780 220 lb ft 1 1 2 2280 260 lb ft Thread Size Standard Torque M6 12 3 Nm M8 28 7 Nm M10 55 10 Nm M12 100 20 Nm M14 160 30 Nm M16 240 40 Nm M20 460 60 Nm M24 800 100 Nm M30 1600 200 Nm M36 2700 300 Nm ...

Page 146: ...Terex Construction Americas 8800 Rostin Road Southaven MS 38671 888 201 6008 662 393 1800 www terex com ...

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