ASV PT50 Service & Repair Manual Download

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8/17/2016

Service Repair Manual

PT60

SN 00101-03704

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TrackLoaderParts.com

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Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-8156

Summary of Contents for PT50

Page 1: ... SN 00101 03704 English All Language Geographic Region Serial Number Range This manual is complements of TrackLoaderParts com The world s best source for ASV parts Track Loader Parts 6543 Chupp Road Atlanta Georgia 30058 USA 800 616 8156 ...

Page 2: ...2 5 Operator Enclosure Disassembly and Assembly Chapter Overview 5 1 Personal Safety 5 1 Machine Preparation 5 1 Preliminary Checkout 5 1 Operator Enclosure Disassembly and Assembly Procedures 5 1 Light Bar Removal and Installation 5 1 Light Bar Removal 5 1 Light Bar Installation 5 2 Ignition Switch Removal and Installation 5 2 Ignition Switch Removal 5 2 Ignition Switch Installation 5 3 Gauge Rem...

Page 3: ...l and Installation 10 5 Pump Drive Coupler Removal 10 5 Pump Drive Coupler Installation 10 6 11 Undercarriage Disassembly and Assembly Chapter Overview 11 1 Personal Safety 11 1 Machine Preparation 11 1 Preliminary Checkout 11 1 Undercarriage Disassembly and Assembly Procedures 11 1 Center Wheel Removal and Installation 11 1 Wheel Removal 11 2 End Wheel Removal and Installation 11 3 End Wheel Remo...

Page 4: ...e Preparation 14 1 Hydraulic Pressure Adjustment Procedures 12 1 Charge Pressure check 14 1 Charge Pressure Adjustment 14 2 Auxiliary Pressure Check Adjustment 14 2 15 Troubleshooting Chapter Overview 15 1 Personal Safety 15 1 Machine Preparation 15 1 Preliminary Checkout 15 1 Visual Inspection 15 1 Troubleshooting Scenarios 15 2 ...

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Page 6: ...uipment Note This label is used to provide important additional information comments explanations or amplification of the accompanying subject matter The person servicing the Rubber Track Loader may be unfamiliar with many of the systems on the ma chine This makes it important to use caution when performing service work Knowledge of the system and or components is important before the removal or d...

Page 7: ... electro lyte level Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating A spark can cause an explosion from the flammable vapor mixture of hy drogen and oxygen that is released from the electro lyte through the battery outlets Do not let electrolyte solution make contact with skin or eyes Electrolyte solution is an acid In case o...

Page 8: ...o stop the engine 9 Be careful when removing cover plates Gradu ally back off the last two bolts or nuts located at opposite ends of the cover or device Then pry the cover loose to relieve any spring or other pressure before removing the last two nuts or bolts completely 10 Repairs requiring welding should be performed only with the benefit of the appropriate reference information and by personnel...

Page 9: ...as bestos Use a wet method to clean up asbestos debris A vacuum that is equipped with the high efficiency particulate air filter HEPA filter can also be used 2 Use exhaust ventilation on permanent machin ing 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 ...

Page 10: ...Rubber Track Loader 1 Product Safety 1 5 Machine Label and Decal Examples Examples of the labels and decals placed on the machine are shown on this page ...

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Page 12: ...16 27 gpm 61 85 lpm 2800 rpm high idle Relief pressure 3000 psi 20 684 kPa Cooling filtering Auxiliary oil is filtered and cooled at all times In Auxiliary mode the oil is filtered after the attachment to protect the ma chine if the attachment motor fails or contami nants are introduced from the quick couplers Loader Valve Model Husko Relief pressure 3000 psi 20 684 kPa Pilot pressure required to ...

Page 13: ...cc rev Flow 16 27 gpm 61 85 lpm 2800 rpm high idle Relief pressure 3000 psi 20 684 kPa Cooling filtering Auxiliary oil is filtered and cooled at all times In Auxiliary mode the oil is filtered after the attachment to protect the ma chine if the attachment motor fails or contami nants are introduced from the quick couplers Loader Valve Model Husko Relief pressure 3000 psi 20 684 kPa Pilot pressure ...

Page 14: ...ooling system Auxiliary circuit system Drive loop system Figure 3 1 PT 50 60 Filtering and Cooling System Filtering and Cooling System The filtering and cooling system Figure 3 1 contains the following major components Hydraulic reservoir Radiator oil cooler Loader valve 3 001 3 System Diagrams 3 1 ...

Page 15: ...ystem fig 3 2 contains the following major components Loader valve Pilot control manifold Auxiliary gear pump Loader control joystick Figure 3 2 PT 50 60 Auxiliary Circuit System 3 002 3 2 Rubber Track Loader 3 System Diagrams Self leveling optional ...

Page 16: ...ol manifold Drive control joystick Tandem pump Figure 3 3 PT 50 60 Drive Loop System 3 003 3 3 Rubber Track Loader 3 System Diagrams Input Portion joystick Output Portion drive motors tank drive motor brake 2 spd 60 only case drain 2 spd 60 only brake case drain drive motor tandem pump pilot generation block tank ...

Page 17: ...Electrical Attachment Outlet Figure 3 4 PT 50 60 Electrical Attachment Outlet 3 4 Rubber Track Loader 3 System Diagrams ...

Page 18: ...orward until it contacts the pedal then release Pull back on hand lever to decrease RPM Instrumentation The Instruments Figure 4 2 are positioned in the overhead dash panel for ease of access and visibility when seated inside the operator enclosure Instruments include the following components 1 Fuel Level Gauge 2 Warning Indicator Display Engine Oil Pressure Warning Light Engine Temperature Warnin...

Page 19: ... optional switches are listed below 1 Lights front and rear 2 Heater Fan optional 3 Wiper optional 4 Beacon optional 5 Ignition glow plug pre heat 6 Auxiliary Hydraulics 7 Bucket Positioning optional 8 Power Quick Attach optional 4 2 Rubber Track Loader 4 Machine Controls and Instrumentation 4 3 1 2 3 4 5 6 7 8 ...

Page 20: ...minently on the ma chine to inform personnel that the machine is being worked on Before starting any disassembly or assembly proce dures refer to Chapter 1 Product Safety Repair for machine preparation information Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting Operator Enclosure Disassembly and Assembly Procedures Disassembl...

Page 21: ...n pry pocket and gently pry the light assembly out of the light bar Light Bar Installation Figure 5 5 5 005 1 Carefully position the light bar without pinching the wiring harness against the cab roof Figure 5 6 5 006 2 Secure the light bar to the cab roof with the two capscrews Ignition Switch Removal and Installation The tools required for ignition switch removal and installation are listed in Ta...

Page 22: ... ignition switch out from the rear of the dash panel Figure 5 9 5 009 4 Unplug the ignition switch connector Ignition Switch Installation Figure 5 10 5 010 1 Insert the ignition switch from the rear of the dash panel Figure 5 11 5 011 2 Install the nut that secures the ignition switch to the dash panel Figure 5 12 5 012 3 Plug in the ignition switch connector Remove Nut Install Nut ...

Page 23: ...5 3 Required Tools Combination wrench Gauge Removal 1 Lower the light bar Refer to Chapter 5 Light Bar Removal procedure Figure 5 13 5 013 2 Disconnect the connector from the gauge Figure 5 14 5 014 3 Remove the two nuts that secure the gauge to the retaining bracket Figure 5 15 5 015 4 Pull the gauge out from the front of the dash panel Gauge Installation Figure 5 16 5 016 1 Insert the gauge from...

Page 24: ...ssist Spring Removal Raise Lap Bar Shown in Down Position Gas Assist Spring Figure 5 19 5 019 1 Put the lap bar in the UP position to relieve ten sion on the lap bar gas assist spring Remove Retaining Clip Figure 5 20 5 020 2 Using a small screwdriver remove the retaining clip from each end of the gas assist spring Figure 5 21 5 021 3 Remove the gas assist spring by pulling both ends out from the ...

Page 25: ...sembly and Assembly 5 6 Install Endson Ball Joints Figure 5 23 5 023 2 Install the ends of the lap bar gas assist spring onto the ball joints Insert RetainingClip Figure 5 24 5 024 3 Slide the retaining clip on to each end of the gas assist spring ...

Page 26: ...ominently on the ma chine to inform personnel that the machine is being worked on Before starting any disassembly or assembly proce dures refer to Chapter 1 Product Safety Repair for machine preparation information Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting Chassis Disassembly and Assembly Procedures Disassembly and asse...

Page 27: ...ab Plug in the Connector Figure 6 5 6 002 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 insert Seat Bolts Figure 6 6 6 001 3 Position the seat so the holes in the seat mounts are aligned with the bolts in the frame Install the four seat mount nuts and washers Fuel Sending Unit ...

Page 28: ...wires are crossed the fuel gauge will not work If the hoses are crossed the engine will not run Figure 6 8 6 005 4 Remove the fuel sending unit Be careful not to damage the float mechanism when pulling it through the opening in the fuel tank Figure 6 9 6 006 5 The fuel pickup line will also come out with the fuel sending unit Fuel Sending Unit Installation Figure 6 10 6 006 1 Insert the fuel picku...

Page 29: ... movement of the float 3 Connect the hoses and wires to the fuel sending unit and then install the screws that fasten the unit to the tank Note Be careful not to cross the wires or hoses If the fuel sending unit wires are crossed the fuel gauge will not work If the hoses are crossed the engine will not run 4 Install the seat Refer to Chapter 6 Seat Instal lation procedure ...

Page 30: ...ry tape the clamps and remove the key Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Before starting any disassembly or assembly proce dures refer to Chapter 1 Product Safety Repair for machine preparation information Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooti...

Page 31: ... 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 WARNING Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to the heat ers and the engine contain hot coolant and steam Contact can cause severe b...

Page 32: ... lower hose from the oil cooler sec tion Cap the hose and fitting Figure 7 4 7 002 4 Remove the upper hose from the oil cooler sec tion Cap the hose and fitting Figure 7 5 7 011 5 Remove the upper hose from the radiator sec tion Cap the hose and fitting Figure 7 6 7 012 6 Remove the lower hose from the radiator sec tion Cap the hose and fitting Figure 7 7 7 003 Remove Hose Remove Bolts ...

Page 33: ...mpartment Radiator Cooler Installation Figure 7 9 7 013 1 Install the engine shroud and position the radia tor cooler in the engine compartment Figure 7 10 7 003 2 With the radiator cooler in position install the three mounting bolts on each side of the radia tor cooler Figure 7 11 7 012 3 Remove the hose and fitting caps and install the lower hose on the radiator section Figure 7 12 7 011 Install...

Page 34: ...the radiator section Figure 7 13 7 002 5 Remove the hose and fitting caps and install the upper hose on the oil cooler section Figure 7 14 7 010 6 Remove the hose and fitting caps and install the lower hose on the oil cooler section 7 Close the petcock and fill the radiator with cool ant and the hydraulic reservoir with oil Install Hose ...

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Page 36: ...the machine to inform personnel that the machine is being worked on Before starting any disassembly or assembly procedures refer to Chapter 1 Product Safety Repair for machine preparation information Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting Hydraulic Reservoir Disassembly and Assembly Procedures Disassembly and assembl...

Page 37: ...voir 3 Remove the filter manifold assembly Reverse steps for installation Access Cover Removal and Installation The tools required for access cover removal and installation are listed in Table 8 2 Use manufacturer recommended tools whenever possible Table 8 2 Required Tools Combination Wrench Access Cover Assembly Removal WARNING Hot oil can cause personal injury Make sure the oil is cool before r...

Page 38: ... 8 3 Use manufacturer recommended tools whenever possible Table 8 3 Required Tools Combination Wrench Reservoir Gauge Removal WARNING Hot oil can cause personal injury Make sure the oil is cool before removing any components or lines Remove the oil filler cap only when the engine is stopped and the machine has been allowed to cool thoroughly NOTICE Collect and contain liquids in a suitable contain...

Page 39: ...8 10 8 018 1 Install the reservoir gauge in the reservoir using the two mounting bolts washers Figure 8 11 8 017 2 Reach inside the reservoir and install the two nuts that secure the reservoir gauge to the reservoir 3 Install the filter assembly Refer to Chapter 8 Filter Assembly Installation 4 Add manufacturer approved hydraulic fluid Suction Screen Removal and Installation The tools required for...

Page 40: ...fluid Refer to Chapter 13 Hydraulic Fluid and Filter Change 2 Remove the access cover assembly Refer to Chapter 8 Access Cover Assembly Removal Figure 8 12 8 014 3 With a magnet centered in an absorbent rag thoroughly clean the interior of the reservoir to prevent any debris from entering the system when you remove the suction filter Figure 8 13 8 015 4 Reach inside the reservoir and unscrew the s...

Page 41: ... 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 NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates 1 Drain the hydraulic fluid Refer to Chapter 13 Hydraulic Fluid and Filter Change 2 Remove the access cover assembly R...

Page 42: ... bly refer to Chapter 15 Troubleshooting Loader Transmission Controls Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following loader transmission control compo nents Drive Control Joystick Loader Control Joystick Loader Float Magnet Loader Valve Self Level Valve Note Procedures are provided for only those loader transmission control components listed ...

Page 43: ...s described below Note During disassembly cap and plug all hoses and fittings to prevent fluid loss and contamination of the system fluids Relax all hydraulic circuits controls and make sure the oil is cool before disconnecting any compo nent or line from the system Pressurized and or hot hydraulic fluid can cause personal injury 1 Remove the seat from the machine according to the procedure in cha...

Page 44: ...ne equipped with a heater you must disconnect the cool heater lines at the heater unit in order to remove the side panel Cap and plug hoses and ports to minimize coolant loss Loader Float Magnet Removal and Installation The tools required for loader float magnet removal and installation are listed in Table 9 2 Use manufacturer recommended tools whenever possible Table 9 2 Loader Float Magnet Remov...

Page 45: ...ll attach ments and make sure the oil is cool before remov ing any components or lines Remove the oil filler cap only when the engine is stopped and the machine has been allowed to cool thoroughly NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and ...

Page 46: ...he rear valance panel to the chassis to allow for removal Figure 9 14 9 014 8 Carefully remove the rear valance from the machine to allow access to the loader valve Figure 9 15 9 015 9 Locate the loader valve on the side of the hydraulic reservoir Figure 9 16 9 016 10 Disconnect all of the tubes from the loader valve Cap and plug all openings to prevent fluid loss 9 5 Rubber Track Loader 9 Loader ...

Page 47: ...each full mark Figure 9 19 9 019 Self Level Valve Removal and Installation The tools required for loader valve removal and instal lation are listed in Table 9 4 Use manufacturer recom mended tools whenever possible Table 9 4 Loader Valve Removal Hot oil can cause personal injury Lower all attach ments and make sure the oil is cool before remov ing any components or lines NOTICE Collect and contain...

Page 48: ...y proce dures refer to Chapter 1 Product Safety Repair for machine preparation information Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting Hydrostatic and Hydraulic Pump Disassembly and As sembly Procedures Disassembly and assembly procedures are provided for the following transmission and drive components Auxiliary Gear Pump...

Page 49: ...and contamination of the system fluids 1 Lower the lift arms to the ground 2 Turn the ignition switch to the OFF position 3 Relieve any pressure from the auxiliary hydraulic circuit 4 Drain the hydraulic fluid Refer to Chapter 13 Hydraulic Fluid and Filter Change 5 Remove the seat Refer to Chapter 6 Seat Re moval Figure 10 1 10 001 6 View with seat removed Figure 10 2 10 002 7 Remove the access co...

Page 50: ...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 NOTICE 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 prevent fluid loss and contamination of the system fluids ...

Page 51: ...he left hand side of the tandem pump then remove as shown Figure 10 9 10 010 Tandem Pump Installation Figure 10 10 10 010 Figure 10 11 1 Install the pump and mounting bolts washers as found upon removal Apply blue loctite to the threads of each bolt then tighten to 85 ft lb Figure 10 12 10 008 2 Reconnect the hoses and tubes to the tandem pump as found upon removal 3 Install the auxiliary gear pum...

Page 52: ...ntain liquids in a suitable 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 1 Lower the lift arms to the ground 2 Turn the ignition switch to the OFF position 3 Relieve hydraulic pressure from the auxiliary circuit 4 Drain the hydraulic fluid Refer to Chapter...

Page 53: ...cking screw that secures the pump drive coupler to the tandem pump drive shaft 3 Install the tandem pump Refer to Chapter 10 Tandem Pump Installation 4 Install the auxiliary gear pump Refer to Chapter 10 Auxiliary Gear Pump Installation 5 Install the seat Refer to Chapter 6 Seat Instal lation 6 Add fuel and manufacturer approved hydraulic fluid Tandem Pump Drive Shaft Pump Drive Coupler Tighten Lo...

Page 54: ... Place a Do Not Operate tag prominently on the machine to inform personnel that the machine is being worked on Before starting any disassembly or assembly procedures refer to Chapter 1 Product Safety Repair for machine preparation information Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting Undercarriage Disassembly and Assemb...

Page 55: ...006 3 Using a large channel lock pliers remove the wheel cap Figure 11 3 11 007 Figure 11 4 11 008 4 Using a socket remove the nut that fastens the wheel to the shaft Remove the wheel with the wheel extractor Inside Wheel Figure 11 5 11 009 5 To remove an inside wheel slide under the machine and repeat the wheel removal procedure Figure 11 6 11 010 6 With wheels removed inspect the bearings and ax...

Page 56: ...the turnbuckle as shown to lower the drive table and create slack in the track Figure 11 9 11 013 3 Remove the bolts securing the wheel to the hub Figure 11 10 11 014 4 Slide the track outward as you pull on the wheel to remove the wheel Installation 1 To install the end wheels reverse the removal pro cedure Torque the end wheel mounting bolts upon installation to 95 10 Lb Ft 11 3 Rubber Track Loa...

Page 57: ...rack Removal and Installation The tools required for track removal and installation are listed in table 11 4 Use manufacturer recommend ed tools whenever possible Table 11 4 Removal 1 Perform the end wheel removal procedure located on page 11 3 of this chapter Figure 11 13 11 017 2 Once the wheel has been removed pull the track off of the front of the undercarriage then lift over the drive sprocke...

Page 58: ...mponents Remove the mounting plate from the machine Figure 11 17 11 021 3 Use a hammer to tap around the perimeter of the bearing cap This will relieve the outward pressure on the housing and allow the cap to be removed Figure 11 18 11 022 4 Use a snap ring pliers to remove the snap ring retainer from the shaft as shown Figure 11 19 11 023 5 Use a puller to remove the bearing assembly from the mac...

Page 59: ...he drive motor are listed in table 11 7 Use manufacturer rec ommended tools whenever possible Table 11 7 Removal 1 Perform the drive sprocket removal procedure as described on page 11 6 of this chapter Figure 11 21 11 025 2 Remove the bolts securing the drive motor to the drive table as shown Figure 11 22 11 026 3 Disconnect the various hoses from the drive motor noting their positions and orienta...

Page 60: ... hub assembly from the axle shaft fig 11 23 see note below Note If you are removing either of the the inner hub assemblies you must slide the axle item 30 out of the main rail weldment to remove it fig 11 24 4 Using a press and tool 0403 550 press the bearing sleeve out of the hub assembly fig 11 25 11 26 11 7 Rubber Track Loader 11 Undercarriage Disassembly and Assembly 11 23 11 24 Axle 11 25 11 ...

Page 61: ... 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 If the bearings do not roll smooth ly when rotated replace them If the seals appear worn or damaged replace them If the wheels are worn ...

Page 62: ...e rear seal retaining ring into the assembly with tool 0403 547 and exten sion 0403 550 apply blue loc tite around the ring sealing surface in the hub prior to installation fig 11 33 11 34 12 Install the face seal and rubber ring into the retain er as shown Make sure the parts are clean and dry and that the rubber ring seats into the retainer fig 11 35 13 Once the seals are in place wipe the matin...

Page 63: ...the center seal into the hub Work the lip around the bearing sleeve with your fingers prior to pressing it into place fig 11 41 18 Install the front race into the hub as shown above the seal When the race is pressed into place it will push the seal into position fig 11 42 19 Install the bearing cleaned dried and repacked with ASV Multi Purpose EP Lithium Grease onto the bearing sleeve as shown Pre...

Page 64: ...b as shown then reinstall the plug and tighten fig 11 46 23 The hub assembly is now ready to be reinstalled To install it onto the machine reverse steps 1 3 on page 11 7 of this procedure Make sure to read the note below step 3 prior to reinstalling 24 Repeat this procedure throughout the undercar riage as necessary to repair worn or damaged components and restore proper function 11 11 Rubber Trac...

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Page 66: ...fety Repair for machine preparation information Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting Loader Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following loader components Lift Cylinders Tilt Cylinders Low Flow Relief Valve Note Procedures are provided for only those loader ...

Page 67: ...onto a jackstand with the arms resting about 6 inches off the ground 2 Turn the ignition switch to the OFF position Figure 12 1 12 001 3 Remove the bolt on the pin assembly on the loader tower Figure 12 2 12 002 4 Remove the pin assembly Figure 12 3 12 003 5 Remove and cap the hose on the base end of the cylinder Figure 12 4 12 004 6 Remove and cap the hose on the loader end of the cylinder Figure...

Page 68: ...val and Installation The tools required for low flow relief valve removal and installation are listed in Table 12 2 Use manufacturer recommended tools whenever possible Table 12 2 Required Tools Combination Wrench Socket Wrench Pressure Release Valve Removal WARNING Hot oil can cause personal injury Lower all attachments and make sure the oil is cool before removing any components or lines NOTICE ...

Page 69: ...all hoses Figure 12 10 12 009 5 Remove the four bolts that secure the low flow relief valve to the loader frame and remove the valve Quick Coupler Block Pressure Release Valve Installation Figure 12 11 12 009 1 Install the four bolts that secure the low flow relief valve to the loader frame Figure 12 12 12 009 2 Install all hoses Remove Tubes Remove Bolts Install Bolts Install Tubes ...

Page 70: ... Coolant Caterpillar Extended Life Coolant or equivalent antifreeze with the proper SCA Supplemental Cooling Additive Engine Oil Regular oil changes are necessary to maintain a strong running engine ASV recommends a normal oil change interval of 250 hours or every six months This recommendation has been made to help en sure proper lubrication during operation and to pro long engine life under typi...

Page 71: ... Before starting the procedure make sure the ma chine is in a clean working environment Precautions should be taken to prevent any debris from entering the hydrostatic system NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Figure 16 2 16 002 1 Locate and remove the hydraulic fluid drain plug and drain the fluid into a su...

Page 72: ...stem according to the proce dure at the end of this chapter Fuel Specifications In North America diesel fuel distilled from crude oil and identified as NO 1 D or No 2 D in ASTM D975 generally meets the proper specifications Air Cleaner The air cleaner is one of the most important mainte nance items on the machine A poorly maintained air cleaner can seriously shorten the life of the engine Air Filt...

Page 73: ...e jam nut on the track tensioner and clean the threads thoroughly before proceeding 2 Loosen the jam nut You can use the wrench supplied with the machine but a standard wrench is preferred for shop use Figure 16 9 16 007 3 After loosening the jam nut turn the track ten sioner until the track tension is within specifica tions 4 Once proper tension is achieved retighten the jam nut Checking for Prop...

Page 74: ...0 50 and 0 75 Fuse Box Figure 16 12 16 012 The fuse box is located on the left side of the engine compartment The machine should never be oper ated with the fuse box cover removed Grease Fittings Figure 16 13 16 013 The locations of the grease fittings for the left side of the machine are shown above An identical set of fittings is located on the right side of the machine These fitting should be l...

Page 75: ...uired Tools Combination Wrench If the machine has been run out of fuel it may be necessary to bleed the fuel system Figure 11 25 11 006 1 Locate the bleed screw directly above the fuel injection pump 2 Loosen the bleed screw two full turns Figure 11 27 11 004 3 Pump the bulb primer with your hand until fuel flows from the bleed screw without any air bub bles 4 Tighten the bleed screw Bleed Screw ...

Page 76: ...NG Accidental machine starting can cause injury or death to personnel working on the machine To avoid accidental machine starting disconnect the battery cables from the battery tape the clamps and remove the key Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Before starting any disassembly or assembly proce dures refer to Chapter 1 Pr...

Page 77: ...st port Auxiliary Pressure Check Adjustment The service tools required for the auxiliary pressure check and adjustment are listed in Table 14 1 Use manufacturer recommended tools whenever possi ble Table 14 2 Required Tools Pressure Gauge Allen Wrench Figure 14 3 14 110 Insert the hydraulic gauge into one of the attachment quick couplers Figure 14 4 14 111 1 Engage the continuous flow switch next ...

Page 78: ...4 113 4 To adjust the auxiliary pressure loosen the jam nut and turn the adjustment screw in with an al len wrench to increase pressure and turn screw out to decrease pressure Tighten jam nut when after adjustment has been made DO NOT ex ceed 3 000 psi Jam Nut Adjustment Screw ...

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Page 80: ...ause injury or death to personnel working on the machine To avoid accidental machine starting disconnect the battery cables from the battery tape the clamps and remove the key Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Before starting any troubleshooting procedures re fer to Chapter 1 Product Safety Repair for ma chine preparation...

Page 81: ... Poor ground check ground wires on bottom left rear side of hydraulic reservoir 5 Safety relay is not activating 6 Faulty safety solenoid or safety solenoid spool 7 Poor wire connections on fuse relay or safety sole noid 8 Low charge pressure Problem 4 Loader operates but tracks will not move Probable cause 1 Leak in feed line to pilot control 2 Pilot control malfunctioning 3 Low pilot pressure Pr...

Page 82: ...ent magnet Problem 13 Loader will not float labors engine and has down pressure when detented into float Probable cause 1 Engine RPM too low 2 Low charge pressure 3 Pilot control malfunction 4 Loader valve malfunction Problem 14 Hot oil light illuminates hydraulic system operating hot Probable cause 1 Auxiliary hydraulic switch activated sending oil over relief 2 Low oil level 3 Debris plugging oi...

Page 83: ...Terex Construction Americas 8800 Rostin Road Southaven MS 38671 888 201 6008 662 393 1800 www terex com ...

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