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Terex PT100G Forestry, Руководство по обслуживанию

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1. Product Safety

Chapter Overview . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . 1-1
Information Messages . . . . . . . . . . . . . . . . . 1-1
Basic Precautions . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Labels . . . . . . . . . . . . . . . . . . . . . . . 1-1
Protective Equipment . . . . . . . . . . . . . . . . 1-1
Entering and Exiting . . . . . . . . . . . . . . . . . 1-2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Hot Fluids and Components . . . . . . . . . . . 1-2
Corrosion Inhibitor . . . . . . . . . . . . . . . . . . . 1-2
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Pressurized Items . . . . . . . . . . . . . . . . . . . 1-2

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Machine Labels and Decals . . . . . . . . . . . . . 1-4

Product Identification Number . . . . . . . . . . 1-4
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . 1-4

2. Technical Specifications

Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Transmission . . . . . . . . . . . . . . . . . . . . . . . 2-1

Drive Pumps . . . . . . . . . . . . . . . . . . . . . . 2-1
Charge Pump . . . . . . . . . . . . . . . . . . . . . 2-1

Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . 2-1
Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 2-1

Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Critical Torque Specifications . . . . . . . . . . . . 2-1
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3. Circuit Diagrams

Chapter Overview . . . . . . . . . . . . . . . . . . . . . 3-1
Hydraulic Charge Circuit . . . . . . . . . . . . . . . . 3-1
Hydraulic Auxiliary Circuit . . . . . . . . . . . . . . . 3-2
Hydraulic Control Circuit . . . . . . . . . . . . . . . . 3-3
Hydraulic Drive Circuit . . . . . . . . . . . . . . . . . 3-4

Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 3-5
Hydraulic Solenoid Blocks . . . . . . . . . . . . . . 3-6
Electrical Attachment Outlet . . . . . . . . . . . . . 3-7

4. Maintenance

Chapter Overview . . . . . . . . . . . . . . . . . . . . . 4-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 4-1
Lift-Arm Brace . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Tilt-up Cab . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Jacking Procedure . . . . . . . . . . . . . . . . . . . . 4-2
Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . 4-3
Undercarriages . . . . . . . . . . . . . . . . . . . . . . . 4-3
Track Tension . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Planetary Oil Change . . . . . . . . . . . . . . . . . . 4-4
Drive Sprocket Rollers . . . . . . . . . . . . . . . . . 4-5

Track Removal . . . . . . . . . . . . . . . . . . . . . . . 4-6

Track Installation . . . . . . . . . . . . . . . . . . . . . . 4-8

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Water Separator . . . . . . . . . . . . . . . . . . . . . . 4-11
Belt Removal/Installation . . . . . . . . . . . . . . . 4-11

Engine Oil/FIlter Change . . . . . . . . . . . . . . . 4-12

Engine Oil Specifications . . . . . . . . . . . . . . . 4-13

Oil Level Check . . . . . . . . . . . . . . . . . . . . . . 4-13

Hydraulic Fluid/Filter Change . . . . . . . . . . . . 4-14

Radiator/Oil Cooler (cleaning) . . . . . . . . . . . 4-15

Engine (cleaning) . . . . . . . . . . . . . . . . . . . . . 4-15
Case Drain Filter . . . . . . . . . . . . . . . . . . . . . . 4-16
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Maintenance Schedule . . . . . . . . . . . . . . . . . 4-17

5. Machine Controls and Instrumentation

Chapter Overview . . . . . . . . . . . . . . . . . . . . . 5-1
Machine Controls . . . . . . . . . . . . . . . . . . . . . 5-1
Lift Arm Control . . . . . . . . . . . . . . . . . . . . . . . 5-1
Drive Control . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . 5-1

Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

6. Operator Enclosure

Chapter Overview . . . . . . . . . . . . . . . . . . . . . 6-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 6-1
Machine Preparation . . . . . . . . . . . . . . . . . . . 6-1
Removal & Installation . . . . . . . . . . . . . . . . . 6-1

Lap Bar Gas Spring . . . . . . . . . . . . . . . . . . 6-1

Removal Procedure . . . . . . . . . . . . . . . . 6-1
Installation Procedure . . . . . . . . . . . . . . 6-2

Dash Pod Covers . . . . . . . . . . . . . . . . . . . 6-2

Removal Procedure . . . . . . . . . . . . . . . . 6-2
Installation Procedure . . . . . . . . . . . . . . 6-2

Side Panels . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Removal Procedure . . . . . . . . . . . . . . . . 6-3
Installation Procedure . . . . . . . . . . . . . . 6-3

Pillar Harness Panel . . . . . . . . . . . . . . . . . . . 6-3

Removal Procedure . . . . . . . . . . . . . . . . 6-3
Installation Procedure . . . . . . . . . . . . . . 6-3

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Removal Procedure . . . . . . . . . . . . . . . . 6-4
Installation Procedure . . . . . . . . . . . . . . 6-4

Headliner . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Removal Procedure . . . . . . . . . . . . . . . . 6-4
Installation Procedure . . . . . . . . . . . . . . 6-4

Table of Contents

I

Содержание PT100G Forestry

Страница 1: ...PT 100G PT 100G Forestry Part Number 2076 286 Printed 8 10 Service Manual Compact Track Loader...

Страница 2: ......

Страница 3: ...ocedure 4 2 Grease Fittings 4 3 Undercarriages 4 3 Track Tension 4 4 Planetary Oil Change 4 4 Drive Sprocket Rollers 4 5 Track Removal 4 6 Track Installation 4 8 Air Cleaner 4 10 Fuel Filter 4 11 Wate...

Страница 4: ...tion Procedure 9 5 Suction Screen 9 5 Removal Procedure 9 5 Installation Procedure 9 5 10 Lift Arm Drive Controls Chapter Overview 10 1 Personal Safety 10 1 Machine Preparation 10 1 Removal Installati...

Страница 5: ...ssembly 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 5 Drive Pump Drive Relief...

Страница 6: ......

Страница 7: ...is not specifically recommended by Terex you must satisfy yourself that it is safe for you and others You must also ensure that the machine will not be damaged or be made unsafe by the operation lubri...

Страница 8: ...is released from the electrolyte through the battery outlets Do not let electrolyte solution make contact with skin or eyes Electrolyte solution is an acid In case of contact immediately wash skin wit...

Страница 9: ...d with the guid ance of appropriate reference information Determine the type of metal being welded and select the correct welding procedure and filler material to provide a weld that is as strong or s...

Страница 10: ...x replacement parts or parts that meet or exceed original specifications including but not limited to physical dimensions type strength and material Installing lesser components can lead to premature...

Страница 11: ...serious injury or death WARNING NOTICE DANGER Explosion Burn Hazard Will cause death burns or blindness due to ignition of explosive gasses or contact with corrosive acid Keep all flames sparks away N...

Страница 12: ......

Страница 13: ...3 kPa Cooling filtering Oil is filtered and cooled at all times In auxiliary mode the oil is filtered after the attachment to protect the machine if the attach ment motor fails or contaminants are int...

Страница 14: ......

Страница 15: ...c control circuit hydraulic drive cir cuit lift arm control valve hydraulic solenoid blocks and electrical attachment outlet Figure 3 1 PT 100G Hydraulic Charge Circuit Hydraulic Charge Circuit 3 Circ...

Страница 16: ...t Figure 3 2 PT 100G Hydraulic Auxiliary Circuit 3 2 Compact Track Loader 3 Circuit Diagrams TO HIGH FLOW AUX Q C AUXILIARY PUMP LIFT ARM VALVE AUXILIARY PUMP INLET TO LOW FLOW AUX Q C FROM ATTACHMENT...

Страница 17: ...rol Circuit Figure 3 3 PT 100G Hydraulic Control Circuit 3 3 Compact Track Loader 3 Circuit Diagrams LIFT ARM CONTROL VALVE TO LIFT ARM CYL TO BUCKET CYL TO POWER Q A TO TANK CHARGE PRESSURE TEST PORT...

Страница 18: ...T 100G Hydraulic Drive Circuit 3 4 Compact Track Loader 3 Circuit Diagrams DRIVE MOTOR DRIVE PUMP CASE DRAIN TO COOLER BRAKE 2 SPEED SHIFT DRIVE MOTOR CHARGE PRESSURE RELIEF 400 2758 kPa DRIVE PRESSUR...

Страница 19: ...alve 3 5 Compact Track Loader 3 Circuit Diagrams RELIEF VALVE SETTINGS 3989 PSI 27500 kPa 3989 PSI 27500 kPa 4206 PSI 29000 kPa 3481 PSI 24000 kPa 3989 PSI 27500 kPa 4496 PSI 31000 kPa 3989 PSI 27500...

Страница 20: ...Hydraulic Solenoid Blocks Figure 3 6 PT 100G Hyd Solenoid blocks 3 6 Compact Track Loader 3 Circuit Diagrams...

Страница 21: ...Electrical Attachment Outlet Figure 3 7 PT 100G Electrical Attachment Outlet 3 7 Compact Track Loader 3 Circuit Diagrams...

Страница 22: ......

Страница 23: ...orted 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 ma...

Страница 24: ...lift arms if raised per page 4 1 Jacking Procedure Occasionally your machine may need to be suspended off of the ground to perform maintenance Exercise caution when jacking the machine Always use a j...

Страница 25: ...te in harsh working conditions They work in mud gravel debris and various other abrasive materials during operation Terex recommends a daily inspection of the undercarriage assemblies and cleaning if...

Страница 26: ...e 4 8 4 Measure from the bottom of the straight edge to the lug surface top of the track The deflection should measure between 3 4 and 1 1 9 2 5 cm To adjust track tension fig 4 9 1 Loosen the lock nu...

Страница 27: ...sprocket to be removed 2 Remove the sprocket mounting bolts 2 to release sprocket from drive motor then remove the sprocket Note You may need to pry or lift the track upwards with a hoist above the d...

Страница 28: ...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 thr...

Страница 29: ...then remove the wheel fig 4 18 4 19 8 Use a pry bar to peel the track over the inner wheel s toward the outside of the machine fig 4 20 9 Once the track is off of the front wheel s pull the rear of t...

Страница 30: ...pward slightly and in position to slide over the inner idler wheel 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 pro...

Страница 31: ...om spinning as you torque the mounting bolts fig 4 31 10 Install the scraper onto the suspension rail and tighten the bolts to secure it in place fig 4 32 11 Install the outer idler wheel and secure i...

Страница 32: ...nstall the new secondary filter element into the enclosure as found upon disassembly fig 4 37 6 Install the primary element by sliding it into place in the enclosure as found upon disassembly 7 Instal...

Страница 33: ...embly 5 Install the new filter element into the assembly by reversing steps 2 4 Water Separator The water separator item A fig 4 38 removes water from the fuel supply as the engine runs Drain the wate...

Страница 34: ...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 If the old filter gasket fig 4 42 item A is not removed from the fil...

Страница 35: ...ood to gain access to the engine compartment 3 Locate and remove the engine oil dipstick from its tube fig 4 44 item A 4 Wipe the dipstick with a clean shop cloth and re insert it into the tube until...

Страница 36: ...to installing the new filters 9 Prepare the new filters by rubbing a small amount of fresh hydraulic oil onto the filter gasket surface and then threading them onto their respective filter heads Tight...

Страница 37: ...criptio of the operations manual and is cool 2 Wear any appropriate safety clothing 3 Clean the radiator oil cooler using compressed air or a pressure washer and direct spray forward as shown Note Mak...

Страница 38: ...hich is located behind the panel cover in the right rear corner of the interior of the cab behind the operator seat In the event of an electrical malfunction the most logical place to start is at the...

Страница 39: ...ily Adjust tension as necessary Air cleaners Inspect Daily Replace if damaged or heavily soiled Radiator oil cooler Inspect Daily Clean often as necessary Undercarriages Inspect Daily Clean often as n...

Страница 40: ......

Страница 41: ...elec trical signals to attachments connected to the outlet located at the end of the lift arms Throttle The mechnical foot throttle floor mounted pedal item 3 controls engine rpm Instrumentation The...

Страница 42: ...ion Switch optional 3 Air Temperature Control optional 4 Work Light Switch 5 Bucket Positioning Switch optional 6 High Flow Aux Switch forward 7 High Flow Aux Switch reverse 8 Power Quick Attach Switc...

Страница 43: ...eath to personnel working on a Compact Track Loader As a precaution disconnect the battery cables from the battery terminals tape the battery clamps and remove the key from the ignition switch prior t...

Страница 44: ...pose the connectors Disconnect the switches and display from the cab harness then remove the cover fig 6 5 Note The connectors on the harness are labeled as are the wires in the cover Use these labels...

Страница 45: ...utlet then remove the panel from the machine fig 6 9 Installation 1 To install the side panels reverse the removal procedure Pillar Harness Panels Removal 1 Remove the fasteners securing the pillar pa...

Страница 46: ...val procedure Headliner Removal 1 Remove the finishing caps with a blade type screwdriver to gain access to screws as shown fig 6 14 2 Remove all screws with a phillips screwdriver fig 6 15 3 Lower th...

Страница 47: ...tery clamps and remove the key from the ignition switch prior to performing any service work on a Compact Track Loader Place a Do Not Operate tag prominently on the machine to inform personnel that th...

Страница 48: ...clamps that secure the return and vent hoses to the left and right rear of the fuel tank fig 7 5 4 Disconnect and plug the ends of the hoses to prevent fuel leakage 5 Carefully remove the zip tie fro...

Страница 49: ...7 9 9 Lift and remove the tank from the machine fig 7 10 Installation 1 To install the fuel tank reverse the removal procedure Footwell Removal 1 Raise and support the lift arms as described on page...

Страница 50: ...lation 1 To install the footwell reverse the removal procedure Foot Throttle Assembly Removal Note The foot throttle assembly may be removed with the footwell still installed in the machine 1 Perform...

Страница 51: ...from hood spring tension bracket on each side of machine fig 7 17 2 Attach lifting device with hood in open position as shown in 7 18 3 Remove the allen head bolts from each side of the hood hinges fi...

Страница 52: ......

Страница 53: ...rsonnel working on a Compact Track Loader As a precaution disconnect the battery cables from the battery terminals tape the battery clamps and remove the key from the ignition switch prior to performi...

Страница 54: ...ow clearance to remove the shroud and fan fig 8 3 2 Remove the bolts 6 securing the radiator and shroud to the radiator support fig 8 4 3 Push the shroud forward to allow access to the fan mounting bo...

Страница 55: ...8 8 5 Remove the upper hydraulic cooler hose Cap or plug the exposed ends of the engine cooler and hose upon removal fig 8 9 6 Loosen and disconnect the lower hydraulic line from the cooler Cap and pl...

Страница 56: ...d ends of the radiator and hose fig 8 11 8 12 8 Tilt the radiator rearward and then remove it from the machine fig 8 13 9 Tilt the fan shroud rearward and remove it from the machine fig 8 14 Installat...

Страница 57: ...n procedures are provided for the following hydraulic components Hydraulic Reservoir tank Suction Screen Note Procedures are provided for only those hydraulic components listed above However exploded...

Страница 58: ...Using one wrench keep the pilot tube steady to ensure it does not twist with another wrench separate the tubes Then remove the pressure tube from the machine fig 9 4 9 Loosen the hose clamp on bottom...

Страница 59: ...cted to the hydraulic filter Then remove cooler inlet tube from the check valve adapter fig 9 9 Both tubes can then be removed from the machine 14 Remove both the auxiliary inlet and return hoses from...

Страница 60: ...the tubes to be removed 18 Remove the hydraulic oil fill tube and other hoses from the top of the tank on each side fig 9 14 19 Disconnect the lower hoses on the back of the tank on each side fig 9 15...

Страница 61: ...any tubes hoses connected to the flange weldment that may interfere with removal 3 Remove the bolts and washers 12 securing the flange to the hydraulic reservoir 4 Slide the assembly out of the reser...

Страница 62: ......

Страница 63: ...ttery terminals tape the battery clamps and remove the key from the ignition switch prior to performing any service work on a Compact Track Loader Place a Do Not Operate tag prominently on the machine...

Страница 64: ...the lower portion of the boot to the joystick body then lift it upwards figure 10 2 5 Remove the four bolts to disconnect the joystick from the mount fig 10 3 6 Disconnect wire harness from joystick f...

Страница 65: ...bolts 3 securing the loader valve to the chassis then remove the valve fig 10 9 Note The carriage bolts have a partial square shank that mates with a square hole in the chassis to keep them from rota...

Страница 66: ......

Страница 67: ...hydraulic component service according to the procedure described on page 4 14 Removal and Installation Removal and installation procedures are provided for the following hydraulic components Charge Pu...

Страница 68: ...rt debris from entering the engine during operation Auxiliary Pump Removal 1 Raise and support lift arms as described on page 4 1of this manual 2 Turn the ignition switch to the OFF position and remov...

Страница 69: ...ing disassembly plug and cap hoses and fittings to prevent fluid loss and or contamination 1 Perform the auxiliary pump removal procedure found in this chapter 2 Disconnect the case drain hose from th...

Страница 70: ...moving the hose once the tandem pump has been removed 7 Attach a lifting device to elevate and secure the tandem pump as it is disconnected from the engine Lift up to approximately 1 2 fig 11 12 8 Det...

Страница 71: ...rocedure from page 4 5 of this manual Note Label the drive hoses drive motor and drive table to ensure correct installation and proper orientation during reassembly 3 Remove the hoses from the drive m...

Страница 72: ...sliding it away from the chassis and then out of the drive table fig 11 19 Installation 1 To install the drive motor into the undercarriage reverse the removal procedure Compact Track Loader 11 Hydrau...

Страница 73: ...ompact Track Loader As a precaution disconnect the battery cables from the battery terminals tape the battery clamps and remove the key from the ignition switch prior to performing any service work on...

Страница 74: ...ll it away from the studs fig 12 5 4 Remove the tension springs that secure the middle pipe section to the head upper pipe and muffler inlet lower pipe fig 12 6 5 Remove the upper and middle pipe sect...

Страница 75: ...th a rubber mallet or dead blow hammer to loosen the joints fig 12 10 Note Use caution not to damage the pipe or connection point during removal Note Use caution when striking the pipes with a mallet...

Страница 76: ...e yellow slide lock on the air cleaner housing outward as shown Next turn the cover approximately 1 8 turn CCW and pull to remove fig 12 15 3 Remove the primary element filter fig 12 16 4 Remove the s...

Страница 77: ...to starting this procedure 2 Remove the hood assembly as described on page 7 5 of this manual 3 Raise and support the operator enclosure cab as described on page 4 2 of this manual 4 Perform steps 2...

Страница 78: ...r from the ECU computer located behind the oil dip stick on the right side of the engine compartment and then loosen the center bolt on the connector to allow it to be unplugged fig 12 25 12 Remove th...

Страница 79: ...17 Attach a device that is capable of safely lifting the engine to the lifting points located on the top of the front and back of the engine Then slide the engine rearward and upward to clear the radi...

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Страница 81: ...switch prior to performing any service work on a Compact Track Loader Place a Do Not Operate tag prominently on the machine to inform personnel that the machine is being worked on Removal and Installa...

Страница 82: ...ring wheel removal replacement it is necessary to remove inspect and clean all components prior to reassembly to ensure proper function 5 Remove both wheels from the hub fig 13 5 Note Take care not to...

Страница 83: ...ress to push the axle and far side bearing out of the hub as shown fig 13 8 13 9 7 If it is necessary to remove the other bearing for replacement press it out as well If not you may leave this bearing...

Страница 84: ...od seal fig 13 13 13 Once the seals are in place wipe the mating surfaces 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 out...

Страница 85: ...it with 2 ounces of 10W 30 API CH 4 engine oil Then reinstall the plug fig 13 21 13 22 22 Repeat this procedure on the other half of the bogie assembly if necessary prior to installing the two halves...

Страница 86: ...below Note If you are removing the inner front hub assembly you will have to slide the axle item 41 out of the main rail weldment to remove it fig 13 24 13 25 Note If you are removing the outer or re...

Страница 87: ...ed press the rear bear ing race out of the assembly from the front of the hub with tools 0403 337 and 0403 333 fig 13 31 8 Press the bearing sleeve out of the rear bearing using tool 0403 336 fig 13 3...

Страница 88: ...roughly then 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 i...

Страница 89: ...clean installed and oiled into the hub with tool 0403 336 until seated fig 13 42 19 Flip the hub over support the bearing sleeve from the bottom with tool 0403 335 and set it onto the press for cente...

Страница 90: ...cation fig 13 48 26 Remove the allen plug in the center portion of the hub fig 13 49 27 Add 2 oz of 10W 30 API CH 4 engine oil to the hub as shown then reinstall the plug and tighten fig 13 50 28 The...

Страница 91: ...ure the drive hose guides located on both the right and left sides of the chassis fig 13 54 5 Support each undercarriage with a suitable lifting device then slide each of the undercarriages out ward a...

Страница 92: ...steady on the lifting device as they are lowered Installation 1 To install rear and front axles reverse the removal procedure Note Before installing each undercarriage onto the rear and front axles c...

Страница 93: ...a Do Not Operate tag prominently on the machine to inform personnel that the machine is be ing worked on The hydraulic system fluid should be changed follow ing any hydraulic component service accordi...

Страница 94: ...e 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...

Страница 95: ...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 fittin...

Страница 96: ...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...

Страница 97: ...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 t...

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Страница 99: ...tery terminals tape the battery clamps and remove the key from the ignition switch prior to per forming any service work on a Compact Track Loader Place a Do Not Operate tag prominently on the machine...

Страница 100: ...e 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...

Страница 101: ...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...

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Страница 103: ...rs Lift Arm Control Valve Drive Pump Reliefs Drive Pump Solenoids Spools Auxiliary Pump Note Procedures are provided for only those components listed above However exploded parts diagrams exist in the...

Страница 104: ...eakage 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 p...

Страница 105: ...move the end gland outer seal from the end gland fig 16 10 16 Thoroughly clean all parts to prevent contamina tion of hydraulic oil when reinstalled Assembly 1 Install new seals and components in plac...

Страница 106: ...seals for damage replace if necessary fig 16 15 5 Remove the spool covers and inspect the seals for damage replace if necessary fig 16 16 16 17 6 Once the spool covers have been removed the spool may...

Страница 107: ...rings for damage replace if necessary fig 16 23 11 Remove reliefs from valve inspect relief and o rings for damage replace if necessary fig 16 24 Assembly 1 Install new seals and components in place...

Страница 108: ...the valve over then tighten the nut to increase the pressure setting CW or loosen it to decrease the pressure setting CCW fig 16 28 Drive Pump Solenoid Spool Disassembly 1 Make sure the machine isoff...

Страница 109: ...ing fig 16 32 3 Inspect o rings for proper shape and condition Replace if necessary fig 16 33 4 Remove the Allen bolts securing the cover onto the pump fig 16 34 5 Lift the cover off to expose the pum...

Страница 110: ...7 8 Remove the piston barrel assembly and inspect the slipper faces for scratches or any other dam age that can be felt with a fingernail fig 16 38 Assembly 1 To reassemble reverse the disassembly pro...

Страница 111: ...ounts of debris found within the 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 inspec...

Страница 112: ...ecessary 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 p...

Страница 113: ...tivate 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 ac...

Страница 114: ...Make certain all couplers fittings and hoses used during this process are clean and free of contaminants that may potentially cause damage to the hydraulic pump and or system components Drive pressur...

Страница 115: ...ferent circuits pumps perform step 8 for both 10 If both readings are low on one pump disconnect the drive hoses from the suspected ports and plug them at the pump Cap the hoses to prevent con taminat...

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Страница 117: ...lowing items Track tension Fluid levels Fan belt tension and condition Hoses no visible sign of wear Fittings no apparent leaks Battery cables Fuse panel fuses in place and operational Controls for ne...

Страница 118: ...iliary flow hydraulics do not work check for a Main auxiliary relief malfunction check pres sures If the possible causes found here do not appear to address your problem refer to the Control system tr...

Страница 119: ...sed position 6 Damaged or missing brush ring around fan 7 Aftermarket non OEM shrouding or guarding installed in or around engine compartment obstructing airflow 8 Auto Reversing fan malfunction see c...

Страница 120: ...inputs off Propel disabled Switch faulty wiring connection faulty switch out of adjustment Restore connections adjust or replace switches then cycle power by turning the key off then back on Lap Bar S...

Страница 121: ...hen cycle power by turning the key off then back on Drive Enable Solenoid short circuit to power Propel disabled Faulty connections or wires to or from drive enable solenoid faulty solenoid Restore co...

Страница 122: ...ey off then back on Loss of communications between Main Controller and Output Module Boom control disabled Faulty connections or wires between main controller and output module Restore communications...

Страница 123: ...adjustment Restore connections adjust or replace switch then cycle power by turning the key off then b on Bucket Curl solenoid short circuit Bucket curl dump disabled Work enable solenoid de energized...

Страница 124: ...isabled Parameter values not in proper low to high sequence Perform High flow female calibration procedure Lap Bar Switch Fault both inputs off Load sharing disabled Switch faulty wiring connection fa...

Страница 125: ...w flow male disabled Parameter setting out of valid range Perform low flow male end current calibration procedure Low Flow Female not calibrated Low flow female disabled Parameter setting out of valid...

Страница 126: ...lt Quick attach output de energized Solenoid shorted to battery faulty wires connections Restore connections then cycle power by turning the key off then back on Work Enable solenoid fault Quick attac...

Страница 127: ...machine Download the service tool by visiting www sauer danfoss com Steps 1 Select Products 2 Select Mobile Electronics 19 Service Tool 19 1 Personal Safety Improper or incomplete maintenance repair...

Страница 128: ...3 Select PLUS 1TM GUIDE 4 Select PLUS 1TM GUIDE Downloads 5 Select PLUS 1TM GUIDE Service Tool Software License 6 Select exe file 7 Select Save 19 2 Compact Track Loader 19 Service Tool...

Страница 129: ...manager 15 Once the license manager window appears select get license from the options at the top of the win dow This should automatically load a license help pdf document that will walk you through...

Страница 130: ...machine parameters click the upload parameters button in the top toolbar to read the parameters stored in the onboard computer through the service tool Note To ensure your machine is connected properl...

Страница 131: ...nable screens display components systems and sensors that affect the particular function they are associated with ground drive propel work valve boom bucket etc If there is a problem with one of the p...

Страница 132: ...there is a prob lem with one of the prerequisites for normal operation they would be displayed in red In most cases this indicates that there is a malfunction of some sort or a condition that requires...

Страница 133: ...d These values affect operating characteristics and should be changed only when following the calibration procedure for the particular function see chapter 00 This will ensure you are not altering a v...

Страница 134: ...opriate cali bration procedure then select it by clicking the down load box to the left of the row check mark Once selected press the download parameters button to establish the new value within the o...

Страница 135: ...e to download Locate it on your computer and click open The DownloadFile Tab will then appear as shown at right Click start download to begin the process 5 A confirmation window will then appear ensur...

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Страница 137: ...erex Long Life 50 50 Antifreeze Coolant Capacity 4 3 gallons 16 3l P N 0300 766 1 gallon P N 0402 841 6 gallons Hydraulic Oil Mobil DTE 10 Excel 46 Service Capacity 22 gal 83 3l incl filters P N 0404...

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Страница 139: ...r port material is non ferrous Thread Size Standard Torque 1 4 9 2 lb ft 5 16 18 4 lb ft 3 8 35 7lb ft 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 l...

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Страница 142: ...Terex Construction Americas 8800 Rostin Road Southaven MS 38671 888 201 6008 662 393 1800 www terex com...

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