Terex PT-30 User manual

PT-30
Part Number: 2010-513
Printed (1-11)
Service Manual
Compact Track Loader

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i
Table of Contents
1. Product Safety
Chapter Overview ...................................................1-1
Basic Precautions ...................................................1-1
Safety Labels.....................................................1-1
Personal 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 ID Number............................................1-4
Safety Label Examples......................................1-4
2. Technical Specifications
Chapter Overview ...................................................2-1
PT-30 Specifications...............................................2-1
3. System Diagrams
Chapter Overview ...................................................3-1
Filtering and Cooling System ..................................3-1
Auxiliary Circuit System ..........................................3-2
Drive Loop System..................................................3-3
4. Machine Controls and Instrumentation
Chapter Overview ...................................................4-1
Machine Controls....................................................4-1
Loader Control...................................................4-1
Drive Control......................................................4-1
Throttle ..............................................................4-1
Instrumentation .......................................................4-1
Switches..................................................................4-2
5. Operator Enclosure Disassembly
and Assembly
Chapter Overview ...................................................5-1
Personal Safety.......................................................5-1
Machine Preparation...............................................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 Removal and Installation.............................5-4
Gauge Removal.................................................5-4
Gauge Installation..............................................5-4
Lap Bar Gas Assist Spring Removal
and Installation........................................................5-5
Lap Bar Gas Assist Spring Removal..................5-5
Lap Bar Gas Assist Spring Installation...............5-5
6. Chassis Disassembly and Assembly
Chapter Overview...................................................6-1
Personal Safety.......................................................6-1
Machine Preparation...............................................6-1
Chassis Disassembly and Assembly
Procedures..............................................................6-1
Seat Removal and Installation ................................6-1
Seat Removal....................................................6-1
Seat Installation.................................................6-2
Fuel Sending Unit Removal and Installation ...........6-2
Fuel Sending Unit Removal...............................6-3
Fuel Sending Unit Installation............................6-3
Fuel Tank Removal and Installation.......................6-4
Fuel Tank Removal ...........................................6-4
Fuel Tank Installation.........................................6-6
7. Radiator/Oil Cooler Disassembly
and Assembly
Chapter Overview...................................................7-1
Personal Safety.......................................................7-1
Machine Preparation...............................................7-1
Radiator/Oil Cooler Disassembly and Assembly
Procedures..............................................................7-1
Fan Guard Removal and Installation.......................7-1
Fan Guard Removal ..........................................7-2
Fan Guard Installation .......................................7-2
Fan and Fan Shroud Removal and Installation.......7-2
Fan and Fan Shroud Removal...........................7-2
Fan and Fan Shroud Installation........................7-3
Radiator/Cooler Removal and Installation...............7-4
Radiator/Cooler Removal ..................................7-4
Radiator/Cooler Installation ...............................7-6
Radiator/Oil Cooler Adjustment Procedures ..........7-7
Fan Shroud Adjustment.....................................7-7
Fan Guard Adjustment.......................................7-8
8. Hydraulic Reservoir Disassembly
and Assembly
Chapter Overview...................................................8-1
Personal Safety.......................................................8-1
Machine Preparation...............................................8-1
Hydraulic Reservoir Disassembly and Assembly
Procedures..............................................................8-1
Filter Element Removal and Installation..................8-1
Filter Assembly Removal and Installation ...............8-1
Filter Assembly Removal...................................8-2
Filter Assembly Installation................................8-3
Access Cover Assembly Removal and Installation.8-4
Access Cover Assembly Removal.....................8-4
Access Cover Assembly Installation..................8-4
Reservoir Gauge Removal and Installation.............8-5
Reservoir Gauge Removal ................................8-5
Reservoir Gauge Installation .............................8-6
Suction Screen Removal and Installation ...............8-6
Suction Screen Removal...................................8-6
Suction Screen Installation................................8-7
Hydraulic Reservoir Cleaning Procedures .............8-7

Compact Track Loader
Table of Contents
ii
9. Loader/Transmission Controls Disassembly
and Assembly
Chapter Overview ...................................................9-1
Personal Safety.......................................................9-1
Machine Preparation...............................................9-1
Loader/Transmission Controls Disassembly and
Assembly Procedures .............................................9-1
Loader Control Joystick/Drive Control Joystick
Removal and Installation.........................................9-1
Loader Control Joystick/Drive Control Joystick
Removal ............................................................9-2
Loader Control Joystick/Drive Control Joystick
Installation..........................................................9-3
Loader Float Magnet Removal and Installation.......9-3
Loader Float Magnet Removal...........................9-3
Loader Float Magnet Installation........................9-4
Loader Valve Removal and Installation..................9-4
Loader Valve Removal ......................................9-4
Loader Valve Installation ...................................9-6
10. Transmission and Drive Disassembly
and Assembly
Chapter Overview .................................................10-1
Personal Safety.....................................................10-1
Machine Preparation.............................................10-1
Transmission and Drive Disassembly
and Assembly Procedures ....................................10-1
Brake Cylinder Removal and Installation ..............10-1
Drive Motor Removal and Installation ...................10-1
Auxiliary Gear Pump Removal and Installation.....10-2
Auxiliary Gear Pump Removal.........................10-2
Auxiliary Gear Pump Installation......................10-3
Tandem Pump Removal and Installation ..............10-4
Tandem Pump Removal..................................10-4
Tandem Pump Installation...............................10-5
Pump Drive Coupler Removal and Installation......10-6
Pump Drive Coupler Removal .........................10-6
Pump Drive Coupler Installation ......................10-7
11. Engine Components Disassembly and As-
sembly
Chapter Overview .................................................11-1
Personal Safety.....................................................11-1
Machine Preparation.............................................11-1
Engine Components Disassembly and
Assembly Procedures ...........................................11-1
Primary Air Filter Removal and Installation ...........11-1
Safety Air Filter Removal and Installation .............11-1
Engine Oil Filter Removal and Installation ............11-1
Fuel Filter Removal and Installation.....................11-1
Muffler Removal and Installation..........................11-2
Muffler Removal...............................................11-2
Muffler Installation............................................11-2
Exhaust Pipe Removal and Installation.................11-3
Exhaust Pipe Removal ....................................11-3
Exhaust Pipe Installation .................................11-4
Battery Removal and Installation...........................11-5
Battery Removal..............................................11-5
Battery Installation...........................................11-6
Bleeding the Fuel System………………………….11-7
12. Undercarriage Disassembly and Assembly
Chapter Overview.................................................12-1
Personal Safety.....................................................12-1
Machine Preparation.............................................12-1
Undercarriage Disassembly and Assembly
Procedures............................................................12-1
Wheel Removal and Installation...........................12-1
Wheel Removal...............................................12-2
Wheel Installation............................................12-3
Track Removal and Installation.............................12-3
Track Removal...............................................12-3
Track Installation............................................12-3
Sprocket Bearing Plate Removal and Installation .12-6
Sprocket Bearing Plate Removal ...................12-7
Sprocket Bearing Plate Installation ................12-8
Sprocket Roller Removal and Installation .............12-8
Sprocket Roller Removal...............................12-8
Sprocket Roller Installation............................12-9
Sprocket Removal and Installation........................12-9
Sprocket Removal.........................................12-9
Sprocket Installation....................................12-10
Drive Motor Removal and Installation ................12-10
Drive Motor Removal..................................12-11
Drive Motor Installation...............................12-11
13. Loader Disassembly and Assembly
Chapter Overview.................................................13-1
Personal Safety.....................................................13-1
Machine Preparation.............................................13-1
Loader Disassembly and Assembly Procedures..13-1
Lift Cylinder/Tilt Cylinder Removal
and Installation......................................................13-1
Lift Cylinder/Tilt Cylinder Removal...................13-1
Lift Cylinder/Tilt Cylinder Installation................13-3
Lift Cylinder/Tilt Cylinder Seal Kit Removal
and Installation......................................................13-3
Seal Kit Removal ............................................13-3
Seal Kit Installation .........................................13-5
Lift Arm Bushing Removal and Installation...........13-6
Upper Friction Points.......................................13-6
Lower Friction Points.......................................13-8
Low-Flow Relief Valve Removal and Installation ..13-9
Low Flow Relief Valve Removal......................13-9
Low Flow Relief Valve Installation.................13-10
14. Quick Attach Disassembly and Assembly
Chapter Overview.................................................14-1
Personal Safety.....................................................14-1
Machine Preparation.............................................14-1
Quick Attach Disassembly and Assembly
Procedures............................................................14-1
Latch Pin Assembly Removal and Installation ......14-1
Latch Pin Assembly Removal..........................14-1
Latch Pin Assembly Installation.......................14-2
Quick Attach Assembly Removal and Installation.14-2
Quick Attach Assembly Removal.....................14-2
Quick Attach Assembly Installation..................14-3

Compact Track Loader
Table of Contents
iii
15. Troubleshooting
Chapter Overview .................................................15-1
Personal Safety.....................................................15-1
Machine Preparation.............................................15-1
Visual Inspection..............................................15-1
Troubleshooting ....................................................15-2
16. Maintenance
Chapter Overview .................................................16-1
Maintenance Schedule..........................................16-1
Engine Oil .............................................................16-1
Oil Change Procedures ...................................16-1
Engine Oil Specifications.................................16-1
Hydraulic Fluid and Filter ......................................16-2
Hydraulic Fluid and Filter Change
Procedures ......................................................16-2
Fuel Filter..............................................................16-3
Fuel Filter Change Procedures........................16-3
Fuel Specifications...........................................16-3
Air Cleaner............................................................16-3
Air Filter Change Procedures...........................16-3
Track Tension .......................................................16-4
Track Tension Adjustment Procedures............16-4
Checking for Proper Track Adjustment............16-4
Fuse Box...............................................................16-5
Grease Fittings......................................................16-5
Lift Arm Bushings..................................................16-6
17. Hydraulic Pressure Check & Adjustment
Chapter Overview .................................................17-1
Personal Safety.....................................................17-1
Machine Preparation.............................................17-1
Charge Pressure check……………………………. 17-1
Charge Pressure Adjustment………………………17-2
Drive Pressure Adjustment…………………………17-3
Auxiliary Pressure Check & Adjustment…………..17-4

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Chapter Overview
This chapter contains product safety information for the
Terex PT-30 Compact Track Loaders. Read and under-
stand all product safety information before attempting
to service any Compact Track Loader.
Safety Alert Symbol
This symbol means: Attention! Be
alert! Your safety is involved!
The safety alert symbol is used to alert you to potential
personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or
death.
This symbol is used as an attention-getting device
throughout this manual as well as on decals and labels
fixed to the machinery to assist in potential hazard
recognition and prevention.
Property or equipment damage warnings in this publi-
cation are identified by the signal word "NOTICE".
The word “Note” is used throughout this manual to
draw your attention to specific topics or to supplement
the information provided in that section.
The person(s) in charge of servicing a Compact 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 the machine are not all-
inclusive. They are intended to make you aware of
potential risks and encourage a safe approach to
performing service work. If you use a tool, proce-
dure, work method or operating technique that 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,
lubrication, maintenance or repair procedures that
you choose.
Basic Precautions
Safety Labels
Safety labels have been included and are displayed in
various places throughout the machine to serve as
warnings of potentially dangerous conditions. Read
and understand all "Safety" labels on any Compact
Track Loader before attempting to operate, maintain or
repair it. Replace any damaged, illegible or missing
labels immediately, prior to service.
Personal Protective Equipment
Personal protection equipment is recommended when
performing maintenance or service on a machine.
Always wear appropriate protective equipment for
working conditions when working on or around the
machine. Loose clothing should not be worn and long
hair should be restrained. Wear hard hats, protective
face/eyewear, safety shoes and any other equipment
necessary to ensure your safety and the safety of oth-
ers around you as you work.
1. Product Safety
1-1
“NOTICE” Indicates a hazardous situation which,
if not avoided, could result in property or equip-
ment damage.
NOTICE
Improper or incomplete maintenance/repair of a
Compact Track Loader can be dangerous and
may result in machine damage, injury or death.
Do not attempt to perform any type of repair or main-
tenance on a Compact Track Loader until you have
read and fully understood both this manual and the
machine specific operation and maintenance manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation and
maintenance techniques before operating or servicing
any Compact Track Loader.

Entering and Exiting
Always use steps and handholds when entering or
exiting a Compact Track Loader. Clean any mud or
debris from steps or work platforms before using them.
Always face the machine when using steps and hand-
holds. When it is not possible to use the designed
entry/exit system, utilize ladders, scaffolds, or work
platforms to safely gain access to the machine.
Lifting
Use a hoist when lifting components that weigh 50 Ib
(23 kg) or more, to avoid back injury. Make sure all
chains, hooks, slings, etc., are in good condition and
are of the correct capacity. Be sure hooks are posi-
tioned correctly and equipped with a spring latch.
Lifting eyes are not to be side loaded during a lifting
operation.
Hot Fluids and Components
Stay clear of hot components and system fluids of the
engine, exhaust, radiator/oil cooler and hydraulic
lines/tubes. Also, use caution when removing fill caps,
breathers and plugs on the machine. Hold a rag over
the cap or plug to prevent being sprayed or splashed
by liquids under pressure. Be especially careful if the
machine has been operated recently, fluids may still be
hot. To ensure your safety, allow the machine to cool
before attempting any service procedure that involves
hot fluids or components.
Corrosion Inhibitor
Corrosion inhibitor contains alkali. Avoid contact with
eyes. Avoid prolonged or repeated contact with skin.
Do not take internally. In case of contact, wash skin
immediately with soap and water. For eyes, flush 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 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 with soap and
water. For eyes, flush with large amounts of water for
at least 15 minutes. Call Physician. Keep out of reach
of children.
Pressurized Items
1. Do not use hands or any other body part to check
for fluid leaks in the hydraulic system. Always use
a solid material like wood or metal to check for this
type of leak. Leaking fluid under pressure can pen-
etrate body tissue. Fluid penetration can cause
serious injury and even death. If fluid is injected
into your skin, get treatment immediately. Seek
treatment from a doctor that is familiar with this
type of injury.
2. Relieve pressure from the hydraulic system before
disconnecting or removing any lines, fittings or
related items. Do this by relaxing all hydraulic
actuators. If the lift arms are raised, make sure
they are securely braced. Be alert for possible
pressure release when disconnecting any device
from a pressurized system.
3. Lower the lift arms before performing any work on
the machine. If this cannot be done, make sure
they are securely braced to prevent them from
dropping unexpectedly during service.
4. Loose or damaged fuel, oil, hydraulic, lines, tubes
and hoses can cause fires. Do not bend or strike
high pressure lines or install ones that have been
bent or damaged. Check lines, tubes and hoses
carefully. See item 1 for precautions on checking
for fluid leaks.
5. Pressurized air or water can also cause injury.
When pressurized air or water is used for clean-
ing, wear a protective face shield, protective cloth-
ing, and protective shoes. The recommended max-
imum air pressure for cleaning purposes is 30 psi
(205 kPa). When using a pressure washer, keep in
mind that nozzle pressures are typically very high.
Generally, pressures are well above 2000 psi
(13,790 kPa). Follow all recommended practices
provided by the pressure washer manufacturer.
1-2
Compact Track Loader
1. Product Safety

Repair
1. Disconnect the battery and discharge any capaci-
tor before beginning work on a machine. Attach a
Do Not Operate tag in the cab to alert any opera-
tor that service is in progress.
2. If possible, make all repairs with the machine
parked on a level, hard surface. Use blocks to pre-
vent the machine from rolling while working on or
under the machine.
3. Do not work on or under any machine that is sup-
ported only by a hydraulic jack or hoist. Always
use some sort of mechanical support to ensure
that the machine will not fall.
4. Make sure the work area around the machine is
safe and make yourself aware of any hazardous
conditions that may exist. If the engine needs to
be started inside an enclosure, make sure that the
engine’s exhaust is properly vented.
5. Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before beginning any service task. If a guard
or shield must be removed to perform the repair
work, use extra caution.
6. Always use the appropriate tools for the work to be
performed. Tools should be in good condition and
you should understand how to use them properly
before performing any service work.
7. When replacing fasteners, use parts of equivalent
grade and size. Do not use a lesser quality fasten-
er if replacements are necessary.
8. Be prepared to stop an engine if it has been re-
cently overhauled or the fuel system has been
recently serviced. If the engine has not been
assembled correctly, or if the fuel settings are not
correct, 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 bolts completely.
10. Repairs requiring welding should be performed
only by personnel adequately trained and knowl-
edgeable in welding procedures and 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
stronger than the original weld.
11. Take precautions to avoid damaging wiring during
removal and installation operations. Carefully route
wires so that they will not contact sharp corners,
objects or hot surfaces during operation.
12. When performing service that requires the lift arms
to be in the raised position, always utilize the lift
arm brace located on the rear of the loader tower.
13. Relieve hydraulic system pressure by relaxing all
hydraulic actuators prior to attempting any
hydraulic maintenance or repair.
14. Always tighten connections to the correct torque
specification. Make sure that all shields, clamps
and guards are installed correctly to avoid exces-
sive heat, vibration or unwanted contact between
parts during operation. Shields that protect
exhaust components from oil spray in event of a
line, tube or seal failure must be correctly installed.
15. Do not operate a machine if any rotating part is
damaged or contacts other parts during operation.
Any high speed rotating component that has been
damaged or altered should be checked for balance
before reusing. Make sure all protective devices,
including guards and shields, are properly installed
and functioning correctly before starting the engine
or operating the machine.
1-3
Compact Track Loader
1. Product Safety
Accidental machine starting can cause injury
or even death 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 to per-
forming 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 serviced.