Terex R160T Operating instructions

8/17/2016
Service Repair Manual
R160T
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English
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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 Parts..........................................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
R160T Specifications..............................................2-1
R190T Specifications..............................................2-2
3. System Diagrams
Chapter Overview ...................................................3-1
Filtering and Cooling System ..................................3-1
Auxiliary Circuit System ..........................................3-2
Drive Loop System .................................................3-3
Electrical Attachment Outlet ...................................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
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
Radiator/Cooler Removal and Installation...............7-2
Radiator/Cooler Removal ..................................7-2
Radiator/Cooler Installation ...............................7-4
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 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
Hydraulic Reservoir Cleaning............................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
Joystick Removal and Installation...........................9-1
Joystick Removal...............................................9-2
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
Self Level Valve Removal and Installation.............9-6
10. Drive and Auxiliary Pump Disassembly
and Assembly
Chapter Overview .................................................10-1
Personal Safety.....................................................10-1
Machine Preparation.............................................10-1
Hydraulic Drive & Auxiliary Pump Disassembly
and Assembly Procedures ....................................10-1
Auxiliary Pump Removal and Installation..............10-1
Auxiliary Gear Pump Removal.........................10-1
Auxiliary Gear Pump Installation......................10-3
Tandem Drive Pump Removal and Installation.....10-3
Tandem Drive Pump Removal.........................10-3
Tandem Drive Pump Installation......................10-5
Pump Drive Coupler Removal and Installation......10-5
Pump Drive Coupler Removal .........................10-5
Pump Drive Coupler Installation ......................10-5
11. Undercarriage Disassembly and Assembly
Chapter Overview .................................................11-1
Personal Safety.....................................................11-1
Machine Preparation.............................................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 Removal........................................11-3
End Wheel Installation.....................................11-3
Sprocket Roller Removal and Installation ............11-4
Track Removal and Installation............................11-4
Track Removal.................................................11-4
Track Installation..............................................11-4
Outboard Bearing Removal and Installation..........11-5
Bearing Removal.............................................11-5
Bearing Installation..........................................11-5
Drive Sprocket Removal and Installation ..............11-6
Sprocket Removal ...........................................11-6
Sprocket Installation ........................................11-6
Drive Motor Removal and Installation ..................11-6
Drive Motor Removal.......................................11-6
Drive Motor Installation....................................11-6
Idler Wheel Hub Service Procedures ....................11-7
Disassembly Procedure...................................11-7
Assembly Procedure........................................11-9
12. Loader Disassembly and Assembly
Chapter Overview.................................................12-1
Personal Safety.....................................................12-1
Machine Preparation.............................................12-1
Loader Disassembly and Assembly Procedures..12-1
Lift Cylinder/Tilt Cylinder Removal
and Installation......................................................12-1
Lift Cylinder/Tilt Cylinder Removal...................12-1
Lift Cylinder/Tilt Cylinder Installation................12-3
Q/C Block Relief Valve Removal and Installation..12-3
Q/C Block Relief Valve Removal.....................12-3
Q/C Block Relief Valve Installation ..................12-4
13. Maintenance
Chapter Overview.................................................13-1
Maintenance Schedule .........................................13-1
Engine Oil .............................................................13-1
Oil Change Procedures ...................................13-1
Engine Oil Specifications.................................13-1
Hydraulic Fluid and Filter ......................................13-2
Hydraulic Fluid and Filter Change
Procedures......................................................13-2
Fuel/Water Separator............................................13-3
Fuel Filter..............................................................13-3
Fuel Filter Change Procedures........................13-3
Fuel Specifications ..........................................13-3
Air Cleaner............................................................13-3
Air Filter Change Procedures ..........................13-3
Track Tension.......................................................13-4
Track Tension Adjustment Procedures............13-4
Checking for Proper Track Adjustment............13-4
Fuse Box...............................................................13-5
Grease Fittings......................................................13-5
Bleeding the Fuel System.....................................13-6
14. Hydraulic Pressure Check & Adjustment
Chapter Overview.................................................14-1
Personal Safety.....................................................14-1
Machine Preparation.............................................14-1
Hydraulic Pressure Adjustment Procedures..........12-1
Charge Pressure check……………………………. 14-1
Charge Pressure Adjustment………………………14-1
Auxiliary Pressure Check & Adjustment…………..14-2
DA Control set Procedure ………………………….14-3
15. Troubleshooting
Chapter Overview.................................................15-1
Personal Safety.....................................................15-1
Machine Preparation.............................................15-1
Preliminary Inspection...........................................15-1
Visual Inspection .............................................15-1
Troubleshooting Scenarios………………………...15-2

Chapter Overview
This chapter contains product safety information for the
Terex R160T/R190T Compact Track Loaders. Read
and understand 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
publication 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.
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
others 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
maintenance on a Compact Track Loader until you
have read and fully understood both this manual and
the machine specific operation and maintenance man-
ual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation and
maintenance techniques before operating or servicing
any Compact Track Loader.
It is not possible to anticipate every potential
hazard. The safety messages included in this
document 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, procedure, 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.

Entering and Exiting
Always use steps and handholds when entering or
exiting a Compact Track Loader. Clean any foreign
materials from steps or work platforms before using
them. Always face the machine when using steps and
handholds. When it is not possible to use the designed
entry/exit system, utilize appropriate ladders, scaffolds,
or work platforms to safely gain access to the machine.
Lifting
Use a hoist when lifting components that weigh 50 lb
(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
positioned 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.
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 or death.
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
cleaning, wear a protective face shield, protective
clothing, and protective shoes. The recommended
maximum 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 (13790 kPa). Follow all recommended
practices provided by the pressure washer
manufacturer.
1-2
Compact Track Loader
1. Product Safety
To ensure your safety, allow the machine to
cool before attempting any service procedure
that involves hot fluids or components.
Fluid injected into skin must be surgically
removed within a few hours by a doctor familiar
with this type of injury or gangrene will result.

Repair
1. Disconnect the battery and discharge any
capacitor before beginning work on a machine.
Attach a Do Not Operate tag in the cab to alert
any operator that service is in progress.
2. If possible, make all repairs with the machine
parked on a level, hard surface. Use blocks to
prevent the machine from rolling while working on
or under the machine.
3. Do not work on or under any machine that is
supported only by a hydraulic jack or hoist. Always
use suitable mechanical supports 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
correctly 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
fastener 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. Back off
the last two bolts or nuts located on opposite sides
of the cover slightly, but leave them threaded in
place. 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
knowledgeable in welding procedures and with the
guidance 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
excessive 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 cor-
rectly 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
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 serviced.
When replacement parts are required for your
machine, use only genuine Terex 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
failures, product damage, personal injury or death.

Attachments
Only use compatible attachments as defined by the
machine specific operation and maintenance manual.
Make sure that all necessary guards and protective
equipment are in place and functioning prior to
operating any attachment.
Wear protective glasses and protective equipment as
required by conditions or as recommended in the
attachment specific operation manual.
Ensure that all personnel are far enough away from
the work area so they will not be struck by flying
ob-jects.
Stay clear of the cutting edges, pinching surfaces or
crushing surfaces of the attachment while performing
any attachment maintenance, testing or adjustments.
Machine Labels and Decals
Labels and decals placed on the machine provide
safety information and operating instructions.
Familiarize yourself with the location and significance
of these labels to ensure your safety.
Product Identification Number
The Product Identification Number (PIN) is located
inside the cab enclosure next to the seat (figure 1-1).
Always provide the PIN when contacting the dealer
about parts, service, warranty or accessories. No war-
ranty claims will be processed unless the PIN has
been provided.
Safety Label Examples (ANSI)
Examples of the labels and decals displayed on the
machine are shown on this page.
1-4
Compact Track Loader
1. Product Safety
1-1
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment.
Keep clear of lift arms and
attachments. 2030-592
CRUSH HAZARD
Contact with moving machine can
result in death or serious injury.
Keep clear of moving machine.
2030-593
Fall Hazard
Serious injury or death can result
from falling.
Use the provided access system when
entering or exiting the machine.
2030-597
Entanglement Hazard
Rotating parts can cause personal injury.
Keep away from fan and belt while the
engine is running. Stop engine before
servicing.
2030-600
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment. Install lift arm brace prior to servicing.
2030-594
Burn Hazard
Hot fluid under pressure can scald.
Allow the machine to cool thoroughly
before opening.
2030-595
Injection Hazard
Escaping fluid under pressure can
penetrate skin, causing serious injury.
• Relieve internal pressure before
disconnecting any line or fitting.
• Keep away from leaks or pinholes.
• Use cardboard to check for leaks.
Fluid injected into skin must be surgi-
cally removed within a few hours by a
doctor familiar with this type of injury
or gangrene will result. 2030-602

1-5
Compact Track Loader
1. Product Safety
Improper operation or maintenance
can result in serious injury or death.
Read and understand the opera-
tor’s manual and all safety signs
prior to operating or maintaining
the machine.
Fire Hazard
Flammable debris can collect near
hot components and lead to a fire.
Read Operator’s Manual
Keep the engine, exhaust and
chassis areas free of debris.
Do not use the bucket/attachment
as a work platform.
Fall Hazard
Falling can result in serious injury
or death.
2046-299
Crush Hazard
Rollover can crush and result in
serious injury or death.
Fasten Seat Belt
Fall Hazard
Falling from a machine can result
in serious injury or death
No Riders
Rollover/Ejection Hazard
Serious injury or death can result.
Carry loads low. Load unload and
turn on level ground. Travel on
inclines with heaviest end of
machine uphill. 2046-300

Safety Label Examples (ISO)
Examples of the labels and decals displayed on the
machine are shown on this page.
1-6
Compact Track Loader
1. Product Safety
2046-146 2046-147
Carry loads low
Ca
arry loads low
2030-415
2030-416
2030-425
2030-551
2030-417
2030-418
2030-553

2-1
2.Technical Specifications
R160T Specifications
Engine
Model: Perkins 404D-22
Displacement: 2.2 liter
Gross horsepower: 50 hp, 37.3 kW
Torque: 105 lb-ft.143 Nm
Idle rpm: 2800 (high idle); 1175 (low idle)
Average water /thermostat temperature:
190°F, 87.8°C
Transmission
Model: H1 (38.5cc) tandem (Sauer-Danfoss)
Drive pumps
Displacement: 2.349 in3/rev (38.5 cc/rev)
Relief pressure: 5500 psi, 380 bar
Flow: 28 gpm (106 lpm) @ 2800 rpm (high
idle)
Charge pump
Displacement: 1.098 in3/rev (18 cc/rev)
Relief pressure: 400-450 psi
Drive Motors
Model: Rexroth MCR 05C
Displacement: 37.8 in3/rev (620 cc/rev)
Control Handles
Model: 4TH6 (Rexroth)
Auxiliary Pump
Make: Haldex-Barnes #180-2061
Displacement: 1.343 in3/rev (22 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 required to move spools: 180-
220 psi (1241-1517 kPa)
Cooler
Burst pressure: 400 psi (2757 kPa)
Operating pressure: 250 psi (1724 kPa)
Bypass relief pressure: 80 psi (689 kPa)
Hot oil sending unit: 225°F (107.2°C)
Critical Torque Specs
Transmission Mounting Bolts
o85 ft-lb. w/Blue Loctite
Drive Sprocket Drive Teeth Bolts
o88 ft-lb. -Dry
Center Bogie Wheel Retaining Nut
o111 ft-lb. –Dry
End Wheel Axle Retaining Nut
o300 ft-lb. -Dry
−Drive Sprocket Lug Nut
o129 ft-lb. -Dry
−Drive Motor Mounting Bolts
o177 ft-lbs. -Dry

Compact Track Loader
2. Technical Specifications
2-2
R190T Specifications
Engine
Model: Perkins 404D-22 T
Displacement: 2.2 liter
Gross horsepower: 60 hp, 44.7 kW
Torque: 140 lb-ft.190 Nm
Idle rpm: 2800 (high idle); 1175 (low idle)
Average water /thermostat temperature:
190°F, 87.8°C
Transmission
Model: H1 (38.5cc) tandem (Sauer-Danfoss)
Drive pumps
Displacement: 2.349 in3/rev (38.5 cc/rev)
Relief pressure: 5500 psi, 380 bar
Flow: 28 gpm (106 lpm) @ 2800 rpm (high
idle)
Charge pump
Displacement: 1.098 in3/rev (18 cc/rev)
Relief pressure: 400-450 psi ( 2758-3103 kpa)
Drive Motors
Model: Rexroth MCR 5 (2-speed)
Displacement: 50 in3/rev (820 cc/rev)
Control Handles
Model: 4TH6 (Rexroth)
Auxiliary Pump
Make: Haldex-Barnes #180-2061
Displacement: 1.343 in3/rev (22 cc/rev)
Flow: 17.4 gpm (65.9 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: Husco
Relief pressure: 3000 psi (20,684 kPa)
Pilot pressure required to move spools: 40-
320 psi (275.8-2206 kPa)
Cooler
Burst pressure: 400 psi (2757 kPa)
Operating pressure: 250 psi (1724 kPa)
Bypass relief pressure: 80 psi (689 kPa)
Hot oil sending unit: 225°F (107.2°C)
Critical Torque Specs
Transmission Mounting Bolts
o85 ft-lb. (230 Nm) w/Blue Loctite
Drive Sprocket Drive Teeth Bolts
o105 ft-lb. (142 Nm) -Dry
Wheel Axle Retaining Nut
o300 ft-lb. (407 Nm)-Dry
−Drive Sprocket Lug Nut
o129 ft-lb. (175 Nm)-Dry
−Drive Motor Mounting Bolts
o177 ft-lbs. (480 Nm) -Dry
−Center Idler Wheel Mounting Bolts
o105 ft-lbs. (142 Nm) -Dry

Chapter Overview
This chapter contains diagrams for the following
R160T/R190T systems.
• Filtering and cooling system
• Auxiliary circuit system
• Drive loop system
Figure 3-1
R160T/R190T 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
100 PSI
COOLER RELIEF
50 MICRON
SUCTION SCREEN HOT OIL TEMP.
SENDING UNIT
10 MICRON
RETURN FILTER

Auxiliary Circuit System
The auxiliary circuit system (fig. 3-2) contains the
following major components.
• Loader valve
• Pilot generation block
• Auxiliary gear pump
• Loader control joystick
Figure 3-2
R160T/R190T Auxiliary Circuit System
3-002
3-2
Compact Track Loader
3. System Diagrams
Self leveling (optional)

Drive Loop System
The drive loop system (fig. 3-3) contains the
following major components.
• Drive motors
• Pilot generation block
• Drive control joystick
• Tandem drive pump
Figure 3-3
R160T/R190T Drive Loop System 3-003
3-3
Compact Track Loader
3. System Diagrams
Input Portion (joystick)
Output Portion (drive motors)
tank
drive motor
brake
case drain
brake case drain
drive motor
tandem drive pump
pilot generation
block
tank
charge
R160T

Electrical Attachment Outlet
Figure 3-4 R160T/R190T Electrical Attachment Outlet
3-4
Compact Track Loader
3. System Diagrams
Output Portion (drive motors)
drive motor
brake
(R190T 2-spd)
case drain
(R190T 2-spd)
brake case drain
drive motor
tandem drive pump
pilot generation
block
tank
charge
R190T (2-spd)
Drive Loop System (continued)

Chapter Overview
This chapter contains an overview of the machine con-
trols and instrumentation. For further information
regarding machine controls, instrumentation or opera-
tion, refer to the operation and maintenance manual
for your particular machine. Included here are illustra-
tions of the following controls and instrumentation com-
ponents and a description of their functions.
• Machine Controls
• Instrument Location and Function
• Switch Location and Function
Machine Controls (fig. 4-1)
There are three primary machine controls: lift arm con-
trol (2), drive control (1) and throttle (3).
Lift Arm Control
The lift arm control (2) is a pilot operated joystick that
allows the operator to raise or lower the loader and
dump or curl the quick attach mechanism.
Drive Control
The drive control (1) is also a pilot operated joystick. It
allows the operator to change the direction and speed
of the machine.
Throttle
The hand throttle (3) controls engine 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 Gauge
(2) Tachometer (optional)
(3) Engine Coolant Temp. Gauge (optional)
(4) Hour Meter
(5) Warning Indicator Display
• Engine Oil Pressure Warning Light
• Engine Temperature Warning Light
• Hydraulic Oil Temperature Warning Light
• Battery Voltage Warning Light
The glow plug operation light illuminates only when the
key switch is turned to engine pre-heat, showing nor-
mal operation.
4. Machine Controls and
Instrumentation
4-1
2
3
4-1
1
4-2
15 4
23
If the engine temperature, engine oil pressure or
hydraulic oil temperature lights illuminate or should
the eng. coolant temp. gauge read excessive tempera-
tures during normal machine operation, shut the
machine down immediately (in a safe location).
Diagnose the problem and make any necessary
repairs before resuming normal operation.
NOTICE
If the battery low-voltage light should illuminate dur-
ing operation, drive the machine to a suitable location
and shut the engine off. Diagnose the problem and
make any needed repairs before resuming operation.
NOTICE

R160T/R190T Switches
The various switches (Figure 4-3) are positioned to
provide good access and visibility. The standard and
optional switches are listed below.
(1) Work lights
(2) Heater fan (optional)
(3) Front wiper (optional)
(4) Beacon light (optional)
(5) Ignition, glow plug (pre-heat)
(6) Auxiliary hydraulics
(7) Bucket Positioning (optional)
(8) Power Quick Attach (optional)
4-2
Compact Track Loader
4. Machine Controls and Instrumentation
4-3
1 2 3 4 5 6 7 8

5-1
5.Operator Enclosure
Disassembly and Assembly
Chapter Overview
This chapter provides disassembly and assembly
procedures for the operator enclosure assembly.
Personal Safety
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in ma-
chine damage, injury or death.
Do not attempt to perform any type of repair or mainte-
nance on a Compact Track Loader until you have read
and fully understood the information in this manual.
Refer to the Operation and Maintenance manual for in-
structions regarding proper machine operation techniques
before operating any Compact Track Loader.
Prior to performing any type of service work on a
Compact Track Loader, read and understand Chap-
ter 1 (Product Safety) for personal safety infor-
mation.
Machine Preparation
Accidental machine starting can cause injury or
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 Load-
er.
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is be-
ing worked on.
Operator Enclosure
Disassembly and Assembly
Procedures
Disassembly and assembly procedures are provided
for the following operator enclosure components.
Light Bar
Ignition Switch
Gauges
Lap Bar Gas Assist Spring
Note: Procedures are provided for only those operator
enclosure components listed above. However, information
for removal and installation of other operator enclosure
components can be obtained from the machine specific
parts manual.
Light Bar Removal and
Installation
The tools required for light bar console removal and
installation are listed in Table 5-1. Use manufacturer
recommended tools whenever possible.
Table 5-1
Required Tools
Combination Wrench
Light Bar Removal
Figure 5-1
1. Loosen the two cap screws that attach the light
bar to the cab frame.

Compact Track Loader
5. Operator Enclosure Disassembly and Assembly
5-2
Figure 5-2
2. Carefully lower the light bar with the wire har-
ness attached.
Figure 5-3
3. View of light bar interior components. Interior
components are now accessible for servicing.
Figure 5-4
4. View of dome light. If removal is required, simply
insert a lever (blade-type screw driver) at oppo-
site end of switch in pry-pocket, and gently pry
the light assembly out of the light bar.
Light Bar Installation
Figure 5-5
1. Carefully position the light bar, without pinching
the wiring harness against the cab roof.
Figure 5-6
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 Table 5-2. Use manufactur-
er-recommended tools whenever possible.
Table 5-2
Required Tools
Combination Wrench
Ignition Switch Removal
1. Lower the light bar. Refer to Chapter 5. Light Bar
Removal procedure.

Compact Track Loader
5. Operator Enclosure Disassembly and Assembly
5-3
Figure 5-7
2. Remove the nut that secures the ignition switch
to the dash panel.
Figure 5-8
3. Pull the ignition switch out from the rear of the
dash panel.
Figure 5-9
4. Unplug the ignition switch connector.
Ignition Switch Installation
Figure 5-10
1. Insert the ignition switch from the rear of the
dash panel.
Figure 5-11
2. Install the nut that secures the ignition switch to
the dash panel.
Figure 5-12
3. Plug in the ignition switch connector.
Remove Nut
Install Nut