Service Manual

Compact Track Loader

PT-30 CE/ROW
Part Number: 2010-254
Printed (1-11)
 Table of Contents

1. Product Safety 6. Chassis Disassembly and Assembly

Chapter Overview ................................................... 1-1 Chapter Overview ................................................... 6-1
Basic Precautions ................................................... 1-1 Personal Safety....................................................... 6-1
Safety Labels ..................................................... 1-1 Machine Preparation ............................................... 6-1
Personal Protective Equipment.......................... 1-1 Chassis Disassembly and Assembly
Entering and Exiting ........................................... 1-2 Procedures.............................................................. 6-1
Lifting ................................................................. 1-2 Seat Removal and Installation ................................ 6-1
Hot Fluids and Components .............................. 1-2 Seat Removal .................................................... 6-1
Corrosion Inhibitor ............................................. 1-2 Seat Installation ................................................. 6-2
Batteries ............................................................ 1-2 Fuel Sending Unit Removal and Installation ........... 6-2
Pressurized Items .............................................. 1-2 Fuel Sending Unit Removal ............................... 6-3
Repair ..................................................................... 1-3 Fuel Sending Unit Installation ............................ 6-3
Attachments ............................................................ 1-4 Fuel Tank Removal and Installation ....................... 6-4
Machine Labels and Decals .................................... 1-4 Fuel Tank Removal ........................................... 6-4
Product ID Number ............................................ 1-4 Fuel Tank Installation......................................... 6-6
Safety Label Examples ...................................... 1-4
7. Radiator/Oil Cooler Disassembly
2. Technical Specifications and Assembly
PT-30 CE Specifications ......................................... 2-1 Chapter Overview ................................................... 7-1
PT-30 ROW Specifications ..................................... 2-2 Personal Safety....................................................... 7-1
Machine Preparation ............................................... 7-1
3. System Diagrams Radiator/Oil Cooler Disassembly and Assembly
Chapter Overview ................................................... 3-1 Procedures.............................................................. 7-1
Filtering and Cooling System .................................. 3-1 Fan Guard Removal and Installation ....................... 7-1
Auxiliary Circuit System .......................................... 3-2 Fan Guard Removal .......................................... 7-2
Drive Loop System .................................................. 3-3 Fan Guard Installation ....................................... 7-2
Fan and Fan Shroud Removal and Installation ....... 7-2
4. Machine Controls and Instrumentation Fan and Fan Shroud Removal ........................... 7-2
Chapter Overview ................................................... 4-1 Fan and Fan Shroud Installation........................ 7-3
Machine Controls .................................................... 4-1 Radiator/Cooler Removal and Installation ............... 7-4
Loader Control ................................................... 4-1 Radiator/Cooler Removal .................................. 7-4
Drive Control ...................................................... 4-1 Radiator/Cooler Installation ............................... 7-6
Throttle .............................................................. 4-1 Radiator/Oil Cooler Adjustment Procedures .......... 7-7
Instrumentation ....................................................... 4-1 Fan Shroud Adjustment ..................................... 7-7
Switches .................................................................. 4-2 Fan Guard Adjustment....................................... 7-8

5. Operator Enclosure Disassembly 8. Hydraulic Reservoir Disassembly

and Assembly and Assembly
Chapter Overview ................................................... 5-1 Chapter Overview ................................................... 8-1
Personal Safety ....................................................... 5-1 Personal Safety....................................................... 8-1
Machine Preparation ............................................... 5-1 Machine Preparation ............................................... 8-1
Operator Enclosure Disassembly and Assembly Hydraulic Reservoir Disassembly and Assembly
Procedures .............................................................. 5-1 Procedures.............................................................. 8-1
Light Bar Removal and Installation.......................... 5-1 Filter Element Removal and Installation .................. 8-1
Light Bar Removal ............................................. 5-1 Filter Assembly Removal and Installation ............... 8-1
Light Bar Installation .......................................... 5-2 Filter Assembly Removal ................................... 8-2
Ignition Switch Removal and Installation ................. 5-2 Filter Assembly Installation ................................ 8-3
Ignition Switch Removal .................................... 5-2 Access Cover Assembly Removal and Installation . 8-4
Ignition Switch Installation ................................. 5-3 Access Cover Assembly Removal ..................... 8-4
Gauge Removal and Installation ............................. 5-4 Access Cover Assembly Installation .................. 8-4
Gauge Removal ................................................. 5-4 Reservoir Gauge Removal and Installation ............. 8-5
Gauge Installation .............................................. 5-4 Reservoir Gauge Removal ................................ 8-5
Lap Bar Gas Assist Spring Removal Reservoir Gauge Installation ............................. 8-6
and Installation ........................................................ 5-5 Suction Screen Removal and Installation ............... 8-6
Lap Bar Gas Assist Spring Removal .................. 5-5 Suction Screen Removal ................................... 8-6
Lap Bar Gas Assist Spring Installation ............... 5-5 Suction Screen Installation ................................ 8-7
Hydraulic Reservoir Cleaning Procedures ............. 8-7

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Table of Contents

9. Loader/Transmission Controls Disassembly 12. Undercarriage Disassembly and Assembly

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

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 Compact Track Loader
Table of Contents

15. Troubleshooting
Chapter Overview ................................................. 15-1
Personal Safety ..................................................... 15-1
Machine Preparation ............................................. 15-1
Preliminary Inspection……………………………...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
Hydraulic Pressure Adjustment Procedures……..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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 1. Product Safety

Chapter Overview The person(s) in charge of servicing a Compact Track

This chapter contains product safety information for the Loader may be unfamiliar with many of the systems on
Terex PT-30 Compact Track Loaders. Read and the machine. This makes it especially important to use
understand all product safety information before caution when performing service tasks. Familiarize
attempting to service any Compact Track Loader. yourself with the affected system(s) and components
before attempting any type of maintenance or service.
Safety Alert Symbol
This symbol means: Attention! Be alert! Your It is not possible to anticipate every potential
safety is involved! hazard. The safety messages included in this
document and displayed on the machine are not
The safety alert symbol is used to alert you to potential all-inclusive. They are intended to make you aware
personal injury hazards. Obey all safety messages of potential risks and encourage a safe approach
that follow this symbol to avoid possible injury or to performing service work. If you use a tool,
death. procedure, work method or operating technique
that is not specifically recommended by Terex, you
This symbol is used as an attention-getting device must satisfy yourself that it is safe for you and
throughout this manual as well as on decals and labels others. You must also ensure that the machine will
fixed to the machinery to assist in potential hazard not be damaged or be made unsafe by the
recognition and prevention. operation, lubrication, maintenance or repair
procedures that you choose.
Property or equipment damage warnings in this
publication are identified by the signal word "NOTICE".
Basic Precautions
NOTICE
“NOTICE” Indicates a hazardous situation which, Safety Labels
if not avoided, could result in property or Safety labels have been included and are
equipment damage. displayed in various places throughout the machine to
serve as warnings of potentially dangerous conditions.
The word “Note” is used throughout this manual to Read and understand all "Safety" labels on any
draw your attention to specific topics or to supplement Compact Track Loader before attempting to operate,
the information provided in that section. maintain or repair it. Replace any damaged, illegible or
missing labels immediately, prior to service.

Improper or incomplete maintenance/repair of a

Compact Track Loader can be dangerous and
Personal Protective Equipment
may result in machine damage, injury or death. Personal protection equipment is recommended when
performing maintenance or service on a machine.
Do not attempt to perform any type of repair or
Always wear appropriate protective equipment for
maintenance on a Compact Track Loader until you
have read and fully understood both this manual and working conditions when working on or around the
the machine specific operation and maintenance machine. Loose clothing should not be worn and long
manual. hair should be restrained. Wear hard hats, protective
face/eyewear, safety shoes and any other equipment
Refer to the Operation and Maintenance manual for
necessary to ensure your safety and the safety of
instructions regarding proper machine operation and
maintenance techniques before operating or servicing others around you as you work.
any Compact Track Loader.

1-1
Compact Track Loader
1. Product Safety

Entering and Exiting Pressurized Items

Always use steps and handholds when entering or 1. Do not use hands or any other body part to check
exiting a Compact Track Loader. Clean any mud or for fluid leaks in the hydraulic system. Always use
debris from steps or work platforms before using them. a solid material like wood or metal to check for this
Always face the machine when using steps and type of leak. Leaking fluid under pressure can
handholds. When it is not possible to use the designed penetrate body tissue. Fluid penetration can cause
entry/exit system, utilize ladders, scaffolds, or work serious injury and even death. If fluid is injected
platforms to safely gain access to the machine. into your skin, get treatment immediately. Seek
treatment from a doctor that is familiar with this
Lifting type of injury.
Use a hoist when lifting components that weigh 23 kg
(50 Ib) or more, to avoid back injury. Make sure all 2. Relieve pressure from the hydraulic system before
chains, hooks, slings, etc., are in good condition and disconnecting or removing any lines, fittings or
are of the correct capacity. Be sure hooks are related items. Do this by relaxing all hydraulic
positioned correctly and equipped with a spring latch. actuators. If the lift arms are raised, make sure
Lifting eyes are not to be side loaded during a lifting they are securely braced. Be alert for possible
operation. pressure release when disconnecting any device
from a pressurized system.
Hot Fluids and Components 3. Lower the lift arms before performing any work on
Stay clear of hot components and system fluids of the the machine. If this cannot be done, make sure
engine, exhaust, radiator/oil cooler and hydraulic they are securely braced to prevent them from
lines/tubes. Also, use caution when removing fill caps, dropping unexpectedly during service.
breathers and plugs on the machine. Hold a rag over
the cap or plug to prevent being sprayed or splashed 4. Loose or damaged fuel, oil, hydraulic, lines, tubes
by liquids under pressure. Be especially careful if the and hoses can cause fires. Do not bend or strike
machine has been operated recently, fluids may still be high pressure lines or install ones that have been
hot. To ensure your safety, allow the machine to cool bent or damaged. Check lines, tubes and hoses
before attempting any service procedure that involves carefully. See item 1 for precautions on checking
hot fluids or components. for fluid leaks.

Corrosion Inhibitor 5. Pressurized air or water can also cause injury.

Corrosion inhibitor contains alkali. Avoid contact with When pressurized air or water is used for
eyes. Avoid prolonged or repeated contact with skin. cleaning, wear a protective face shield, protective
Do not take internally. In case of contact, wash skin clothing, and protective shoes. The recommended
immediately with soap and water. For eyes, flush with maximum air pressure for cleaning purposes is
large amounts of water for at least 15 minutes. Call 205 kPa (30 psi). When using a pressure washer,
Physician. Keep out of reach of children. keep in mind that nozzle pressures are typically
very high. Generally, pressures are well above
13790 kPa (2000 psi). Follow all recommended
Batteries practices provided by the pressure washer
Do not smoke when inspecting the battery electrolyte manufacturer.
level. Never disconnect any charging unit circuit or
battery circuit cable from the battery when the charging
unit is operating. A spark can cause an explosion from
the flammable vapor mixture of 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.

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 Compact Track Loader
1. Product Safety

Repair 8. Be prepared to stop an engine if it has been

Accidental machine starting can cause injury or recently overhauled or the fuel system has been
even death to personnel working on a Compact recently serviced. If the engine has not been
Track Loader. assembled correctly, or if the fuel settings are not
As a precaution, disconnect the battery cables from correct, the engine can possibly overspeed and
the battery terminals, tape the battery clamps and cause bodily injury, death or property damage. Be
remove the key from the ignition switch prior to prepared to shut off the fuel and air supply to the
performing any service work on a Compact Track engine in order to stop the engine.
Loader.
Place a “Do Not Operate” tag prominently on the 9. Be careful when removing cover plates. Gradually
machine to inform personnel that the machine is back off the last two bolts or nuts located on
being serviced. opposite sides of the cover. Then, pry the cover
loose to relieve any spring or other pressure
before removing the last two nuts or bolts
1. Disconnect the battery and discharge any completely.
capacitor before beginning work on a machine.
Attach a Do Not Operate tag in the cab to alert 10. Repairs requiring welding should be performed
any operator that service is in progress. only by personnel adequately trained and
knowledgeable in welding procedures and with the
2. If possible, make all repairs with the machine guidance of appropriate reference information.
parked on a level, hard surface. Use blocks to Determine the type of metal being welded and
prevent the machine from rolling while working on select the correct welding procedure and filler
or under the machine. material to provide a weld that is as strong or
stronger than the original weld.
3. Do not work on or under any machine that is v
supported only by a hydraulic jack or hoist. Always 11. Take precautions to avoid damaging wiring during
use some sort of mechanical support to ensure removal and installation operations. Carefully route
that the machine will not fall. Terex jack stands wires so that they will not contact sharp corners,
work well to support the machine while performing objects or hot surfaces during operation.
maintenance or repair work.
12. When performing service that requires the lift arms
4. Make sure the work area around the machine is to be in the raised position, always utilize the lift
safe and make yourself aware of any hazardous arm brace located on the rear of the loader tower.
conditions that may exist. If the engine needs to
be started inside an enclosure, make sure that the 13. Relieve hydraulic system pressure by relaxing all
engine’s exhaust is properly vented. hydraulic actuators prior to attempting any
hydraulic maintenance or repair.
5. Be sure all protective devices including guards and
shields are properly installed and functioning 14. Always tighten connections to the correct torque
correctly before beginning any service task. If a specification. Make sure that all shields, clamps
guard or shield must be removed to perform the and guards are installed correctly to avoid
repair work, use extra caution. excessive heat, vibration or unwanted contact
between parts during operation. Shields that
6. Always use the appropriate tools for the work to be protect exhaust components from oil spray in
performed. Tools should be in good condition and event of a line, tube or seal failure must be
you should understand how to use them properly correctly installed.
before performing any service work.
15. Do not operate a machine if any rotating part is
7. When replacing fasteners, use parts of equivalent damaged or contacts other parts during operation.
grade and size. Do not use a lesser quality Any high speed rotating component that has been
fastener if replacements are necessary. 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.

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Compact Track Loader
1. Product Safety

Attachments Safety Label Examples

Only use attachments that are recommended by Terex. Examples of the labels and decals displayed on the
machine are shown on this page.
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’s operation manual.
2030-415

When replacement parts are required for your

machine, use only genuine Terex replacement
parts or parts that meet or exceed original speci-
fications including, but not limited to physical dimen-
sions, type, strength and material.
Installing lesser components can lead to premature
failures, product damage, personal injury or death. 2030-416

Ensure that all personnel are far enough away from

the work area so they will not be struck by flying
objects.

Stay clear of the cutting edges, pinching

surfaces or crushing surfaces of the attachment
2030-425
while performing any attachment maintenance, testing
or adjustments.

Machine Labels and Decals

Labels and decals placed on the machine provide 2030-417

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 on 2030-551

the left side of the firewall next to the operator seat.

(figure 1-1). Always provide the PIN when contacting
the dealer about parts, service, warranty or
accessories. No warranty claims will be processed
unless the PIN is provided.
2030-418

2030-427

1-1

1-4
 Compact Track Loader
1. Product Safety

2030-420

2030-426

2030-565 2030-552

2030-553

1-5
 2. Technical Specifications
& Service Tools

PT-30CE Specifications Oil Cooler

- Operating pressure: 250 psi (1724 kPa)
Engine - Bypass relief pressure: 80 psi (551.6 kPa)
- Model: Perkins 403-D15 - Hot oil sending unit: 225°F (107.2°C)
- Displacement: 1.5 liter - Avg. oil operating temp. 50-60°F (10-16°C) above
- Gross horsepower: 29.5 hp (22 kW) ambient. (extreme application 80°F , 27°C above
- Peak Torque: 70.81 lb-ft. (96 Nm) ambient.)
- Idle rpm: 1175 (low idle), 2200 (high idle)
- Average water /thermostat temperature: 190°F, Critical Torque Specs
87.8°C - Transmission Mounting Bolts
-- 80 ft-lb (108 Nm). w/Blue Loctite
Transmission - Drive Sprocket Drive Teeth Bolts
- Model: Cat A10VG18 tandem (Rexroth) -- 62 ft-lb (84 Nm). -Dry
- Bogie Wheel Retaining Nuts
-- 110 ft-lb (149 Nm). - Dry
Drive Pumps (2)
- Drive Sprocket Retainer Bolt
- Displacement: 1.098 in3/rev (18 cc/rev)
-- 270 ft-lb (366 Nm)
- Relief pressure: 3800 psi (26,200 kPa)
- Flow: 10.45 gpm (39.6 lpm) @ 2200 rpm
(per pump) Service Tools
Listed below are common service tools which are
Charge Pumps (2) identified and utilized in the service procedures
- Displacement: .33 in3/rev (5.4 cc/rev) x2 described in this manual. Use tools recommended by
- Relief pressure: 360 +/- 20 psi (24.82 bar) Terex whenever possible to reduce risk of injury and or
- Flow: 3.2 gpm (12.11 lpm) @2200 rpm machine damage during service.

Drive Motors • Terex Jack Stands (2) (P/N: 0402-900)

• Heavy Duty Hydraulic Jack (5-ton rating)
- Model: Rexroth Sauer Danfoss
• Test Gauge Kit (P/N: 0402-935)
- Displacement: 19.215 in3/rev (314.9 cc/rev)
• Long Pry Bar(s)
• Service Cart (0402-871)
Pilot Controls (Joysticks)
- Model: Rexroth 4TH6

Auxiliary Pump
- Make: Rexroth
- Type: Gear
- Displacement: 0.87 in3/rev (14.3 cc/rev)
- Max Flow: 8.11 gpm (30.7 lpm) @ 2200 rpm
- Relief pressure: 3000 psi (20,684 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
attachment motor fails or contaminants are
introduced from the quick couplers.

Lift Arm Control Valve

- Make: Husco
- Relief Pressure: 3000 psi (20,684 kPa)
- Pilot pressure required to move spools: 180-220psi
(1241-1517 kPa)

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Compact Track Loader
2. Technical Specifications & Service Tools

PT-30 ROW Specifications Oil Cooler

- Operating pressure: 250 psi (1724 kPa)
Engine - Bypass relief pressure: 80 psi (551.6 kPa)
- Model: Perkins 403-D15 - Hot oil sending unit: 225°F (107.2°C)
- Displacement: 1.5 liter - Avg. oil operating temp. 50-60°F (10-16°C) above
- Gross horsepower: 32.7 hp (25.1 kW) ambient. (extreme application 80°F , 27°C above
- Peak Torque: 70.81 lb-ft. (96 Nm) ambient.)
- Idle rpm: 1175 (low idle), 2800 (high idle)
- Average water /thermostat temperature: 190°F, Critical Torque Specs
87.8°C - Transmission Mounting Bolts
-- 80 ft-lb (108 Nm). w/Blue Loctite
Transmission - Drive Sprocket Drive Teeth Bolts
- Model: Cat A10VG18 tandem (Rexroth) -- 62 ft-lb (84 Nm). -Dry
- Bogie Wheel Retaining Nuts
-- 110 ft-lb (149 Nm). - Dry
Drive Pumps
- Drive Sprocket Retainer Bolt
- Displacement: 1.098 in3/rev (18 cc/rev)
-- 60 ft-lb (81 Nm). w/Blue Loctite
- Relief pressure: 3800 psi (26,200 kPa)
- Flow: 13 gpm ( 11.4lpm) @ 2800 rpm (per pump)
Service Tools
Charge Pumps (2) Listed below are common service tools which are
- Displacement: .33 in3/rev (5.4 cc/rev) x2 identified and utilized in the service procedures
- Relief pressure: 360 +/- 20 psi (24.82 bar) described in this manual. Use tools recommended by
- Flow: 3 gpm (11.4 lpm combined) @1175 rpm Terex whenever possible to reduce risk of injury and or
- Flow: 8.1 gpm (30.7 lpm combined) @2800 rpm machine damage during service.

Drive Motors • Terex Jack Stands (2) (P/N: 0402-900)

• Heavy Duty Hydraulic Jack (5-ton rating)
- Model: Rexroth Sauer Danfoss
• Test Gauge Kit (P/N: 0402-935)
- Displacement: 19.215 in3/rev (314.9 cc/rev)
• Long Pry Bar(s)
• Service Cart (0402-871)
Pilot Controls (Joysticks)
- Model: Rexroth 4TH6

Auxiliary Pump
- Make: Rexroth
- Type: Gear
- Displacement: 0.87 in3/rev (14.3 cc/rev)
- Max Flow: 10 gpm (37.9 lpm) @ 2800 rpm
- Relief pressure: 3000 psi (20,684 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
attachment motor fails or contaminants are
introduced from the quick couplers.

Lift Arm Control Valve

- Make: Husco
- Relief Pressure: 3000 psi (20,684 kPa)
- Pilot pressure required to move spools: 180-220psi
(1241-1517 kPa)

2-2
 3. Circuit Diagrams

Chapter Overview Filtering and Cooling System

This chapter contains diagrams for the following The filtering and cooling system (Figure 3-1) contains
Compact Track Loader systems. the following major components.

• Filtering and cooling system • Hydraulic reservoir

• Auxiliary circuit system • Radiator/oil cooler
• Drive loop system • Loader valve
• Auxiliary gear pump
• Pilot control manifold
Figure 3-1 PT-30 Filtering and Cooling System

100psi (689.5 kPa)

3-1
Compact Track Loader
3. Circuit Diagrams

Auxiliary Circuit System

The auxiliary circuit system (Figure 3-2) contains the
following major components.
• Loader valve
• Pilot control manifold
• Auxiliary gear pump
• Loader control joystick

Figure 3-2 PT-30 Auxiliary Circuit System

3-2
 Compact Track Loader
3. Circuit Diagrams

Drive Loop System

The drive loop system (Figure 3-3) contains the fol-
lowing major components.
• Tandem pump
• Drive motors
• Pilot control manifold
• Drive control joystick

Figure 3-3 PT-30 Drive Loop System

TANDEM PUMP (WITH DRIVE

AND CHARGE PRESSURE
RELIEF VALVES.)
TO IMPLEMENT
VALVE
BRAKE

DRIVE MOTOR

TANK

Charge Reliefs
CASE DRAIN Drive Reliefs

CASE DRAIN

CHARGE PRESSURE
TEST PORT DRIVE MOTOR
DRIVE CONTROL

3-3
 4. Machine Controls and
Instrumentation

Chapter Overview Instrumentation

This chapter contains an overview of the machine The Instruments (Figure 4-2, 4-3) are positioned in the
controls and instrumentation. For further information overhead dash panel for ease of access and visibility
regarding machine controls, instrumentation or when seated inside the operator enclosure.
operation, refer to the operation and maintenance Instruments include the following components.
manual for your particular machine. Included here are
illustrations of the following controls and (1) Fuel Gauge
instrumentation components and a description of their (2) Tachometer
functions. (3) Engine Coolant Temp. Gauge
(4) Hour Meter
• Machine Controls (5) Warning Indicator Display
• Instrument Location and Function • Engine Oil Pressure Warning Light
• Switch Location and Function • Engine Temperature Warning Light
• Hydraulic Oil Temperature Warning Light
Machine Controls (fig. 4-1) • Battery Voltage Warning Light
There are three primary machine controls: loader
CE 2 3 4
control (1), drive control (2) and throttle (3).

Loader Control
The loader control (1) is a pilot operated joystick that
allows the operator to raise or lower the loader and
dump or curl the quick attach mechanism.
1 5
4-2
Drive Control
The drive control (2) is also a pilot operated joystick. It
allows the operator to change the direction and speed ROW 1 5 4

of the machine.

Throttle

4-3

NOTICE
If the engine temperature, engine oil pressure or hydraulic oil
1 2 temperature lights illuminate or should the eng. coolant temp.
gauge read excessive temperatures 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.
3

4-1 NOTICE
If the battery low-voltage light should illuminate during
The hand throttle (3) controls engine rpm. operation, drive the machine to a suitable location and shut
the engine off. Diagnose the problem and make any needed
repairs before resuming operation.

The glow plug operation light illuminates only when the

key switch is turned to engine pre-heat, showing
normal operation.

4-1
Compact Track Loader
4. Machine Controls and Instrumentation

PT-30 CE Switches
1 2 3 4 5 6 7 8 9 10 11

4-4

The various switches (Figure 4-4) are positioned to

provide good access and visibility. The standard and
optional switches are listed below.

(1) Driving lights (road mode) (7) Beacon light (optional)

(2) Work lights (8) Road mode (on road operation)
(3) Front wiper (optional) (9) Ignition, glow plug (pre-heat)
(4) Heater fan (optional) (10) Auxiliary hydraulics
(5) Turn signals (road mode) (11) Parking brake
(6) Hazard lights (road mode)

PT-30 ROW Switches

1 2 3 4 5 6

4-5

The various switches (Figure 4-5) 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

4-2
 5. Operator Enclosure
Disassembly and Assembly

Chapter Overview Operator Enclosure

This chapter provides disassembly and assembly Disassembly and Assembly
procedures for the operator enclosure assembly.
Procedures
Disassembly and assembly procedures are provided
Personal Safety for the following operator enclosure components.
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in Light Bar
machine damage, injury or death. Ignition Switch
Do not attempt to perform any type of repair or Gauges
maintenance on a Compact Track Loader until you have Lap Bar Gas Assist Spring
read and fully understood the information in this manual.

Refer to the Operation and Maintenance manual for Note: Procedures are provided for only those operator
instructions regarding proper machine operation enclosure components listed above. However, information
techniques before operating any Compact Track Loader. for removal and installation of other operator enclosure
components can be obtained from the machine specific
Prior to performing any type of service work on a parts manual.
Compact Track Loader, read and understand
Chapter 1 (Product Safety) for personal safety
information. Light Bar Removal and
Installation
Machine Preparation The tools required for light bar console removal and
installation are listed in Table 5-1. Use manufacturer
Accidental machine starting can cause injury or recommended tools whenever possible.
death to personnel working on a Compact Track
Loader. Table 5-1

As a precaution, disconnect the battery cables from Required Tools

the battery terminals, tape the battery clamps and Combination Wrench
remove the key from the ignition switch prior to
performing any service work on a Compact Track Light Bar Removal
Loader.

Place a “Do Not Operate” tag prominently on the

machine to inform personnel that the machine is
being worked on.

Figure 5-1

1. Loosen the two cap screws that attach the light

bar to the cab frame.

5-1
Compact Track Loader
5. Operator Enclosure Disassembly and Assembly

Light Bar Installation

Figure 5-2

2. Carefully lower the light bar with the wire

Figure 5-5
harness attached.
1. Carefully position the light bar, without pinching
the wiring harness against the cab roof.

Figure 5-3

3. View of light bar interior components. Interior

components are now accessible for servicing.

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
Figure 5-4
installation are listed in Table 5-2. Use
4. View of dome light. If removal is required, simply manufacturer-recommended tools whenever
insert a lever (blade-type screw driver) at possible.
opposite end of switch in pry-pocket, and gently Table 5-2
pry the light assembly out of the light bar.
Required Tools
Combination Wrench

5-2
 Compact Track Loader
5. Operator Enclosure Disassembly and Assembly

Ignition Switch Removal 4. Unplug the ignition switch connector.

1. Lower the light bar. Refer to Chapter 5. Light Bar
Removal procedure.
Ignition Switch Installation

Remove Nut

Figure 5-7 Figure 5-10

2. Remove the nut that secures the ignition switch 1. Insert the ignition switch from the rear of the
to the dash panel. dash panel.

Install Nut

Figure 5-8 Figure 5-11

3. Pull the ignition switch out from the rear of the 2. Install the nut that secures the ignition switch to
dash panel. the dash panel.

Figure 5-9 Figure 5-12

5-3
Compact Track Loader
5. Operator Enclosure Disassembly and Assembly

3. Plug in the ignition switch connector. 3. Remove the two nuts that secure the gauge to
the retaining bracket.
4. Install the light bar. Refer to Chapter 5. Light Bar
Installation procedure.

Gauge Removal and

Installation
The tools required for gauge removal and installation
are listed in Table 5-3. Use manufacturer
recommended tools whenever possible.
Table 5-3

Required Tools
Combination wrench
Figure 5-15

4. Pull the gauge out from the front of the dash

Gauge Removal panel.
1. Lower the light bar. Refer to Chapter 5. Light Bar
Removal procedure. Gauge Installation

Figure 5-13 Figure 5-16

2. Disconnect the connector from the gauge. 1. Insert the gauge from the front of the dash
panel.

Figure 5-14

Figure 5-17

5-4
 Compact Track Loader
5. Operator Enclosure Disassembly and Assembly

2. Install the two nuts that secure the gauge to the

retaining bracket.

Remove
Retaining Clip

Figure 5-20

Figure 5-18 2. Using a small screwdriver, remove the retaining

clip from each end of the gas assist spring.
3. Reconnect the gauge connector.

4. Install the light bar. Refer to Chapter 5. Light Bar

Installation procedure.

Lap Bar Gas Assist Spring

Removal and Installation
The tools required for gas assist spring removal and
installation are listed in Table 5-4. Use
manufacturer-recommended tools whenever
possible.
Figure 5-21
Table 5-4

Required Tools 3. Remove the gas assist spring by pulling both

ends out from the ball joints.
Screwdriver

Lap Bar Gas Assist Spring Installation

Lap Bar Gas Assist Spring Removal

Gas Assist
Gas Assist Spring Location
Spring

Raise Lap Bar

Raise Lap Bar (Shown in Down
(Shown in Down Position)
Position)
Figure 5-22
Figure 5-19
1. Put the lap bar in the UP position to minimize
1. Put the lap bar in the UP position to relieve tension on the lap bar gas assist spring during
tension on the lap bar gas assist spring. installation.

5-5
Compact Track Loader
5. Operator Enclosure Disassembly and Assembly

Install Ends on
Ball Joints

Figure 5-23

2. Install the ends of the lap bar gas assist spring

onto the ball joints.

Insert
Retaining Clip

Figure 5-24

3. Slide the retaining clip on to each end of the gas

assist spring.

5-6
 6. Chassis
Disassembly and Assembly

Chapter Overview Chassis Disassembly and

This chapter provides disassembly and assembly Assembly Procedures
procedures for the chassis assembly.
Disassembly and assembly procedures are provided
for the following chassis components.
Personal Safety • Seat
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in
• Fuel Sending Unit
machine damage, injury or death. • Fuel Sending Unit Hose
Do not attempt to perform any type of repair or • In-Tank Weight
maintenance on a Compact Track Loader until you have
read and fully understood the information in this manual. • Fuel Tank
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation Note: Procedures are provided for only those chassis
techniques before operating any Compact Track Loader. components listed above. However, information for
removal and installation of other chassis components can
Prior to performing any type of service work on a be obtained from the exploded view illustration provided in
Compact Track Loader, read and understand the machine specific parts manual.
Chapter 1 (Product Safety) for personal safety
information.
Seat Removal and Installation
The tools required for seat removal and installation
Machine Preparation are listed in Table 6-1. Use manufacturer-
recommended tools whenever possible.
Accidental machine starting can cause injury or
death to personnel working on a Compact Track Table 6-1
Loader.
Required Tools
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and Socket Wrench
remove the key from the ignition switch prior to
performing any service work on a Compact Track Seat Removal
Loader.
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is
being worked on.
Remove Seat Bolts

Figure 6-1

1. Remove the four bolts that fasten the seat

mounts to the frame.

6-1
Compact Track Loader
6. Chassis Disassembly and Assembly

Unplug
Connector
Plug in the Connector
Figure 6-2
Figure 6-5
2. Tilt the seat forward and reach behind the seat
to unplug the seat switch wiring harness. 2. Tilt the seat forward and reach behind the seat
to plug in the seat switch connector

Note: The machine will not operate unless the seat switch
connector is plugged in.

insert Seat Bolts

Figure 6-3

3. Remove the seat. Be careful not to scratch the

control panel or sides of the cab.
Figure 6-6

Seat Installation 3. Position the seat so the holes in the seat mounts
are aligned with the holes in the frame. Insert
the four seat mount bolts and washers.

Fuel Sending Unit Removal

and Installation
The tools required for fuel sending unit removal and
installation are listed in Table 6-2. Use
manufacturer-recommended tools whenever
possible.
Table 6-2
Figure 6-4
Required Tools
1. With the seat mounts attached, place the seat in Screwdriver
the cab. Be careful not to scratch the control Combination Wrench
panel or sides of the cab. Socket Wrench

6-2
 Compact Track Loader
6. Chassis Disassembly and Assembly

Fuel Sending Unit Removal

1. Remove the seat. Refer to Chapter 6. Seat
Removal procedure.
2. Pump fuel from the tank until there is no fuel
remaining above the sending unit.

Collect and contain liquids in a suitable

container. Dispose of all liquids according to local
regulations and mandates.

Figure 6-9

Fuel 5. The fuel pickup line will also come out with the
Sending fuel sending unit.
Unit

Fuel Sending Unit Installation

Figure 6-7

3. Remove the hoses and wires from the fuel

sending unit, then remove the screws that fasten
the unit to the tank. Mark the wires and hoses.

Note: If the fuel sending unit wires are crossed, the fuel
gauge will not work. If the hoses are crossed, the engine
will not run. Figure 6-10

1. Insert the fuel pickup line into the fuel tank

opening. The pickup line is attached to the fuel
sending unit.

Note: The weight on the end of the fuel pickup line must
rest on the bottom of the tank for proper operation.

Figure 6-8

4. Remove the fuel sending unit. Be careful not to

damage the float mechanism when pulling it
through the opening in the fuel tank.

6-3
Compact Track Loader
6. Chassis Disassembly and Assembly

Fuel Tank Removal and

Installation
The tools required for fuel tank removal and
installation are listed in Table 6-3. Use
manufacturer-recommended tools whenever
possible.
Table 6-3

Required Tools
Screwdriver
Combination Wrench
Figure 6-11 Socket Wrench

2. Insert the fuel sending unit float mechanism into

the fuel tank opening. Be careful not to damage
the float when pushing it through the opening.
Fuel Tank Removal
1. Remove the seat. Refer to Chapter 6. Seat
Note: Make sure that the wire on the sending unit is not Removal procedure.
bent and the fuel pickup line does not interfere with the
movement of the float.

Fuel
Sending
Unit

Figure 6-13

2. View of fuel tank with seat removed.

Figure 6-12

3. Connect the hoses and wires to the fuel sending 3. Pump all fuel from the fuel tank.
unit, then install the screws that fasten the unit
to the tank.
Collect and contain liquids in a suitable
container. Dispose of all liquids according to local
Note: Be careful not to cross the wires or hoses. If the
regulations and mandates.
fuel sending unit wires are crossed, the fuel gauge will not
work. If the hoses are crossed, the engine will not run.

4. Install the seat. Refer to Chapter 6. Seat

Installation procedure.

6-4
 Compact Track Loader
6. Chassis Disassembly and Assembly

Remove Floor
Pan Bolts
Remove
Filler Piece

Figure 6-14 Figure 6-17

4. Remove the four bolts that hold the floor pan to 7. Remove the steel filler piece behind the fuel
the frame. tank.

Remove
Bolt

Figure 6-15 Figure 6-18

5. Remove the floor pan. 8. Remove the bolt that fastens the fuel tank to the
frame.

Fuel
Sending
Unit
Disconnect
Vent Hose

Figure 6-16
Figure 6-19
6. Remove the hoses and wires from the fuel
sending unit. 9. Disconnect the rubber vent hose from the fuel
tank.

6-5
Compact Track Loader
6. Chassis Disassembly and Assembly

Attach
Remove
Filler Hose
Filler Hose

Figure 6-20 Figure 6-23

10. Remove the rubber filler hose from the back end 2. Attach the filler hose to the rear of the tank.
or the tank.

Connect
Vent Hose

Figure 6-24
Figure 6-21
3. Connect the vent hose to the fuel tank.
11. Remove the tank carefully from the machine.

Fuel Tank Installation

Insert
Bolt and
Washer

Figure 6-25

4. Insert the bolt and washer that connect the fuel

Figure 6-22
tank to the frame.

1. Place the fuel tank in the machine in

approximately its normal position.

6-6
 Compact Track Loader
6. Chassis Disassembly and Assembly

Install Floor Pan

Bolts and Washers

Insert
Filler Piece

Figure 6-26 Figure 6-29

5. Insert the steel filler piece behind the fuel tank. 8. Install the four floor pan bolts and washers.
9. Install the seat. Refer to Chapter 6. Seat
Installation procedure.
Fuel
Sending
Unit

Figure 6-27

6. Attach the hoses and wiring to the fuel sending

unit.

Figure 6-28

7. Replace the floor pan.

6-7
 7. Radiator/Oil Cooler
Disassembly and Assembly

Chapter Overview Radiator/Oil Cooler

This chapter provides disassembly and assembly Disassembly and Assembly
procedures for the radiator/oil cooler assembly. Ad-
justment procedures are also included for selected Procedures
radiator/oil cooler components. Disassembly and assembly procedures are provided
for the following radiator/oil cooler components.

Personal Safety • Fan Guard

Improper or incomplete maintenance/repair of a Compact • Fan Shroud
Track Loader can be dangerous and may result in ma-
chine damage, injury or death. • Fan
• Multi-Wing Fan
Do not attempt to perform any type of repair or mainten-
ance on a Compact Track Loader until you have read and • Radiator/Cooler
fully understood the information in this manual.
Note: Procedures are provided for only those radiator/oil
Refer to the Operation and Maintenance manual for in- cooler components listed above. However, information for
structions regarding proper machine operation techniques removal and installation of other radiator/oil cooler compo-
before operating any Compact Track Loader. nents can be obtained from the machine specific parts
Prior to performing any type of service work on a manual.
Compact Track Loader, read and understand Chap-
ter 1 (Product Safety) for personal safety informa-
tion. Note: Refer to Figure 3-1 for an overview of the filtering
and cooling system.

Machine Preparation Fan Guard Removal and

Accidental machine starting can cause injury or
death to personnel working on a Compact Track
Installation
Loader. The tools required for fan guard removal and instal-
lation are listed in Table 7-1. Use manufacturer-
As a precaution, disconnect the battery cables from recommended tools whenever possible.
the battery terminals, tape the battery clamps and Table 7-1
remove the key from the ignition switch prior to per-
forming any service work on a Compact Track Load- Required Tools
er.
Combination Wrench
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is be-
ing worked on.

7-1
Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly

Fan Guard Removal Fan and Fan Shroud Removal

and Installation
The tools required for fan and fan shroud removal
and installation are listed in Table 7-2. Use manufac-
turer-recommended tools whenever possible.
Table 7-2

Fan Required Tools

Guard Combination Wrench
Mount
Fan Socket Wrench
Guard

Figure 7-1
Fan and Fan Shroud Removal
1. Remove the capscrews that secure the fan
guard to the fan guard mounts. Hot fluids can cause burns. Allow the machine
to cool thoroughly prior to proceeding.

2. Remove the fan guard from the engine com-

partment.

Remove
Hose
Fan Guard Installation
1. Position the fan guard over the fan and against
the fan shroud.

Figure 7-3

1. Remove the upper hose from the oil cooler sec-

Fan tion. Cap the hose and fitting.
Guard
Mount
Fan
Guard 2. Remove the fan guard. Refer to Chapter 7. Fan
Guard Removal.

Figure 7-2

2. Install the capscrews that secure the fan guard

to the fan guard mounts.

7-2
 Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly

Remove
Bolts

Figure 7-4 Figure 7-7

3. Remove the three bolts from each side of the 6. Remove the shroud from the engine compart-
fan shroud that secure the shroud to the radia- ment.
tor/cooler.

Fan and Fan Shroud Installation

Fan
Shroud

Remove
Bolts

Figure 7-5

Figure 7-8
4. With the shroud pulled back, reach between the
radiator/cooler and the fan and remove the four
1. Place the fan shroud in the engine compartment.
bolts that secure the fan to the engine.

Figure 7-9
Figure 7-6
2. Place the fan in the engine compartment.
5. Remove the fan from the engine compartment.

7-3
Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly

Radiator/Cooler Removal and

Installation
The tools required for radiator/cooler removal and
installation are listed in Table 7-3. Use manufactur-
er-recommended tools whenever possible.
Table 7-3

Required Tools
Install
Bolts Combination Wrench
Socket Wrench
Screwdriver
Figure 7-10

3. Holding the fan in position between the radia-

tor/cooler and the fan shroud, install the four Radiator/Cooler Removal
bolts that secure the fan to the fan drive motor.

Hot oil can cause personal injury. Make sure the

oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
Install stopped and has been allowed to cool thoroughly.
Bolts

Personal injury can result from hot coolant,

steam and alkali.
At operating temperature, engine coolant is hot and
under pressure. The radiator and hoses contain hot
coolant and steam. Allow the machine to cool tho-
roughly prior to performing service or repair proce-
dures to avoid burns.
Figure 7-11
Remove the filler cap slowly to relieve pressure only
4. Pull the shroud over the fan and install the three when the engine is stopped and the machine has been
bolts on each side of the fan shroud that secure allowed to cool thoroughly.
the shroud to the radiator/cooler. Cooling system conditioner contains alkali. Avoid
contact with skin and eyes.
5. Install the fan guard. Refer to Chapter 7. Fan
Guard Installation.
Collect and contain liquids in a suitable contain-
er. Dispose of all liquids according to local regula-
tions and mandates.

Install
Hose 1. Remove fan and shroud. Refer to Chapter 7.
2. Drain the hydraulic fluid. Refer to Chapter 16.
Hydraulic Fluid and Filter Change.

Figure 7-12

6. Install the upper hose on the oil cooler section.

7-4
 Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly

Remove
Hose

Figure 7-13 Figure 7-16

3. Remove the bolts from the lower engine com- 6. Remove the upper hose from the oil cooler sec-
partment screen. tion. Cap the hose and fitting.

Drain
Coolant

Figure 7-14 Figure 7-17

4. Remove the lower engine compartment screen 7. Remove the upper hose from the radiator sec-
and drain the coolant using the petcock on the tion. Cap the hose and fitting.
bottom of the radiator.

Figure 7-15 Figure 7-18

5. Remove the lower hose from the oil cooler sec- 8. Remove the lower hose from the radiator sec-
tion. Cap the hose and fitting. tion. Cap the hose and fitting.

7-5
Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly

Remove Install
Bolts Bolts

Figure 7-19 Figure 7-22

9. Remove the three mounting bolts on each side 2. With the radiator/cooler in position, install the
of the radiator/cooler. three mounting bolts on each side of the radia-
tor/cooler.

Figure 7-20
Figure 7-23
10. Remove the radiator/cooler from the engine
compartment. 3. Remove the hose and fitting caps and install the
lower hose on the radiator section.
Radiator/Cooler Installation

Figure 7-24
Figure 7-21
4. Remove the hose and fitting caps and install the
1. Position the radiator/cooler in the engine com- upper hose on the radiator section.
partment.

7-6
 Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly

8. Fill the radiator with coolant and the hydraulic

reservoir with oil.

Install
Hose
Radiator/Oil Cooler
Adjustment Procedures
Adjustment procedures are provided for the follow-
ing radiator/oil cooler components.

• Fan Shroud
• Fan Guard
Figure 7-25

5. Remove the hose and fitting caps and install the Fan Shroud Adjustment
upper hose on the oil cooler section.
The tools required for fan shroud adjustment are
listed in Table 7-4. Use manufacturer-recommended
tools whenever possible.
Table 7-4

Tool Name
Combination Wrench

Loosen
Bolts
to Adjust

Figure 7-26

6. Remove the hose and fitting caps and install the

lower hose on the oil cooler section.

Figure 7-28

1. The fan shroud can adjusted upward or down-

ward. To adjust, loosen the bolts on each side of
the shroud and move the shroud in the desired
direction. Tighten the bolts when finished.

Figure 7-27

7. Position the lower engine compartment screen

and secure with the mounting bolts.

7-7
Compact Track Loader
7. Radiator/Oil Cooler Disassembly and Assembly

Fan Guard Adjustment

The tools required for fan guard adjustment are
listed in Table 7-5. Use manufacturer-recommended
tools whenever possible.
Table 7-5

Tool Name
Combination Wrench

Loosen
Capscrews
to Adjust

Figure 7-29

1. The fan guard can adjusted forward or rearward.

To adjust, loosen the capscrews that fasten the
fan guard to the fan guard mounts. Tighten the
capscrews when finished.

7-8
 8. Hydraulic Reservoir
Disassembly and Assembly

Chapter Overview Hydraulic Reservoir

This chapter provides disassembly and assembly Disassembly and Assembly
procedures for the hydraulic reservoir assembly.
Cleaning procedures are also included for the Procedures
hydraulic reservoir. Disassembly and assembly procedures are provided
for the following hydraulic reservoir components.

Personal Safety • Filter Element

Improper or incomplete maintenance/repair of a Compact • Filter Assembly
Track Loader can be dangerous and may result in
• Filler Cap Assembly
machine damage, injury or death.
• Access Cover Assembly
Do not attempt to perform any type of repair or • Reservoir Gauge
maintenance on a Compact Track Loader until you have
read and fully understood the information in this manual. • Suction Screen

Refer to the Operation and Maintenance manual for

Note: Procedures are provided for only those hydraulic
instructions regarding proper machine operation
reservoir components listed above. However, information
techniques before operating any Compact Track Loader.
for removal and installation of other hydraulic reservoir
Prior to performing any type of service work on a components can be obtained from the Compact Track
Compact Track Loader, read and understand Loader Parts List manual.
Chapter 1 (Product Safety) for personal safety
information.
Note: Refer to Figure 3-1 for an overview of the filtering
and cooling system.

Machine Preparation
Accidental machine starting can cause injury or Filter Element Removal and
death to personnel working on a Compact Track
Loader. Installation
Refer to Chapter 16. Maintenance – Hydraulic Fluid
As a precaution, disconnect the battery cables from and Filter for removal and installation of the filter.
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. Filter Assembly Removal and
Place a “Do Not Operate” tag prominently on the
Installation
machine to inform personnel that the machine is The tools required for filter assembly removal and
being worked on. installation are listed in Table 8-1. Use
manufacturer-recommended tools whenever
possible.
Table 8-1

Required Tools
Combination/Socket Wrenches
Needle Nose Pliers

8-1
Compact Track Loader
8. Hydraulic Reservoir Disassembly and Assembly

Filter Assembly Removal

Hot oil can cause personal injury. Make sure the

oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and the machine has been allowed to cool
thoroughly

Note: During disassembly, cap all hoses and fittings to

prevent fluid loss and contamination of the system fluids.

Figure 8-3

3. Remove the filter from the reservoir as shown.

Figure 8-1

1. Remove the screws securing the cover to the

filter assembly.
Figure 8-4

4. Disconnect the hose from the filter assembly.

Figure 8-2

2. Remove the cap from the filter assembly as

shown. Figure 8-5

5. Remove the bolts securing the filter head

assembly to the reservoir.

8-2
 Compact Track Loader
8. Hydraulic Reservoir Disassembly and Assembly

Figure 8-6 Figure 8-9

6. Remove the filter head and gasket from the 3. Reconnect the hose to the filter head and
reservoir. secure.

Filter Assembly Installation

Figure 8-10

Figure 8-7
4. Reinstall the filter and filter tube into the
reservoir as shown.
1. Place the filter assembly gasket in position on
top of the reservoir. Replace if damaged.

Figure 8-11

Figure 8-8 5. Install the cap onto the filter head as shown.
2. Position the filter head onto the gasket with the
mounting holes aligned, install bolts.

8-3
Compact Track Loader
8. Hydraulic Reservoir Disassembly and Assembly

1. Slightly loosen the access cover bolt to separate

the upper cap from the oval-shaped clamping
disk on the underside of the assembly. This will
allow the assembly to be removed. Do not
remove the bolt entirely or the oval-shaped
clamp will fall into the reservoir.

Figure 8-12

6. Install the cap bolts and tighten to secure.

Access Cover Removal and

Installation
The tools required for access cover removal and Figure 8-14
installation are listed in Table 8-2. Use
manufacturer-recommended tools whenever 2. Remove the access cover assembly from the
possible. reservoir.
Table 8-2

Required Tools Access Cover Assembly Installation

Combination Wrench

Access Cover Assembly Removal

Hot oil can cause personal injury. Make sure the

oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and the machine has been allowed to cool
thoroughly

Figure 8-15

1. Insert the access cover assembly with the

clamping disk extending completely through the
opening in the top of the reservoir and into the
tank.

Figure 8-13

8-4
 Compact Track Loader
8. Hydraulic Reservoir Disassembly and Assembly

Figure 8-16 Figure 8-17

2. Tighten the access cover bolt. 3. View of hydraulic reservoir with filter assembly
removed.

Reservoir Gauge Removal and

Installation
The tools required for reservoir gauge removal and
installation are listed in Table 8-3. Use
manufacturer-recommended tools whenever
possible.
Table 8-3

Required Tools
Combination Wrenches

Reservoir Gauge Removal Figure 8-18

4. Reach inside the reservoir and remove the two

Hot oil can cause personal injury. Make sure the nuts that fasten the reservoir gauge to the
oil is cool before removing any components or lines. reservoir.
Remove the oil filler cap only when the engine is
stopped and the machine has been allowed to cool
thoroughly

Collect and contain liquids in a suitable Remove Re-

container. Dispose of all liquids according to local servoir Gauge
regulations and mandates. with Mounting
Bolts/Washers

Note: During disassembly, cap all hoses and fittings to

prevent fluid loss and contamination of the system fluids.

Figure 8-19
1. Drain the hydraulic fluid. Refer to Chapter 16.
Hydraulic Fluid and Filter Change. 5. Pull the reservoir gauge and the two mounting
bolts/washers off the reservoir. DO NOT
2. Remove the filter assembly. Refer to Chapter 8. misplace the rubber washers or the reservoir will
Filter Assembly Removal. leak.

8-5
Compact Track Loader
8. Hydraulic Reservoir Disassembly and Assembly

Reservoir Gauge Installation Table 8-4

Required Tools
Combination Wrench

Suction Screen Removal

Insert Reser-
voir Gauge
with Mounting
Bolts/Washers Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and the machine has been allowed to cool
thoroughly

Figure 8-20
Collect and contain liquids in a suitable
1. Install the reservoir gauge in the reservoir using container. Dispose of all liquids according to local
the two mounting bolts/washers. regulations and mandates.

Note: It is normally not necessary to replace the suction

screen unless there has been a catastrophic failure and
there is debris in the reservoir.

1. Drain the hydraulic fluid. Refer to Chapter 16.

Hydraulic Fluid and Filter Change.

2. Remove the access cover assembly. Refer to

Chapter 8. Access Cover Assembly Removal.

Figure 8-2113

2. Reach inside the reservoir and install the two

nuts that secure the reservoir gauge to the
reservoir.

3. Install the filter assembly. Refer to Chapter 8.

Filter Assembly Installation.

4. Add manufacturer-approved hydraulic fluid.

Suction Screen Removal and

Installation
Figure 8-22
The tools required for suction screen removal and
installation are listed in Table 8-4. Use 3. With a magnet centered in an absorbent rag,
manufacturer-recommended tools whenever thoroughly clean the interior of the reservoir to
possible. prevent any debris from entering the system
when you remove the suction filter.

8-6
 Compact Track Loader
8. Hydraulic Reservoir Disassembly and Assembly

Hydraulic Reservoir Cleaning

Procedures
Cleaning procedures are provided for the following
hydraulic reservoir components.

• Hydraulic Reservoir

Hydraulic Reservoir Cleaning

The tools required for hydraulic reservoir cleaning
are listed in Table 8-5. Use
manufacturer-recommended tools whenever
Figure 8-23 possible.
Table 8-5
4. Reach inside the reservoir and unscrew the
suction screen. Remove the suction screen from Tool Name
the reservoir.
Combination Wrench

Suction Screen Installation

Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and the machine has been allowed to cool
thoroughly

Collect and contain liquids in a suitable

container. Dispose of all liquids according to local
regulations and mandates.

1. Drain the hydraulic fluid. Refer to Chapter 16.

Figure 8-24 Hydraulic Fluid and Filter Change.

1. Insert the suction screen in the reservoir through 2. Remove the access cover assembly. Refer to
the access cover opening. Chapter 8. Access Cover Assembly Removal.

2. Reach inside the reservoir and screw the suction 3. Thoroughly wipe out the interior of the hydraulic
screen into the bottom of the reservoir. reservoir with a magnet and a clean rag.

3. Install the access cover assembly. Refer to 4. Install the access cover assembly. Refer to
Chapter 8. Access Cover Assembly Installation. Chapter 8. Access Cover Assembly Installation.

4. Add manufacturer-approved hydraulic fluid. 5. Add manufacturer-approved hydraulic fluid.

8-7
 9. Loader/Transmission Controls
Disassembly and Assembly

Chapter Overview Loader/Transmission Controls

This chapter provides disassembly and assembly Disassembly and Assembly
procedures for the loader and transmission controls. Procedures
Disassembly and assembly procedures are provided
Personal Safety for the following loader/transmission control
Improper or incomplete maintenance/repair of a Compact components.
Track Loader can be dangerous and may result in machine • Drive Control Joystick
damage, injury or death. • Loader Control Joystick
• Loader Float Magnet
Do not attempt to perform any type of repair or maintenance
• Loader Valve
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 instructions Note: Procedures are provided for only those
regarding proper machine operation techniques before loader/transmission control components listed above.
operating any Compact Track Loader. However, information for removal and installation of
other loader/transmission control components can be
Prior to performing any type of service work on a Compact obtained from the Compact Track Loader Parts List
Track Loader, read and understand Chapter 1 (Product manual.
Safety) for personal safety information.
Note: Refer to Figure 3-2 for an overview of the
Machine Preparation auxiliary circuit system and Figure 3-3 for an overview
Accidental machine starting can cause injury or death to of the drive loop system.
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 Loader Control Joystick/Drive
key from the ignition switch prior to performing any service Control Joystick Removal and
work on a Compact Track Loader.
Installation
Place a “Do Not Operate” tag prominently on the machine to
inform personnel that the machine is being worked on.
There are two joysticks that control the operation of the
machine: a drive control joystick and a loader control
joystick.

Drive Control Joystick Operation – The left-hand

joystick controls the speed and direction of the
ma-chine. The further the joystick is pushed, the faster
the machine travels. The joystick operates on
hy-draulic charge pressure. When the joystick is
moved, oil is sent to the hydrostatic transmission. The
transmission then delivers oil, in the correct amount, to
the drive motors.

9-1
Compact Track Loader
9. Loader/Transmission Controls

Loader Control Joystick Operation – The right-hand

joystick controls the loader arm and the at-tachment tilt
cylinder. It allows the operator to raise, lower and pivot
the attachment. The joystick operates on hydraulic
charge pressure.

The loader control also has a float position, which is

activated by moving the joystick completely forward
until it is held in detent. The joystick is held in the
forward float position by an electromagnet.

The tools required for loader/drive control joystick

removal and installation are listed in Table 9 1. Use Figure 9-1
manufacturer recommended tools whenever possible. 5. Remove the various screws holding the plastic
side consoles to the cab enclosure as shown.
Table 9-1

Required Tools
Combination/Socket Wrenches
Screwdriver (phillips)

Loader Control Joystick/Drive Control

Joystick Removal

Note: The procedures for removing both joystick

controls are nearly identical, as a result, only the right
control joystick procedure is described below.

Note: During disassembly, cap and plug all hoses and

fittings to prevent fluid loss and contamination of the Figure 9-2
system fluids. 6. Pivot the panel away from the joystick, then lift and
remove it from the machine.
Relax all hydraulic circuits/controls and make
sure the oil is cool before disconnecting any
component or line from the system.
Pressurized and or hot hydraulic fluid can cause
personal injury.

1. Remove the seat from the machine according to

the procedure in chapter 6, seat removal.

2. Lower the lift arms to the ground.

Figure 9-3
3. Turn the ignition switch to the OFF position.
7. Remove the three nuts securing the joystick mount
to the cab enclosure from the outside of the
4. Relax all hydraulic circuits. machine.

9-2
 Compact Track Loader
9. Loader/Transmission Controls

Note: If it is neccessary to remove the left joystick on a

machine equipped with a heater, you must disconnect
the heater lines at the heater unit in order to remove
the side panel. Cap and plug hoses and ports to
minimize coolant loss.

Loader Float Magnet Removal and

Installation
The tools required for loader float magnet removal and
installation are listed in Table 9-2. Use manufacturer
Figure 9-4 recommended tools whenever possible.
8. Pull the joystick away from the cab wall as shown. Table 9-2
Required Tools
Allen (hex) Wrenches
Combination Wrenches
Screwdriver

Loader Float Magnet Removal

Figure 9-5
9. The hydraulic hoses are now accessible. Label
them and the ports they connect to to aid during
reassembly, then disconnect them and cap and
Figure 9-7
plug the openings to prevent spills.
1. Remove the zip tie securing the lower portion of
the joystick boot to the joystick as shown.

Remove

Figure 9-6
10. Disconnect the electrical connections shown to
Figure 9-8
free the joystick from the machine, then remove.
2. Lift the boot to expose the magnet and joystick
mounting bolts. Remove the joystick mounting
11. Reverse the removal procedure to reinstall the joy bolts to allow the joystick to be moved upward
stick. Take care to ensure all connections are to within the bracket.
the appropriate ports on the joystick and that they
are tight and leak free.

9-3
Compact Track Loader
9. Loader/Transmission Controls

Loader Valve Removal and

Installation
The tools required for loader valve removal and
installation are listed in Table 9 3. Use manufacturer-
recommended tools whenever possible.
Table 9-3
Required Tools
Combination Wrenches

Loader Valve Removal

Figure 9-9
Hot oil can cause personal injury. Lower all
3. Use an allen (hex) wrench to remove the bolt
attach-ments and make sure the oil is cool
securing the magnet to the joystick. before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and the filler cap is cool enough to touch
with your hands.

Collect and contain liquids in a suitable

container. Dispose of all liquids according to
local regulations and mandates.

Note: During disassembly, cap all hoses and fittings to

prevent fluid loss and contamination of the system
fluids.
Figure 9-10
4. Lift the joystick out of the mounting bracket slightly 1. Lower the lift arms to the ground.
to allow the magnet connector to pass between
them, then remove the magnet.
2. Turn the engine start switch to the OFF position.

5. To install the float magnet, reverse the removal

procedure. 3. Relieve hydraulic pressure from the auxiliary cir
cuit.

4. Drain the hydraulic fluid. Refer to Chapter 16.

Hydraulic Fluid and Filter Change.

9-4
 Compact Track Loader
9. Loader/Transmission Controls

Figure 9-11 Figure 9-14

5. Disconnect the gas springs, then press the spring 8. Carefully remove the rear valance from the
latches inward as shown to remove the hood. machine to allow access to the loader valve.

Figure 9-12 Figure 9-15

6. Carefully remove the hood from the machine and 9. Locate the loader valve on the side of the
set it aside. hydraulic reservoir.

Figure 9-13 Figure 9-16

7. Remove the bolts securing the rear valance panel 10. Disconnect the tubes from the top and bottom of
to the chassis to allow for removal. the loader valve. Cap and plug all openings to
prevent fluid loss.

9-5
Compact Track Loader
9. Loader/Transmission Controls

Figure 9-17 Figure 9-20

11. Disconnect the tubes from the side of the loader 14. Remove the valve from the machine.
valve. Cap and plug all openings to prevent fluid
loss.
15. Installation is the reverse of the removal
procedure.

16. Once all components have been reinstalled and

are secure, add manufacturer approved hydraulic
fluid until full mark is reached on the level gauge.

Note: To eliminate trapped air from the system,

activate all hydralic circuits and run machine through
its paces including moving the lift arms up and down,
curling and tilting the Q/A, driving forward and in
reverse, and activating the auxiliary circuit. Then,
Figure 9-18 check hydraulic fluid level and add as required to
12. Disconnect the hoses from the rear and side of the reach full mark.
loader valve. Cap and plug all openings to prevent
fluid loss.

Figure 9-19
13. Remove the nuts securing the valve to the
reservoir as shown.

9-6
 10. Transmission and Drive
Disassembly and Assembly

Chapter Overview Transmission and Drive

This chapter provides disassembly and assembly Disassembly and Assembly
procedures for the transmission and drive assembly.
Procedures
Disassembly and assembly procedures are provided
Personal Safety for the following transmission and drive components.
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in Drive Motors
machine damage, injury or death. Auxiliary Gear Pump
Do not attempt to perform any type of repair or Tandem Pump
maintenance on a Compact Track Loader until you have
Pump Drive Coupler
read and fully understood the information in this manual.

Refer to the Operation and Maintenance manual for Note: Procedures are provided for only those transmission
instructions regarding proper machine operation and drive components listed above. However, information
techniques before operating any Compact Track Loader. for removal and installation of other transmission and drive
components can be obtained from the machine specific
Prior to performing any type of service work on a parts manual.
Compact Track Loader, read and understand
Chapter 1 (Product Safety) for personal safety
information. Note: Refer to Figure 3-2 for an overview of the auxiliary
circuit system and Figure 3-3 for an overview of the drive
loop system.
Machine Preparation
Accidental machine starting can cause injury or
death to personnel working on a Compact Track
Drive Motor Removal and
Loader. Installation
Refer to Chapter 12. Undercarriage Disassembly
As a precaution, disconnect the battery cables from and Assembly – Drive Motor Removal and
the battery terminals, tape the battery clamps and Installation for removal and installation of the drive
remove the key from the ignition switch prior to motors.
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.

10-1
Compact Track Loader
10. Transmission and Drive Disassembly and Assembly

Auxiliary Gear Pump Removal

and Installation
The tools required for auxiliary gear pump removal
and installation are listed in Table 10-1. Use
manufacturer-recommended tools whenever
possible.
Auxiliary
Table 10-1 Gear
Pump
Required Tools
Screwdriver
Combination Wrench
Socket Wrench
Figure 10-1

7. View of auxiliary gear pump with seat and fuel

Auxiliary Gear Pump Removal tank removed.

Hot oil can cause personal injury. Make sure the

oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and has been allowed to cool thoroughly.

Collect and contain liquids in a suitable

container. Dispose of all liquids according to local
regulations and mandates. Remove
Hose

Note: During disassembly, cap all hoses and fittings to

prevent fluid loss and contamination of the system fluids.
Figure 10-2

8. Remove the hose from the left side of the

1. Lower the lift arms to the ground. auxiliary gear pump.

2. Turn the engine start switch to the OFF position. Loosen

Clamp and
Slide to Lower
3. Relieve hydraulic pressure from the auxiliary Manifold
Left Trans-
circuit. Tube
mission
Hose
4. Drain the hydraulic fluid. Refer to Chapter 16.
Hydraulic Fluid and Filter Change.

5. Remove the seat. Refer to Chapter 6. Seat

Removal.

6. Remove the fuel tank. Refer to Chapter 6. Fuel

Figure 10-3
Tank Removal.
9. Loosen the clamp that secures the transmission
hose to the lower manifold tube and slide the
clamp to the left.

10-2
 Compact Track Loader
10. Transmission and Drive Disassembly and Assembly

Note: It is not necessary to separate the lower manifold

tube from the gear pump: this can be done after the pump
is removed, if necessary.
Remove
Bolt

Auxiliary Gear Pump Installation

Tandem
Pump
Auxiliary
Figure 10-4
Gear
Pump
Trans-
10. Remove the bolt on the left side of the auxiliary mission
gear pump. Hose
Lower
Manifold
Tube

Figure 10-7

1. With the lower manifold tube attached to the

auxiliary gear pump, align the mounting bolt
holes in the auxiliary gear pump with the holes in
the tandem pump. It will be necessary to slide
Remove the manifold tube into the transmission hose to
Bolt properly position the auxiliary gear pump.

Figure 10-5

11. Remove the bolt on the right side of the auxiliary

gear pump.

Install
Bolt

Figure 10-8

2. Install the bolt on the right side of the auxiliary

gear pump.

Figure 10-6

12. Remove the auxiliary gear pump by sliding the

lower manifold tube out of the transmission
hose.

10-3
Compact Track Loader
10. Transmission and Drive Disassembly and Assembly

Tandem Pump Removal and

Installation
Install The tools required for tandem pump removal and
Bolt installation are listed in Table 10-2. Use
manufacturer-recommended tools whenever
possible.
Table 10-2

Required Tools
Screwdriver
Combination Wrench
Figure 10-9 Socket Wrench

3. Install the bolt on the left side of the auxiliary

Tandem Pump Removal
gear pump.
Hot oil can cause personal injury. Make sure the
Slide Hose oil is cool before removing any components or lines.
Clamp to Remove the oil filler cap only when the engine is
Right and Lower
Manifold stopped and has been allowed to cool thoroughly.
Tighten Trans-
mission Tube
Hose
Collect and contain liquids in a suitable
container. Dispose of all liquids according to local
regulations and mandates.

Note: During disassembly, cap all hoses and fittings to

prevent fluid loss and contamination of the system fluids.

Figure 10-10
1. Lower the lift arms to the ground.
4. With the end of the lower manifold tube inserted
in the transmission hose, slide the hose clamp to
the right and tighten the clamp. 2. Turn the engine start switch to the OFF position.

5. Install the fuel tank. Refer to Chapter 6. Fuel 3. Relieve hydraulic pressure from the auxiliary
Tank Installation. circuit.

6. Install the seat. Refer to Chapter 6. Seat 4. Drain the hydraulic fluid. Refer to Chapter 16.
Installation. Hydraulic Fluid and Filter Change.

7. Add fuel and manufacturer-approved hydraulic 5. Remove the seat. Refer to Chapter 6. Seat
fluid. Removal.

6. Remove the fuel tank. Refer to Chapter 6. Fuel

Tank Removal.

7. Remove the auxiliary gear pump. Refer to

Chapter 10. Auxiliary Gear Pump Removal.

10-4
 Compact Track Loader
10. Transmission and Drive Disassembly and Assembly

Pump Drive
Coupler

Remove Pump
Hoses and Mounting
Tubes Plate

Figure 10-11
Figure 10-14

8. Remove all hoses and tubes from the tandem 11. Remove the tandem pump (with pump drive
pump. Cap the hoses and tubes. coupler attached) from the pump mounting plate.

Tandem Pump Installation

Pump Drive
Coupler

Flywheel
Remove Gear
Bolt

Pump
Figure 10-12
Mounting
Plate
9. Remove the mounting bolt (with spring lock
washer and flat washer) from the right-hand side Figure 10-15
of the tandem pump.
1. With the pump drive coupler attached to the
tandem pump, position the tandem pump
against the pump mounting plate. Make sure the
Remove teeth on the pump drive coupler mesh properly
Bolt with the flywheel gear teeth.

Figure 10-13

10. Remove the mounting bolt (with spring lock

washer and flat washer) from the left-hand side
of the tandem pump.

10-5
Compact Track Loader
10. Transmission and Drive Disassembly and Assembly

5. Install the auxiliary gear pump. Refer to Chapter

10. Auxiliary Gear Pump Installation.
Install
Bolt
6. Install the fuel tank. Refer to Chapter 6. Fuel
Tank Installation.

7. Install the seat. Refer to Chapter 6. Seat

Installation.

8. Add fuel and manufacturer-approved hydraulic

fluid.
Figure 10-16

2. Install the mounting bolt (with spring lock washer

Pump Drive Coupler Removal
and flat washer) on the left-hand side of the and Installation
tandem pump.
The tools required for pump drive coupler removal
and installation are listed in Table 10-3. Use
manufacturer-recommended tools whenever
possible.
Table 10-3

Required Tools
Screwdriver
Combination Wrench
Socket Wrench
Install
Bolt
Pump Drive Coupler Removal
Figure 10-17 Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
3. Install the mounting bolt (with spring lock washer
Remove the oil filler cap only when the engine is
and flat washer) on the right-hand side of the stopped and has been allowed to cool thoroughly.
tandem pump.

Collect and contain liquids in a suitable

container. Dispose of all liquids according to local
regulations and mandates.

Note: During disassembly, cap all hoses and fittings to

prevent fluid loss and contamination of the system fluids.

Install
Hoses and 1. Lower the lift arms to the ground.
Tubes
2. Turn the engine start switch to the OFF position.
Figure 10-18
3. Relieve hydraulic pressure from the auxiliary
4. Install the hoses and tubes on the tandem circuit.
pump.

10-6
 Compact Track Loader
10. Transmission and Drive Disassembly and Assembly

4. Drain the hydraulic fluid. Refer to Chapter 16. Pump Drive Coupler Installation
Hydraulic Fluid and Filter Change.

Tandem Pump
5. Remove the seat. Refer to Chapter 6. Seat Drive Shaft
Removal.

6. Remove the fuel tank. Refer to Chapter 6. Fuel

Tank Removal.

7. Remove the auxiliary gear pump. Refer to

Chapter 10. Auxiliary Gear Pump Removal. Pump
Drive
Coupler
8. Remove the tandem pump. Refer to Chapter 10.
Tandem Pump Removal. Figure 10-21

1. Slide the pump drive coupler all the way onto the
Loosen tandem pump drive shaft.
Locking
Screw
Tighten
Locking
Screw

Pump
Drive
Coupler
Tandem
Pump Pump
Drive
Coupler
Figure 10-19 Tandem
Pump
9. Loosen the locking screw that secures the pump
drive coupler to the drive shaft extending from Figure 10-22
the end of the tandem pump.
2. Tighten the locking screw that secures the pump
drive coupler to the tandem pump drive shaft.
Tandem Pump
Drive Shaft 3. Install the tandem pump. Refer to Chapter 10.
Tandem Pump Installation.

4. Install the auxiliary gear pump. Refer to Chapter

10. Auxiliary Gear Pump Installation.

5. Install the fuel tank. Refer to Chapter 6. Fuel

Pump Tank Installation.
Drive
Coupler
6. Install the seat. Refer to Chapter 6. Seat
Figure 10-20 Installation.

10. Slide the pump drive coupler off the tandem

pump drive shaft. 7. Add fuel and manufacturer-approved hydraulic
fluid.

10-7
 11. Engine Components
Disassembly and Assembly

Chapter Overview Engine Components

This chapter provides disassembly and assembly Disassembly and Assembly
procedures for the engine components.
Procedures
Disassembly and assembly procedures are provided
Personal Safety for the following engine components.
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in • Muffler
machine damage, injury or death. • Battery
Do not attempt to perform any type of repair or • Exhaust Pipe
maintenance on a Compact Track Loader until you have
• Bleeding the Fuel System
read and fully understood the information in this manual.

Refer to the Operation and Maintenance manual for Note: Procedures are provided for only those engine
instructions regarding proper machine operation components listed above. However, information for
techniques before operating any Compact Track Loader. removal and installation of other engine components can
be obtained from the machine specific parts manual.
Prior to performing any type of service work on a
Compact Track Loader, read and understand
Chapter 1 (Product Safety) for personal safety Primary Air Filter Removal and
information.
Installation
Refer to Chapter 16. Maintenance – Air Cleaner for
Machine Preparation removal and installation of the primary air filter.

Accidental machine starting can cause injury or

death to personnel working on a Compact Track Safety Air Filter Removal and
Loader.
Installation
As a precaution, disconnect the battery cables from Refer to Chapter 16. Maintenance – Air Cleaner for
the battery terminals, tape the battery clamps and removal and installation of the safety air filter.
remove the key from the ignition switch prior to
performing any service work on a Compact Track
Loader. Engine Oil Filter Removal and
Place a “Do Not Operate” tag prominently on the Installation
machine to inform personnel that the machine is Refer to Chapter 16. Maintenance – Engine Oil for
being worked on. removal and installation of the engine oil filter.

Fuel Filter Removal and

Installation
Refer to Chapter 16. Maintenance – Fuel Filter for
removal and installation of the fuel filter.

11-1
Compact Track Loader
11. Engine Components Disassembly and Assembly

2. Spray the joint with penetrating lube, and then

Muffler Removal and slide the curved pipe out of the muffler inlet. A
Installation pry bar may be helpful in removing this pipe
section.
The tools required for muffler removal and
installation are listed in Table 11-1. Use
manufacturer-recommended tools whenever
possible. Remove
Bolts
Table 11-1

Required Tools
Socket/Combination Wrenches
Pry Bar
Penetrating Lubricant
Rubber Mallet/Plastic Hammer

Muffler Removal

The exhaust system gets very hot during Figure 11-3

operation! Allow the machine to cool thoroughly prior
to performing service on the exhaust system. 3. Remove the four bolts that fasten the muffler to
the chassis. They can be accessed from the
underside of the machine (right rear corner).

Loosen
Nuts 4. Carefully guide the muffler out of the engine
compartment.

Muffler Installation
Position
the Muffler
over the
four
Mounting
Holes
Figure 11-1

1. Loosen the nuts on the muffler clamp.

Figure 11-4

1. Guide the muffler outlet pipe into its opening at

the rear of the engine compartment, then
position the muffler over the mounting locations.

Figure 11-2

11-2
 Compact Track Loader
11. Engine Components Disassembly and Assembly

Tighten
Nuts

Install
Bolts

Figure 11-5 Figure 11-7

2. From the underside, install the four muffler 4. Install the muffler clamp and secure in place.
mounting bolts and washers/shims as found
upon disassembly.
Exhaust Pipe Removal and
Installation
The tools required for exhaust pipe removal and
installation are listed in Table 11-2. Use
manufacturer-recommended tools whenever
possible.
Table 11-2

Required Tools
Socket/Combination Wrench
Pry Bar
Penetrating Lubricant
Rubber Mallet/Plastic Hammer
Figure 11-6
Exhaust Pipe Removal
3. Carefully slide the curved pipe into the muffler
inlet. You may need to tap it into place with a The exhaust system gets very hot during
rubber mallet or similar device. operation! Allow the machine to cool thoroughly prior
to performing service on the exhaust system.
NOTICE
If it is necessary to tap the pipe section into the muffler, do
Loosen
so carefully as the pipe walls are thin and easily distorted.
Nuts
Use caution and care as you install the pipe section.

Figure 11-8

1. Loosen the nuts on the muffler clamp

11-3
Compact Track Loader
11. Engine Components Disassembly and Assembly

4. Spray the joint with penetrating lube, and then

slide the curved pipe out of the muffler inlet. A
pry bar may be helpful in removing this pipe
section.

Exhaust Pipe Installation

Remove
Bolts

Figure 11-9

2. Remove the four bolts that secure the exhaust

pipe to the exhaust manifold.

Figure 11-12

5. Carefully slide the curved pipe into the muffler

inlet. You may need to tap it into place with a
rubber mallet or similar device.

NOTICE
If it is necessary to tap the pipe section into the muffler, do
so carefully as the pipe walls are thin and easily distorted.
Use caution and care as you install the pipe section.
Figure 11-10

3. Remove the exhaust pipe gasket from the

exhaust manifold, then remove the retaining
springs and center pipe from the assembly.

Note: The gasket may come off with the exhaust pipe.

Figure 11-13

6. Install the center section of pipe as found upon

disassembly and install the retaining springs.
Then, position the exhaust gasket for
reinstallation and start one bolt to hold it in
Figure 11-11
place.

11-4
 Compact Track Loader
11. Engine Components Disassembly and Assembly

Battery Removal

Install
Bolts Negative Positive
Terminal Terminal

Figure 11-14

7. With the exhaust pipe gasket in place, install the Figure 11-16
remaining bolts that secure the exhaust pipe to
the exhaust manifold. 1. Identify the positive and negative battery
terminals.

Tighten Disconnect
Nuts Negative
Cable

Figure 11-15
Figure 11-17
8. Reinstall the muffler clamp, then tighten the nuts
to secure. 2. Disconnect the battery cable from the negative
battery terminal.

Battery Removal and Installa-

tion
The tools required for battery removal and Disconnect
installation are listed in Table 11-3. Use Positive
manufacturer-recommended tools whenever Cable
possible.
Table 11-3

Required Tools
Combination Wrench
Socket Wrench
Figure 11-18

3. Disconnect the battery cable from the positive

battery terminal.

11-5
Compact Track Loader
11. Engine Components Disassembly and Assembly

1. Place the battery in position in the engine

compartment.
Remove
Capscrews

Install
Capscrews

Figure 11-19

4. Remove the two capscrews from the battery

holdown bracket and remove the bracket.
Figure 11-22

2. Position the battery holdown bracket and install

the two capscrews and nuts.

Connect
Positive
Cable

Figure 11-20

5. Rotate the battery 90 degrees counter-

clockwise. Tilt up the front of the battery and
Figure 11-23
remove the battery from the machine.
3. Connect the battery cable to the positive battery
terminal.
Battery Installation

Connect
Negative
Cable

Figure 11-21 Figure 11-24

11-6
 Compact Track Loader
11. Engine Components Disassembly and Assembly

4. Connect the battery cable to the negative battery

terminal.

Bleeding the Fuel System

The tools required for muffler removal and
installation are listed in Table 11-1. Use
manufacturer-recommended tools whenever
possible.
Table 11-4

Required Tools
Combination Wrench
Figure 11-26

If the machine has been run out of fuel, it may be 1. Locate the bleed screw directly above the fuel
necessary to bleed the fuel system. There are two injectors.
types of bleeding methods depending on the serial
number of your machine. 2. Loosen the bleed screw two full turns.
For serial numbers 001 through 1357.

Figure 11-27
Figure 11-25

1. Locate the bleed screw directly above the fuel 3. Pump the bulb primer with your hand until fuel
injectors. flows from the bleed screw without any air
bubbles.
2. Loosen the bleed screw two full turns
4. Tighten the bleed screw.

3. Turn-over the engine from the operator’s

compartment until fuel is flowing from the bleed
screw without any air bubbles.

4. Tighten the bleed screw.

5. Engine should now start within 10 seconds.

For serial numbers 1358 and higher.

11-7
 12. Undercarriage
Disassembly and Assembly

Chapter Overview Undercarriage Disassembly

This chapter provides disassembly and assembly and Assembly Procedures
procedures for the following undercarriage
assemblies. Disassembly and assembly procedures are provided
for the following undercarriage components.
Track
Wheels (also see track procedure)
Suspension
Sprockets
Sprocket rollers
Personal Safety Sprocket bearing plates
Improper or incomplete maintenance/repair of a Tracks
Compact Track Loader can be dangerous and may
result in machine damage, injury or death. Drive motors

Do not attempt to perform any type of repair or Note: Procedures are provided for only those
maintenance on a Compact Track Loader until you undercarriage components listed above. However,
have read and fully understood the information in information for removal and installation of other
this manual. undercarriage components can be obtained from the
machine specific parts manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation
techniques before operating any Compact Track Wheel Removal and
Loader.
Installation
Prior to performing any type of service work on a
Compact Track Loader, read and understand The tools required for wheel removal and installation
Chapter 1 (Product Safety) for personal safety are listed in Table 12-1. Use manufacturer-
information. recommended tools whenever possible.
Table 12-1

Machine Preparation Required Tools

Accidental machine starting can cause injury or Wheel Extractor
death to personnel working on a Compact Track Channel Lock Pliers
Loader. Socket Wrench
Snap-ring Pliers
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and Wheel Removal
remove the key from the ignition switch prior to
performing any service work on a Compact Track
Loader. Note: If the track is to be removed, perform the track
removal process on page 12-3 of this chapter.
Place a “Do Not Operate” tag prominently on the
Note: For important wheel and bearing information, see
machine to inform personnel that the machine is
“Bearings” in the track removal procedure on page 12-4,
being worked on. prior to removing or reinstalling the idler wheels.
Note: The procedure for removing the Idler wheels and
Bogie wheels are similar. Only the front outside idler wheel
is described here. Any exception will be explained in the
instructions as a note. See figure 12-1 for wheel diagram.

12-1
Compact Track Loader
12. Undercarriage Disassembly and Assembly

Rear Front
Idler Bogie Idler
Wheels Wheels Wheels
Figure 12-4
Figure 12-1

1. Loosen up the track tensioner as described in 4. Remove the nut that fastens the wheel to the
the track removal procedure on page 12-3, steps shaft with the correct size socket.
1-4.

Figure 12-2 Figure 12-5

2. Remove the snap ring securing the wheel cap 5. Remove the washer.
with snap ring pliers.

Figure 12-3

3. Remove the wheel cap using a large channel Figure 12-6

lock pliers.
6. Remove the bearing.

12-2
 Compact Track Loader
12. Undercarriage Disassembly and Assembly

Note: Bogie wheels will have a large washer that is

installed before the wheel.
2. Install the bearing, washer, and wheel nut to the
axle. Torque the nut to 110 ft-lbs (149Nm).
3. Install the cap and secure it with the snap-ring.
Make sure the snap-ring is fully seated in its
grove.

Track Removal and

Figure 12-7 Installation
7. Remove the idler wheel with a wheel
extractor as shown in figure 12-7. The tools required for track removal and installation
are listed in Table 12-2. Use manufacturer-
Note: If removing a bogie wheel, remove the large recommended tools whenever possible.
inside washer.
Table 12-2
8. Inspect the exposed axle(s) for wear or damage.
Required Tools
9. To remove any idler wheels, or bogie wheels,
Socket Wrench Heavy Duty Floor Jack
located on the inside of the suspension nearest
Combination Wrench Straight Edge
the chassis; position the machine securely on
Crowbar Tape Measure
jack-stands. Repeat the wheel removal
Jack Stands
procedure.

Track Removal
Wheel Installation
To remove the tracks, the machine must be jacked
Note: Refer to bearing illustration on figure 12-9 of this up and placed on jack stands sturdy enough to support the
chapter to ensure proper installation of each style of weight of the machine. Terex approved jack stands are
bearing. recommended.

Figure 12-8

1. Mount the outer front idler wheel onto the axle

as shown.
Note: During installation carefully slide the wheel
onto the axle shaft to prevent seal damage.

12-3
Compact Track Loader
12. Undercarriage Disassembly and Assembly

NOTE: Bearings

Tapered Roller Bearing

Ball Bearing

Figure 12-11

2. Remove the nut from the bolt that fastens the

In the illustration above, the rear wheel is shown track tensioner to the drive sprocket assembly.
with a tapered roller style bearing while the center
wheel is shown with a ball type bearing. It is
important to note that these bearings are positioned
within the undercarriage as they are, in order to
adequately bear the differing loads/forces applied to
them.
When replacing bearings or removing wheels,
always make sure the front and rearmost wheels
in the undercarriage are equipped with tapered
“roller” type bearings, while the eight interior
wheels are to be equipped with “ball” type
bearings. They are not interchangeable in this
application.
Figure 12-12
Figure 12-9
3. Using a pry bar, pivot the drive table assembly
upward and support it until the track
tensioner bolt can be removed. Remove the bolt.

Jam nut

Figure 12-10

1. Loosen the jam nut located on the track

tensioner using the correct size wrench. Turn
the track tensioner until the track has significant Figure 12-13
slack.
4. Pry the drive table assembly upward, away from
the tensioner. Then pivot the tensioner forward
as shown. Once the tensioner is out of the way,
lower the drive table until it rests on the rail.

12-4
 Compact Track Loader
12. Undercarriage Disassembly and Assembly

Track Installation

To remove the tracks, the machine must be jacked

up and placed on jack stands sturdy enough to support the
weight of the machine. Terex approved jack stands are
recommended.

A
Figure 12-14

5. Locate the wheel marked “A” in fig. 12-14.

Track
Drive
Lugs

Figure 12-17

1. Place the track around the rear wheels and on

top of the drive sprocket. Make sure the track
drive lugs mesh with the sprocket.

Figure 12-15

6. Perform steps 1-7 of the wheel removal

procedure in this chapter to remove the outer Apply
front idler wheel. Soap

Figure 12-18

2. Using soap, lubricate the front inside wheel. Pull

Track the track around the outside wheel shaft and
Drive onto the front inside wheel. The soap will help
Lugs the track slide onto the wheel.

Figure 12-16

7. With the wheel removed and the drive sprocket

table lowered, the track is ready for removal.
8. Pull the track outward as shown.

12-5
Compact Track Loader
12. Undercarriage Disassembly and Assembly

Figure 12-19 Figure 12-22

3. Install the front wheel. Refer to Chapter 12. 6. Install the remaining wheels making sure the
Wheel Installation pg 12-3. bearing, washer, wheel nuts, wheel caps, and
snap-rings are properly installed. Refer to
Chapter 12. Wheel Installation pg 12-3.

Align
Holes Jam Nut

Track
Tensioner

Figure 12-20

4. Pry the sprocket up until the holes in the track

Figure 12-23
tensioner and drive table are aligned. A floor
jack or a second pry bar may be needed to get
7. Tighten the track by turning the track
the drive table off the rail.
tensioner. When proper track tension has been
achieved, tighten the jam nut on the track
tensioner.

8. Check for proper track tension. Refer to

Chapter 16. Maintenance – Checking for Proper
Track Adjustment
Tighten
Bolt Sprocket Bearing Plate
Removal and Installation
The tools required for sprocket bearing plate
removal and installation are listed in table 12-3
Figure 12-21 below. Use manufacturer-recommended tools
whenever possible.
5. Install and tighten the track tensioner bolt and
nut.

12-6
 Compact Track Loader
12. Undercarriage Disassembly and Assembly

Table 12-3

Required Tools
Socket Wrench Combination Wrench
Bearing Puller Tool Torque Wrench

Sprocket Bearing Plate Removal

1. Remove the track. Refer to Chapter 12. Track
Removal.

Figure 12-26

Castle nut 5. Remove the four bolts that secure the bearing
assembly to the bearing plate, remove the
bearing plate.

Cotter pin

Figure 12-24

2. Remove the cotter pin from the castle nut on the

Figure 12-27
end of the sprocket assembly.
6. Remove bearing from sprocket with bearing
puller tool. Inspect sprocket rollers for wear. If
replacement is needed, refer to sprocket roller
Spacer removal on page 12-8 of this chapter.

Sprocket Bearing Plate Installation

1. To install the sprocket bearing plate, reverse
removal procedure with following added
instructions.

Two bolts Bearing

flange w/
zerk
Figure 12-25
Bearing
3. Remove the spacer washer. grease
track
4. Remove the two bolts securing the bearing plate
to the drive table.

Figure 12-28

12-7
Compact Track Loader
12. Undercarriage Disassembly and Assembly

2. Align the grease hole of the bearing flange with

zerk and the grease track on the bearing as
shown in figure 12-28.
3. Ensure that the concave side of the washer is
contacting the sprocket.
4. Torque castle nut is to 270 ft-lb (366 Nm) and
then rotate until the next hole is visible to install
the cotter key. Position Drive
Sprocket to
Access Roller
Sprocket Roller Removal and Bolt
Installation Figure 12-30
The tools required for sprocket roller removal and
1. Rotate the drive sprocket to allow access to the
installation are listed in table 12-4 below. Use
sprocket roller bolt. Remove the bolt.
manufacturer-recommended tools whenever
possible.

Sprocket Roller Removal

Table 12-4

Required Tools
Socket/Combination Wrench

Note: The rollers should be inspected every 50 hours for

rotation and wear-through. The rollers on the drive
sprocket are easily replaceable. The track DOES NOT
need to be removed to replace these rollers.
Figure 12-31

Pin Washer
Roller 2. Remove the roller and steel pin from the drive
sprocket.

Sprocket
Steel Pin Roller

Figure 12-32A

3. Inspect the rollers for wear and replace as

Note: In order to remove the sprocket rollers and pins, you necessary. The steel pin will normally not need
must remove the torsion axle retaining bolts and washers, replacing unless the roller has worn completely
then slide the undercarriage away from the chassis slightly
(approx. 1”, 2.54 cm). This will provide clearance for the
away and the steel pin is worn from engaging
sprocket bolts to be removed for roller/pin replacement. the track (fig. 12-32A & B).

Figure 12-29

12-8
 Compact Track Loader
12. Undercarriage Disassembly and Assembly

Sprocket Removal and

Installation
The tools required for sprocket removal and
installation are listed in table 12-5 below. Use
manufacturer-recommended tools whenever
possible.

Sprocket Removal
Table 12-5

Required Tools
Socket Wrench Impact Driver
Figure 12-32B Sprocket Puller

Sprocket Roller Installation 1. Remove the sprocket bearing plate as described

on page 12-7.

Puller holes
Figure 12-33

1. With the drive sprocket rotated to the desired Figure 12-35

position, position the composite roller and steel
2. Install the puller by positioning the push bolt into
pin in the drive sprocket.
the end of the sprocket shaft and then threading
the puller bolts into the holes in the fac e of the
drive sprocket. (fig. 12-35 & 12-36).

Figure 12-34

2. Insert the sprocket roller bolt from the rear.

Torque to 62 ft. lbs.
Figure 12-36

12-9
Compact Track Loader
12. Undercarriage Disassembly and Assembly

3. Operate the puller by tightening the push bolt

with a wrench until the sprocket is pulled off the
drive motor shaft as shown in figure 12-36. Re-
move sprocket and inspect sprocket rollers for
wear. If replacement is needed, refer to Sprock-
et roller removal on page 12-8 of this chapter.

Sprocket Installation

Figure 12-39

3. Align the key on the shaft with the key-way in

the drive sprocket, and then slide the sprocket
onto the shaft. Install the bolt into the end of the
sprocket shaft and finger- tighten. Complete the
next step as soon as possible to prevent the
Loc-tite from drying before the sprocket is
tightened.

Figure 12-37

1. After inspecting and cleaning the shaft, spray

7471 Loctite Primer on to the shaft.

Figure 12-40

Note: Using a torque wrench, tighten the sprocket bolt

to275 lb-ft (366 Nm).
4. Remove the drive motor fittings by turning the
motor so that the fittings face upward. Then tilt
the motor in the table as shown & pull upward
Figure 12-38 and outward to remove.

2. Once the primer has dried spread 680 Loc-tite

Retaining Compound onto the shaft. The
retaining compound is very important; it fills in
small inconsistencies in the shaft and creates a
Drive Motor Removal and
better bond between the shaft and the sprocket. Installation
Use manufacturer-recommended tools whenever
possible.

Table 12-6

Required Tools
Socket/Combination Wrench

12-10
 Compact Track Loader
12. Undercarriage Disassembly and Assembly

Note: During disassembly, cap all hoses and fittings to

prevent fluid loss and contamination of the system fluids.

Drive Motor Removal

Top Large

Angled Small

Figure 12-43

3. Remove the four bolts that secure the drive

motor to the drive table using a thin wall socket.

Straight Small
Bottom Large

Fittings
Figure 12-41
on top
1. Locate four drive motor hoses in back of drive
motor.

“T” marking Plug

Figure 12-44

4. Remove drive motor by turning motor with the

hydraulic hose fittings facing upward and
angle the motor out of the table weldment and
pull in upward motion.

Figure 12-42
Drive Motor Installation
2. Mark the top (T) and bottom (B) large hoses to
ensure proper re-installation. For ease of 1. Position the drive motor so the hydraulic fittings
removal, remove hoses in this order: angled enter in the correct location. Install the drive
small, top large, straight small, bottom large. It motor bolts. Clean and inspect the drive motor
is important to cap fittings and plug drive shaft.
hoses to ensure hydraulic systems is free from
2. Re-install all hoses and fitting in the same order
debris.
instructions direct in removal.
3. Re-install drive sprocket as outlined above.

12-11
 13. Lift Arm
Disassembly and Assembly

Chapter Overview Lift Arm Disassembly and

This chapter provides disassembly and assembly
procedures for the loader assembly.
Assembly Procedures
Disassembly and assembly procedures are provided
for the following loader components.
Personal Safety
Lift Cylinders
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in Tilt Cylinders
machine damage, injury or death.
Pressure Release Valve
Do not attempt to perform any type of repair or Lift Arm Bushings
maintenance on a Compact Track Loader until you have
read and fully understood the information in this manual.
Note: Procedures are provided for only those loader
Refer to the Operation and Maintenance manual for components listed above. However, information for
instructions regarding proper machine operation removal and installation of other loader components can
techniques before operating any Compact Track Loader. be obtained from the machine specific parts manual.
Prior to performing any type of service work on a Compact
Track Loader, read and understand Chapter 1 (Product
Safety) for personal safety information.
Lift Cylinder/Tilt Cylinder
Removal and Installation
Machine Preparation The tools required for lift cylinder and tilt cylinder
Accidental machine starting can cause injury or death to removal and installation are listed in Table 13-1. Use
personnel working on a Compact Track Loader. manufacturer-recommended tools whenever
possible.
As a precaution, disconnect the battery cables from the
battery terminals, tape the battery clamps and remove the Table 13-1
key from the ignition switch prior to performing any service
work on a Compact Track Loader. Required Tools
Combination Wrench
Place a “Do Not Operate” tag prominently on the machine
to inform personnel that the machine is being worked on. Socket Wrench

Lift Cylinder/Tilt Cylinder Removal

Note: The procedures for removing the lift cylinders and

tilt cylinders are very similar, as a result only the lift
cylinder procedure is described below.

Hot oil can cause personal injury. Make sure the

oil is cool before removing any components or lines.

13-1
Compact Track Loader
13. Loader Disassembly and Assembly

5. Disconnect and cap the hose on the rear end of

Collect and contain liquids in a suitable the cylinder.
container. Dispose of all liquids according to local
regulations and mandates.

Note: During disassembly, cap all hoses and fittings to

prevent fluid loss and contamination of the system fluids. Disconnect
Hose
1. To remove lift cylinders raise the lift arms and
support them with the lift arm brace as described
in Ch 16 of this manual.
Note: When removing tilt cylinder(s), lower the loader
arms onto a mechanical support with the arms resting
about 6 inches off the ground.
2. Turn the ignition switch to the OFF position and
remove the key to avoid accidental start.

Figure 13-3

6. Disconnect and cap the hose on the forward end

of the cylinder.
Zip tie

Remove
Bolt

Figure 13-1

3. Remove the zip tie that secures the hydraulic

hose to the lift cylinder.
4. Release hydraulic pressure by performing step 3 Figure 13-4
on page 13-6 of this chapter.
7. Remove the forward pin assembly bolt.

Lift
Cylinder

Disconnect
Hose

Figure 13-5

8. Support the cylinder from the underside then

Figure 13-2 remove the forward pin assembly.

13-2
 Compact Track Loader
13. Loader Disassembly and Assembly

Remove
bolt and
then pin

End gland

Figure 13-6 Figure 13-7

9. Remove the bolt and pin from the loader tower. 1. Secure the cylinder into a vice and remove the
10. Again support the cylinder from the underside end gland by turning counter clockwise with
then remove the lift cylinder from the machine. channel lock pliers. Be sure to have a container
to catch draining hydraulic fluid.

Lift Cylinder/Tilt Cylinder Installation

1. To install the lift/tilt cylinder, reverse the removal
procedure.
2. Add removable locktite to all fittings.
3. Add grease to loader pin zerks to ensure
lubrication of bushings.

Lift Cylinder/Tilt Cylinder

Seals Removal Figure 13-8
Table 13-2 2. Remove the rod from cylinder by pulling
outward using both hands as shown.
Required Tools
Channel Lock Pliers
Bench Vice
Blade Type Screwdriver
Socket
Rubber Mallet

Lift Cylinder / Tilt Cylinder Seal Removal

Note: The procedures for removing seals on the lift
cylinders and tilt cylinders are similar, only the lift cylinder
procedure is described below.

Figure 13-9

3. Secure the rod in the bench vice as shown.

13-3
Compact Track Loader
13. Loader Disassembly and Assembly

O-rings

Figure 13-13

7. Remove the three o-rings located on the outside

of the end gland with a small blade type
Figure 13-10
screwdriver paying close attention to the order
they are removed to aid during installation of
4. Remove the nut from the rod end using the new seals.
correct size socket.

Piston

O-ring
Rod seal

Wiper

Figure 13-14
Figure 13-11
8. Remove the shaft wiper and then the rod seal
5. Remove the piston and the o-ring off the rod by from the inside of the end gland with a small
sliding them upward and off. blade type screwdriver. Pay attention to seal
orientation upon removal to aid during
installation of new seals.
End gland

Figure 13-12

6. Remove the end gland by sliding upward and off

the rod.

13-4
 Compact Track Loader
13. Loader Disassembly and Assembly

11. To remove cylinder bushings, place cylinder in

vice and find a socket the same diameter as the
bushing. Remove the bushing with a rubber
mallet and the socket. You may need to use a
Back-up ring
punch tool to complete the removal of the
bushing.
12. Thoroughly clean and dry all parts prior to
installation of new seals to prevent
contamination of hydraulic oil when cylinders are
reassembled and installed.

Lift Cylinder/Tilt Cylinder Seal Kit Install

Note: The procedures for installing the seal kits on the lift
cylinders and tilt cylinders are similar, only the lift cylinder
Figure 13-15 procedure is described below.

9. Remove the back-up ring on the inside of the Lift Cylinder Seal Kit: P/N 2010-552
end gland with a small blade type screwdriver. Tilt Cylinder Seal Kit: P/N 2010-548
1. Reverse the cylinder seal removal procedure to
install seal kits on both the lift and tilt cylinders.

Piston seal 2. Make sure your work area is clean and that all
tools are clean before beginning seal install.
Lubricate all seals with new hydraulic oil prior to
install.

Socket
Wear ring

Piston
Wiper

Figure 13-16

10. Remove piston seal and wear ring from piston

using a blade type screwdriver.

Figure 13-18

3. Use a rubber mallet and a socket or section of

pipe with the same outside diameter as the seal
to drive into place.
4. Reverse steps 1-6 of the seal removal
procedure to reassemble the cylinder.
5. Add removable locktite to the nut and torque to
75 ft. lbs.
6. Torque the cap gland to 100 ft. lbs.

Figure 13-17

13-5
 Compact Track Loader
13. Loader Disassembly and Assembly

2. Turn the engine start switch to the OFF position

Lift Arm Bushing Removal and and remove the key to avoid accidental start.
Installation
The tools required for lift arm and lift arm bushing
removal and installation are listed in Table 13-3. Use
manufacturer-recommended tools whenever
possible.
Table 13-3

Required Tools
Socket
Dead Blow Hammer
Combination Wrench
Crescent Wrench
Mechanical Support Figure 13-21
Lifting Device 3. Remove the bolts from each side of the lift arm
Pry Bar that secure the pins to the chassis.
Lift Arm Bushing Placement

Upper
Friction
Point

Lower
Friction
Point
Bushings
Figure 13-22
Figure 13-19 4. Remove the pins from each side of the chassis.
Upper Friction Points:
Note: Each worn bushing will be removed one at a
time.

Figure 13-23
5. Raise the lifting device until arm has cleared the
chassis and the hydraulic hoses. Use a pry bar
to guide the lift arm upward if necessary.
Figure 13-20
6. Inspect the bushings for wear according to the
1. Lower the lift arm to the chassis stops. Then procedure in page 16-6, step 3. If it is
attach suitable lifting device to them as shown, determined that replacement is needed,
to secure them during the procedure. continue onto step 7 of this procedure.

13-6

Pry bar
 Compact Track Loader
13. Loader Disassembly and Assembly

Figure 13-24
7. Compress a replacement bushing to fit the hole
size and start the insertion with a dead blow Figure 13-26
hammer as shown. As you drive the new 12. With an assistant, lower lifting device to drop lift
bushings into the lift arm, the old bushings will arm back into position to re-install pins. A pry
be forced out of the opposite side of the lift arm. bar may be used to aid in aligning chassis and
lift arm pin holes.

Do not use fingers to align pin holes.

Figure 13-25
8. Complete the insertion of the first bushing with a
socket and hammer until the bushing is flush
with the surface of the lift arm.
9. Repeat Step 8 to install the second Figure 13-27
bushing. This action will force the remaining
worn bushing out and drive the first replacement 13. Insert the pin into the chassis and through the lift
bushing to its permanent position. arm.

10. Clean and remove any debris, then apply

anti-seize to the inside of the bushings.
11. Perform steps 7-10 on opposite side of lift arm to
remove remaining bushings.

Figure 13-28

14. Install bolt and nut to secure pin to chassis.

15. Perform steps 12-13 for opposite side of lift arm.

13-7
Compact Track Loader
13. Loader Disassembly and Assembly

Figure 13-29 Figure 13-32

16. Add grease to the zerks located on each of the 2. Remove bolt from pins that secure the tilt
lift pins to lubricate them. cylinder to the quick attach.
Lower Friction Points:
Note: Each worn bushing will be removed one at a
time.

Figure 13-33

3. Remove pin from the cylinder and quick attach.

Figure 13-30

Bolt

Figure 13-31
Figure 13-34
1. Lower lift arms onto a mechanical support, 4. Remove bolt from pins that secure the quick
with quick attach resting about 1 ft. off the attach to the lift arm.
ground. Then attach a lifting device to secure
the lift arm in position.

13-8
 Compact Track Loader
13. Loader Disassembly and Assembly

9. Complete insertion of the bushing with a socket

and the hammer until the bushing is flush with
the surface of the lift arm. This action will force
the worn bushing out the opposite side of the lift
arm for removal.
10. Repeat steps 7-9 for opposite side of lower lift
arm.
11. Clean and remove any debris, then apply
anti-seize to the inside of the bushings

12. Reverse steps 2-6 to install the pins and bolts.

Figure 13-35

5. Remove pin.
6. Perform steps 2-5 on opposite side of quick
attach.
7. Inspect the lower lift arm bushings for wear
according to the procedure in page 16-6, step 3.
If it is determined that replacement is needed,
continue onto step 8 of this procedure.

Figure 13-38

13. Add grease to the zerks located on each of the

lift pins and lubricate them.

Quick-Coupler Block /
Pressure Release Valve
Removal and Installation
The tools required for quick coupler block removal
and installation are listed in Table 13-4. Use
manufacturer-recommended tools whenever
Figure 13-36 possible.
8. Compress a replacement bushing to fit the hole
Table 13-4
size and start the insertion with a dead blow
hammer.
Required Tools
Combination Wrench
Socket Wrench

Quick Coupler Block Removal

Hot oil can cause personal injury. Make sure the

oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and the machine has been allowed to cool
thoroughly.

Figure 13-37

13-9
Compact Track Loader
13. Loader Disassembly and Assembly

Collect and contain liquids in a suitable

container. Dispose of all liquids according to local
regulations and mandates.

Note: During disassembly, cap all hoses and fittings to

prevent fluid loss and contamination of the system fluids. Remove
Bolts
1. Lower the lift arms to the ground.
2. Turn the engine start switch to the OFF position
and remove the key to avoid accidental start.

Figure 13-41

5. Remove the four bolts that secure the quick

coupler block to the loader frame and remove
the block.

Quick Coupler Block / Pressure Release

Valve Installation

Figure 13-39 Install

Bolts
3. Press the button on top of the quick coupler
block to release hydraulic pressure.

Figure 13-42
Disconnect
Tubes 1. Install the four bolts that secure the quick
coupler block to the loader frame.

Figure 13-40
Reconnect
4. Disconnect and cap all three hydraulic tubes. Tubes

Figure 13-43

2. Reconnect all three hydraulic tubes.

13-10
 14. Quick Attach
Disassembly and Assembly

Chapter Overview Quick Attach Disassembly and

This chapter provides disassembly and assembly Assembly Procedures
procedures for the quick attach assembly.
Disassembly and assembly procedures are provided
for the following quick attach components.
Personal Safety Latch Mechanism
Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in
Quick Attach Assembly
machine damage, injury or death.
Note: Procedures are provided for only those quick attach
Do not attempt to perform any type of repair or components listed above. However, information for
maintenance on a Compact Track Loader until you have removal and installation of other quick attach components
read and fully understood the information in this manual. can be obtained from the machine specific parts manual.

Refer to the Operation and Maintenance manual for

instructions regarding proper machine operation
techniques before operating any Compact Track Loader.
Prior to performing any type of service work on a
Latch Mechanism Removal
Compact Track Loader, read and understand and Installation
Chapter 1 (Product Safety) for personal safety The tools required for latch mechanism removal and
information. installation are listed in Table 14-1. Use
manufacturer recommended tools whenever
possible.
Machine Preparation Table 14-1
Accidental machine starting can cause injury or
Required Tools
death to personnel working on a Compact Track
Loader. Socket/Combination Wrench

As a precaution, disconnect the battery cables from

the battery terminals, tape the battery clamps and Latch Mechanism Assembly Removal
remove the key from the ignition switch prior to
1. Remove any attachments and place support
performing any service work on a Compact Track
blocks beneath the quick attach. Then tilt the
Loader.
quick attach assembly forward and lower the lift
arms until the quick attach assembly rests
Place a “Do Not Operate” tag prominently on the
securely on the blocks (approximately 6 inches
machine to inform personnel that the machine is
off the ground).
being worked on.

Figure 14-1

14-1
Compact Track Loader
14. Quick Attach Disassembly and Assembly

2. Turn the engine start switch to the OFF position.

Figure 14-4

6. Disassemble as necessary and replace worn

components to ensure proper function.
Figure 14-2
Latch Mechanism Installation
3. Remove the bolt securing the latch mechanism
1. Latch installation is the reverse of the removal
to the quick attach spring block using an allen
procedure.
wrench.
2. Add removable lock tite to allen bolt threads.

Quick Attach Assembly

Removal and Installation
The tools required for quick attach assembly
removal and installation is listed in Table 14-2. Use
manufacturer-recommended tools whenever
possible.
Table 14-2

Required Tools
Combination Wrench

Figure 14-3
Quick Attach Assembly Removal
4. Remove the bolt and nut using to two wrenches. 1. Remove any attachments and place support
5. Slide the latch mechanism out for parts blocks beneath the quick attach. Then tilt the
inspection. quick attach assembly forward and lower the lift
arms until the quick attach assembly rests
securely on the blocks (approximately 6 inches
or 15.24 cm off the ground).
2. Turn the engine start switch to the OFF position.

14-2
 Compact Track Loader
14. Quick Attach Disassembly and Assembly

Remove

Remove
Pin

Insert
Pin

Install

Figure 14-5 Figure 14-7

3. Remove the bolt and push out the pin that 2. Insert the pin and install the bolt that secures
secures each end of the quick attach assembly each end of the quick attach assembly to the
to the tilt cylinders. loader frame.

Install

Insert
Pin

Remove
Pin

Remove

Figure 14-6 Figure 14-8

4. Remove the bolt and push out the pin that 3. Insert the pin and install the bolt that secures
secures each end of the quick attach assembly each end of the quick attach assembly to the tilt
to the loader frame. cylinders.

5. The quick attach assembly is now free and

ready to be moved by a forklift.

Quick Attach Assembly Installation

1. With a forklift, move the quick attach assembly

in position to be secured to the loader frame and
tilt cylinders.

14-3
 15. Troubleshooting

Chapter Overview Preliminary Inspection

This chapter contains basic troubleshooting A simple visual inspection and operational check
procedures for the Compact Track Loader. can identify many problems without the need for
extensive troubleshooting. If these checks indicate a
Additional troubleshooting aids are provided in
problem that requires further analysis, proceed to
Chapter 3. System Diagrams and in those chapters
Troubleshooting in this section.
containing disassembly and assembly procedures
for the appropriate component or assembly.
Visual Inspection
Prior to troubleshooting, perform a visual inspection
Personal Safety of the machine. Look for missing, loose or worn
Improper or incomplete maintenance/repair of a Compact parts. Perform the following visual checks.
Track Loader can be dangerous and may result in
machine damage, injury or death. Track tension
Do not attempt to perform any type of repair or Fluid levels
maintenance on a Compact Track Loader until you have
read and fully understood the information in this manual. Fan belt tension and condition
Hoses (no visible sign of wear)
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation Fittings (no leaks)
techniques before operating any Compact Track Loader.
Battery cables
Prior to performing any type of service work on a
Compact Track Loader, read and understand Fuse box (fuses in place and operational)
Chapter 1 (Product Safety) for personal safety
Controls (for neutral)
information.

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
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.

15-1
Compact Track Loader
15. Troubleshooting

8. Low charge pressure.

Troubleshooting
This section identifies selected problems and Problem 4
suggests probable causes. Loader operates but tracks will not move.
Probable cause
Problem 1 1. Leak in feed line to pilot control.
Machine will not crank over. 2. Pilot control malfunctioning.
Probable cause
1. Auxiliary hydraulic switch activated. Problem 5
2. Weak or dead battery. Tracks operate but loader will not operate.
3. Battery cables loose or corroded. Probable cause
4. Ignition fuse blown. 1. Auxiliary direction switch activated sending oil over
5. Main starter fuse blown. relief.
6. Starter relay malfunctioning. 2. Check to see if auxiliary flow works. (If auxiliary
7. Bad ignition switch. flow works, skip to number 5).
8. Bad starter. 3. Main auxiliary relief malfunction.
9. Poor wire connections at key, relay, or starter. 4. Auxiliary pump bad.
5. Leak in feed line to loader control pilot.
Problem 2 6. Loader control pilot malfunctioning.
Machine cranks but will not start.
Problem 6
Probable cause
Auxiliary flow does not work. Loader works.
1. Injection pump fuse blown.
2. Main power fuse B blown. Probable cause
3. Main power relay B not activating. 1. Auxiliary hydraulic fuse blown.
4. Poor wire connection at injection pump or fuse. 2. Faulty ground wire.
5. Glow plugs not heating. (Will see black smoke.) a) Clean ground connections on left rear side of
hydraulic tank.
a) Main glow plug fuse blown.
3. Auxiliary hydraulic direction switch failure.
b) Glow plug relay not activating.
4. Poor wire connections at fuse, direction switch, or
c) Poor wire connections at ignition switch, relay, pin connector P17.
or glow plug strip.
5. Auxiliary hydraulic pilot generation spool stuck.
d) Failed glow plugs.
6. Bad or not fully connected Quick-Coupler
e) Bad ignition switch.

Problem 7
Problem 3
Auxiliary hydraulic part-time thumb switch operates but
Machine starts but hydraulics will not operate. full-time flow direction switch will not operate.
Probable cause Probable cause
1. Lap bar must be in down position, operator must be 1. Auxiliary direction switch faulty.
seated in seat, and front door (if installed) must be
closed. 2. Poor wire connections at mode switch or direction
switch.
2. Safety fuse blown.
3. Faulty operator presence switch.
a) Test continuity through seat, lap bar, and door
switch. Adjust or replace as necessary. Lap bar
is a magnetic switch and should be adjusted to
approximately 1/16 inch (.16 cm) away from
steel pickup bracket. Door switch is a pressure
button that actives with pressure from door
frame when in closed position. Ensure it is not
plugged with debris.
4. Poor ground (check ground wires on bottom left rear
side of hydraulic reservoir).
5. Safety relay is not activating.
6. Faulty safety solenoid or safety solenoid spool.
7. Poor wire connections on fuse, relay, or safety
solenoid.

15-2
 Compact Track Loader
15. Troubleshooting

Problem 8 Problem 13
Auxiliary hydraulic full-time direction switch operates but Loader will not float; labors engine and has down pressure
part-time thumb switch will not operate. when detented into float.
Probable cause Probable cause
1. Auxiliary hydraulic thumb switch malfunction. 1. Engine RPM too low.
2. Poor wire connections at direction switch, thumb a) Float must be operated at a minimum of half
switch, or pin connector P17. throttle.
2. Low charge pressure.
Problem 9 3. Pilot control malfunction.
Auxiliary hydraulics will only flow one way. 4. Loader valve malfunction.
Probable cause
1. Auxiliary hydraulic relay 1 or 2 failure. Problem 14
2. Auxiliary hydraulic pilot generation coil faulty. Hot oil light illuminates; hydraulic system operating hot.
3. Auxiliary hydraulic pilot generation spool faulty. Probable cause
4. Poor wire connections at relay, pilot generation 1. Auxiliary hydraulic switch activated sending oil over
solenoid, pin connector P16 or P21. relief.
5. Loader valve malfunction. 2. Low oil level.
3. Debris plugging oil cooler limiting airflow.
Problem 10 4. Broken fan blades.
No power to numerous auxiliary functions or accessories 5. Loose fan belt.
in ON or RUN position. 6. Improper attachment.
Probable cause a) Attachment must be rated at a minimum of 10
1. Main power relay A or B fuse blown. gallons per minute (37.8 lpm) and 3000 psi
2. Main relay A or B faulty. (20,680 kPa).
3. Ignition switch malfunction. b) Attachment hose size must be a minimum of 3/8
inch (.95 cm).
4. Poor wire connections at ignition switch, fuse, or
relay. 7. Faulty hot oil sending unit.
a) Hot oil light should illuminate at 225 F
Problem 11 (107.2 °C).
Battery will not charge and/or battery goes dead. 8. Faulty quick coupler.
9. Cooler bypass relief.
Probable cause
a) Cooler bypass relief should open at 100 psi
1. Alternator fuse blown.
(689.5 kPa).
2. Alternator diode defective or inserted backwards.
3. Poor wire connections at battery, alternator, diode,
Problem 15
or fuse.
Track makes popping noise.
4. Excessive draw in off position.
a) Fuel gauge and hour meter should draw only Probable cause
0.01 amps in off position. 1. Track too loose. (Refer to track adjustment section.)
5. Bad battery. 2. Worn or stuck drive teeth. Outer roller should pivot
6. Bad alternator. as lug comes into sprocket.
3. Loose or worn sprocket.
Problem 12 4. Worn track lugs.
Loader control will not lock in float position.
Probable cause
1. Float magnet fuse blown.
2. Poor wire connections at fuse, float detent magnet,
or pin connector P18.
3. Faulty float detent magnet.

15-3
 16. Maintenance

Chapter Overview Lift Arm Brace

This chapter contains maintenance requirements The lift arm brace is intended to keep service
and procedures for the following Compact Track personnel safe when it is necessary to work on a
Loader components. machine with the lift arms in the raised position. It is
not safe to rely on the hydraulic system to hold the
• Engine oil • Air cleaner
lift arms in the raised position just as it is not safe to
• Hydraulic fluid and filter • Fuse box crawl under a machine support only by one jack.
• Fuel filter • Grease fittings The lift arm brace is used support the weight of the
lift arms much mechanical supports bear the vehicle
• Track tension • Lift Arm Brace
weights.
• Lift arm bushings
To install the lift arm brace:

Maintenance Schedule 1. Park the machine on level ground in a safe area

for performing service work.
Maintenance schedule is listed in Table 16-1.
2. Remove any attachments that may be
Table 16-1 fastened to the quick attach.
Item Frequency Lubricant Capacity 3. Have an assistant remove the retaining pins that
Hydraulic Fluid 1000 hrs Mobile DTE10 8 gal/30 l secure the lift arm brace and remove it from the
Excel Series machine.
Hydraulic Filter 250 hrs 4. Make sure bystanders are clear of the lift arms,
Engine Oil 250 hrs HD Diesel En- 4 qt/3.79 l and then raise them to the upper limit.
gine Oil, or
equivalent 5. Have an assistant install the brace around the
Engine Filter 250 hrs cylinder shaft as shown and reinstall the pins to
Fuel Filter 500 hrs secure it to the cylinder as shown in Figure 16-1.
Primary Air Check daily, clean and reuse as needed 6. Lower the lift arms slowly until the come to rest
Filter up to 5 times; change at least once per on the brace.
year
Secondary Air Every 3 cleanings 7. It is now safe to shut the engine off and exit the
Filter of primary filter machine.
Grease Fittings 10 hrs Lithium Grease To remove the lift arm brace:
Track Tension As needed
Do not work on or near the machine with the lift
NOTICE arms in the raised position unless the lift arm brace
has been correctly installed.
When replacing engine coolant, use Terex Long Life
50/50 Antifreeze/Coolant or equivalent antifreeze with 1. Start the machine and raise the lift arms until
the proper SCA (Supplemental Cooling Additive) they are clear of the brace.
2. Once clear, have an assistant remove the brace
for the cylinder and stow it on the machine with
the pins.
3. Once the brace has been stowed and the
assistant is clear of the lift arms, lower the arms
to the ground and shut the engine off to
complete the procedure.

16-1
Compact Track Loader
16. Maintenance

2. Remove drain plug from bottom of the engine.

3. Drain oil into suitable container.
4. Remove engine oil filter, making sure the gasket
is also removed.
5. Apply a light coat of fresh oil to the new filter
gasket, then install new filter.
6. Tighten filter to specifications on filter label or
box.
7. Refill the engine to capacity with engine oil, as
Braced position specified.
with pins
Engine Oil Specifications
Figure 16-1 Due to the variations in the quality and performance
of commercially available oils, Terex Heavy Duty
Diesel Engine Oil – 10W30 is recommended. If
Terex lubricants are not available, use a substitute
meeting the following qualifications:
Stowed position
with pins - API CH-4 multi-grade engine oil

Hydraulic Fluid and Filter

The hydraulic fluid should be changed every 500
service hours, and the hydraulic filter should be
changed every 250 hours. Hydrostatic components
require extremely clean oil for long service life.
Figure 16-2

Engine Oil Hydraulic Fluid and Filter Change

Regular oil changes are necessary to maintain a Procedures
strong running engine. A normal oil change interval
of 250 hours or every six months is recommended. Hot oil can cause personal injury. Make sure the
oil is cool before removing any components or lines.
This recommendation has been made to help
ensure proper lubrication during operation and to Allow the machine to cool thoroughly and relax all
prolong engine life under typical operating hydraulic circuits before performing this procedure.
conditions. Oil Change Procedures
NOTICE
1. Run the engine for a few minutes to warm the
engine oil. Extreme care must be taken when changing the hydraulic
fluid. Before starting the procedure, make sure the
machine is in a clean working environment. Precautions
should be taken to prevent any debris from entering the
hydrostatic system.

Collect and contain liquids in a suitable

container. Dispose of all liquids according to local
regulations and mandates.

Oil
Filter Oil Drain Plug

Figure 16-3

16-2
 Compact Track Loader
16. Maintenance

4. Remove the filter element and replace it. Install

as found upon removal.
5. Fill with manufacturer-approved hydraulic fluid.

Fuel Filter
The fuel filter should be changed every 500 service
Hydraulic Fluid hours, or as needed. A plugged fuel filter can cause
Drain Plug loss of engine power, rough running, or no start.

Collect and contain liquids in a suitable

container. Dispose of all liquids according to local
Figure 16-4
regulations and mandates.
1. Locate and remove the hydraulic fluid drain plug
and drain the fluid into a suitable container.
Fuel Filter Change Procedures

Filter
Assembly

Figure 16-5 Figure 16-7

2. Clean the area around the filter assembly, which 1. Clean the outside of the filter thoroughly.
is located on the top of the hydraulic reservoir. 2. Remove the retaining bolt (top of assembly)
securing the filter to the head, then removes.
3. Pour diesel fuel into the new filter until it is full.
4. Install the new filter by reversing step 2.

Fuel Specifications
In North America, diesel fuel distilled from crude oil
and identified as NO. 1-D or No. 2-D in “ASTM
D975” generally meets the proper specifications.
Filter
Element
Air Cleaner
The air cleaner is one of the most important
maintenance items on the machine. A poorly
maintained air cleaner can seriously shorten the life
of the engine.
Figure 16-6

3. Remove the retaining bolts and cover, and then

remove the cover to access the filter.

16-3
Compact Track Loader
16. Maintenance

Air Filter Change Procedures Track Tension

NOTICE Proper track tension is very important for optimum
performance and long track life. Tracks that are run
When working in dusty conditions, the air cleaner too loose can cause misfeeding and ratcheting
elements should be checked and changed more frequently
than when working under normal conditions.
possibly causing damage to the track. During the
first 50 hours of operation, the tracks will “break in”
and will most likely require adjustment.
NOTICE
Do not clean the primary air cleaner element by bumping
and tapping. This could damage the seals. Do not use Track Tension Adjustment Procedures
elements with damaged pleat gaskets or seals.

1. Open the hood, release the latches on either Jam

side of the air cleaner, and then remove the Nut
cover.

Primary
Element Track
Tensioner

Figure 16-10

1. Locate the jam nut on the track tensioner and

clean the threads thoroughly before proceeding.

2. Loosen the jam nut.

Figure 16-8

2. Remove the primary element. The primary

element can be cleaned and reused up to five
times, but it should be changed at least once a
year.

Secondary
Element

Figure 16-11

3. After loosening the jam nut, turn the track

tensioner until the track tension is within
specifications.
4. Once proper tension is achieved, retighten the
Figure 16-9 jam nut
3. Remove the secondary element. The secondary
element is not serviceable or washable. It should
be replaced with every three cleanings of the
primary element.

16-4
 Compact Track Loader
16. Maintenance

Checking for Proper Track Adjustment Fuse Box

1. Drive the machine forward five feet to remove
slack from the lower and rearward portions of
the track.

Figure 16-14

Figure 16-12 The fuse box is located on the left side of the engine
compartment. The machine should never be
2. Lay a straightedge along the top of the track operated with the fuse box cover removed.
between the sprocket and the front idler wheel.
3. Using a rope or wire, put 50 pounds (23.68 kg)
of down force on the track at the midpoint of the Grease Fittings
straightedge.

Figure 16-15

The locations of the grease fittings for the left side of

the machine are shown above. An identical set of
fittings is located on the right side of the machine.
Figure 16-13
These fitting should be lubricated at least after every
10 hours of operation using Terex Multi Purpose
4. Using a ruler, measure the distance between the
EP Lithium Grease, or other high-quality,
straightedge and track. The track should not
low-temperature grease.
deflect more than 0.75 inch (1.9 cm) between
the top of the track and the straightedge.
5. If the track deflects more than 0.75 inch (1.9
cm), tighten the track.

16-5
Compact Track Loader
16. Maintenance

Lift Arm Bushings

Quick Attach Wear Inspection
Daily inspection can be carried out by
performing the following steps:
1. Lower the lift arm until it makes contact with the
chassis stops. Rotate the bucket against the
ground repeatedly. Have an assistant look for
independent movement between the bucket and
the lift arm. Any movement should be readily
noticeable by the attendant. If movement is
detected, bushing will need further inspection.
2. Rotate the bucket downward to approximately
45° from level. Then lower the lift arm until the
bucket contacts the ground repeatedly. Have an
assistant look for independent movement
between the:
• Lift arms & chassis
• Lift arms & lift cylinder
• Lift cylinder & chassis
Any movement will be readily noticeable by the
attendant. If movement is detected, bushings will
need further inspection as shown in the following
step.
3. Refer to Chapter 13 of Lift Arm Bushing
Removal and Installation procedure to access
bushings for measurement inspection.
Note: Inspect the bushing for wear and replace as
necessary. Maximum recommended wear on the
bushing is 50% as shown in figure 16-16.

Lift Arm Bushings

.063”
Service
Limit

New bushing Max recommended

wear: 50%

Figure 16-16

16-6
 17. Hydraulic Pressure
Check & Adjustment

Chapter Overview
This chapter provides an overview of checking and Hydraulic Pressure
setting pressures. It is important to contact the
manufacturer for assistance before beginning these Adjustment Procedures
procedures. Adjustment and test procedures are provided for the
following transmission and drive components.
Personal Safety Charge Pressure Check & Adjustment
Improper or incomplete maintenance/repair of a Compact
Drive-Pressure Relief Valve Adjustment
Track Loader can be dangerous and may result in
machine damage, injury or death. Auxiliary Valve Pressure Check & Adjustment
Do not attempt to perform any type of repair or
maintenance on a Compact Track Loader until you have
read and fully understood the information in this manual. Charge Pressure Check
Refer to the Operation and Maintenance manual for
The service tools required for the charge pressure
instructions regarding proper machine operation check are listed in Table 17-1. Use manufacturer-
techniques before operating any Compact Track Loader. recommended tools whenever possible.
Prior to performing any type of service work on a Table 17-1
Compact Track Loader, read and understand
Chapter 1 (Product Safety) for personal safety Required Tools
information. Pressure Gauge
Combination Wrench
Socket Wrench
Machine Preparation
Accidental machine starting can cause injury or Note: The fuel tank SHOULD NOT be removed to
death to personnel working on a Compact Track perform this procedure.
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 worked on.

Figure 17-1

1. Remove the floor pan.

17-1
Compact Track Loader
17. Hydraulic Pressure Check & Adjustment

Hot oil can cause personal injury. Make sure the

oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and has been allowed to cool thoroughly.

Collect and contain liquids in a suitable

Attach container. Dispose of all liquids according to local
Gauge regulations and mandates.

Note: During disassembly, plug all hoses and tubes to

Figure 17-2 prevent fluid loss and contamination of the system fluids.

2. Attach the gauge to the pilot control manifold

test port. Located under the fuel tank, you will
not need to remove the fuel tank.

3. Start the engine.

4. Check the pressure with the engine at wide

open throttle. Make sure the engine is properly
warmed up before running wide open.

5. Turn the engine start switch to the OFF position.

Figure 17-3

6. Remove the gauge from the pilot control

1. Remove belly pan and locate the charge
manifold test port.
pressure relief valves on the left side of the tandem
7. Install the floor pan pump.

Charge Pressure Relief Valve Adjust-

ment
The service tools required for charge pressure relief
valve adjustment are listed in Table 17-2. Use
manufacturer-recommended tools whenever Remove
possible. Hose

Table 17-2

Required Tools
Combination Wrench
Socket Wrench
Figure 17-4
2. Remove the hose coupling from the tandem
Note: In the following procedure, some components are
pump T-adapter to allow access to the front charge
shown detached from the machine to facilitate the pressure relief valve locking screw.
description. However, the charge pressure check is
normally performed from under the machine with only the
center skid plate removed.

17-2
 Compact Track Loader
17. Hydraulic Pressure Check & Adjustment

9. Connect the hose coupling on the tandem pump

T-adapter.

Remove 10. Check the charge pressure.

Cap
11. Install the belly pan.

Drive-Pressure Relief Valve Adjustment

The service tools required for drive-pressure relief
valve adjustment are listed in Table 17-3. Use
manufacturer-recommended tools whenever
possible.

Figure 17-5 Table 17-3

3. Unscrew and remove the charge pressure relief Required Tools

valve locking screw. The valve piston and o-ring will Combination Wrench
remain attached to the locking screw when the Socket Wrench
locking screw is removed.

Hot oil can cause personal injury. Make sure the

oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is
stopped and has been allowed to cool thoroughly.

Collect and contain liquids in a suitable

container. Dispose of all liquids according to local
regulations and mandates.
Spring, Locking
Spring Screw,
Collar and Valve Piston Note: During disassembly, plug all hoses and tubes to
Shims and O-ring prevent fluid loss and contamination of the system fluids.

Figure 17-6

4. Extract the spring, spring collar and shims from 1. Remove the seat. Refer to Chapter 6. Seat
the charge pressure relief valve cavity. The front and Removal.
rear charge pressure relief valves are identical.

2. Remove the fuel tank. Refer to Chapter 6. Fuel

5. Adjust the charge pressure by adding or tank Removal.
removing shims. Contact Manufacturer.
3. Remove belly pan.
6. Insert the spring, spring collar and shims in the
charge pressure relief valve cavity.

7. Install the charge pressure relief valve locking

screw (with valve piston and o-ring attached).

8. Repeat procedure on remaining charge

pressure relief valve. The charge pressure relief
valves must have the same number of shims.

17-3
Compact Track Loader
17. Hydraulic Pressure Check & Adjustment

6. Extract the high-pressure relief valve collar,

valve spring, spring loading nut and pressure
spring from the valve cavity.
7. Adjust the drive pressure by turning the spring
loading nut. Turning Clockwise will increase
Drive-Pressure Relief pressure. Never adjust by more than a quarter
Valves (Reverse) turn before checking pressure.

Drive-Pressure Relief 8. Insert the high-pressure relief valve collar, valve

Valves (Forward)
spring, spring loading nut and pressure spring in
the valve cavity.

9. Replace the high-pressure relief valve locking

Figure 17-7
screw and o-ring.
4. Locate the drive-pressure relief valves.

Remove Auxiliary Pressure Check & Adjustment

Locking The service tools required for the auxiliary pressure
Screw check and adjustment are listed in Table 17-4. Use
manufacturer-recommended tools whenever
possible.
Table 17-4

Required Tools
Pressure Gauge
Allen Wrench

Figure 17-8

5. Unscrew and remove the necessary

drive-pressure relief valve locking screw. The
drive-pressure relief valve o-ring will remain
attached to the locking screw when the locking
screw is removed.

Figure 17-10

1. Insert the hydraulic gauge into one of the

attachment quick couplers.

Figure 17-9

17-4
 Compact Track Loader
17. Hydraulic Pressure Check & Adjustment

Figure 17-11

2. Engage the continuous flow switch located on

the right side of the dash panel. Make sure it is
in the direction that sends flow to the gage.

Jam Nut Adjustment

Screw

Figure 17-12

3. Loosen the jam nut and turn the adjustment

screw in with an allen wrench to increase
pressure and turn screw out to decrease
pressure. Tighten jam nut after adjustment has
been made.

17-5
Purchasing spare parts
Terex I Ersatzteile GmbH
Postfach 12 64 • D-91534 Rothenburg
Erlbacher Str. 115 • D-91541 Rothenburg
Phone + 49 (0) 9861/972-0
Fax + 49 (0) 9861/972-410

Customer Service
Terex Construction
Motherwell
Scotland
UK
ML1 5RY
Phone +44 (0) 16 98 50 30 77
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