Terex PT-30 Service Manual

PT-30

Part Number: 2010-513

Printed (1-11)

Service Manual

Compact Track Loader

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Table of Contents

1. Product Safety

Chapter Overview ................................................... 1-1

Basic Precautions ................................................... 1-1

Safety Labels ..................................................... 1-1

Personal Protective Equipment .......................... 1-1

Entering and Exiting ........................................... 1-2

Lifting ................................................................. 1-2

Hot Fluids and Components .............................. 1-2

Corrosion Inhibitor ............................................. 1-2

Batteries ............................................................ 1-2

Pressurized Items .............................................. 1-2

Repair ..................................................................... 1-3

Attachments ............................................................ 1-4

Machine Labels and Decals .................................... 1-4

Product ID Number ............................................ 1-4

Safety Label Examples ...................................... 1-4

2. Technical Specifications

Chapter Overview ................................................... 2-1

PT-30 Specifications ............................................... 2-1

3. System Diagrams

Chapter Overview ................................................... 3-1

Filtering and Cooling System .................................. 3-1

Auxiliary Circuit System .......................................... 3-2

Drive Loop System .................................................. 3-3

4. Machine Controls and Instrumentation

Chapter Overview ................................................... 4-1

Machine Controls .................................................... 4-1

Loader Control ................................................... 4-1

Drive Control ...................................................... 4-1

Throttle .............................................................. 4-1

Instrumentation ....................................................... 4-1

Switches .................................................................. 4-2

6. Chassis Disassembly and Assembly

Chapter Overview ................................................... 6-1

Personal Safety ....................................................... 6-1

Machine Preparation ............................................... 6-1

Chassis Disassembly and Assembly

Procedures .............................................................. 6-1

Seat Removal and Installation ................................ 6-1

Seat Removal .................................................... 6-1

Seat Installation ................................................. 6-2

Fuel Sending Unit Removal and Installation ........... 6-2

Fuel Sending Unit Removal ............................... 6-3

Fuel Sending Unit Installation ............................ 6-3

Fuel Tank Removal and Installation ....................... 6-4

Fuel Tank Removal ........................................... 6-4

Fuel Tank Installation......................................... 6-6

7. Radiator/Oil Cooler Disassembly
and Assembly

Chapter Overview ................................................... 7-1

Personal Safety ....................................................... 7-1

Machine Preparation ............................................... 7-1

Radiator/Oil Cooler Disassembly and Assembly

Procedures .............................................................. 7-1

Fan Guard Removal and Installation ....................... 7-1

Fan Guard Removal .......................................... 7-2

Fan Guard Installation ....................................... 7-2

Fan and Fan Shroud Removal and Installation ....... 7-2

Fan and Fan Shroud Removal ........................... 7-2

Fan and Fan Shroud Installation ........................ 7-3

Radiator/Cooler Removal and Installation ............... 7-4

Radiator/Cooler Removal .................................. 7-4

Radiator/Cooler Installation ............................... 7-6

Radiator/Oil Cooler Adjustment Procedures .......... 7-7

Fan Shroud Adjustment ..................................... 7-7

Fan Guard Adjustment....................................... 7-8

5. Operator Enclosure Disassembly
and Assembly

Chapter Overview ................................................... 5-1

Personal Safety ....................................................... 5-1

Machine Preparation ............................................... 5-1

Operator Enclosure Disassembly and Assembly

Procedures .............................................................. 5-1

Light Bar Removal and Installation .......................... 5-1

Light Bar Removal ............................................. 5-1

Light Bar Installation .......................................... 5-2

Ignition Switch Removal and Installation ................. 5-2

Ignition Switch Removal .................................... 5-2

Ignition Switch Installation ................................. 5-3

Gauge Removal and Installation ............................. 5-4

Gauge Removal ................................................. 5-4

Gauge Installation .............................................. 5-4

Lap Bar Gas Assist Spring Removal

and Installation ........................................................ 5-5

Lap Bar Gas Assist Spring Removal .................. 5-5

Lap Bar Gas Assist Spring Installation ............... 5-5

8. Hydraulic Reservoir Disassembly
and Assembly

Chapter Overview ................................................... 8-1

Personal Safety ....................................................... 8-1

Machine Preparation ............................................... 8-1

Hydraulic Reservoir Disassembly and Assembly

Procedures .............................................................. 8-1

Filter Element Removal and Installation .................. 8-1

Filter Assembly Removal and Installation ............... 8-1

Filter Assembly Removal ................................... 8-2

Filter Assembly Installation ................................ 8-3

Access Cover Assembly Removal and Installation . 8-4

Access Cover Assembly Removal ..................... 8-4

Access Cover Assembly Installation .................. 8-4

Reservoir Gauge Removal and Installation ............. 8-5

Reservoir Gauge Removal ................................ 8-5

Reservoir Gauge Installation ............................. 8-6

Suction Screen Removal and Installation ............... 8-6

Suction Screen Removal ................................... 8-6

Suction Screen Installation ................................ 8-7

Hydraulic Reservoir Cleaning Procedures ............. 8-7

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Compact Track Loader

Table of Contents

9. Loader/Transmission Controls Disassembly
and Assembly

Chapter Overview ................................................... 9-1

Personal Safety ....................................................... 9-1

Machine Preparation ............................................... 9-1

Loader/Transmission Controls Disassembly and

Assembly Procedures ............................................. 9-1

Loader Control Joystick/Drive Control Joystick

Removal and Installation ......................................... 9-1

Loader Control Joystick/Drive Control Joystick

Removal ............................................................ 9-2

Loader Control Joystick/Drive Control Joystick

Installation.......................................................... 9-3

Loader Float Magnet Removal and Installation ....... 9-3

Loader Float Magnet Removal ........................... 9-3

Loader Float Magnet Installation ........................ 9-4

Loader Valve Removal and Installation .................. 9-4

Loader Valve Removal ...................................... 9-4

Loader Valve Installation ................................... 9-6

10. Transmission and Drive Disassembly
and Assembly

Chapter Overview ................................................. 10-1

Personal Safety ..................................................... 10-1

Machine Preparation ............................................. 10-1

Transmission and Drive Disassembly

and Assembly Procedures .................................... 10-1

Brake Cylinder Removal and Installation .............. 10-1

Drive Motor Removal and Installation ................... 10-1

Auxiliary Gear Pump Removal and Installation ..... 10-2

Auxiliary Gear Pump Removal ......................... 10-2

Auxiliary Gear Pump Installation ...................... 10-3

Tandem Pump Removal and Installation .............. 10-4

Tandem Pump Removal .................................. 10-4

Tandem Pump Installation ............................... 10-5

Pump Drive Coupler Removal and Installation ...... 10-6

Pump Drive Coupler Removal ......................... 10-6

Pump Drive Coupler Installation ...................... 10-7

11. Engine Components Disassembly and As­sembly

Chapter Overview ................................................. 11-1

Personal Safety ..................................................... 11-1

Machine Preparation ............................................. 11-1

Engine Components Disassembly and

Assembly Procedures ........................................... 11-1

Primary Air Filter Removal and Installation ........... 11-1

Safety Air Filter Removal and Installation ............. 11-1

Engine Oil Filter Removal and Installation ............ 11-1

Fuel Filter Removal and Installation ..................... 11-1

Muffler Removal and Installation .......................... 11-2

Muffler Removal ............................................... 11-2

Muffler Installation ............................................ 11-2

Exhaust Pipe Removal and Installation ................. 11-3

Exhaust Pipe Removal .................................... 11-3

Exhaust Pipe Installation ................................. 11-4

Battery Removal and Installation........................... 11-5

Battery Removal .............................................. 11-5

Battery Installation ........................................... 11-6

Bleeding the Fuel System………………………….11-7

12. Undercarriage Disassembly and Assembly

Chapter Overview ................................................. 12-1

Personal Safety ..................................................... 12-1

Machine Preparation ............................................. 12-1

Undercarriage Disassembly and Assembly

Procedures ............................................................ 12-1

Wheel Removal and Installation ........................... 12-1

Wheel Removal ............................................... 12-2

Wheel Installation ............................................ 12-3

Track Removal and Installation ............................. 12-3

Track Removal ............................................... 12-3

Track Installation ............................................ 12-3

Sprocket Bearing Plate Removal and Installation . 12-6

Sprocket Bearing Plate Removal ................... 12-7

Sprocket Bearing Plate Installation ................ 12-8

Sprocket Roller Removal and Installation ............. 12-8

Sprocket Roller Removal ............................... 12-8

Sprocket Roller Installation ............................ 12-9

Sprocket Removal and Installation ........................ 12-9

Sprocket Removal ......................................... 12-9

Sprocket Installation .................................... 12-10

Drive Motor Removal and Installation ................ 12-10

Drive Motor Removal.................................. 12-11

Drive Motor Installation ............................... 12-11

13. Loader Disassembly and Assembly

Chapter Overview ................................................. 13-1

Personal Safety ..................................................... 13-1

Machine Preparation ............................................. 13-1

Loader Disassembly and Assembly Procedures .. 13-1
Lift Cylinder/Tilt Cylinder Removal

and Installation ...................................................... 13-1

Lift Cylinder/Tilt Cylinder Removal ................... 13-1

Lift Cylinder/Tilt Cylinder Installation ................ 13-3

Lift Cylinder/Tilt Cylinder Seal Kit Removal

and Installation ...................................................... 13-3

Seal Kit Removal ............................................ 13-3

Seal Kit Installation ......................................... 13-5

Lift Arm Bushing Removal and Installation ........... 13-6

Upper Friction Points ....................................... 13-6

Lower Friction Points ....................................... 13-8

Low-Flow Relief Valve Removal and Installation .. 13-9

Low Flow Relief Valve Removal ...................... 13-9

Low Flow Relief Valve Installation ................. 13-10

14. Quick Attach Disassembly and Assembly

Chapter Overview ................................................. 14-1

Personal Safety ..................................................... 14-1

Machine Preparation ............................................. 14-1

Quick Attach Disassembly and Assembly

Procedures ............................................................ 14-1

Latch Pin Assembly Removal and Installation ...... 14-1

Latch Pin Assembly Removal .......................... 14-1

Latch Pin Assembly Installation ....................... 14-2

Quick Attach Assembly Removal and Installation . 14-2

Quick Attach Assembly Removal ..................... 14-2

Quick Attach Assembly Installation .................. 14-3

ii

15. Troubleshooting

Chapter Overview ................................................. 15-1

Personal Safety ..................................................... 15-1

Machine Preparation ............................................. 15-1

Visual Inspection .............................................. 15-1

Troubleshooting .................................................... 15-2

16. Maintenance

Chapter Overview ................................................. 16-1

Maintenance Schedule .......................................... 16-1

Engine Oil ............................................................. 16-1

Oil Change Procedures ................................... 16-1

Engine Oil Specifications ................................. 16-1

Hydraulic Fluid and Filter ...................................... 16-2

Hydraulic Fluid and Filter Change

Procedures ...................................................... 16-2

Fuel Filter .............................................................. 16-3

Fuel Filter Change Procedures ........................ 16-3

Fuel Specifications ........................................... 16-3

Air Cleaner ............................................................ 16-3

Air Filter Change Procedures........................... 16-3

Track Tension ....................................................... 16-4

Track Tension Adjustment Procedures ............ 16-4

Checking for Proper Track Adjustment ............ 16-4

Fuse Box ............................................................... 16-5

Grease Fittings ...................................................... 16-5

Lift Arm Bushings .................................................. 16-6

17. Hydraulic Pressure Check & Adjustment

Chapter Overview ................................................. 17-1

Personal Safety ..................................................... 17-1

Machine Preparation ............................................. 17-1

Charge Pressure check……………………………. 17-1

Charge Pressure Adjustment………………………17-2
Drive Pressure Adjustment…………………………17-3

Auxiliary Pressure Check & Adjustment…………..17-4

Compact Track Loader

Table of Contents

iii

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Chapter Overview

This chapter contains product safety information for the
Terex PT-30 Compact Track Loaders. Read and under­stand all product safety information before attempting
to service any Compact Track Loader.

Safety Alert Symbol
This symbol means: Attention! Be
alert! Your safety is involved!

The safety alert symbol is used to alert you to potential
personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or
death.

This symbol is used as an attention-getting device
throughout this manual as well as on decals and labels
fixed to the machinery to assist in potential hazard
recognition and prevention.

Property or equipment damage warnings in this publi­cation are identified by the signal word "NOTICE".

The word “Note” is used throughout this manual to
draw your attention to specific topics or to supplement
the information provided in that section.

The person(s) in charge of servicing a Compact Track
Loader may be unfamiliar with many of the systems on
the machine. This makes it especially important to use
caution when performing service tasks. Familiarize
yourself with the affected system(s) and components
before attempting any type of maintenance or service.

It is not possible to anticipate every potential haz­ard. The safety messages included in this docu­ment and displayed on the machine are not all­inclusive. They are intended to make you aware of
potential risks and encourage a safe approach to
performing service work. If you use a tool, proce­dure, work method or operating technique that is
not specifically recommended by Terex, you must
satisfy yourself that it is safe for you and others.
You must also ensure that the machine will not be
damaged or be made unsafe by the operation,
lubrication, maintenance or repair procedures that
you choose.

Basic Precautions

Safety Labels

Safety labels have been included and are displayed in
various places throughout the machine to serve as
warnings of potentially dangerous conditions. Read
and understand all "Safety" labels on any Compact
Track Loader before attempting to operate, maintain or
repair it. Replace any damaged, illegible or missing
labels immediately, prior to service.

Personal Protective Equipment

Personal protection equipment is recommended when
performing maintenance or service on a machine.
Always wear appropriate protective equipment for
working conditions when working on or around the
machine. Loose clothing should not be worn and long
hair should be restrained. Wear hard hats, protective
face/eyewear, safety shoes and any other equipment
necessary to ensure your safety and the safety of oth­ers around you as you work.

1. Product Safety

1-1

“NOTICE” Indicates a hazardous situation which,
if not avoided, could result in property or equip­ment damage.

NOTICE

Improper or incomplete maintenance/repair of a
Compact Track Loader can be dangerous and
may result in machine damage, injury or death.

Do not attempt to perform any type of repair or main­tenance on a Compact Track Loader until you have
read and fully understood both this manual and the
machine specific operation and maintenance manual.

Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation and
maintenance techniques before operating or servicing
any Compact Track Loader.

Entering and Exiting

Always use steps and handholds when entering or
exiting a Compact Track Loader. Clean any mud or
debris from steps or work platforms before using them.
Always face the machine when using steps and hand­holds. When it is not possible to use the designed
entry/exit system, utilize ladders, scaffolds, or work
platforms to safely gain access to the machine.

Lifting

Use a hoist when lifting components that weigh 50 Ib
(23 kg) or more, to avoid back injury. Make sure all
chains, hooks, slings, etc., are in good condition and
are of the correct capacity. Be sure hooks are posi­tioned correctly and equipped with a spring latch.
Lifting eyes are not to be side loaded during a lifting
operation.

Hot Fluids and Components

Stay clear of hot components and system fluids of the
engine, exhaust, radiator/oil cooler and hydraulic
lines/tubes. Also, use caution when removing fill caps,
breathers and plugs on the machine. Hold a rag over
the cap or plug to prevent being sprayed or splashed
by liquids under pressure. Be especially careful if the
machine has been operated recently, fluids may still be
hot. To ensure your safety, allow the machine to cool
before attempting any service procedure that involves
hot fluids or components.

Corrosion Inhibitor

Corrosion inhibitor contains alkali. Avoid contact with
eyes. Avoid prolonged or repeated contact with skin.
Do not take internally. In case of contact, wash skin
immediately with soap and water. For eyes, flush with
large amounts of water for at least 15 minutes. Call
Physician. Keep out of reach of children.

Batteries

Do not smoke when inspecting the battery electrolyte
level. Never disconnect any charging unit circuit or 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.

Pressurized Items

1. Do not use hands or any other body part to check

for fluid leaks in the hydraulic system. Always use
a solid material like wood or metal to check for this
type of leak. Leaking fluid under pressure can pen­etrate body tissue. Fluid penetration can cause
serious injury and even death. If fluid is injected
into your skin, get treatment immediately. Seek
treatment from a doctor that is familiar with this
type of injury.

2. Relieve pressure from the hydraulic system before
disconnecting or removing any lines, fittings or
related items. Do this by relaxing all hydraulic
actuators. If the lift arms are raised, make sure
they are securely braced. Be alert for possible
pressure release when disconnecting any device
from a pressurized system.

3. Lower the lift arms before performing any work on
the machine. If this cannot be done, make sure
they are securely braced to prevent them from
dropping unexpectedly during service.

4. Loose or damaged fuel, oil, hydraulic, lines, tubes
and hoses can cause fires. Do not bend or strike
high pressure lines or install ones that have been
bent or damaged. Check lines, tubes and hoses
carefully. See item 1 for precautions on checking
for fluid leaks.

5. Pressurized air or water can also cause injury.
When pressurized air or water is used for clean­ing, wear a protective face shield, protective cloth­ing, and protective shoes. The recommended max­imum air pressure for cleaning purposes is 30 psi
(205 kPa). When using a pressure washer, keep in
mind that nozzle pressures are typically very high.
Generally, pressures are well above 2000 psi
(13,790 kPa). Follow all recommended practices
provided by the pressure washer manufacturer.

1-2

Compact Track Loader

1. Product Safety

Repair

1. Disconnect the battery and discharge any capaci-

tor before beginning work on a machine. Attach a
Do Not Operate tag in the cab to alert any opera­tor that service is in progress.

2. If possible, make all repairs with the machine
parked on a level, hard surface. Use blocks to pre­vent the machine from rolling while working on or
under the machine.

3. Do not work on or under any machine that is sup­ported only by a hydraulic jack or hoist. Always
use some sort of mechanical support to ensure
that the machine will not fall.

4. Make sure the work area around the machine is
safe and make yourself aware of any hazardous
conditions that may exist. If the engine needs to
be started inside an enclosure, make sure that the
engine’s exhaust is properly vented.

5. Be sure all protective devices including guards and
shields are properly installed and functioning cor­rectly before beginning any service task. If a guard
or shield must be removed to perform the repair
work, use extra caution.

6. Always use the appropriate tools for the work to be
performed. Tools should be in good condition and
you should understand how to use them properly
before performing any service work.

7. When replacing fasteners, use parts of equivalent
grade and size. Do not use a lesser quality fasten­er if replacements are necessary.

8. Be prepared to stop an engine if it has been re­cently overhauled or the fuel system has been
recently serviced. If the engine has not been
assembled correctly, or if the fuel settings are not
correct, the engine can possibly overspeed and
cause bodily injury, death or property damage. Be
prepared to shut off the fuel and air supply to the
engine in order to stop the engine.

9. Be careful when removing cover plates. Gradually
back off the last two bolts or nuts located on 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 completely.

10. Repairs requiring welding should be performed
only by personnel adequately trained and knowl­edgeable in welding procedures and with the guid­ance of appropriate reference information.
Determine the type of metal being welded and
select the correct welding procedure and filler
material to provide a weld that is as strong or
stronger than the original weld.

11. Take precautions to avoid damaging wiring during
removal and installation operations. Carefully route
wires so that they will not contact sharp corners,
objects or hot surfaces during operation.

12. When performing service that requires the lift arms
to be in the raised position, always utilize the lift
arm brace located on the rear of the loader tower.

13. Relieve hydraulic system pressure by relaxing all
hydraulic actuators prior to attempting any
hydraulic maintenance or repair.

14. Always tighten connections to the correct torque
specification. Make sure that all shields, clamps
and guards are installed correctly to avoid exces­sive heat, vibration or unwanted contact between
parts during operation. Shields that protect
exhaust components from oil spray in event of a
line, tube or seal failure must be correctly installed.

15. Do not operate a machine if any rotating part is
damaged or contacts other parts during operation.
Any high speed rotating component that has been
damaged or altered should be checked for balance
before reusing. Make sure all protective devices,
including guards and shields, are properly installed
and functioning correctly before starting the engine
or operating the machine.

1-3

Compact Track Loader

1. Product Safety

Accidental machine starting can cause injury
or even death to personnel working on a
Compact Track Loader.

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

Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is
being serviced.

Attachments

Only use attachments that are recommended by Terex.

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.
Ensure that all personnel are far enough away from
the work area so they will not be struck by flying ob-

jects.

Stay clear of the cutting edges, pinching surfaces or
crushing surfaces of the attachment while performing
any attachment maintenance, testing or adjustments.

Machine Labels and Decals

Labels and decals placed on the machine provide
safety information and operating instructions.
Familiarize yourself with the location and significance
of these labels to ensure your safety.

Product Identification Number

The Product Identification Number (PIN) is located on
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.

Safety
Label

1-4

Compact Track Loader

1. Product Safety

1-1

When replacement parts are required for your
machine, use only genuine Terex replacement

parts or parts that meet or exceed original
specifications including, but not limited to physical
dimensions, type, strength and material.

Installing lesser components can lead to premature
failures, product damage, personal injury or death.

WARNING

Crush Hazard

Death or serious injury can result
from contact with moving lift arm or
attachment.

WARNING

WARNING

CRUSH HAZARD

Contact with moving machine can
result in death or serious injury.

WARNING

Fall Hazard

Serious injury or death can result
from falling.

WARNING

WARNING

Crush Hazard

Death or serious injury can result
from contact with moving lift arm or
attachment.

Keep clear of lift arms and
attachments.

Keep clear of moving machine.

Use the provided access system when
entering or exiting the machine.

Install lift arm brace prior to servicing.

2030-593

WARNING

Entanglement Hazard

Rotating parts can cause personal injury.

WARNING

Burn Hazard

Hot fluid under pressure can scald.

NOTICE

Fire Hazard

Flammable debris can collect near hot
components and lead to a fire.

Keep away from fan and belt while the
engine is running. Stop engine before
servicing.

Allow the machine to cool thoroughly
before opening.

Read Operator’s manual

Keep engine, exhaust and chassis
areas free of debris.

2030-600

2030-595

1-5

Compact Track Loader

1. Product Safety

WARNING

Rollover can crush and result in serious injury or death.

Crush Hazard

Fasten Seat Belt

WARNING

Improper operation or maintenance can re­sult in serious injury or death.

Read Operator’s Manual

Read and understand the operator’s manual
and all safety signs prior to operating or
maintaining the machine.

WARNING

Fall Hazard

Falling can result in serious injury or death.

Do not use the bucket/attachment as a work platform.

WARNING WARNING

Fall Hazard

Falling from a machine can result in serious
injury or death

.

Carry loads low. Load unload and turn on

No Riders

level ground. Travel on inclines with heaviest
end of machine uphill.

Rollover/Ejection Hazard

Serious injury or death can result.

WARNING

Injection Hazard

Escaping fluid under pressure can
penetrate skin, causing serious injury.

• Relieve internal pressure before
disconnecting any line or fitting.

• Keep away from leaks or pinholes.

• Use cardboard to check for leaks.

Fluid injected into skin must be surgi­cally removed within a few hours by a
doctor familiar with this type of injury
or gangrene will result.

1-6

PT-30 Specifications

Engine

- Model: Perkins 403-D15

- Displacement: 1.5 liter

- Gross horsepower: 33.7 hp (25.1 kW)

- Peak Torque: 64.39 lb-ft. (87 Nm)

- Idle rpm: 1175 (low idle), 2800 (high idle)

- Average water /thermostat temperature: 190°F,

87.8°C

Transmission

- Model: A10VG18 tandem (Rexroth)

Drive Pumps

- Displacement: 1.098 in3/rev (18 cc/rev)

- Relief pressure: 3800 psi (26,200 kPa)

- Flow: 13 gpm ( 11.4lpm) @ 2800 rpm (per pump)

Charge Pumps (2)

- Displacement: .33 in3/rev (5.4 cc/rev) x2

- Relief pressure: 360 +/- 20 psi (24.82 bar)

- Flow: 3 gpm (11.4 lpm combined) @1175 rpm

- Flow: 8.1 gpm (30.7 lpm combined) @2800 rpm

Drive Motors

- Model: Rexroth Sauer Danfoss

- Displacement: 19.215 in3/rev (314.9 cc/rev)

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)

Oil Cooler

- Operating pressure: 250 psi (1724 kPa)

- Bypass relief pressure: 80 psi (551.6 kPa)

- Hot oil sending unit: 225°F (107.2°C)

- Avg. oil operating temp. 50-60°F (10-16°C) above

ambient. (extreme application 80°F , 27°C above
ambient.)

Critical Torque Specs

- Transmission Mounting Bolts

-- 80 ft-lb (108 Nm). w/Blue Loctite

- Drive Sprocket Drive Teeth Bolts

-- 62 ft-lb (84 Nm). -Dry

- Bogie Wheel Retaining Nuts

-- 110 ft-lb (149 Nm). - Dry

- Drive Sprocket Retaining Bolt

(Serial # 00101-05000)

-- 60 ft-lb (81 Nm). w/Blue Loctite

- Drive Sprocket Retaining Castle Nut

(Serial # 05001-Current)

-- 270 ft-lb (366 Nm)

Service Tools

Listed below are common service tools which are iden­tified and utilized in the service procedures described
in this manual. Use tools recommended by Terex
whenever possible to reduce risk of injury and or
machine damage during service.

• Heavy Duty Hydraulic Jack (5-ton rating)

• Test Gauge Kit (P/N: 0402-935)

• Long Pry Bar(s)

2. Technical Specifications
& Service Tools

2-1



Chapter Overview

This chapter contains diagrams for the following
Compact Track Loader systems.

• Filtering and cooling system

• Auxiliary circuit system

• Drive loop system

Figure 3-1 PT-30 Filtering and Cooling System

Filtering and Cooling System

The filtering and cooling system (Figure 3-1) contains
the following major components.

• Hydraulic reservoir

• Radiator/oil cooler

• Loader valve

• Auxiliary gear pump

• Pilot control manifold

3. Circuit Diagrams

3-1

100psi (689.5 kPa)

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 fol­lowing major components.

• Tandem pump

• Drive motors

• Pilot control manifold

• Drive control joystick

Figure 3-3 PT-30 Drive Loop System

3-3

Compact Track Loader

3. Circuit Diagrams

DRIVE MOTOR

DRIVE MOTOR

CHARGE PRESSURE

TEST PORT

DRIVE CONTROL

TANK

CASE DRAIN

BRAKE

TANDEM PUMP (WITH DRIVE
AND CHARGE PRESSURE
RELIEF VALVES.)

CASE DRAIN

TO IMPLEMENT

VALV E

Drive Reliefs

Charge Reliefs



Chapter Overview

This chapter contains an overview of the machine con­trols and instrumentation. For further information
regarding machine controls, instrumentation or opera­tion, refer to the operation and maintenance manual
for your particular machine. Included here are illustra­tions of the following controls and instrumentation com­ponents and a description of their functions.

• Machine Controls

• Instrument Location and Function

• Switch Location and Function

Machine Controls (fig. 4-1)

There are three primary machine controls: loader 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.

Drive Control

The drive control (2) is also a pilot operated joystick. It
allows the operator to change the direction and speed
of the machine.

Throttle

The hand throttle (3) controls engine rpm.

Instrumentation

The Instruments (Figure 4-2) are positioned in the
overhead dash panel for ease of access and visibility
when seated inside the operator enclosure.
Instruments include the following components.

(1) Fuel Gauge
(2) Tachometer (optional)
(3) Engine Coolant Temp. Gauge (optional)
(4) Hour Meter
(5) Warning Indicator Display

• Engine Oil Pressure Warning Light

• Engine Temperature Warning Light

• Hydraulic Oil Temperature Warning Light

• Battery Voltage Warning Light

If the engine temperature, engine oil pressure or hydraulic oil
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.
If the battery low-voltage light should illuminate during 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. Machine Controls and
Instrumentation

4-1

1

3

4-1

2

4-2

1

5 4

NOTICE

NOTICE

PT-30 Switches

The various switches (Figure 4-3) are positioned to
provide good access and visibility. The standard and
optional switches are listed below.

(1) Work lights
(2) Heater fan (optional)
(3) Front wiper (optional)
(4) Beacon light (optional)
(5) Ignition, glow plug (pre-heat)
(6) Auxiliary hydraulics

4-2

Compact Track Loader

4. Machine Controls and Instrumentation

4-3

1 2 3

4

5 6

5. Operator Enclosure

Disassembly and Assembly

Chapter Overview

This chapter provides disassembly and assembly
procedures for the operator enclosure assembly.

Personal Safety

Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in ma­chine damage, injury or death.

Do not attempt to perform any type of repair or mainten­ance on a Compact Track Loader until you have read and
fully understood the information in this 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
Compact Track Loader, read and understand Chap­ter 1 (Product Safety) for personal safety 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.

Operator Enclosure
Disassembly and Assembly
Procedures

Disassembly and assembly procedures are provided
for the following operator enclosure components.

• Light Bar

• Ignition Switch

• Gauges

• Lap Bar Gas Assist Spring

Note: Procedures are provided for only those operator
enclosure components listed above. However, information
for removal and installation of other operator enclosure
components can be obtained from the machine specific
parts manual.

Light Bar Removal and
Installation

The tools required for light bar console removal and
installation are listed in Table 5-1. Use manufacturer
recommended tools whenever possible.

Table 5-1

Required Tools

Combination Wrench

Light Bar Removal

Figure 5-1

1. Loosen the two cap screws that attach the light
bar to the cab frame.

5-1

Compact Track Loader

5. Operator Enclosure Disassembly and Assembly

Figure 5-2

2. Carefully lower the light bar with the wire har­ness attached.

Light Bar Installation

Figure 5-5

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 5-4

4. View of dome light. If removal is required, simply
insert a lever (blade-type screw driver) at oppo­site end of switch in pry-pocket, and gently pry
the light assembly out of the light bar.

Figure 5-6

2. Secure the light bar to the cab roof with the two
capscrews

Ignition Switch Removal and
Installation

The tools required for ignition switch removal and
installation are listed in Table 5-2. Use manufactur­er-recommended tools whenever possible.

Table 5-2

Required Tools

Combination Wrench

Ignition Switch Removal

1. Lower the light bar. Refer to Chapter 5. Light Bar

Removal procedure.

5-2

Compact Track Loader

5. Operator Enclosure Disassembly and Assembly

Remove Nut

Figure 5-7

2. Remove the nut that secures the ignition switch
to the dash panel.

Ignition Switch Installation

Figure 5-10

1. Insert the ignition switch from the rear of the
dash panel.

Install Nut

Figure 5-8

3. Pull the ignition switch out from the rear of the
dash panel.

Figure 5-9

4. Unplug the ignition switch connector.

Figure 5-11

2. Install the nut that secures the ignition switch to
the dash panel.

Figure 5-12

3. Plug in the ignition switch connector.

5-3

Compact Track Loader

5. Operator Enclosure Disassembly and Assembly

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 manufacturer­recommended tools whenever possible.

Table 5-3

Required Tools

Combination wrench

Gauge Removal

Figure 5-15

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

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

Figure 5-13

2. Disconnect the connector from the gauge.

Gauge Installation

Figure 5-16

1. Insert the gauge from the front of the dash pan­el.

Figure 5-14

3. Remove the two nuts that secure the gauge to
the retaining bracket.

Figure 5-17

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

5-4

Compact Track Loader

)

g

p

)

5. Operator Enclosure Disassembly and Assembly

Remove

Retainin

Cli

Figure 5-18

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.

Table 5-4

Required Tools

Screwdriver

Lap Bar Gas Assist Spring Removal

Figure 5-20

2. Using a small screwdriver, remove the retaining
clip from each end of the gas assist spring.

Figure 5-21

3. Remove the gas assist spring by pulling both
ends out from the ball joints.

Gas Assist

Spring

Raise Lap Bar

(Shown in Down

Position

Figure 5-19

1. Put the lap bar in the UP position to relieve ten­sion on the lap bar gas assist spring.

Lap Bar Gas Assist Spring Installation

Gas Assist

Spring Location

Figure 5-22

1. Put the lap bar in the UP position to minimize
tension on the lap bar gas assist spring during
installation.

5-5

Raise Lap Bar

(Shown in Down

Position

Compact Track Loader

g

p

5. Operator Enclosure Disassembly and Assembly

Ins ta ll End s on

B a ll J o in ts

Figure 5-23

2. Install the ends of the lap bar gas assist spring
onto the ball joints.

Insert

R e ta in in

Cli

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

This chapter provides disassembly and assembly
procedures for the chassis assembly.

Personal Safety

Improper or incomplete maintenance/repair of a Compact
Track Loader can be dangerous and may result in ma­chine damage, injury or death.

Do not attempt to perform any type of repair or mainten­ance on a Compact Track Loader until you have read and
fully understood the information in this 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
Compact Track Loader, read and understand Chap­ter 1 (Product Safety) for personal safety 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.

Chassis Disassembly and
Assembly Procedures

Disassembly and assembly procedures are provided
for the following chassis components.

• Seat

• Fuel Sending Unit

• Fuel Sending Unit Hose

• In-Tank Weight

• Fuel Tank

Note: Procedures are provided for only those chassis
components listed above. However, information for re­moval and installation of other chassis compone nts can be
obtained from the exploded view illustration provided in
the machine specific parts manual.

Seat Removal and Installation

The tools required for seat removal and installation
are listed in Table 6-1. Use manufacturer­recommended tools whenever possible.

Table 6-1

Required Tools

Socket Wrench

Seat Removal

Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is be­ing worked on.

Remove Seat B olts

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

Figure 6-2

2. Tilt the seat forward and reach behind the seat
to unplug the seat switch wiring harness.

Plug in the Connector

Figure 6-5

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.

Figure 6-3

3. Remove the seat. Be careful not to scratch the
control panel or sides of the cab.

Seat Installation

insert Seat Bolts

Figure 6-6

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.

Figure 6-4

1. With the seat mounts attached, place the seat in
the cab. Be careful not to scratch the control
panel or sides of the cab.

Table 6-2

Required Tools

Screwdriver
Combination Wrench
Socket Wrench

6-2

Fuel Sending Unit Removal

1. Remove the seat. Refer to Chapter 6. Seat Re-

moval procedure.

2. Pump fuel from the tank until there is no fuel
remaining above the sending unit.

Collect and contain liquids in a suitable contain-

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

Compact Track Loader

6. Chassis Disassembly and Assembly

Fuel
Sending
Unit

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 6-9

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

Fuel Sending Unit Installation

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