PT-70/80 Part Number: 2046-310Printed (4-10)Service ManualRubber Track Loader
AttachmentsOnly use attachments that are recommended by Terex.Make sure that all necessary guards and protectiveequipment are in place and functioning
1. Rest the lift arms on an Terex approved jack standto provide clearance for lift cylinder removal. (fig.14-1)2. Disconnect the inlet and outlet hose
7. Remove the cylinder from the machine for serviceor inspection. (fig. 14-7)Note: At this time the pivot bushings and pivot pins areeasily accessible
4. Remove the bolt securing the lower pin to thequick attach. (fig. 14-10)5. Remove the bolt securing the upper pin to the liftarm weldment. (fig. 14-
10. Remove the pin from the cylinder while supportingthe cylinder. (fig. 14-16)11. Remove the cylinder from the machine. (fig. 14-17)Installation1. To
14-6
Chapter OverviewThis chapter provides removal and installation proce-dures for the quick attach and associated components.Personal SafetyImproper or i
2. Remove the bolts (3) securing the upper guard tothe quick attach weldment. (fig. 15-2)3. Remove the upper guard from the quick attach.(fig. 15-3)4.
Pivot Pin (quick attach)Removal 1. Rest the lift arms on an Terex approved jack standto provide clearance for quick attach disassembly.(fig. 15-8)2. R
Chapter OverviewThis chapter provides information on inspection, disas-sembly and assembly of major hydraulic components. Personal SafetyImproper or i
1-5Rubber Track Loader1. Product SafetyWARNINGImproper operation or maintenancecan result in serious injury or death.Read and understand the opera-tor
4. Use an open end or pipe wrench to turn andremove the end gland. (figure 16-2)5. Use a pry bar or similar device to pull the rod andpiston from the
11. Remove the seals and piston ring taking care notto scratch the piston. Also, pay close attention toseal and ring orientation and position to aid w
Lift Arm Control Valve Disassembly1. With machine off and cool and with hydraulic actu-ators relaxed, remove the lift arm control valveaccording to th
Note: Figure 16-19 displays the assembly order of thespool and associated components.Note: The lift arm and bucket control spools are eachequipped wit
Assembly1. Install new seals and components in place of theoriginals as necessary paying close attention tolocation and orientation to ensure proper f
4. Remove the brake spring and shims. Make sure tonote the order of assembly to ensure correctreassembly. (fig. 16-27)5. Insert an air nozzle into the
Drive Motor (motor portion)Disassembly1. Mark the casing across the parting lines as shownto ensure correct reassembly of the drive motor.(fig. 16-33)
6. Once the snap rings and retainers are removed,slide the piston assemblies out one at a time andinspect them for damage. (fig. 16-39, 16-40)Note: Wh
4. Flip the valve over, then tighten the nut to increasethe pressure setting (CW) or loosen it to decreasethe pressure setting (CCW).Assembly & Te
3. Remove the valve plate and inspect it for damageor wear, specifically, scratches that can be felt witha fingernail. (fig. 16-49)4. Inspect the end
7. Using a rubber mallot, gently tap the shaft andbearing out of the casing for inspection or replace-ment. (fig. 16-55)Drive Pump Assembly1. Using a
4. Flip the assembly over and lay it on a table, thenremove the pivot caps from both sides as shown.(fig. 16-58)Note: Behind each cap is a pivot that
Auxiliary Pump Disassembly1. With machine off and cool and with hydraulic actu-ators relaxed, remove the drive pump from themachine by following the p
8. Remove the piston/barrel assembly and inspectthe slipper faces for scratches or any other dam-age that can be felt with a fingernail. (fig. 16-70)A
16-16
Chapter OverviewThis chapter provides hydraulic pressure and flowcheck, adjustment and troubleshooting procedures. Personal SafetyImproper or incomple
1. Attach the gauge to test port A. (fig. 17-1) Routethe gauge so that you or an assistant can read itduring testing.2. Make sure any bystanders are c
Auxiliary Pressure CheckAuxiliary pressure is used to drive flow style attach-ments. Low auxiliary pressure can produce poor per-formance in attachmen
Lift Arm Pressure CheckLift arm pressure is used to lift loads or “break-out”.Low lift arm pressure can produce a weak lift arm func-tion while high l
Check your readings against that stated below. If yourreadings differ, relief replacement and or componentrepair may be required. Pressures should re
PT-70 SpecificationsEngine- Model: Perkins 804C-33T- Displacement: 3.3 liter- Gross horsepower: 71 hp (53 kW)- Torque: 173 lb-ft. (234 Nm)- Idle rpm:
6. If your reading is low, remove the cap and loosenthe jam nut on the posi-power adjustment screwand turn it counter clockwise until it stops thenret
Note: The charts pictured give the acceptable rangesfor fluid flow when loaded to the levels indicated. Thelow flow values are to be understood as acc
Chapter OverviewThis chapter contains basic troubleshooting proce-dures for PT-70/80 Rubber Track Loaders.Additional troubleshooting aids are provided
Problem 2:Machine cranks, but will not start.Possible causes1. Fuel tank empty, fuel filter plugged or fuel linerestricted.2. Battery discharged (engi
Problem 9:Lift arm control joystick will not lock into floatposition.Possible causes1. Float magnet fuse blown.2. Loose, broken, or disconnected wir
18-4
Chapter OverviewWhen replacing or replenishing the fluids and lubri-cants in an Terex Rubber Track Loader, use Terexproducts. This ensures that the ne
19-2
20. Service Aids &Supplements 20-1General Torque SpecificationsInch Fasteners Metric FastenersThread Size Standard Torque1/4" 9 +/- 2 lb ft5/
PT-80 SpecificationsEngine- Model: Perkins 804D-33T- Displacement: 3.3 liter- Gross horsepower:80 hp (60 kW)- Torque: 186 lb-ft. (253 Nm)- Idle rpm: 1
Terex Construction Americas8800 Rostin RoadSouthaven, MS 38671(888)-201-6008(662)-393-1800www.terex.com
Chapter OverviewThis chapter contains diagrams for the following PT-70/80 circuits: hydraulic charge circuit, hydraulic auxil-iary circuit, hydraulic
Hydraulic Auxiliary CircuitFigure 3-2 PT-70/80 Hydraulic Auxiliary Circuit3-2Rubber Track Loader3. Circuit DiagramsOIL COOLERTO TANKTO ATTACHMENTCASE
Hydraulic Drive Circuit Figure 3-3 PT-70/80 Hydraulic Drive Circuit3-3Rubber Track Loader3. Circuit DiagramsDRIVE MOTORDRIVE MOTORDRIVE PUMPDRIVE CO
Lift Arm Control ValveFigure 3-4 PT-70/80 Lift Arm Control Valve3-4Rubber Track Loader3. Circuit DiagramsRELIEF VALVE SETTINGS(B3) 3307 PSI(22800 kPa)
Hydraulic Pilot GenerationBlock Figure 3-5 PT-70/80 Hyd. Pilot Generation Block 3-5Rubber Track Loader3. Circuit Diagrams
Electrical Attachment OutletFigure 3-6 PT-70/80 Electrical Attachment Outlet3-6Rubber Track Loader3. Circuit Diagrams
Drive Control (line routing)Figure 3-7 PT-70/80 Standard Drive Control3-7Rubber Track Loader3. Circuit Diagrams
Lift Arm Control (line routing)Figure 3-8 PT-70/80 Lift Arm Control3-8Rubber Track Loader3. Circuit Diagrams
Chapter OverviewThis chapter provides information on general mainte-nance procedures for the PT-70/80. If there is an issuethat requires troubleshooti
Tilt-Up Cab The ROPS/FOPS approved cab (A) tilts up to alloweasier access while performing maintenance. It fea-tures a gas spring assist and a brace m
Grease FittingsThe PT-70/80 are equipped with grease fittings at pivot points throughout the machine. The illustration aboveshows the locations of all
Track Tension Proper track tension must be maintained for optimalperformance and track/undercarriage life. Running atrack that is too loose may cause
Drive Sprocket Rollers Terex rubber track loaders utilize rollers on the drivesprockets to drive the track. These rollers help mini-mize friction betw
Track Removal/InstallationTracks may need to be removed periodically to inspectundercarriage components or for replacement if wornor damaged. This sec
6. Remove the outer scraper plate from the suspension rail. (fig. 4-17)7. Remove the bolts securing the inner wheel to the hub, then remove the wheel.
1. Product SafetyChapter Overview . . . . . . . . . . . . . . . . . . . . . 1-1Safety Messages . . . . . . . . . . . . . . . . . . . . . 1-1Informati
Track Installation 1. Slide the track over the drive sprocket at the rear of the machine. (fig. 4-23, 4-24)2. Slide the front of the
9. Once the track is in position over the idler wheels, install the inner idler wheel onto the hub and secure it in place with the mounting bolts. Tor
Air CleanerThe PT-70/80 are equipped with two air filter elementsto remove contaminants from the air used for combus-tion. Regular inspection and repl
7. Once the inspection has been performed, install the new secondary filter element into the enclosureas found upon disassembly. (fig. 4-39)8. Install
Accessory Belt Tension Drive belts typically stretch and wear during their serv-ice life. The fan and A/C belts should be checked fortension, conditio
Fan Belt Removal & InstallationTo remove the fan belt:1. Follow steps 1 and 2 of the belt adjustment procedure.2. Once loose, pivot the alternator
Engine Oil/Filter ChangeRegular oil changes are necessary to maintain astrong running engine. Terex recommends a normal oilchange interval of 250 hour
10. Remove the oil filler cap and fill the enginecrankcase with Terex 10W-30 Heavy Duty EngineOil (capacity: 9 qt./8.5l including filter). (fig. 4-51)
Hydraulic Fluid/Filter ChangeHydrostatic components require extremely clean oil inorder to have a long service life. Use extreme cautionwhen changing
Radiator/Oil CoolerThe Radiator and Oil Cooler must be kept clean toensure proper operation. Engine and hydraulic systemoverheating, damage and even f
6. Operator EnclosureChapter Overview . . . . . . . . . . . . . . . . . . . . . 6-1Personal Safety . . . . . . . . . . . . . . . . . . . . . . 6-1Mac
Case Drain FilterThe PT machines are also equipped with a filter in theauxiliary circuit case drain line. It protects the mainhydraulic system in the
Maintenance ItemService requiredInterval NotesService Capacity Grease fittings Lubricate Daily Grease often. Fluid levels Check Daily Adjust levels
Chapter OverviewThis chapter contains an overview of the machine con-trols and instrumentation. For further informationregarding machine controls, ins
SwitchesThe various switches (Figure 5-3, 5-4, 5-5) are posi-tioned to provide good access and visibility. The stan-dard and optional switches are lis
Chapter OverviewThis chapter provides information on the assembly anddisassembly of the operator enclosure assembly. Ifthere is an issue that requires
Pillar Switch Panels Removal 1. Remove the screws/bolts securing the pillar switchpanel to the cab enclosure. (fig. 6-3)2. Remove the forward end of t
Side Panels/Gauges Removal1. Remove the screws securing the forward sidepanel to the operator enclosure. (fig. 6-9)2. Pull the side panel away from th
Seat Removal1. Remove the bolts (2) securing the cab to the chas-sis. They are located inside the cab in the upperfront corners of the foot well. (fig
Chapter OverviewThis chapter provides information on the assembly anddisassembly of the chassis. If there is an issue thatrequires troubleshooting, re
12. EngineChapter Overview . . . . . . . . . . . . . . . . . . . . . 12-1Personal Safety . . . . . . . . . . . . . . . . . . . . . . 12-1Removal &
5. Remove the screws securing the fuel sending unitto the tank. (fig. 7-2)6. Remove the sending unit by pulling it through theopening in the fuel tank
6. Loosen the hose clamp securing the main fuel lineto the tank outlet in the front right corner of themachine. (fig. 7-8)7. Disconnect this line and
FootwellRemoval1. Raise and support the lift arms as described onpage 4-1 of this manual. (optional)2. Tilt and support the operator enclosure (cab) a
Foot Throttle AssemblyRemovalNote: The foot throttle assembly may be removed withthe footwell still installed in the machine. 1. Perform steps 3 and 4
3. Have an assistant help you to remove the hoodassembly from the machine. (fig. 7-23)4. Carefully set the hood assembly aside. (fig. 7-24)Installatio
Chapter OverviewThis chapter provides information on the disassemblyand assembly of the radiator/oil cooler and associatedcomponents. If there is an i
2. Remove bolts (5) securing the fan guard halves tothe fan shroud. (fig. 8-2, 8-3)3. Remove both halves of the guard from themachine. (LT side shown,
4. Remove the bolts securing the fan and spacer tothe engine, then remove the fan and spacer frombetween the shroud and radiator as shown. (fig. 8-8,
4. Remove the bolts (6) securing the outer shroud tothe chassis, then remove the shroud. (fig. 8-13)5. Remove the upper hydraulic cooler hose. Cap orp
Chapter OverviewThis chapter provides removal and installation proce-dures for the hydraulic reservoir.Personal SafetyImproper or incomplete maintenan
1. Remove the center and rear belly pans from themachine.2. Drain the hydraulic fluid. Refer to page 4-16 for thehydraulic fluid and filter change pro
9. Gently move the hard lines out of the way to allowfor reservoir removal then zip tie them to the motormount to keep them secure. (fig. 9-7)10. Dis
14. Disconnect the main oil cooler line from the fittingat the filter. (fig. 9-13)15. Disconnect the main oil cooler line from the junc-tion block, th
18. Slide the two fuel lines through the chassis open-ing and into the engine compartment so that theaux. hyd. tubes can be removed. (fig. 9-19, 9-20)
23. Remove the lower hose restraints to allow thehoses to be pulled through the chassis. (fig. 9-25)24. Pull the hoses up through the chassis opening
29. Make sure there is nothing that would visibly pre-vent the reservoir from being removed or is stillattached to other components within the machine
Suction Screen Removal Note: The suction screen may be removed with thereservoir (tank) still in the machine. If this is necessary,remove the center b
Chapter OverviewThis chapter provides removal and installation proce-dures for the lift-arm and drive control components.Personal SafetyImproper or in
1. Relax all hydraulic actuators to relieve pressure inthe hydraulic system prior to service.2. Turn the ignition switch to the OFF position,remove th
9. Remove the fittings on the back of the joystick (liftarm control joystick only). (fig. 10-7)10. Remove the bolts and nuts securing the joystick tot
Chapter OverviewThis chapter contains product safety information for theTerex PT-70/80 Rubber Track Loaders. Read andunderstand all product safety inf
Lift Arm Control Valve Removal1. Perform the footwell removal procedure on page 7-4 of this manual.2. Drain the hydraulic system as described on page4
Chapter OverviewThis chapter provides removal and installation proce-dures for the hydraulic pumps and motors.Personal SafetyImproper or incomplete ma
1. Lower the lift arms to the ground and relax thebucket tilt/curl cylinders to relieve pressure withinthe hydraulic system.2. Turn the ignition switc
Auxiliary Pump Removal1. Loosen the bolts securing the spilt flange clamp tothe upper front port on the aux. pump. (fig. 11-4)2. Remove the clamp and
7. Use a pry-bar to pry the inlet weldment out of thehoses. (This can be difficult, lubricating the inlettubes with a penetrating lubricant may makere
11-5Rubber Track Loader11. Hydraulic Pumps/Motors3. Support the pump with a hoist or floor jack to pre-vent it from falling as the mounting bolts are
Drive MotorRemoval1. Remove the track from the undercarriage by per-forming the track removal procedure on page 4-6of this manual.2. Remove the three
7. Remove the snap ring securing the bearingassembly to the outer sprocket shaft. (fig. 11-24)8. Use a jaw style puller and an impact wrench toremove
13. Note the orientation of the hoses as they are con-nected to the drive motor. Label them to ensurecorrect installation and proper orientation durin
Chapter OverviewThis chapter provides procedures for the removal andinstallation of the engine and associated components. Personal SafetyImproper or i
Entering and Exiting Always use steps and handholds when entering orexiting a Rubber Track Loader. Clean any mud ordebris from steps or work platforms
4. Remove the two tension (L) rods by twisting andmaneuvering them out of the chassis mountingholes. (fig. 12-3)5. Lift and remove the battery from th
4. Remove the tension springs that secure the middlepipe section to the head (upper) pipe and mufflerinlet (lower) pipe. (fig. 12-8)5. Remove the uppe
10. You may now remove the tail pipes by sliding themforward within the chassis, then out. (fig, 12-14).Installation1. To install the exhaust system,
4. Remove the air cleaner housing from the machine.(fig. 12-18)Installation1. To install the air cleaner assembly, reverse theremoval procedure.Engine
8. Disconnect the throttle cable from the engine. Note: Once loose, you may want to pull the throttlecable forward through the chassis to make sure it
14. Lay the angle iron across the fenders (or fuel tankif still in place) and attach one or two tie downstraps to serve as a sling to hold the hydraul
Chapter OverviewThis chapter provides removal and installation proce-dures for the undercarriages. Note: For track removal and installation procedures
3. Clean the threads on the turnbuckle thoroughly using a stiff bristle brush.4. Loosen the lock nut on the turnbuckle and spin it to the end of the t
13-3Rubber Track Loader13. Undercarriage10” & 15” Wheels (PT-70)Note: The 15” idler and 10” bogie wheels may beremoved from the PT-70 and PT-80 un
Repair 1. Disconnect the battery and discharge any capaci-tor before beginning work on a machine. Attach aDo Not Operate tag in the cab to alert any o
Bogie Wheel (PT-80 only)Removal & Service Procedure1. Perform steps 1-5 of the 15” idler wheel removalprocedure on page 13-1 to loosen the track a
Note: The metal face seals are a 4-piece design withone rubber outer seal and one metal face seal fittedinto each wheel and one rubber outer seal and
10. Disassemble and clean the face seals and theirrubber outer seals thoroughly, then wipe them dryto ensure a good seal when assembled.11. Once the s
17. Apply red (high strength) thread locking compoundto the wheel retaining bolt as shown. (fig. 13-26) 18. Install the bolt and tighten it. (fig. 13-
Idler Hub Service Procedure PT-801. Remove the hub assemblies from the undercar-riages as required first by following steps 1-7 ofthe track removal pr
5. Remove the bearing out of the front of the hub asshown. (fig. 13-36)6. Press the center seal and front bearing race out ofthe assembly from the rea
Note: Take care not to drop the metal face seal halves.The sealing surfaces are surface ground and have anextremely fine finish. If scratched or disfi
16. Once the seals are in place, wipe the mating sur-faces of the face seals with a clean shop cloth andalcohol in a circular motion ending in a gentl
22. Press the outer bearing race into the hub with tool# 0403-330 until it seats. (fig. 13-54)23. Pack the bearing with Terex Multi-Purpose EPLithium
Chapter OverviewThis chapter provides removal and installation proce-dures for the lift-arm components.Personal SafetyImproper or incomplete maintenan
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