ASV SR-70 Service Manual

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Summary of Contents

Page 1 - Service Manual

PT-70/80 Part Number: 2046-310Printed (4-10)Service ManualRubber Track Loader

Page 2

AttachmentsOnly use attachments that are recommended by Terex.Make sure that all necessary guards and protectiveequipment are in place and functioning

Page 3 - Table of Contents

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

Page 4

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

Page 5

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-

Page 6

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

Page 8

Chapter OverviewThis chapter provides removal and installation proce-dures for the quick attach and associated components.Personal SafetyImproper or i

Page 9

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.

Page 10 - Machine Labels and Decals

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

Page 12

Chapter OverviewThis chapter provides information on inspection, disas-sembly and assembly of major hydraulic components. Personal SafetyImproper or i

Page 13 - & Service Tools

1-5Rubber Track Loader1. Product SafetyWARNINGImproper operation or maintenancecan result in serious injury or death.Read and understand the opera-tor

Page 14 - Service Tools

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

Page 15 - 3. Circuit Diagrams

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

Page 16 - Hydraulic Auxiliary Circuit

Lift Arm Control Valve Disassembly1. With machine off and cool and with hydraulic actu-ators relaxed, remove the lift arm control valveaccording to th

Page 17 - Hydraulic Drive Circuit

Note: Figure 16-19 displays the assembly order of thespool and associated components.Note: The lift arm and bucket control spools are eachequipped wit

Page 18

Assembly1. Install new seals and components in place of theoriginals as necessary paying close attention tolocation and orientation to ensure proper f

Page 19 - Hydraulic Pilot Generation

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

Page 20 - Electrical Attachment Outlet

Drive Motor (motor portion)Disassembly1. Mark the casing across the parting lines as shownto ensure correct reassembly of the drive motor.(fig. 16-33)

Page 21 - (line routing)

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

Page 22 - Lift Arm Control

4. Flip the valve over, then tighten the nut to increasethe pressure setting (CW) or loosen it to decreasethe pressure setting (CCW).Assembly & Te

Page 23 - 4. Maintenance

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

Page 25 - Grease Fitting Locations

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

Page 26 - Track Tension

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

Page 27 - Drive Sprocket Rollers

Auxiliary Pump Disassembly1. With machine off and cool and with hydraulic actu-ators relaxed, remove the drive pump from themachine by following the p

Page 28 - Track Removal/Installation

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

Page 29

16-16

Page 30

Chapter OverviewThis chapter provides hydraulic pressure and flowcheck, adjustment and troubleshooting procedures. Personal SafetyImproper or incomple

Page 31

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

Page 32 - Air Cleaner

Auxiliary Pressure CheckAuxiliary pressure is used to drive flow style attach-ments. Low auxiliary pressure can produce poor per-formance in attachmen

Page 33 - Water Separator

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

Page 34 - Accessory Belt Tension

Check your readings against that stated below. If yourreadings differ, relief replacement and or componentrepair may be required. Pressures should re

Page 35

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:

Page 36 - Engine Oil/Filter Change

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

Page 37 - Oil Level Check

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

Page 39 - Radiator/Oil Cooler

Chapter OverviewThis chapter contains basic troubleshooting proce-dures for PT-70/80 Rubber Track Loaders.Additional troubleshooting aids are provided

Page 40 - Fuse Panel

Problem 2:Machine cranks, but will not start.Possible causes1. Fuel tank empty, fuel filter plugged or fuel linerestricted.2. Battery discharged (engi

Page 41

Problem 9:Lift arm control joystick will not lock into floatposition.Possible causes1. Float magnet fuse blown.2. Loose, broken, or disconnected wir

Page 43 - Instrumentation

Chapter OverviewWhen replacing or replenishing the fluids and lubri-cants in an Terex Rubber Track Loader, use Terexproducts. This ensures that the ne

Page 45 - 6. Operator Enclosure

20. Service Aids &Supplements 20-1General Torque SpecificationsInch Fasteners Metric FastenersThread Size Standard Torque1/4" 9 +/- 2 lb ft5/

Page 46 - Pillar Switch Panels

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

Page 48 - Rear Interior Panel

Terex Construction Americas8800 Rostin RoadSouthaven, MS 38671(888)-201-6008(662)-393-1800www.terex.com

Page 49 - 7. Chassis and Fuel Tank

Chapter OverviewThis chapter contains diagrams for the following PT-70/80 circuits: hydraulic charge circuit, hydraulic auxil-iary circuit, hydraulic

Page 50 - Fuel Tank

Hydraulic Auxiliary CircuitFigure 3-2 PT-70/80 Hydraulic Auxiliary Circuit3-2Rubber Track Loader3. Circuit DiagramsOIL COOLERTO TANKTO ATTACHMENTCASE

Page 51

Hydraulic Drive Circuit Figure 3-3 PT-70/80 Hydraulic Drive Circuit3-3Rubber Track Loader3. Circuit DiagramsDRIVE MOTORDRIVE MOTORDRIVE PUMPDRIVE CO

Page 52 - Footwell

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)

Page 53 - Hood Assembly

Hydraulic Pilot GenerationBlock Figure 3-5 PT-70/80 Hyd. Pilot Generation Block 3-5Rubber Track Loader3. Circuit Diagrams

Page 55 - 8. Radiator and Oil Cooler

Electrical Attachment OutletFigure 3-6 PT-70/80 Electrical Attachment Outlet3-6Rubber Track Loader3. Circuit Diagrams

Page 56 - Fan & Fan Shroud

Drive Control (line routing)Figure 3-7 PT-70/80 Standard Drive Control3-7Rubber Track Loader3. Circuit Diagrams

Page 57

Lift Arm Control (line routing)Figure 3-8 PT-70/80 Lift Arm Control3-8Rubber Track Loader3. Circuit Diagrams

Page 58

Chapter OverviewThis chapter provides information on general mainte-nance procedures for the PT-70/80. If there is an issuethat requires troubleshooti

Page 59 - 9. Hydraulic Reservoir

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

Page 60

Grease FittingsThe PT-70/80 are equipped with grease fittings at pivot points throughout the machine. The illustration aboveshows the locations of all

Page 61

Track Tension Proper track tension must be maintained for optimalperformance and track/undercarriage life. Running atrack that is too loose may cause

Page 62

Drive Sprocket Rollers Terex rubber track loaders utilize rollers on the drivesprockets to drive the track. These rollers help mini-mize friction betw

Page 63

Track Removal/InstallationTracks may need to be removed periodically to inspectundercarriage components or for replacement if wornor damaged. This sec

Page 64

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.

Page 65

1. Product SafetyChapter Overview . . . . . . . . . . . . . . . . . . . . . 1-1Safety Messages . . . . . . . . . . . . . . . . . . . . . 1-1Informati

Page 66 - Suction Screen

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

Page 67 - 10. Lift-Arm/Drive Controls

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

Page 68

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

Page 69 - Lift Arm Float Magnet

7. Once the inspection has been performed, install the new secondary filter element into the enclosureas found upon disassembly. (fig. 4-39)8. Install

Page 70

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

Page 71 - 11. Hydraulic Pumps/Motors

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

Page 72

Engine Oil/Filter ChangeRegular oil changes are necessary to maintain astrong running engine. Terex recommends a normal oilchange interval of 250 hour

Page 73

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)

Page 74 - Tandem (Drive) Pump

Hydraulic Fluid/Filter ChangeHydrostatic components require extremely clean oil inorder to have a long service life. Use extreme cautionwhen changing

Page 75

Radiator/Oil CoolerThe Radiator and Oil Cooler must be kept clean toensure proper operation. Engine and hydraulic systemoverheating, damage and even f

Page 76 - Drive Motor

6. Operator EnclosureChapter Overview . . . . . . . . . . . . . . . . . . . . . 6-1Personal Safety . . . . . . . . . . . . . . . . . . . . . . 6-1Mac

Page 77

Case Drain FilterThe PT machines are also equipped with a filter in theauxiliary circuit case drain line. It protects the mainhydraulic system in the

Page 78

Maintenance ItemService requiredInterval NotesService Capacity Grease fittings Lubricate Daily Grease often. Fluid levels Check Daily Adjust levels

Page 80 - Exhaust System

Chapter OverviewThis chapter contains an overview of the machine con-trols and instrumentation. For further informationregarding machine controls, ins

Page 81

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

Page 82

Chapter OverviewThis chapter provides information on the assembly anddisassembly of the operator enclosure assembly. Ifthere is an issue that requires

Page 83

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

Page 84

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

Page 85

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

Page 86

Chapter OverviewThis chapter provides information on the assembly anddisassembly of the chassis. If there is an issue thatrequires troubleshooting, re

Page 87 - 13. Undercarriage

12. EngineChapter Overview . . . . . . . . . . . . . . . . . . . . . 12-1Personal Safety . . . . . . . . . . . . . . . . . . . . . . 12-1Removal &

Page 88

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

Page 89 - 10” & 15” Wheels (PT-70)

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

Page 90 - Bogie Wheel (PT-80 only)

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

Page 91

Foot Throttle AssemblyRemovalNote: The foot throttle assembly may be removed withthe footwell still installed in the machine. 1. Perform steps 3 and 4

Page 92

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

Page 93

Chapter OverviewThis chapter provides information on the disassemblyand assembly of the radiator/oil cooler and associatedcomponents. If there is an i

Page 94 - Idler Hub

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,

Page 95 - Part #: 0403-336

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,

Page 96 - Part #: 0403-330

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

Page 97 - Part #: 0403-335

Chapter OverviewThis chapter provides removal and installation proce-dures for the hydraulic reservoir.Personal SafetyImproper or incomplete maintenan

Page 99 - 14. Lift-Arm Components

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

Page 100

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

Page 101 - Bucket/Tilt Cylinder

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

Page 102

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)

Page 103 - Quick Coupler Block PRV

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

Page 104

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

Page 105 - 15. Quick Attach

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

Page 106

Chapter OverviewThis chapter provides removal and installation proce-dures for the lift-arm and drive control components.Personal SafetyImproper or in

Page 107 - Pivot Pin (quick attach)

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

Page 108

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

Page 109 - 16. Hydraulic Component

Chapter OverviewThis chapter contains product safety information for theTerex PT-70/80 Rubber Track Loaders. Read andunderstand all product safety inf

Page 110

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

Page 111 - Assembly

Chapter OverviewThis chapter provides removal and installation proce-dures for the hydraulic pumps and motors.Personal SafetyImproper or incomplete ma

Page 112 - Lift Arm Control Valve

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

Page 113

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

Page 114 - Drive Motor (brake portion)

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

Page 115

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

Page 116 - Drive Motor (motor portion)

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

Page 117 - Disassembly & Adjustment

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

Page 118 - Drive Pump

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

Page 119

Chapter OverviewThis chapter provides procedures for the removal andinstallation of the engine and associated components. Personal SafetyImproper or i

Page 120

Entering and Exiting Always use steps and handholds when entering orexiting a Rubber Track Loader. Clean any mud ordebris from steps or work platforms

Page 121

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

Page 122 - Auxiliary Pump

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

Page 123

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,

Page 124

4. Remove the air cleaner housing from the machine.(fig. 12-18)Installation1. To install the air cleaner assembly, reverse theremoval procedure.Engine

Page 125 - Test & Troubleshooting

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

Page 126

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

Page 128 - Drive Pressure Check

Chapter OverviewThis chapter provides removal and installation proce-dures for the undercarriages. Note: For track removal and installation procedures

Page 129 - Posi-Power Pressure Check

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

Page 130 - Auxiliary Flow Test

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

Page 131 - Flow Troubleshooting

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

Page 132

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

Page 133 - 18. Troubleshooting

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

Page 134

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

Page 135

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-

Page 136

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

Page 137 - Specifications

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

Page 138

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

Page 139 - Supplements

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

Page 140

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

Page 141

Chapter OverviewThis chapter provides removal and installation proce-dures for the lift-arm components.Personal SafetyImproper or incomplete maintenan

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