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Summary of Contents for Track Loader Parts Terex PT30CE
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8/17/2016 Language: English Geographic Region: Not USA Serial Number Range: SN ETA00101-Current PT30CE Operation and Maintenance Manual This manual is complements of TrackLoaderParts.com The world's best source for Terex parts. Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 (800)616-8156...
1 INTRODUCTION 1.1 Product Identification (PIN) The machine PIN is located on the identification plate, behind and to the left of the operator seat. Please state the model of the machine and PIN when making inquiries in regards to parts, service, or warranty.
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1 INTRODUCTION 1.3 Safety Alert System 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. 1.4 Intended Use The machine with standard dirt bucket is intended to be used solely for work consistent with its design.
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1 INTRODUCTION 1.6 Warranty Your Terex PT-30 is warranted under the Terex Rubber Track Loader and Utility Vehicle Standard Limited New Product Warranty (“Warranty”). A copy of the Warranty certificate is included with this manual and is also available from your Authorized Terex Distributor. 1.7 Declaration of Conformity We the undersigned: ASV Inc.
2 SAFETY 2.1 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.
2 SAFETY 2.2 Pictograms Symbol Description Engine Start Engine Stop Engine Pre-heat Battery Engine Speed: Fast Transmission Range: High Wiper Speed: High Engine Speed: Slow Transmission Range: Low Wiper Speed: Low Unlock Lock Windshield Washer Windshield Wiper...
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2 SAFETY Symbol Description Beacon Light Tie Down Auxiliary Hydraulics Auxiliary Hydraulics (high flow) Power Quick Attach (unlock) Power Quick Attach (lock) Air Conditioning Oil Pressure Engine Oil Temperature Hydraulic Oil Temperature...
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2 SAFETY Symbol Description High Beam Lights Low Beam Lights Work Lights Left Turn Signal Right Turn Signal Hazard Indicator Lights Parking Brake Road Mode Bucket Positioning...
2 SAFETY 2.3 Safety Symbols Hazard Avoidance Description Hazard: Injection Avoidance: Use a piece of cardboard or paper to search for leaks. Do not use your hand. Fluid injectied into the skin must be surgi- cally removedwithin a few hours by a doctor familiar with this type of injury or gangrene will result.
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2 SAFETY Hazard Avoidance Description Hazard: Falling Avoidance: Use three points of contact when entering or exiting the machine. Hazard: Falling (no riders) Avoidance: Do not allow riders in or on the machine at any time. Hazard: Burn Avoidance: Allow surfaces to cool before servicing.
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2 SAFETY Hazard Avoidance Description Hazard: Falling (from buck- et or attachment) Avoidance: Keep away. Do not use the bucket or attach- ment as a work platform. Hazard: Run Over / Crush Avoidance: Keep away from the machine while it is in operation.
2 SAFETY 2.4 Safety Signs The safety signs are located in/on the machine as indicated. (Descriptions of the symbols are provided in section 2.3) 2030-553 2030-415 2030-427 2030-418 2030-425 2030-565 2030-417 2030-416 Falling hazard Skin (oil) injection hazard Crushing hazard (lift arms) Fire hazard (read manual) (inside cab) Pressurized fluid/gas hazard (engine area) Battery acid/explosion hazard (engine area)
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2 SAFETY Note: If any of the safety signs shown in this section are missing or dam- aged, contact your dealer to obtain a replacement. 2030-553 2030-551 2030-417 2030-552 2030-415 2030-426 2030-416 2030-420 Key (continued) 10. Hot surfaces hazard (engine area) 11.
2 SAFETY 2.5 General Safety Notes • Read and understand all safety signs and operator’s manuals prior to operation. • Never jump off of the machine. Instead use the hand holds and step designed for entering and exiting the machine. Face the machine and use three points of contact to ensure your safety.
2 SAFETY 2.6 Personal Protection Equipment (PPE) The machine is designed to accommodate and protect an operator during operation from foreseeable injury when used as intended and when equipped properly for the task(s) being performed. Operators should not wear rings, scarves, open jackets, and should ensure that all clothing is tightly secured.
2 SAFETY 2.8 Operation Earth moving machines are only to be operated and serviced by individuals who • are physically and mentally able to operate and / or service the machine in a safe manner. • have been instructed in the proper operation or maintenance of the machine and have demonstrated competence in these areas.
2 SAFETY 2.9 Stability The machine must always be operated with caution in order to maxi- mize machine stability and guard against the possibility of a rollover. • Travel only at speeds appropriate for the local conditions. • Do not exceed the operating capacity of the machine. •...
2 SAFETY 2.11 Fire Prevention Rubber track loaders have components that operate at high temper- atures. It is important to observe all inspection, operation and main- tenance guidelines to minimize the possibility of fire. • Turn the engine off when refueling. •...
2 SAFETY 2.12 Crush and Burn Avoidance • Do not work under the lift arms unless they are resting safely on the ground or supported by the lift arm brace. • Do not use any restraining devices such as cables or chains that are damaged or do not have sufficient carrying capacity.
2 SAFETY 2.13 Placing into Operation • Every time before placing the machine into operation, perform a thorough walk-around inspection of the machine. • Check the machine for loose pins, cracks, tears, wear, leaks and deliberate damage. • Never place a damaged machine into operation. •...
2 SAFETY 2.15 Jobsite Safety • Before beginning work, become acquainted with any special features or requirements of the work site. These may include, for example, obstructions in the work area, the carrying capaci- ty of the ground and requirements to close the work site off from public traffic.
2 SAFETY 2.16 Parking the Machine • If possible, turn the machine off only on an even and solid sur- face. • Lower the lift arms to the frame stop and rest the bucket on the ground. • Turn off the engine as described in the operating instructions. •...
2 SAFETY 2.18 Transporting the Machine • Use only suitable transport and lifting equipment with sufficient carrying capacity. • Load the machine on firm and level ground. • Before driving onto the ramps, clean them and the machine tracks of any materials that may cause slippage (snow, ice, sludge, etc.).
2 SAFETY 2.19 Maintenance • Do not perform any maintenance work or repair task that you do not understand thoroughly. • Park the machine on firm and level ground in a well lit and well ventilated area suitable for performing service or maintenance work.
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2 SAFETY • When performing service that requires the lift arms to be in the raised position, always utilize the lift arm brace. • If safety equipment needs to be dismantled to fit equipment or perform maintenance or repairs, it must be reattached and test ed immediately after the maintenance and repair jobs are com- pleted.
2 SAFETY • Do not attempt to lift heavy parts. Use work aids with sufficient carrying capacity designed for that purpose. Fasten and secure individual parts and large assemblies carefully on lifting equip- ment to minimize the possibility of objects falling. Use only suit- able lifting equipment with no technical defects.
2 SAFETY 2.21 Hydraulic Hoses/Lines • Repairs to hydraulic hoses and hydraulic hose lines are forbid- den! These repairs must be performed by trained personnel. • All hoses, hose lines and screw connections must be checked regularly, at least once a year, for leaks and externally visible damage! Replace any damaged parts immediately! Oil spraying out can cause injuries and burns.
3 TECHNICAL DATA 3.2 Views 80.25 in. 71 in. 2038 mm 1803 mm 10 in. 254mm 55 in. 11 in. 1397 mm 280mm 91 in. 2311 mm 48 in. 112 in. 1219mm 2845 mm 3.3 Engine Perkins Make Type 403-D15 3 cylinders in line Design Displacement...
4 MACHINE DESCRIPTION / CONTROLS 4.2 Controls The PT-30 has two hydraulic pilot joystick controls. The joysticks are used to control machine speed and direction as well as lift arm and bucket functions. 4.2.1 Lift Arm Control The lift arm joystick is used to control the lift arms, bucket, and to engage the float function.
4 MACHINE DESCRIPTION / CONTROLS 4.3 Throttle The throttle (hand lever) is located to the right of the operator’s right leg when seated in the machine. The throttle controls engine rpm. • Move the lever forward to increase engine RPM. •...
4 MACHINE DESCRIPTION / CONTROLS 4.5-1 4.5-2 4.5 Auxiliary Hydraulics The PT-30 models come equipped with an auxiliary hydraulic system designed to power approved hydraulic attachments. To operate, connect the attachment to the quick couplers (fig. 4.5-1). To release residual pressure in the sys- 4.5-3 tem, press the button labeled 1 (fig.
4 MACHINE DESCRIPTION / CONTROLS 4.6-1 4.6 Road Mode When it is necessary to operate the machine on public roads, you must utilize the machine in road mode (see notes below). To implement road mode: Install the clear plastic side shields (windows) with included hardware onto the sides of the cab enclosure from the inside.
4 MACHINE DESCRIPTION / CONTROLS R LV 4.7-1 4.7 Remote Lift Arm Valve The lift arms on the PT-30 can be lowered from the exterior of the machine in an emergency. To lower lift arms: Make sure all bystanders are clear of the normal movement path of the lift arms and any attachment that may be fastened to the quick attach.
5 OPERATION 5.1 General Information Operating a Terex Rubber Track Loader is intended to be as safe and simple as possible. This section expands on the machine con- trols portion of the manual and also covers safe operation proce- dures to follow while operating. 5.2 Pre-Operation Safety Checklist Before operating the machine, perform a pre-operation safety check.
5 OPERATION 5.3-1 5.3-2 5.3 Starting Procedure Before starting the engine, perform the pre-start checklist. Once complete, you may proceed by following this procedure: Enter machine with lift arms all the way down. Maintain three points of contact with the machine (fig. 5.3-1). Sit down into the operator’s seat, fasten seat belt, then lower lap bar into position.
5 OPERATION 5.4 Surface Preservation Terex rubber track loaders 5.4-1 are designed to produce minimal ground disturbance while operating on finished surfaces like turf, however, care should be taken while operating on these surfaces to prevent blemishes from occurring. Turning poses the greatest risk of surface disturbance during opera- tion.
5 OPERATION 5.6 Grading Steps: (see illustration) 1. Lower the lift arms until they rest on the frame. 2. Tilt the bucket slowly forward until the cutting edge engages the ground. 3. Drive the machine forward making slight bucket angle adjust- ments to vary cut depth as necessary.
5 OPERATION 5.8 Loading Steps: (see illustration) 1. Raise the lift arms upward, carefully maintaining the bucket angle, until the bottom of the bucket clears the side of the truck bed or trailer. 2. Once clear, drive the machine forward until the pivot point of the bucket clears the bed side.
5 OPERATION 5.10 Unfastening Attachments Lower the lift arms so that the attachment is just barely off of the ground. Pull the locking levers on the quick attach mechanism upwards and toward the out side of the machine to unlock 5.9-1 the attachment.
5 OPERATION 5.11 Operation on Inclines By design, Rubber Track Loaders are very stable on inclines. Machine weight is distributed evenly throughout the chassis and the suspended undercarriage track system provides excellent traction and floatation on nearly all surfaces. Even with these capabilities, caution should always be exer- cised while operating the machine on an incline.
5 OPERATION 5.13 Lift Arm Brace When the lift arms must be left in the raised position, the lift arm brace must be engaged. To engage: Lower the lift arms, remove any attachments and park the machine on 5.13-1 firm and level ground. Remove the pin that secures the brace to the fender.
6 TRANSPORTATION 6.1 Transporting At times, you will most likely need to transport the machine to dis- tant locations with a transport vehicle. To do this safely, there are some precautions that must be observed. When transporting: Always make sure the transport vehicle (trailer or truck) being used to haul the machine is capable of bearing the weight and size of the machine over the distance and terrain that will be covered.
6 TRANSPORTATION 6.2 Towing/Retrieving In the event that the PT-30 needs to be towed or retrieved, it will not roll freely. You must perform the following procedure in order to pull it to safety. Locate the drive sprockets (as 6.2-1 Remove shown in figure 6.2-1) on each side of the machine.
6 TRANSPORTATION 6.3 Transport Loading / Unloading procedure Load the machine only on firm and level ground. Before driving onto the ramps, clean them and the machine tracks of any materials that may cause slippage (snow, ice, sludge, etc.). Properly align the machine with the loading ramp. Have a guide give the machine operator any necessary signs to maximize safety during loading.
6 TRANSPORTATION 6.4 Lifting Procedure At times, the PT-30 may need to be lifted with the optional lift kit. This section addresses the proper proce- dures and attachment points for these activities. Lifting 6.4-1 Lifting the machine from above should only be done with the optional lift kit installed as shown.
7 MAINTENANCE 7.1 General The operating condition and life expectancy of a machine is largely influenced by care and maintenance. For this reason, it is in every machine owner’s interest to perform the specified maintenance work and comply with the service intervals. This chapter describes periodic maintenance, inspection and lubri- cating tasks.
7 MAINTENANCE 7.4 Lubrication Points The illustration below shows the location of grease points found on the left side of the machine. Identical points also exist on the oppo- site side of the machine. Lubricate all points daily, prior to operation.
7 MAINTENANCE 7.5 Engine Oil Check Park the machine on level ground, lower the lift arms, stop the engine and remove the key. Open the hood to gain access to the engine compartment. Locate and remove the 7.5-1 engine oil dipstick (1) from its tube.
7 MAINTENANCE 7.6-1 7.6 Engine Oil Change Regular oil changes are necessary to maintain a strong running engine. Terex recommends a normal oil change interval of 250 hours or every six months. Allow the machine to cool thoroughly prior to performing maintenance or service. Wear safety glasses, safety gloves and any other items necessary to ensure your safety.
7 MAINTENANCE 7.7 Hydraulic Oil Change 7.7-1 7.7-2 The hydraulic oil should be 7.7-3 changed every 500 service hours. Before beginning the pro- cedure, make sure the machine is in a clean working environ- ment. Take any necessary measures to prevent dirt or debris from entering the hydraulic system.
7 MAINTENANCE 7.8 Hydraulic Filter Change The hydraulic filter should be changed every 250 hours. Hydrostatic components require extremely clean oil in order to have a long serv- ice life. Use caution when changing the hydraulic filter. Before begin- ning the procedure, make sure the machine is in a clean working environment.
7 MAINTENANCE 7.10 Water Separator The water separator (fig. 7.10-1), located on the left side of the hyd. reservoir) removes water from the fuel supply as the engine runs. Drain the water separator daily to maintain proper function. 7.10-1 To drain the water separator: With the engine off and cool, and key removed from the igni tion, open the hood at the rear of the machine to access the water separator.
7 MAINTENANCE 7.12 General Undercarriage Information The undercarriage assemblies typically operate in harsh working conditions. They work in mud, gravel, debris and various other abra- sive materials during operation. Terex recommends a daily inspec- tion of the undercarriage assemblies and cleaning if necessary. Materials that are particularly sticky or abrasive like clay, mud, or gravel should be cleaned from the undercarriages often to minimize component wear.
7 MAINTENANCE 7.13-2 7.13-1 7.14 Track Tension Adjust With the engine off and the key removed from the igni- tion, locate jam nut on track tension device and clean the threads thoroughly before proceeding. (fig. 7.14-1 7.14-1). Using a wrench, loosen the jam nut on the track tension device.
7 MAINTENANCE 7.15 Drive Sprocket Rollers 7.15-1 Rubber Track Loaders use Steel Pin 7.15-2 rollers on each drive tooth of the drive sprockets. These rollers help minimize friction between lugs on the track and the sprocket. Sprocket rollers should be treated as wear Normal Roller Wear items that are inspected regu- New Roller...
7 MAINTENANCE 7.16 Air Cleaner Removal / Inspection The air cleaner is one of the most important maintenance items on the machine. Regular inspection and replacement is necessary to ensure proper performance and to prolong engine life. Inspect the air cleaner elements daily. If damaged or heavily soiled, clean or replace the elements.
7 MAINTENANCE 7.17 Air Cleaner Cleaning procedure Remove loose dirt from the element with compressed air or water hose. • Compressed air: 690 kPa max. .32cm diameter nozzle at least 5cm away from the filter element. • Water: 276 kPa max. without nozzle. Soak the filter element in a non sudsing detergent solution for at least 15 minutes moving it gently through the solution to fur ther clean the element.
7 MAINTENANCE 7.18 Radiator / Oil Cooler Cleaning Procedure The radiator and oil cooler must be clean to ensure prop- er operation. Engine and hydraulic system overheating, damage and even failure can 7.18-1 result if the radiator/oil cooler is not kept clean. A pressure washer or compressed air nozzle work well to blow debris clear of the fins in the...
7 MAINTENANCE 7.20 Chassis Cleaning Procedure Periodic cleaning of the chas- sis area beneath the cab and engine compartment is also necessary to maintain safe operation. Clean as neces- 7.20-1 sary. (fig. 7.20-1) To clean the chassis/engine: With the engine off and cool and the key removed from the ignition, remove the belly pans on the underside of the machine.
7 MAINTENANCE 7.21 Electrical System PT-30CE ELECTRICAL PANEL 4010-051 L. AUX HYD R. AUX HYD PWR RELAY A. IGN. HAZARD BEACON SAFTEY ALT. DIODE PWR RELAY B. INJ. PUMP HRN-LT-SW AUX HYD MODE GLOW PLUG LIGHTS SAFTEY TAIL LTS LIGHTS STARTER BKUP ALM HEATER...
7 MAINTENANCE 7.22 Storage It may be necessary to store your Terex Rubber Track Loader for an extended period of time. Perform the following tasks to prepare the machine for storage. 7.22.1 Storage Preparation • Thoroughly clean the machine (inside and out) including the engine compartment and underbody.
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7 MAINTENANCE 7.22.2 Removal From Storage Perform the following tasks to remove the Terex Rubber Track Loader from storage and return to operating condition. Return to Operating Condition: • Remove protective lubricant from cylinder rods. • Lubricate all chassis, loader and undercarriage points. •...
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