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8/17/2016 Language: English Geographic Region: Not USA Serial Number Range: SN ETE00101-Current PT60CE 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...
CONTENTS The operator must read and understand all the instructions in this manual before operating the machine. Introduction............2 Safety ..............5 Technical Data..........31 Machine Description / Controls....37 Operation............47 Transportation..........57 Maintenance ............. 63 Service Log ............83...
PIN when making inquiries in regards to parts, service, or warranty. 1.2 Introduction Thank you for purchasing a Terex Compact Track Loader. We are confident that the machine you have chosen will provide excellent performance and effi- cient operation. The information contained in this manual is intended to provide the operator with all necessary information for the proper use of the machine.
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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.
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1 INTRODUCTION 1.6 Warranty Your Terex PT-60 is warranted under the Terex Compact 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.
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.
2 SAFETY 2.2 Safety Pictorials 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 Graphical Symbols Hazard Avoidance Pictorial Pictorial Description Hazard: Skin/Oil Injection Avoidance: • Relieve internal pressure before disconnecting any line or fitting. • Keep away from leaks or pin- holes. • 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...
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2 SAFETY Hazard Avoidance Pictorial Pictorial Description Hazard: Fall Avoidance: Use the provided access system when entering or exiting the machine. Hazard: Fall Avoidance: No Riders. Hazard: Burn Avoidance: Do not touch hot surfaces. Hazard: Crush Avoidance: Fasten seat belt. Hazard: Entanglement Avoidance: Stop machine and remove key before servicing.
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2 SAFETY Hazard Avoidance Pictorial Pictorial Description Hazard: Fall Avoidance: Do not use the bucket or attachment as a work platform. Hazard: Crush Avoidance: Keep clear of moving machine. Hazard: Crush Avoidance: Keep clear of lift arms and attachments. 2030-417 Hazard: Fire Avoidance: Read and understand the operator’s manual.
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 damaged, contact your dealer to obtain a replacement. 2030-553 2030-417 2030-551 2030-415 2030-552 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. • If safety signs are obstructed by dirt or debris, clean them using mild soap and water prior to operation. • If safety signs are damaged or illegible, replace them immediately, prior to operation.
2 SAFETY 2.6 Personal Protection Equipment The machine is designed to accommodate and protect an operator during opera- tion from foreseeable injury when used as intended and when equipped prop- erly 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 maximize 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 Compact Track loaders have components that operate at high temperatures. It is important to observe all inspection, operation and maintenance guidelines to min- imize 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 capacity of the ground and requirements to close the work site off from public traffic.
2 SAFETY 2.16 Parking the Machine • Stop the machine only on an even and solid surface. • Lower the lift arms to the frame stop and rest the bucket on the ground. • Shut the machine down as described in section 5.13. •...
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, water, mud, sludge, oil, etc.).
Do not work on or under any machine that is supported only by a hydraulic jack or hoist. Always use mechanical supports to ensure that the machine will not fall. Terex jack stands work well to support the machine while per forming maintenance or repair work.
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Do not use flammable liquids to clean the machine. • Perform tasks on the machine that involve welding or grinding only if approved by Terex. Clean the machine and the work area of dust and any combustible materials before welding or grinding to avoid fire or explosion. •...
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 equipment to minimize the possibility of objects falling. Use only suitable lifting equipment with no technical defects. Do not work under suspended loads.
2 SAFETY 2.21 Hydraulic Hoses/Lines • Repairs to hydraulic hoses and hydraulic hose lines are forbidden! 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 115 in. 2921 mm 77 in. 1956 mm 12 in. 305 mm 59 in. 15 in. 1499 mm 381mm 66 in. 100 in. 1676 mm 2540 mm 128 in. 3251 mm 3.3 Engine Make Perkins Type 404D-22T Design...
4 MACHINE DESCRIPTION / CONTROLS 4.2 Controls The PT-60 has two hydraulic pilot joystick controls. The joysticks are used to con- trol 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 4.6-1 4.6-2 4.6 Auxiliary Hydraulics The PT-60 models come equipped with an auxiliary hydraulic system designed to power approved hydraulic attachments. To operate, connect the attachment to the appropriate quick couplers (fig. 4.6-1). To connect couplers: 1.
4 MACHINE DESCRIPTION / CONTROLS 4.7-1 4.7-2 4.7 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 side shields with included hardware onto the sides of the cab enclosure from the inside.
4 MACHINE DESCRIPTION / CONTROLS 4.8 Bucket Positioning (optional) The PT-60 machines can be equipped with feature commonly referred to as “bucket positioning”. The bucket positioning system does not automatically level your attachment. Instead, it will maintain the current angle of the quick attach (relative to level) throughout the upward cycle of the lift arms.
4 MACHINE DESCRIPTION / CONTROLS 4.10-1 4.10-2 4.10 Electric Attachment Control Attachments for the PT-60 are controlled by pressing various buttons on the machines joysticks. Most attachments are controlled hydraulically, but some require both hydraulic and electrical inputs. The 4 buttons on the left joystick (4.10-1) send electrical current to the receptacle on the lift arms (4.10-2).
5 OPERATION 5.1 General Information Operating a Terex Compact Track Loader is intended to be as safe and simple as possible. This section expands on the machine controls portion of the manual and also covers safe operation procedures to follow while operating.
5 OPERATION 5.3-1 5.3-2 5.3 Starting Procedure Before starting the engine, perform the pre-operation safety checklist. Once com- plete, you may proceed by following this procedure: 1. Enter machine with lift arms all the way down. Maintain three points of contact with the machine (fig.
5 OPERATION 5.4 Surface Preservation Terex rubber track loaders are 5.4-1 designed to produce minimal ground disturbance while operat- ing on finished surfaces like turf, however, care should be taken while operating on these surfaces to prevent blemishes from occur- ring.
5 OPERATION 5.6 Grading Steps: (see illustration) Lower the lift arms until they rest on the frame. Tilt the bucket slowly forward until the cutting edge engages the ground. Drive the machine forward making slight bucket angle adjust ments to vary cut depth as necessary.
5 OPERATION 5.8 Loading Steps: (see illustration) Engage the bucket positioning function (if equipped), then raise the lift arms upward until the bottom of the bucket clears the side of the truck bed or trailer. Once clear, drive the machine forward until the pivot point of the bucket clears the bed side.
5 OPERATION 5.10 Unfastening Attachments (see also section 5.11) 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 outside of the machine to unlock the attachment. Lay the attachment gently onto the ground 5.10-1 by moving the lift arm control joy stick...
5 OPERATION 5.12 Operation on Inclines By design, Compact 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. Caution should always be exercised while operating the machine on an incline.
5 OPERATION 5.14 Lift Arm Brace When the lift arms must be left in the raised position, the lift arm brace must be engaged. To install: Lower the lift arms, remove any attachments and park the 5.14-1 machine on firm and level ground.
6 TRANSPORTATION 6.1 Transporting At times, you will most likely need to transport the machine to distant 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 (13) In the event that the PT-60 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 motor (as 6.2-1 Tool: 5mm hex key shown in figure 6.2-1) in each...
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, water, mud, sludge, oil, etc.). Properly align the machine with the loading ramp.
6 TRANSPORTATION 6.4 Lifting Procedure At times, the PT-60 may need to be lifted with the optional lift kit. This section addresses the proper procedures and attach- ment points for these activities. Lifting Lifting the machine from above should only 6.4-1 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 lubricating 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 opposite side of the machine. Lubricate all points daily, prior to operation.
7 MAINTENANCE 7.5 Engine Oil Check Shut the machine down according to the procedure in section 5.13. Open the hood to gain access to the engine compartment. Locate and remove the engine oil 7.5-1 dipstick (1) from its tube. (fig. 7.5-1) Wipe the dipstick with a clean shop cloth and reinsert it into the Full...
7.6-2 7.6 Engine Oil Change Regular oil changes are necessary to maintain a strong running engine. Terex rec- ommends a normal oil change interval of 250 hours or every six months. Allow the machine to cool prior to service. Wear safety glasses, safety gloves and any other items necessary to ensure your safety while performing maintenance or service.
7 MAINTENANCE 7.7 Hydraulic Oil Change 7.7-1 7.7-2 The hydraulic oil should be changed 7.7-3 every 1000 service hours. Before beginning the procedure, make sure the machine is in a clean working environment. 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 service life. Use caution when changing the hydraulic filter. Before beginning 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 engine) 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: Shut the machine down according to the procedure in section 5.13, allow the machine to cool.
The undercarriage assemblies typically operate in harsh working conditions. They work in mud, gravel, debris and various other abrasive materials during operation. Terex recommends a daily inspection of the undercarriage assemblies and clean- ing 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 Shut the machine down according to the procedure in section 5.13, then locate the jam nut on the 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.
Visually inspect rollers every 50 hours and replace any that show signs of crack- ing or wear-through. Drive sprocket removal and roller / pin replacement should be performed by your local Terex dealer.
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 further clean the element.
7 MAINTENANCE 7.18 Radiator / Oil Cooler Cleaning Procedure The radiator and oil cooler must be clean to ensure proper operation. Engine and hydraulic system over- heating, damage and even failure can result if the radiator/oil cooler is 7.18-1 not kept clean. A pressure washer or compressed air nozzle work well to blow debris clear of the fins in the oil cooler and radiator.
7 MAINTENANCE Coolant and machine components can be HOT! Allow the machine to cool thoroughly prior to performing maintenance or service to avoid the possibility of burns. 7.20 Chassis Cleaning Periodic cleaning of the chassis area beneath the cab and engine compartment is also necessary to maintain safe operation.
7 MAINTENANCE 7.21 Electrical System PT-50/60CE ELECTRICAL PANEL AUX LDR 1 AUX LDR 2 AUX LDR 3 AUX LDR 4 40 A . RELAY 40 A . RELAY 40 A . RELAY 40 A . RELAY # 87417B # 87417B # 87417B # 87417B L .
7 MAINTENANCE 7.22 Storage It may be necessary to store your Terex Compact 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 compart- ment and underbody.
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7 MAINTENANCE 7.22.2 Removal From Storage Perform the following tasks to remove the Terex Compact Track Loader from stor- age and return to operating condition. Return to Operating Condition: • Remove protective lubricant from cylinder rods. • Lubricate all chassis, loader and undercarriage points.