Terex PT60 Operation And Maintenance Manual
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Terex PT60 Operation And Maintenance Manual

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8/17/2016
Language:
English
Geographic Region:
USA
Serial Number Range:
SN DTE02742-DTE03309
PT60
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
USA
(800)616-8156

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  • Page 1 8/17/2016 Language: English Geographic Region: Serial Number Range: SN DTE02742-DTE03309 PT60 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...

  • Page 2: Table Of Contents

    CONTENTS The operator must read and understand all the instructions in this manual before operating the machine. Page Introduction ..........2 Safety ............5 Technical Data..........33 Machine Description / Controls..... 39 Operation ............. 47 Transportation ..........57 Maintenance ..........63 California Proposition 65 ......

  • Page 3: Introduction

    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.
  • Page 4 1.6 Warranty Your Terex PT-50/60 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...

  • Page 6: Safety

    2 SAFETY Page 2.1 Safety Alert System ........ 7 2.2 Symbols ..........8 2.3 Graphical Symbols ......... 10 2.4 Safety Signs (ANSI) ........ 14 2.4.1 Safety Signs (ISO)........ 16 2.5 General Notes ........18 2.6 Personal Protection Equipment....19 2.7 Hazard Zone........... 19 2.8 Operation ..........

  • Page 8: Safety Alert System

    2 SAFETY 2.1 Safety Alert System 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.

  • Page 9: Symbols

    2 SAFETY 2.2 Symbols Symbol Description Engine Pre-heat Battery Engine Speed: Fast Transmission Range: High Engine Speed: Slow Transmission Range: Low Windshield Wiper Beacon Light Oil Pressure Engine Coolant Temperature Hydraulic Oil Temperature Air Conditioning...
  • Page 10 2 SAFETY Symbol Description Work Lights Bucket Positioning...

  • Page 11: Graphical Symbols

    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...
  • Page 12 2 SAFETY Hazard Avoidance Pictorial Pictorial Description Hazard: Explosion/Burn Avoidance: • Keep all flames/sparks away! • No Smoking! • Read and understand all manuals. Hazard: Fall Avoidance: Use the provided access system when entering or exiting the machine. Hazard: Fall Avoidance: No Riders.
  • Page 13 2 SAFETY Hazard Avoidance Pictorial Pictorial Description Hazard: Entanglement Avoidance: Stop machine and remove key before servicing. Hazard: Rollover / Ejection Avoidance: Carry loads low, keep heaviest end of machine uphill at all times while operating on inclines. Hazard: Fall Avoidance: Do not use the bucket or attachment as a work platform.
  • Page 14 2 SAFETY Hazard Avoidance Pictorial Pictorial Description Hazard: Crush Avoidance: Install lift arm brace 2030-417 before servicing. Hazard: The safety alert symbol is used to alert you to potential per- sonal injury hazards. Obey all safe- ty messages that follow this sym- bol to avoid possible injury or death.

  • Page 15: Safety Signs (Ansi)

    2 SAFETY 2.4 ANSI Safety Sign Location The safety signs are located in/on the machine as indicated. (Descriptions of the symbols are provided in section 2.3) • Relieve internal pressure before disconnecting any line or fitting. • Keep away from leaks or pinholes. •...
  • Page 16 2 SAFETY Note: If any of the safety signs shown in this section are missing or damaged, contact your dealer to obtain a replacement. • Relieve internal pressure before disconnecting any line or fitting. • Keep away from leaks or pinholes. •...

  • Page 17: Safety Signs (Iso)

    2 SAFETY 2.4.1 ISO Safety Sign Location 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 Fall hazard Crush hazard (lift arms) Skin (oil) injection hazard Fire hazard (read manual) Burn hazard...
  • Page 18 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 2030-551 2030-417 2030-552 2030-415 2030-426 2030-416 2030-420 Key (continued) 10. Burn hazard 11. Belt/fan entanglement hazard 12.

  • Page 19: General Notes

    2 SAFETY 2.5 General Safety Notes • Read and understand all safety signs and operator’s manuals prior to opera- tion. • If safety signs are obstructed by dirt or debris, clean them using mild soap and water prior to operation. •...

  • Page 20: Personal Protection Equipment

    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.

  • Page 21: Operation

    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.

  • Page 22: Stability

    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. •...

  • Page 23: Fire Prevention

    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. •...

  • Page 24: Crush / Burn Avoidance

    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.

  • Page 25: Placing Into Operation

    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. •...

  • Page 26: Jobsite Safety

    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.

  • Page 27: Parking The Machine

    2 SAFETY 2.16 Parking the Machine • If possible, turn the machine off only on an even and solid surface. • 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. •...

  • Page 28: Transporting

    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.).

  • Page 29: Maintenance

    • When replacing parts or fasteners, use parts of equivalent quality, grade and/or size. Use original Terex components to ensure the proper form, fit, and function of replacement parts. • When performing maintenance work, always wear appropriate safety clothing for the task to be performed.
  • Page 30 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. •...

  • Page 31: Battery

    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.

  • Page 32: Hydraulic Lines / Hoses

    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.

  • Page 34: Technical Data

    3 TECHNICAL DATA Page 3.1 General Structure ........35 3.2 Views ............. 36 3.3 Engine............ 36 3.4 Electrical System........36 3.5 Undercarriage ........36 3.6 Transmission .......... 37 3.7 Auxiliary Hydraulics ........ 37 3.8 Ground Pressure ........37 3.9 Operating Specifications......37 3.10 Service / Refill Capacities.....

  • Page 36: General Structure

    3 TECHNICAL DATA 3.1 General Structure Bucket Lift Arm Operator Enclosure (R.O.P.S./F.O.P.S. approved) Hydraulic Oil (fill location) Diesel Fuel (fill location) Hood (engine cover) Engine Drive Motor and Sprocket Undercarriage 10. Quick Attach 11. Product PIN Plate (beside operator seat, inside enclosure)

  • Page 37: Views

    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 PT-50 [PT-60] Make Perkins Perkins...

  • Page 38: Transmission

    3 TECHNICAL DATA 3.6 Transmission PT-50 [PT-60] Make Rexroth Rexroth Type A22VG A22VG Design Variable disp. / axial piston Variable disp. / axial piston Discplacement 2.35 in. ³ (38.5 cc)/revolution 2.35 in. ³ (38.5 cc)/revolution Relief Pressure 5500 psi (37,920 kPa) 5500 psi (37,920 kPa) 3.7 Auxiliary Hydraulics PT-50...

  • Page 39: Fluid Specifications

    3 TECHNICAL DATA 3.11 Fluid Specifications (applies to both machines) Specifications Designation Specification/standard Diesel Fuel Fuel EN590 or ASTM D975 1-D / 2-D Engine Oil Engine Oil SAE 10W-30 (API CH-4) Engine Coolant Coolant Antifreeze/Water w/SCA additive Hydraulic Oil Hydraulic Oil Mobil DTE 10 Excel Series 46 Lubricating Points MP Grease...

  • Page 40: Machine Description / Controls

    4 MACHINE DESCRIPTION / CONTROLS Page 4.1 Display Elements........41 4.2 Controls..........42 4.3 Throttle........... 43 4.4 Two Speed ..........43 4.5 Bucket Positioning........43 4.6 Auxiliary Hydraulics ........ 44 4.7 Electric Attachment Control ....45 4.8 Emergency Exits........45...

  • Page 42: Display Elements

    4 MACHINE DESCRIPTION / CONTROLS 4.1 Display Elements Learn the location and function of these items prior to operation. Switch Panels 1 - Work lights 2 - Heater fan (optional) 3 - Front wiper (optional) 4 - Beacon light (optional) 9 - Auxiliary hydraulics 10 - Bucket positioning (optional) 11 - Power Q/A (optional)

  • Page 43: Controls

    4 MACHINE DESCRIPTION / CONTROLS 4.2 Controls The PT-50/60 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.

  • Page 44: Throttle

    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. •...

  • Page 45: Auxiliary Hydraulics

    4 MACHINE DESCRIPTION / CONTROLS 4.6-1 4.6-2 4.6 Auxiliary Hydraulics The PT 50/60 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.

  • Page 46: Electric Attachment Control

    4 MACHINE DESCRIPTION / CONTROLS 4.7-1 4.7-2 4.7 Electric Attachment Control Attachments for the PT-50/60 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 (4.7-1) send electrical current to the receptacle on the lift arms (4.7-2).

  • Page 48: Operation

    5 OPERATION Page 5.1 General Information........ 49 5.2 Pre-Operation Safety Checklist....49 5.3 Starting Procedure ......... 50 5.4 Surface Preservation ......51 5.5 Filling the Bucket ........51 5.6 Grading ..........52 5.7 Leveling ..........52 5.8 Loading ..........53 5.9 Fastening Attachments ......

  • Page 50: General Information

    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.

  • Page 51: Starting Procedure

    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: 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.

  • Page 52: Surface Preservation

    5 OPERATION 5.4 Surface Preservation Terex Compact 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.

  • Page 53: Grading

    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 adjustments to vary cut depth as necessary.

  • Page 54: Loading

    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.

  • Page 55: Unfastening Attachments

    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. 5.10-1 unlock Lay the attachment gently onto the ground...

  • Page 56: Operation On Inclines

    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. Even with these capabilities, extreme caution should always be exercised while operating the machine on an incline.

  • Page 57: Lift Arm Brace

    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.

  • Page 58: Transportation

    6 TRANSPORTATION Page 6.1 Transporting ........... 59 6.2 Towing / Retrieving......... 59 6.3 Loading / Unloading Procedure ..... 60 6.4 Lifting Procedure........61...

  • Page 60: Transporting

    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.

  • Page 61: Loading / Unloading Procedure

    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.

  • Page 62: Lifting Procedure

    6 TRANSPORTATION 6.4 Lifting Procedure At times, the PT-50/60 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.

  • Page 64: Maintenance

    7 MAINTENANCE Page 7.1 General ..........65 7.2 Care and Cleaning........65 7.3 Maintenance Intervals ......66 7.4 Lubrication Points........67 7.5 Engine Oil Check ........68 7.6 Engine Oil Change........69 7.7 Hydraulic Oil Change ......70 7.8 Hydraulic Filter Change ......71 7.9 Accessory Belt........

  • Page 66: General

    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.

  • Page 67: Maintenance Intervals

    7 MAINTENANCE 7.3 Maintenance Intervals 7.3-1 Daily Maintenance Tasks Daily Page Check hydraulic oil level (figure 7.7-3, p-70) Check engine oil level Check fuel level (gauge on instrument panel) Check fan belt tension / condition Check track tension / condition Check for proper control operation Check for proper switch and lighting operation Check / clean air cleaner elements...

  • Page 68: Lubrication Points

    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.

  • Page 69: Engine Oil Check

    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 dipstick (1) from its tube. (fig. 7.5-1) 7.5-1 Wipe the dipstick with a clean shop cloth and reinsert it into the tube...

  • Page 70: Engine Oil Change

    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.

  • Page 71: Hydraulic Oil Change

    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.

  • Page 72: Hydraulic Filter Change

    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.

  • Page 73: Water Separator

    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, then open the hood at the rear of the machine to access the water separator.

  • Page 74: General Undercarriage

    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.

  • Page 75: Track Tension Adjustment

    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 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.

  • Page 76: Drive Sprocket Rollers

    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.

  • Page 77: Air Cleaner Removal / Inspection

    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.

  • Page 78: Air Cleaner Cleaning

    7 MAINTENANCE 7.17 Air Cleaner Cleaning procedure Remove loose dirt from the element with compressed air or water hose. • Compressed air: 100 psi (690 kPa) max. 1/8 in. (.32cm) diameter nozzle at least 2 in. (5cm) away from the filter element. •...

  • Page 79: Radiator Oil Cooler Cleaning

    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.

  • Page 80: Chassis Cleaning

    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 Procedure Periodic cleaning of the chassis area beneath the cab and engine com- partment is also necessary to main- tain safe operation.

  • Page 81: Electrical System

    7 MAINTENANCE 7.21 Electrical System PT-50/60 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 .

  • Page 82: Storage

    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.
  • Page 83 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.

  • Page 84: California Proposition 65

    California (U.S.A.) state law stipulates that manufacturers of machines operated within its borders must provide a clear warning to customers regarding exposure to substances commonly associated with the machine that are recognized by the state as harmful. Terex/ASV complies with this requirement by providing the following information. CALIFORNIA...

  • Page 85: Service Log

    SERVICE LOG Hours Service Performed Notes...
  • Page 86 SERVICE LOG Hours Service Performed Notes...

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