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Summary of Contents for Terex PT-70
- Page 1 C o m p a c t Tr a c k L o a d e r Operation and Maintenance Manual Version: EN Edition: 2011-09 Part Number: 2047-013 Valid From Serial No: DTH 00682 (70) TTH 00101 (70) DTI 01310 (80) TTI 01294 (80) Original Instructions PT-70/80...
- Page 3 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 4 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 5 1.6 Warranty Your Terex PT-70/80 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 7 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 9 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 10 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 11 2 SAFETY Symbol Description Work Lights Bucket Positioning...
- Page 12 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 13 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 14 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 15 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 16 2 SAFETY 2.4 Safety Signs (ANSI) The safety signs are located in/on the machine as indicated. (Descriptions of the symbols are provided in section 2.3) Improper operation or maintenance • Relieve internal pressure before can result in serious injury or death. disconnecting any line or fitting.
- Page 17 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 18 2 SAFETY 2.4.1 Safety Signs (ISO) The safety signs are located in/on the machine as indicated. (Descriptions of the symbols are provided in section 2.3) 2030-553 2030-565 2030-418 2046-146 2030-425 2030-415 2030-417 2030-416 Crush hazard (lift arms) Fall hazard Read manual / Fire hazard / Fall hazard (inside cab) Skin (oil) injection hazard Explosion / burn hazard (read operator’s manual) (engine area) Burn hazard (engine area)
- Page 19 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 2046-147 2030-416 2030-415 2030-417 Key (continued) 10. Belt/fan entanglement hazard (engine area) 11. Skin (oil) injection hazard 12.
- Page 20 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 21 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 22 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 23 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 24 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 25 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 26 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 27 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 28 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 29 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 30 • 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 31 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 32 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 33 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 35 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 37 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 (on front of operator enclosure)
- Page 38 381mm 71 in. 18 in. / 457 mm 1803 mm 112 in. 70 in. / 1778 mm 2845 mm 142 in. 3607 mm 3.3 Engine PT-70 PT-80 Make Perkins Perkins 804D-33T 804D-33T Type Design 4 cyl. in line (turbo) 4 cyl. in line (turbo) 201.4 in.
- Page 39 2170 lb (984 kg) Operating capacity 35% Note: The Maximum Gross Vehicle Weight of the PT-70 is not to exceed 11,500 lb (5216 kg.) / PT-80 12.500 (5670 kg.). This excludes an operator, but does include accessories, attachments and material being carried.
- Page 40 Recommended Viscosity Grades 5W-20 10W-30 15W-40 20W-50 50°C 122°F Ambient temperature 3.12 Dimensions and Weights PT-70 PT-80 Length w/o bucket 112 in. (2845 mm) 112 in. (2845 mm) Length w/bucket 141 in (3581 mm) 142 in. (3607 mm) Width 66 in. (1676 mm) 72 in.
- Page 41 4 MACHINE DESCRIPTION / CONTROLS Page 4.1 Display Elements........41 4.2 Controls ............42 4.3 Throttle ............43 4.4 Operator Seat ..........43 4.5 Two Speed ..........43 4.6 Auxiliary Hydraulics......... 44 4.7 Bucket Positioning........45 4.8 Electric Attachment Control ....45 4.9 Emergency Exit .........
- Page 43 4 MACHINE DESCRIPTION / CONTROLS 4.1 Display Elements Learn the location and function of these items prior to operation. Instruments: 1. Engine Temperature Gauge 2. Oil Pressure Gauge 3. Fuel Gauge 4. Hydraulic Oil Temp. Gauge 5. Voltmeter Note: The glow plug operation light 6.
- Page 44 4 MACHINE DESCRIPTION / CONTROLS 4.2 Controls The PT-70/80 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 45 Select a higher rpm for faster travel speed or when more power or flow is required for a task. 4.4 Operator Seat Seat Adjustment The PT-70/80 machines are available with a suspension style seat adjustable for both operator weight (spring pre- load) and operator height varia- tion in fore and aft directions.
- Page 46 4.6-1 4.6-2 flow 4.6 Auxiliary Hydraulics The PT-70/80 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: 4.6-3 1.
- Page 47 4 MACHINE DESCRIPTION / CONTROLS 4.7 Bucket Positioning (optional) The PT-70/80 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.
- Page 48 4 MACHINE DESCRIPTION / CONTROLS 4.9 Emergency Exit Familiarize yourself with the emer- gency exit and associated features located in the cab enclosure prior to operation. These features allow an operator to escape from the cab in an emergency. 4.9-1 Operator Escape (Rear Window Exit): Firmly grasp the triangular tag attached to the window molding on the rear win- dow.
- Page 49 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......53 5.10 Unfastening Attachments ....
- Page 51 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 52 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 and fasten the seat belt.
- Page 53 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 54 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 55 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 56 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 Lay the attachment gently onto the ground by moving the lift arm control joystick slowly...
- Page 57 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 58 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 59 6 TRANSPORTATION Page 6.1 Transporting..........59 6.2 Towing / Retrieving ......... 59 6.3 Loading / Unloading Procedure ..60 6.4 Lifting Procedure ........61...
- Page 61 6.2 Towing/Retrieving In the event that the PT-70/80 needs to be towed or retrieved, it will not roll freely. You must drag it to safety. Use only chains that are rated for pulling a machine of this size and weight. Attach these chains to at least two of the D- rings in the front or rear of the machine.
- Page 62 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 63 6 TRANSPORTATION 6.4 Lifting Procedure Lifting the machine should only be done from beneath the machine with a jack of the proper capacity. To safely lift your machine: Remove any attachments that may be fastened to the machine and raise the lift arms.
- Page 65 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 67 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 68 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 69 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. A.
- Page 70 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 tube until it comes to rest in its seated...
- Page 71 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 72 7 MAINTENANCE 7.7 Hydraulic Oil Change 7.7-1 7.7-2 The hydraulic oil should be changed every 1000 service hours. Before Full 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 73 The engine uses a belt to drive accessories like the alternator, water pump, and cooling fan. Belts stretch and wear during their service life. The accessory belt on the PT-70/80 should be visually inspected daily for tension, condition, and pres- ence prior to operation To check drive belt: Shut the machine down according to the procedure in section 5.13, allow...
- Page 74 7 MAINTENANCE 7.10 Water Separator The water separator (item 1) removes water from the fuel supply as the engine runs. (fig. 7.10-1) It is located on the right side of the radia- tor shroud. Drain the water separator daily to maintain proper function. 7.10-1 To drain the water separator: Shut the machine down...
- Page 75 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 76 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 (item 1) on the track tension device.
- Page 77 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 78 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 79 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. (.32 cm) diameter nozzle at least 2 in. (5 cm) away from the filter element. •...
- Page 80 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 81 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. 7.19-1 7.19-2 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 82 7 MAINTENANCE 7.21 Electrical System IGNITION SAFETY AUX LDR LIGHTS PWR OLT BECON START HEATER BKP ALM WIPER HORN QK ATCH FL MAG LT CNTL SLF LVL MICRO VR FLW IJN PMP DIODE AUX FLW 2 SPD MAIN MAIN PWR A PWR B GLOW POWER...
- Page 83 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 84 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 85 7 MAINTENANCE 7.23-1 7.23-2 7.23 Cab Tilt Procedure The ROPS/FOPS approved cab (1) tilts up to allow easy access to components while performing maintenance or service. It is equipped with a gas spring assist and a brace mechanism to hold it in place while tilted.
- Page 86 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 87 SERVICE LOG Hours Service Performed Notes...
- Page 88 SERVICE LOG Hours Service Performed Notes...
- Page 89 SERVICE LOG Hours Service Performed Notes...
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