Terex PT60CE, Operation And Maintenance Manual

Page 1: ...SN ETE00101 Current English Not USA Language Geographic Region Serial Number Range This manual is complements of TrackLoaderParts com The world s best source for Terex parts Track Loader Parts 6543 C...

Page 2: ...Safety 5 Technical Data 31 Machine Description Controls 37 Operation 47 Transportation 57 Maintenance 63 Service Log 83 1 The operator must read and understand all the instructions in this manual befo...

Page 3: ...is imperative that this manual be provided to the end user at the time of pur chase prior to operation and kept with the machine at all times If lost or dam aged contact your dealer immediately to ob...

Page 4: ...the equip ment can be used for corresponding applications The operator must follow the enclosed operating instructions for any externally supplied components or attachments Any use varying from that d...

Page 5: ...ovisions of the following European directives and amendments and the regulations transposing it into national law Machinery Safety Directive 98 37 EC Noise in the Environment Directive 2000 14 EC Meas...

Page 6: ...17 2 7 Hazard Zone 17 2 8 Operation 18 2 9 Stability 19 2 10 Transport of Persons 19 2 11 Fire Prevention 20 2 12 Crush Burn Avoidance 21 2 13 Placing Into Operation 22 2 14 Starting the Machine 22 2...

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Page 8: ...hroughout this manual as well as on decals and labels fixed to the machinery to assist in potential hazard recog nition and prevention Property or equipment damage warnings in this publication are ide...

Page 9: ...top 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 2 2 Safet...

Page 10: ...n 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 Sy...

Page 11: ...2 SAFETY 10 Symbol Description High Beam Lights Low Beam Lights Work Lights Left Turn Signal Right Turn Signal Hazard Indicator Lights Fan Parking Brake Road Mode Bucket Positioning P...

Page 12: ...tor familiar with this type of injury or gangrene will result Hazard Corrosive Avoidance Read and understand the operator s manual Hazard Entanglement Avoidance Stop machine and remove key before serv...

Page 13: ...idance Do not touch hot surfaces Hazard Crush Avoidance Fasten seat belt Hazard Entanglement Avoidance Stop machine and remove key before servicing Hazard Rollover Ejection Avoidance Carry loads low k...

Page 14: ...of lift arms and attachments Hazard Fire Avoidance Read and understand the operator s manual Hazard The safety alert symbol is used to alert you to potential per sonal injury hazards Obey all safety m...

Page 15: ...2 Skin oil injection hazard 3 Crushing hazard lift arms 4 Fire hazard read manual inside cab 5 Pressurized fluid gas hazard engine area 6 Battery acid explosion hazard engine area 7 Tie down location...

Page 16: ...an entanglement hazard engine area 12 Skin oil injection hazard 13 Crushing Hazard Lift arms 14 Read operator s manual Falling hazards inside cab 15 Rollover Ejection hazard inside cab 16 Crushing run...

Page 17: ...Do not use any method of operation inspection or maintenance that may impair safety This machine is only to be used when properly equipped for the task to be performed and when properly inspected and...

Page 18: ...safety shoes and any other equipment necessary to ensure your safety and the safety of others around you as you work 2 7 Hazard Zone The hazard zone encompasses the area around the machine in which pe...

Page 19: ...operation read and understand the instructions in this manual prior to operation and to follow them during operation familiarize him herself with the local worksite conditions and immediately remedy a...

Page 20: ...ly and always carry loads low to maximize machine stability Always keep the heaviest end of the machine facing uphill when travelling on an incline When turning on an incline back down the hill while...

Page 21: ...ulate in these areas and can lead to fire Check the electrical system regularly Have any faults such as loose connections burnt fuses glow lamps and damaged wiring repaired by professional personnel i...

Page 22: ...e objects The entire cooling system is hot and under pressure when it is at or near operating temperature Avoid touching parts that carry coolant to avoid the possibility of burns Allow the machine to...

Page 23: ...will be placed into operation Prior to placing the machine into operation adjust the driver s seat mirrors and ventilation system settings if equipped so you can work in comfort and safety 2 14 Starti...

Page 24: ...eep the machine at an adequate distance from overhead electrical lines When working in the vicinity of overhead electrical lines do not come close to the lines with the machine Injury or death may res...

Page 25: ...rve the correct procedure as described in the operating instructions The machine should be towed only in exceptional cases for example to bring the machine away from an endangered place for repair Che...

Page 26: ...e the ignition key Secure the door windows and hood on the machine Secure the machine and any other items against slipping with chains ropes of the proper capacity Before departure investigate the rou...

Page 27: ...of any hazardous conditions that may exist If the engine needs to be started inside an enclosure make sure that the engine s exhaust is properly vented Be sure all protective devices including guards...

Page 28: ...e welding or grinding to avoid fire or explosion Before cleaning the machine with water or steam jets high pressure cleaner or other cleaning agents cover or seal over all openings in which water stea...

Page 29: ...limbing aids if they were not designed for that purpose If working at significant height use a safety harness of the proper style and capacity to prevent falls Keep all grips steps platforms ladders e...

Page 30: ...may reduce the duration of the usage period for example high temperatures multi shift operation Hoses and hose lines must be replaced if any of the following criteria are encountered during inspectio...

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Page 32: ...stem 34 3 5 Undercarriage 34 3 6 Transmission 35 3 7 Auxiliary Hydraulics 35 3 8 Ground Pressure 35 3 9 Operating Specifications 35 3 10 Sound Vibration 35 3 11 Service Refill Capacities 35 3 12 Fluid...

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Page 34: ...P S F O P S approved 4 Hydraulic Oil fill location 5 Diesel Fuel fill location 6 Hood engine cover 7 Engine 8 Drive Motor and Sprocket 9 Undercarriage 10 Quick Attach 11 Product PIN Plate beside oper...

Page 35: ...er 41 5 kW 2330 RPM Admissible inclined Positions 30 in all directions engine Cooling Water antifreeze for all year operation Operating Voltage 12 V Battery 12V 950 CCA 0 C Alternator 12V 65A Starter...

Page 36: ...Relief Pressure 37 920 kPa Make Barnes Haladex Type 180 2061 Design Gear Displacement 22 cc revolution Relief pressure 20 684 kPa Flow 51 1 lpm 2 330 RPM At operating weight 24 7 kPa At shipping weig...

Page 37: ...CA additive Hydraulic Oil Hydraulic Oil Mobil DTE 10 Excel Series 46 Lubricating Points MP Grease Multi purpose lithium grease 30 22 20 4 10 14 0 32 10 50 20 68 30 86 40 104 50 C 122 F 0W 5W 20 10W 30...

Page 38: ...rols 40 4 3 Throttle 41 4 4 Operator Seat 41 4 5 Two Speed 41 4 6 Auxiliary Hydraulics 42 4 7 Road Mode 43 4 8 Bucket Positioning 44 4 9 Remote Lift Arm Valve 44 4 10 Electric Attachment Control 45 4...

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Page 40: ...Battery voltage light 21 Hydraulic oil temperature light 22 Engine temperature light If the battery voltage light 20 illuminates drive the machine to a suitable location and shut the engine off Diagno...

Page 41: ...ws the relationship between joystick movement and resulting lift arm action Note To activate the float function move the joystick fully forward in a quick motion The joystick will then be held in dete...

Page 42: ...r away from the seat Twist clockwise for heavier operator or counter clockwise for lighter operator To adjust for height Lift upward on the height adjustment lever slide the seat forward or rearward a...

Page 43: ...ously depending on the requirements of the attachment being utilized To engage the hydraulic flow intermittently activate the toggle type switch on the top of the right joystick fig 4 6 2 To engage th...

Page 44: ...ilize it for on road travel fig 4 7 2 6 Install the cutting edge guard onto the bucket and secure 7 Press the road mode switch item 4 on the dash panel to disable unnecessary items and enable road mod...

Page 45: ...osition the attachment manually on the downward cycle 4 9 Remote Lift Arm Valve The lift arms on the PT 60 can be lowered from the exterior of the machine in an emergency To lower lift arms 1 Make sur...

Page 46: ...draulically 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 Approved attachments that...

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Page 48: ...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 54 5 11 Power Quick Attach 54 5 12 Ope...

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Page 50: ...P S F O P S approved operator enclosure is not damaged or distorted structurally in any way 10 The seat belt and lap bar restraint are in good working order 11 All safety signs are in place and legib...

Page 51: ...toward the rabbit icon 4 Turn the ignition key to the left for 6 seconds to pre heat the engine While pre heating the glow plug operation light will illuminate 5 Turn the ignition key to the right to...

Page 52: ...ng on turf make gradual turns see item A If space is limited turn gradually by moving back and forth until facing the desired direction see item B 5 5 Filling The Bucket Steps see illustration 1 Lower...

Page 53: ...lustration 1 Moving forward raise the lift arms as you tilt the bucket slowly forward to evenly spread the material out over the ground 2 Once the load is released tilt the bucket forward to an angle...

Page 54: ...chments see also section 5 11 1 Make sure the locking levers on the quick attach mechanism are in their respective unlocked positions fig 5 10 1 2 Drive the machine to the attachment and hook the top...

Page 55: ...k gently to the right until the quick attach is clear of the attachment 5 Back the machine away from the attachment 5 11 Power Quick Attach Some machines may be equipped with a hydraulic power quick a...

Page 56: ...nd where it is protected from the elements and vandals 3 Lower the lift arms until they rest on the frame stops 4 Reduce engine RPM to a low idle 5 Turn the ignition key to the off position to stop th...

Page 57: ...limit to allow for brace installation 4 Have the assistant place the lift arm brace onto the top side of the cylinder ram and install the retaining pins to secure it there 5 Slowly lower the lift arm...

Page 58: ...6 1 Transporting 59 6 2 Towing Retrieving 60 6 3 Loading Unloading Procedure 61 6 4 Lifting Procedure 62 6 TRANSPORTATION 57...

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Page 60: ...over the distance and terrain that will be covered 2 Secure the machine to the transport vehicle bed facing the direction of travel with heavy chains rated for use with a machine of this nature size...

Page 61: ...Mounting By way of rear housing 2 and brake shaft 16 Brake application Often in mobile applications there is a safety requirement to ensure the motor cannot turn when the machine is not in use The pa...

Page 62: ...nd the auxiliary hydraulic switch are in their neutral positions Remove the ignition key 8 Secure the door windows and hood on the machine 9 Secure the machine and any other items to the transport veh...

Page 63: ...ing device centered over the machine use spreader bars if necessary This will help to balance the machine as well as distribute the weight evenly while being lifted Lift the machine straight up in a s...

Page 64: ...ccessory Belt 71 7 10 Water Separator 72 7 11 Fuel Filter Change 72 7 12 General Undercarriage 73 7 13 Track Tension Check 73 7 14 Track Tension Adjustment 74 7 15 Drive Sprocket Rollers 75 7 16 Air C...

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Page 66: ...and take any necessary precautions to ensure his her safety Wear appropriate personal protec tion equipment for all tasks 7 2 Care and cleaning Cleaning the machine Do not use aggressive detergents t...

Page 67: ...6 9 General visual check for cracks damage completeness 22 49 10 Check for leaks in hoses tubes valves pumps cylinders etc 20 29 49 11 Drain water separator 72 12 Lubricate all grease points 67 13 Ins...

Page 68: ...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 ope...

Page 69: ...ick once again and inspect the end for oil on the level indicator 6 Oil should be present on the dipstick up to but not over the upper full level indicator notch If the level is correct reinstall the...

Page 70: ...the oil into a suitable catch container 5 Remove engine oil filter Upon removal make sure the filter gasket item 2 fig 7 6 1 is still present on the filter If not remove it from the filter port on th...

Page 71: ...ulic fluid drain plug item 1 through the drain hole in the belly pan fig 7 7 1 4 Drain the used oil into a suitable catch container 5 Dispose of the oil according to local mandates 6 Reinstall the dra...

Page 72: ...remove it 5 Remove the old filter from the housing and replace it with a new element Dispose of the used filter according to local mandates 6 Reinstall the cover and rubber plug as found upon disassem...

Page 73: ...f the water has been drained from the catch bowl and close the hood to complete the procedure 7 11 Fuel Filter Change The fuel filter should be changed every 500 service hours or as needed A plugged f...

Page 74: ...ature wear and damage Operation on sand turf or other finished surfaces may require less frequent cleaning but daily inspection is still advised 7 13 Track Tension Check Proper track tension is import...

Page 75: ...the track tension device 3 Once the jam nut is loose turn the tensioner until the track tension is within specification fig 7 14 2 4 Turn the tensioner the opposite direction to loosen the track 5 Onc...

Page 76: ...needed The rollers 1 rotate on steel pins 2 limiting wear to the inside of the rollers As they wear the rollers become thinner but will continue to function and perform as long as they are rotating Vi...

Page 77: ...e the elements 1 Shut the machine down according to the procedure in section 5 13 open the hood release the latches on either side of the air cleaner then remove the cover 2 Remove the primary element...

Page 78: ...the solution to further clean the element Never soak for more than 24 hours 3 Rinse the filter thoroughly with a gentle stream of water to remove all dirt and remaining detergent 4 Allow the filter t...

Page 79: ...7 19 Engine Coolant Change Procedure 1 Shut the machine down according to the procedure in section 5 13 allow the machine to cool Remove the lower rear screen and raise the hood 2 Open the radiator dr...

Page 80: ...essure wash any debris from the engine compartment and chassis area out through the lower opening 4 Re install the belly pans and close the hood to complete the cleaning procedure 7 MAINTENANCE 79 7 2...

Page 81: ...INTENANCE 80 50 40 50 20 30 20 50 80 3 5 5 10 10 5 10 20 25 25 10 15 5 10 10 20 A RELAY 12077866 35A RELAY 12177234 35A RELAY 12177234 10 10 PWR RELAY A PWR RELAY B GLOW PLUG STARTER PWR OUTLET MAIN M...

Page 82: ...a dry place that provides protection from the elements Drain and refill the cooling system with 50 50 pre mixed antifreeze water Replace engine oil and filter ch 7 Replace hydraulic oil and filters ch...

Page 83: ...all fully charged battery Remove exhaust outlet cover Perform pre operation safety checklist in chapter 5 of this manual Perform starting procedure chapter 5 Let engine run while observing engine moni...

Page 84: ...Hours Service Performed Notes SERVICE LOG 83...

Page 85: ...Hours Service Performed Notes SERVICE LOG 84...

Page 86: ...Hours Service Performed Notes SERVICE LOG 85...

Page 87: ...le GmbH Postfach 12 64 D 91534 Rothenburg Erlbacher Str 115 D 91541 Rothenburg Phone 49 0 9861 972 0 Fax 49 0 9861 972 410 Customer Service Terex Construction Motherwell Scotland UK ML1 5RY Phone 44 0...