Terex PT-50 User manual

PT-50/60
Operation and Maintenance Manual
Compact Track Loader
Version: EN
Edition: 2010-04
Part Number: 2030-613
Valid From Serial No: DTC 03133 (50)
DTE 02742 (60)
Original Instructions

CONTENTS
Introduction .................................................. 2
Safety ........................................................ 5
Technical Data.............................................. 31
Machine Description / Controls..................... 37
Operation ..................................................... 45
Transportation .............................................. 55
Maintenance ................................................ 61
California Proposition 65 .............................. 81
Service Log .................................................. 82
1
Page

1 INTRODUCTION
2
1.1 Product Identification (PIN)
The machine PIN is located on the identifi-
cation 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.
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.
It 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 obtain a replacement prior to resuming
operation.
It is very important that the operator read and understand the information in
this manual prior to operating the machine or performing maintenance or
service.
During operation, it is very important that the operator obey the instructions
in this manual to ensure safe and efficient operation.
Should you need clarification or further explanation of the topics in this manual,
please contact your dealer immediately for assistance.
Information describing special equipment or attachments and their operation are
not included in this manual.

1 INTRODUCTION
3
1.3 Intended Use
The machine with standard dirt bucket is intended to be used solely for work con-
sistent with its design. Such work involves loosening, collecting, transporting, and
distributing soil, rock, or similar materials as well as loading these materials onto
trucks, conveyors, or other methods of transport.
After installation of additionally approved special working attachments, 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 described here or any lack of adherence to the operat-
ing instructions, maintenance procedures, or replacement intervals described in
this manual shall be regarded as unintended or improper use. The supplier cannot
be held responsible for any damage resulting from improper use. This risk is
borne solely by the user.
1.4 Copyright
This manual is intended for use by personnel responsible for operation, mainte-
nance, repair, and supervision activities involving the machine described within.
This manual is copyrighted. It shall not, either in whole or in part, be reproduced,
transmitted, or used for the purpose of competition without our prior written con-
sent.
1.5 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
Authorized Terex Distributor.

4

2 SAFETY
5
2.1 Safety Alert System ................................ 7
2.2 Pictograms............................................. 8
2.3 Safety Symbols ...................................... 10
2.4 Safety Signs........................................... 14
2.5 General Notes ........................................ 16
2.6 Personal Protection Equipment............... 17
2.7 Danger 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
2.15 Jobsite Safety ...................................... 23
2.16 Parking the Machine ............................ 24
2.17 Towing / Retrieving............................... 24
2.18 Transporting ......................................... 25
2.19 Maintenance ........................................ 26
2.20 Battery ................................................. 28
2.21 Hydraulic Lines / Hoses........................ 29
Page

6

2.1 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.
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 recog-
nition and prevention.
Hazard Classification
The following signal words used with the safety alert symbol indicate a specific
level of severity of the potential hazard. Signal words used without the safety alert
symbol relate to property damage and protection only. Warnings in this publication
and on the product labels are identified by these symbols.
2 SAFETY
7
DANGER indicates a hazardous situ-
ation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous sit-
uation which, if not avoided, could
result in death or serious injury.
CAUTION, used with the safety alert
symbol, indicates a hazardous situ-
ation which, if not avoided, could
result in minor or moderate injury.
NOTICE is used to address practices
not related to personal injury.
DANGER
WARNING
CAUTION
NOTICE

2.2 Pictograms
Symbol Description
2 SAFETY
8
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

Symbol Description
2 SAFETY
9
Work Lights
Fan
Bucket Positioning

2 SAFETY
10
2.3 Safety Symbols
Hazard Avoidance Description
Hazard: Skin Oil Injection
Escaping fluid under pressure can
penetrate skin, causing serious
injury.
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
result.
Hazard: Corrosive
Contact with corrosive acid will
cause burns or death.
Avoidance: Read and understand
the operator’s manual before using
or maintaining the machine.
Hazard: Belt Entanglement
Rotating parts can cause personal
injury.
Avoidance: Keep away from belt
while the engine is running. Stop
the engine and remove ignition key
before servicing the machine.
Hazard: Burn
Hot fluid under pressure can
scald.
Avoidance: Allow the machine to
cool thoroughly prior to perform-
ing service.

2 SAFETY
11
Hazard Avoidance Description
Hazard: Explosion/Burn
Will cause death, burns or blind-
ness due to ignition of explosive
gasses or contact with corrosive
acid.
Avoidance:
• Keep all flames/sparks away!
• No Smoking!
• Read and understand all manu-
als prior to operation.
Hazard: Fall
Serious injury or death can result
from falling.
Avoidance: Use the provided
access system when entering or
exiting the machine.
Hazard: Fall
Serious injury or death can result
from falling.
Avoidance: No Riders.
Hazard: Burn
Contact with hot surfaces can
cause burns.
Avoidance: Allow surfaces to cool
before servicing.
Hazard: Crush
Rollover can crush and result in
serious injury or death.
Avoidance: Fasten seat belt.

2 SAFETY
12
Hazard Avoidance Description
Hazard: Entanglement
Rotating Parts can cause personal
injury.
Avoidance: Keep away from fan
while the engine is running. Stop
the engine and remove ignition
key before servicing the machine.
Hazard: Rollover / Ejection
Avoidance: Carry loads low, keep
heaviest end of machine uphill at
all times while operating on
inclines.
Hazard: Fall
Falling can result in serious injury
or death.
Avoidance: Do not use the bucket
or attachment as a work platform.
Hazard: Crush
Serious injury or death can result
from contact with moving machine.
Avoidance: Keep clear of moving
machine.
Hazard: Crush
Serious injury or death can result
from contact with moving lift arm
or attachment.
Avoidance: Keep clear of lift arms
and attachments.

2 SAFETY
13
Hazard Avoidance Description
Hazard: Crush
Serious injury or death can result
from contact with moving lift arm
or attachment.
Avoidance: Keep clear of lift
arms and attachments.
Hazard: Attention, Your safety is
involved!
Avoidance: Read and understand
the operator’s manual before using
or maintaining the machine.
Hazard: Fire
Flammable debris can collect
near hot components and lead to
a fire.
Avoidance: Read operator’s man-
ual. Keep engine, exhaust and
chassis areas free of debris.
2030-41
7

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)
Key
1. Fall hazard
2. Skin (oil) injection hazard
3. Crush hazard (lift arms)
4. Fire hazard (read manual)
5. Burn hazard
6. Explosion / burn hazard (read operator’s manual)
7. Tie down location
8. Clean undercarriages notice
9. Crush hazard (run over)
10. Crush hazard (lift arm brace)
2 SAFETY
14
WARNING
CRUSH HAZARD
Contact with moving machine can
result in death or serious injury.
Keep clear of moving machine.
2030-593
WARNING
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment.
Keep clear of lift arms and
attachments.
WARNING
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment. Install lift arm brace prior to servicing.
Burn Hazard
Hot fluid under pressure can scald.
Allow the machine to cool thoroughly
before opening.
2030-595
WARNING
WARNING
Fall Hazard
Serious injury or death can result
from falling.
Use the provided access system when
entering or exiting the machine.
WARNING
Injection Hazard
Escaping fluid under pressure can
penetrate skin, causing serious injury.
• Relieve internal pressure before
disconnecting any line or fitting.
• Keep away from leaks or pinholes.
• Use cardboard to check for leaks.
Fluid injected into skin must be surgi-
cally removed within a few hours by a
doctor familiar with this type of injury
or gangrene will result.
NOTICE
Fire Hazard
Flammable debris can collect near hot
components and lead to a fire.
Read Operator’s manual
Keep engine, exhaust and chassis
areas free of debris.
DANGER
Explosion/Burn Hazard
Will cause death, burns or
blindness due to ignition of
explosive gasses or contact
with corrosive acid.
• Keep all flames/sparks
away!
• No Smoking!
• Read and understand
all manuals prior to
operation. 2030-603
1
2
3
45
6
7
10 9
Inspect undercarriages daily for
accumulation of debris. If debris
is present, clean thoroughly with
a pressure washer. If debris is
allowed to build up, it can cause
premature component wear and
decrease machine performance.
2085-253
NOTICE
8

Note:
If any of the safety signs shown in this section are missing or damaged, contact
your dealer to obtain a replacement.
Key (continued)
11. Belt/fan entanglement hazard
12. Skin (oil) injection hazard
13. Crush hazard (lift arm brace)
14. Crush Hazard (Lift arms)
15. Fall hazard / rollover Hazard / read operator’s manual
16. Crush / fall hazards
17. Crush (run over) hazard
18. Clean undercarriages notice
19. Tie down location
20. Burn hazard
2 SAFETY
15
Burn Hazard
Contact with hot surfaces can
cause burns.
• Do not touch hot
components!
• Allow the machine to
cool thoroughly prior to
servicing. 2030-601
WARNING
Entanglement Hazard
Rotating parts can cause personal injury.
Keep away from fan and belt while the
engine is running. Stop engine before
servicing.
2030-600
WARNING
WARNING
CRUSH HAZARD
Contact with moving machine can
result in death or serious injury.
Keep clear of moving machine.
2030-593
WARNING
Read Operator’s Manual
Read and understand the operator’s manual
and all safety signs prior to operating or
maintaining the machine.
WARNING WARNING
Improper operation or maintenance can re-
sult in serious injury or death.
No Riders
Fall Hazard
Falling from a machine can result in serious
injury or death.
Carry loads low. Load unload and turn on
level ground. Travel on inclines with heaviest
end of machine uphill.
Rollover/Ejection Hazard
Serious injury or death can result.
WARNING
Fasten Seat Belt
Crush Hazard
Rollover can crush and result in serious injury or death.
Do not use the bucket/attachment as a work platform.
Fall Hazard
Falling can result in serious injury or death.
WARNING
WARNING
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment.
Keep clear of lift arms and
attachments.
WARNING
Injection Hazard
Escaping fluid under pressure can
penetrate skin, causing serious injury.
• Relieve internal pressure before
disconnecting any line or fitting.
• Keep away from leaks or pinholes.
• Use cardboard to check for leaks.
Fluid injected into skin must be surgi-
cally removed within a few hours by a
doctor familiar with this type of injury
or gangrene will result.
20
11 12
14
15
16
17
19
WARNING
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment. Install lift arm brace prior to servicing.
13
Inspect undercarriages daily for
accumulation of debris. If debris
is present, clean thoroughly with
a pressure washer. If debris is
allowed to build up, it can cause
premature component wear and
decrease machine performance.
2085-253
NOTICE
18

2.5 General Safety Notes
• Read and understand all safety signs and operator’s manuals prior to opera-
tion.
• 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.
• 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 maintained to ensure safe
operation.
• The manufacturer’s instructions regarding operation, inspection, mainte-
nance, repair and transportation must be followed.
• Never place the machine into operation without having first performed a
thorough walk-around inspection and making any necessary repairs or
adjustments.
• Safety devices on the machine shall not be deactivated or removed.
• Do not make any changes, additions or conversions to the machine that
could have a negative effect on safety without the manufacturer’s approval.
2 SAFETY
16

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. Long hair
should be restrained. Personal Protective Equipment (PPE) must be worn in the
absence of an enclosed cab. In this case PPE would include, but not be limited to,
safety glasses. The use of some attachments may require additional PPE, such as
hearing protection, hardhat, gloves, and steel-toed shoes. In some applications
high visibility/reflective jackets are required.
Personal protection equipment is also recommended when performing mainte-
nance or service on a machine. Always wear appropriate protective equipment for
working conditions when working on or around the machine. Loose clothing
should not be worn and long hair should be restrained. Wear hard hats, protective
face/eyewear, safety shoes and any other equipment necessary to ensure your
safety and the safety of others around you as you work.
2.7 Danger Zone
The danger zone encompasses the area around the machine in which persons
may be injured by movements of the machine during operation, its attachments,
or by falling loads.
Do not position yourself or allow anyone else within this danger zone during
machine operation. Keep a safe distance to ensure your safety while the machine
is in operation.
If someone enters the danger zone, the operator must stop all work and give a
warning signal to the person who may be in danger to leave the danger zone.
Work should not resume until all persons have vacated the danger zone.
To minimize the possibility of a crushing hazard, a sufficient safety distance (min.
0.5 m (1.6 ft)) must be kept from solid objects, e. g. buildings, slopes, scaffolding,
other machines, etc. If that distance cannot be kept, fence off the area between
solid construction elements and the working range of the machine.
If conditions are such that the machine operator’s view of the driving and working
zone is restricted, he must be guided or the driving and working zone must be
secured by means of a solid barricade.
2 SAFETY
17

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.
• can be trusted to perform their assigned duties in a safe and reliable
manner.
• are of the legal minimum age for performing such duties.
It is the responsibility of the operator to
• inspect the machine prior to operation and perform any necessary checks,
adjustments or repairs to ensure safe 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 any fault that may compromise safety.
• use the machine in accordance with the appropriate local job site
organization system to ensure safe coordination with other machines,
vehicles, and people on the job site.
Investigate any work site prior to operation to determine whether any special haz-
ards exist. Take necessary measures to eliminate or reduce any hazard.
Do not operate the machine in unsafe conditions including, but not limited
to: near overhead electric lines, in enclosed areas without proper ventilation, in
contaminated areas without necessary safety equipment and personnel.
2 SAFETY
18