Terex PT-50, PT-60 Service Manual
Service Manual
Rubber Track Loader
PT-50/60
Part Number: 2030-634
Printed (4-10)
Table of Contents
1. Product Safety
Chapter Overview ................................................... 1-1
Basic Precautions ................................................... 1-1
Safety Labels ..................................................... 1-1
Personal Protective Equipment .......................... 1-1
Entering and Exiting ........................................... 1-2
Lifting ................................................................. 1-2
Hot Fluids and Parts .......................................... 1-2
Corrosion Inhibitor ............................................. 1-2
Batteries ............................................................ 1-2
Pressurized Items .............................................. 1-2
Repair ..................................................................... 1-3
Attachments ............................................................ 1-4
Machine Labels and Decals .................................... 1-4
Product ID Number ............................................ 1-4
Safety Label Examples ...................................... 1-4
2. Technical Specifications
PT-50 Specifications ............................................... 2-1
PT-60 Specifications ............................................... 2-2
3. System Diagrams
Chapter Overview ................................................... 3-1
Filtering and Cooling System .................................. 3-1
Auxiliary Circuit System .......................................... 3-2
Drive Loop System ................................................. 3-3
Electrical Attachment Outlet ................................... 3-3
4. Machine Controls and Instrumentation
Chapter Overview ................................................... 4-1
Machine Controls .................................................... 4-1
Loader Control ................................................... 4-1
Drive Control ...................................................... 4-1
Throttle .............................................................. 4-1
Instrumentation ....................................................... 4-1
Switches .................................................................. 4-2
5. Operator Enclosure Disassembly
and Assembly
Chapter Overview ................................................... 5-1
Personal Safety ....................................................... 5-1
Machine Preparation ............................................... 5-1
Operator Enclosure Disassembly and Assembly
Procedures .............................................................. 5-1
Light Bar Removal and Installation .......................... 5-1
Light Bar Removal ............................................. 5-1
Light Bar Installation .......................................... 5-2
Ignition Switch Removal and Installation ................. 5-2
Ignition Switch Removal .................................... 5-2
Ignition Switch Installation ................................. 5-3
Gauge Removal and Installation ............................. 5-4
Gauge Removal ................................................. 5-4
Gauge Installation .............................................. 5-4
Lap Bar Gas Assist Spring Removal
and Installation ........................................................ 5-5
Lap Bar Gas Assist Spring Removal .................. 5-5
Lap Bar Gas Assist Spring Installation ............... 5-5
6. Chassis Disassembly and Assembly
Chapter Overview ................................................... 6-1
Personal Safety ....................................................... 6-1
Machine Preparation ............................................... 6-1
Chassis Disassembly and Assembly
Procedures .............................................................. 6-1
Seat Removal and Installation ................................ 6-1
Seat Removal .................................................... 6-1
Seat Installation ................................................. 6-2
Fuel Sending Unit Removal and Installation ........... 6-2
Fuel Sending Unit Removal ............................... 6-3
Fuel Sending Unit Installation ............................ 6-3
7. Radiator/Oil Cooler Disassembly
and Assembly
Chapter Overview ................................................... 7-1
Personal Safety ....................................................... 7-1
Machine Preparation ............................................... 7-1
Radiator/Oil Cooler Disassembly and Assembly
Procedures .............................................................. 7-1
Fan Guard Removal and Installation ....................... 7-1
Fan Guard Removal .......................................... 7-2
Fan Guard Installation ....................................... 7-2
Radiator/Cooler Removal and Installation ............... 7-2
Radiator/Cooler Removal .................................. 7-2
Radiator/Cooler Installation ............................... 7-4
8. Hydraulic Reservoir Disassembly
and Assembly
Chapter Overview ................................................... 8-1
Personal Safety ....................................................... 8-1
Machine Preparation ............................................... 8-1
Hydraulic Reservoir Disassembly and Assembly
Procedures .............................................................. 8-1
Filter Element Removal and Installation .................. 8-1
Filter Assembly Removal and Installation ............... 8-1
Filter Assembly Removal ................................... 8-2
Filter Assembly Installation ................................ 8-3
Access Cover Removal and Installation .................. 8-4
Access Cover Assembly Removal ..................... 8-4
Access Cover Assembly Installation .................. 8-4
Reservoir Gauge Removal and Installation ............. 8-5
Reservoir Gauge Removal ................................ 8-5
Reservoir Gauge Installation ............................. 8-6
Suction Screen Removal and Installation ............... 8-6
Suction Screen Removal ................................... 8-6
Suction Screen Installation ................................ 8-7
Hydraulic Reservoir Cleaning Procedures ............. 8-7
Hydraulic Reservoir Cleaning ............................ 8-7
i
Rubber Track Loader
Table of Contents
9. Loader/Transmission Controls Disassembly
and Assembly
Chapter Overview ................................................... 9-1
Personal Safety ....................................................... 9-1
Machine Preparation ............................................... 9-1
Loader/Transmission Controls Disassembly and
Assembly Procedures ............................................. 9-1
Joystick Removal and Installation ........................... 9-1
Joystick Removal ............................................... 9-2
Joystick Installation ............................................ 9-3
Loader Float Magnet Removal and Installation ....... 9-3
Loader Float Magnet Removal ........................... 9-3
Loader Float Magnet Installation ........................ 9-4
Loader Valve Removal and Installation .................. 9-4
Loader Valve Removal ...................................... 9-4
Loader Valve Installation ................................... 9-6
Self Level Valve Removal and Installation ............. 9-6
10. Transmission and Drive Disassembly
and Assembly
Chapter Overview ................................................. 10-1
Personal Safety ..................................................... 10-1
Machine Preparation ............................................. 10-1
Hydrostatic and Hydraulic Pump Disassembly
and Assembly Procedures .................................... 10-1
Auxiliary Gear Pump Removal and Installation ..... 10-1
Auxiliary Gear Pump Removal ......................... 10-1
Tandem Pump Removal and Installation .............. 10-3
Tandem Pump Removal .................................. 10-3
Tandem Pump Installation ............................... 10-4
Pump Drive Coupler Removal and Installation ...... 10-5
Pump Drive Coupler Removal ......................... 10-5
Pump Drive Coupler Installation ...................... 10-6
11. Undercarriage Disassembly and Assembly
Chapter Overview ................................................. 11-1
Personal Safety ..................................................... 11-1
Machine Preparation ............................................. 11-1
Undercarriage Disassembly and Assembly
Procedures ............................................................ 11-1
Center Wheel Removal and Installation ................ 11-1
Wheel Removal ............................................... 11-2
End Wheel Removal and Installation .................... 11-3
End Wheel Removal ........................................ 11-3
End Wheel Installation ..................................... 11-3
Sprocket Roller Removal and Installation ............ 11-4
Track Removal and Installation ............................ 11-4
Track Removal ................................................. 11-4
Track Installation .............................................. 11-4
Outboard Bearing Removal and Installation .......... 11-5
Bearing Removal ............................................. 11-5
Bearing Installation .......................................... 11-5
Drive Sprocket Removal and Installation .............. 11-6
Sprocket Removal ........................................... 11-6
Sprocket Installation ........................................ 11-6
Drive Motor Removal and Installation .................. 11-6
Drive Motor Removal ....................................... 11-6
Drive Motor Installation .................................... 11-6
Idler Wheel Hub Service Procedures .................... 11-7
Disassembly Procedure ................................... 11-7
Assembly Procedure ........................................ 11-9
12. Loader Disassembly and Assembly
Chapter Overview ................................................. 12-1
Personal Safety ..................................................... 12-1
Machine Preparation ............................................. 12-1
Loader Disassembly and Assembly Procedures .. 12-1
Lift Cylinder/Tilt Cylinder Removal
and Installation ...................................................... 12-1
Lift Cylinder/Tilt Cylinder Removal ................... 12-1
Lift Cylinder/Tilt Cylinder Installation ................ 12-3
Q/C Block Relief Valve Removal and Installation .. 12-3
Q/C Block Relief Valve Removal ..................... 12-3
Q/C Block Relief Valve Installation .................. 12-4
13. Maintenance
Chapter Overview ................................................. 13-1
Maintenance Schedule ......................................... 13-1
Engine Oil ............................................................. 13-1
Oil Change Procedures ................................... 13-1
Engine Oil Specifications ................................. 13-1
Hydraulic Fluid and Filter ...................................... 13-2
Hydraulic Fluid and Filter Change
Procedures ...................................................... 13-2
Fuel/Water Separator ............................................ 13-3
Fuel Filter .............................................................. 13-3
Fuel Filter Change Procedures ........................ 13-3
Fuel Specifications .......................................... 13-3
Air Cleaner ............................................................ 13-3
Air Filter Change Procedures .......................... 13-3
Track Tension ....................................................... 13-4
Track Tension Adjustment Procedures ............ 13-4
Checking for Proper Track Adjustment ............ 13-4
Fuse Box ............................................................... 13-5
Grease Fittings ...................................................... 13-5
Bleeding the Fuel System ..................................... 13-6
14. Hydraulic Pressure Check & Adjustment
Chapter Overview ................................................. 14-1
Personal Safety ..................................................... 14-1
Machine Preparation ............................................. 14-1
Hydraulic Pressure Adjustment Procedures.......... 12-1
Charge Pressure check……………………………. 14-1
Charge Pressure Adjustment………………………14-1
Auxiliary Pressure Check & Adjustment…………..14-2
15. Troubleshooting
Chapter Overview ................................................. 15-1
Personal Safety ..................................................... 15-1
Machine Preparation ............................................. 15-1
Preliminary Inspection ........................................... 15-1
Visual Inspection ............................................. 15-1
Troubleshooting Scenarios………………………...15-2
ii
Chapter Overview
This chapter contains product safety information for the
Terex PT-50/60 Rubber Track Loaders. Read and
understand all product safety information before
attempting to service any Rubber Track Loader.
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.
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
recognition and prevention.
Property or equipment damage warnings in this publication are identified by the signal word "NOTICE".
The word “Note” is used throughout this manual to
draw your attention to specific topics or to supplement
the information provided in that section.
The person(s) in charge of servicing a Rubber Track
Loader may be unfamiliar with many of the systems on
the machine. This makes it especially important to use
caution when performing service tasks. Familiarize
yourself with the affected system(s) and components
before attempting any type of maintenance or service.
It is not possible to anticipate every potential hazard. The safety messages included in this document and displayed on the machine are not allinclusive. They are intended to make you aware of
potential risks and encourage a safe approach to
performing service work. If you use a tool, procedure, work method or operating technique that is
not specifically recommended by Terex, you must
satisfy yourself that it is safe for you and others.
You must also ensure that the machine will not be
damaged or be made unsafe by the operation,
lubrication, maintenance or repair procedures that
you choose.
Basic Precautions
Safety Labels
Safety labels have been included and are displayed in
various places throughout the machine to serve as
warnings of potentially dangerous conditions. Read
and understand all "Safety" labels on any Rubber
Track Loader before attempting to operate, maintain or
repair it. Replace any damaged, illegible or missing
labels immediately, prior to service.
Personal Protective Equipment
Personal protection equipment is recommended when
performing maintenance 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.
1. Product Safety
1-1
“NOTICE” Indicates a hazardous situation which,
if not avoided, could result in property or equipment damage.
NOTICE
Improper or incomplete maintenance/repair of a
Rubber Track Loader can be dangerous and
may result in machine damage, injury or death.
Do not attempt to perform any type of repair or maintenance on a Rubber Track Loader until you have read
and fully understood both this manual and the
machine specific operation and maintenance manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation and
maintenance techniques before operating or servicing
any Rubber Track Loader.
Entering and Exiting
Always use steps and handholds when entering or
exiting a Rubber Track Loader. Clean any mud or
debris from steps or work platforms before using them.
Always face the machine when using steps and handholds. When it is not possible to use the designed
entry/exit system, utilize ladders, scaffolds, or work
platforms to safely gain access to the machine.
Lifting
Use a hoist when lifting components that weigh 50 lb
(23 kg) or more, to avoid back injury. Make sure all
chains, hooks, slings, etc., are in good condition and
are of the correct capacity. Be sure hooks are positioned correctly and equipped with a spring latch.
Lifting eyes are not to be side loaded during a lifting
operation.
Hot Fluids and Components
Stay clear of hot components and system fluids of the
engine, exhaust, radiator/oil cooler and hydraulic
lines/tubes. Also, use caution when removing fill caps,
breathers and plugs on the machine. Hold a rag over
the cap or plug to prevent being sprayed or splashed
by liquids under pressure. Be especially careful if the
machine has been operated recently, fluids may still be
hot. To ensure your safety, allow the machine to cool
before attempting any service procedure that involves
hot fluids or components.
Corrosion Inhibitor
Corrosion inhibitor contains alkali. Avoid contact with
eyes. Avoid prolonged or repeated contact with skin.
Do not take internally. In case of contact, wash skin
immediately with soap and water. For eyes, flush with
large amounts of water for at least 15 minutes. Call
Physician. Keep out of reach of children.
Batteries
Do not smoke when inspecting the battery electrolyte
level. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging
unit is operating. A spark can cause an explosion from
the flammable vapor mixture of hydrogen and oxygen
that is released from the electrolyte through the battery
outlets. Do not let electrolyte solution make contact
with skin or eyes. Electrolyte solution is an acid. In
case of contact, immediately wash skin with soap and
water. For eyes, flush with large amounts of water for
at least 15 minutes. Call Physician. Keep out of reach
of children.
Pressurized Items
1. Do not use hands or any other body part to check
for fluid leaks in the hydraulic system. Always use
a solid material like wood or metal to check for this
type of leak. Leaking fluid under pressure can penetrate body tissue. Fluid penetration can cause
serious injury and even death. If fluid is injected
into your skin, get treatment immediately. Seek
treatment from a doctor that is familiar with this
type of injury.
2. Relieve pressure from the hydraulic system before
disconnecting or removing any lines, fittings or
related items. Do this by relaxing all hydraulic
actuators. If the lift arms are raised, make sure
they are securely braced. Be alert for possible
pressure release when disconnecting any device
from a pressurized system.
3. Lower the lift arms before performing any work on
the machine. If this cannot be done, make sure
they are securely braced to prevent them from
dropping unexpectedly during service.
4. Loose or damaged fuel, oil, hydraulic, lines, tubes
and hoses can cause fires. Do not bend or strike
high pressure lines or install ones that have been
bent or damaged. Check lines, tubes and hoses
carefully. See item 1 for precautions on checking
for fluid leaks.
5. Pressurized air or water can also cause injury.
When pressurized air or water is used for cleaning, wear a protective face shield, protective clothing, and protective shoes. The recommended maximum air pressure for cleaning purposes is 30 psi
(205 kPa). When using a pressure washer, keep in
mind that nozzle pressures are typically very high.
Generally, pressures are well above 2000 psi
(13790 kPa). Follow all recommended practices
provided by the pressure washer manufacturer.
1-2
Rubber Track Loader
1. Product Safety
Repair
1. Disconnect the battery and discharge any capaci-
tor before beginning work on a machine. Attach a
Do Not Operate tag in the cab to alert any operator that service is in progress.
2. If possible, make all repairs with the machine
parked on a level, hard surface. Use blocks to prevent the machine from rolling while working on or
under the machine.
3. Do not work on or under any machine that is supported only by a hydraulic jack or hoist. Always
use some sort of mechanical support to ensure
that the machine will not fall. Terex jack stands
work well to support the machine while performing
maintenance or repair work.
4. Make sure the work area around the machine is
safe and make yourself aware 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.
5. Be sure all protective devices including guards and
shields are properly installed and functioning correctly before beginning any service task. If a guard
or shield must be removed to perform the repair
work, use extra caution.
6. Always use the appropriate tools for the work to be
performed. Tools should be in good condition and
you should understand how to use them properly
before performing any service work.
7. When replacing fasteners, use parts of equivalent
grade and size. Do not use a lesser quality fastener if replacements are necessary.
8. Be prepared to stop an engine if it has been recently overhauled or the fuel system has been
recently serviced. If the engine has not been
assembled correctly, or if the fuel settings are not
correct, the engine can possibly overspeed and
cause bodily injury, death or property damage. Be
prepared to shut off the fuel and air supply to the
engine in order to stop the engine.
9. Be careful when removing cover plates. Gradually
back off the last two bolts or nuts located on opposite sides of the cover. Then, pry the cover loose
to relieve any spring or other pressure before
removing the last two nuts or bolts completely.
10. Repairs requiring welding should be performed
only by personnel adequately trained and knowledgeable in welding procedures and with the guidance of appropriate reference information.
Determine the type of metal being welded and
select the correct welding procedure and filler
material to provide a weld that is as strong or
stronger than the original weld.
11. Take precautions to avoid damaging wiring during
removal and installation operations. Carefully route
wires so that they will not contact sharp corners,
objects or hot surfaces during operation.
12. When performing service that requires the lift arms
to be in the raised position, always utilize the lift
arm brace located on the rear of the loader tower.
13. Relieve hydraulic system pressure by relaxing all
hydraulic actuators prior to attempting any
hydraulic maintenance or repair.
14. Always tighten connections to the correct torque
specification. Make sure that all shields, clamps
and guards are installed correctly to avoid excessive heat, vibration or unwanted contact between
parts during operation. Shields that protect
exhaust components from oil spray in event of a
line, tube or seal failure must be correctly installed.
15. Do not operate a machine if any rotating part is
damaged or contacts other parts during operation.
Any high speed rotating component that has been
damaged or altered should be checked for balance
before reusing. Make sure all protective devices,
including guards and shields, are properly installed
and functioning correctly before starting the engine
or operating the machine.
1-3
Rubber Track Loader
1. Product Safety
Accidental machine starting can cause injury
or even death to personnel working on a
Rubber Track Loader.
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to performing any service work on a Rubber Track Loader.
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is
being serviced.
Attachments
Only use attachments that are recommended by Terex.
Make sure that all necessary guards and protective
equipment are in place and functioning prior to operating any attachment.
Wear protective glasses and protective equipment as
required by conditions or as recommended in the
attachment’s operation manual.
Ensure that all personnel are far enough away from
the work area so they will not be struck by flying objects.
Stay clear of the cutting edges, pinching surfaces or
crushing surfaces of the attachment while performing
any attachment maintenance, testing or adjustments.
Machine Labels and Decals
Labels and decals placed on the machine provide
safety information and operating instructions.
Familiarize yourself with the location and significance
of these labels to ensure your safety.
Product Identification Number
The Product Identification Number (PIN) is located on
the left side of the firewall next to the operator seat.
(figure 1-1). Always provide the PIN when contacting
the dealer about parts, service, warranty or accessories. No warranty claims will be processed unless
the PIN is provided.
Safety Label Examples
Examples of the labels and decals displayed on the
machine are shown on this page.
1-4
Rubber Track Loader
1. Product Safety
1-1
When replacement parts are required for your
machine, use only genuine Terex replacement
parts or parts that meet or exceed original
specifications including, but not limited to physical
dimensions, type, strength and material.
Installing lesser components can lead to premature
failures, product damage, personal injury or death.
WARNING
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment.
WARNING
CRUSH HAZARD
Contact with moving machine can
result in death or serious injury.
WARNING
Fall Hazard
Serious injury or death can result
from falling.
Keep clear of lift arms and
attachments.
Keep clear of moving machine.
Use the provided access system when
entering or exiting the machine.
2030-593
WARNING
Crush Hazard
Death or serious injury can result
from contact with moving lift arm or
attachment.
WARNING
Entanglement Hazard
Rotating parts can cause personal injury.
WARNING
Burn Hazard
Hot fluid under pressure can scald.
NOTICE
Install lift arm brace prior to servicing.
Keep away from fan and belt while the
engine is running. Stop engine before
servicing.
Allow the machine to cool thoroughly
before opening.
2030-600
2030-595
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.
1-5
Rubber Track Loader
1. Product Safety
WARNING
Rollover can crush and result in serious injury or death.
Crush Hazard
Fasten Seat Belt
WARNING
Improper operation or maintenance can result in serious injury or death.
Read Operator’s Manual
Read and understand the operator’s manual
and all safety signs prior to operating or
maintaining the machine.
WARNING
Fall Hazard
Falling can result in serious injury or death.
Do not use the bucket/attachment as a work platform.
WARNING WARNING
Fall Hazard
Falling from a machine can result in serious
.
injury or death
Carry loads low. Load unload and turn on
No Riders
level ground. Travel on inclines with heaviest
end of machine uphill.
Rollover/Ejection Hazard
Serious injury or death can result.
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.
WARNING
Burn Hazard
Contact with hot surfaces can
cause burns.
• Do not touch hot
components!
• Allow the machine to
cool thoroughly prior to
servicing.
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 surgically removed within a few hours by a
doctor familiar with this type of injury
or gangrene will result.
1-6
PT-50 Specifications
2. Technical Specifications
Engine
− Model: Perkins 404D-22
− Displacement: 2.2 liter
− Gross horsepower: 50 hp, 37.3 kW
− Torque: 105 lb-ft.143 Nm
− Idle rpm: 2800 (high idle); 1175 (low idle)
− Average water /thermostat temperature:
190°F, 87.8°C
Transmission
− Model: A22 (38.5cc) tandem (Rexroth)
Drive pumps
− Displacement: 2.349 in
− Relief pressure: 5500 psi, 380 bar
− Flow: 28 gpm (106 lpm) @ 2800 rpm (high
idle)
Charge pump
− Displacement: 1.098 in
− Relief pressure: 400-450 psi
3
/rev (38.5 cc/rev)
3
/rev (18 cc/rev)
Drive Motors
− Model: Rexroth MCR 05C
3
− Displacement: 37.8 in
/rev (620 cc/rev)
Control Handles
− Model: 4TH6 (Rexroth)
Auxiliary Pump
− Make: Haldex-Barnes #180-2061
3
− Displacement: 1.343 in
− Flow: 16.27 gpm (61.85 lpm) @ 2800 rpm
(high idle)
− Relief pressure: 3000 psi (20,684 kPa)
− Cooling/filtering: Auxiliary oil is filtered and
cooled at all times. In Auxiliary mode, the oil is
filtered after the attachment to protect the machine if the attachment motor fails or contaminants are introduced from the quick couplers.
/rev (22 cc/rev)
Loader Valve
− Model: Husko
− Relief pressure: 3000 psi (20,684 kPa)
− Pilot pressure required to move spools: 180-
220 psi (1241-1517 kPa)
Cooler
− Burst pressure: 400 psi (2757 kPa)
− Operating pressure: 250 psi (1724 kPa)
− Bypass relief pressure: 80 psi (689 kPa)
− Hot oil sending unit: 225°F (107.2°C)
Critical Torque Specs
− Transmission Mounting Bolts
o 85 ft-lb. w/Blue Loctite
− Drive Sprocket Drive Teeth Bolts
o 88 ft-lb. -Dry
− Center Bogie Wheel Retaining Nut
o 111 ft-lb. –Dry
− End Wheel Axle Retaining Nut
o 300 ft-lb. -Dry
− Drive Sprocket Lug Nut
o 129 ft-lb. -Dry
− Drive Motor Mounting Bolts
o 177 ft-lbs. -Dry
2-1
Rubber Track Loader
2. Technical Specifications
PT-60 Specifications
Engine
− Model: Perkins 404D-22 T
− Displacement: 2.2 liter
− Gross horsepower: 60 hp, 44.7 kW
− Torque: 140 lb-ft.190 Nm
− Idle rpm: 2800 (high idle); 1175 (low idle)
− Average water /thermostat temperature:
190°F, 87.8°C
Transmission
− Model: A22VG (38.5cc) tandem (Rexroth)
Drive pumps
− Displacement: 2.349 in
− Relief pressure: 5500 psi, 380 bar
− Flow: 28 gpm (106 lpm) @ 2800 rpm (high
idle)
Charge pump
− Displacement: 1.098 in
− Relief pressure: 400-450 psi ( 2758-3103 kpa)
Drive Motors
− Model: Rexroth MCR 5 (2-speed)
− Displacement: 50 in
Control Handles
− Model: 4TH6 (Rexroth)
3
/rev (38.5 cc/rev)
3
/rev (18 cc/rev)
3
/rev (820 cc/rev)
Loader Valve
− Model: Husco
− Relief pressure: 3000 psi (20,684 kPa)
− Pilot pressure required to move spools: 40-
320 psi (275.8-2206 kPa)
Cooler
− Burst pressure: 400 psi (2757 kPa)
− Operating pressure: 250 psi (1724 kPa)
− Bypass relief pressure: 80 psi (689 kPa)
− Hot oil sending unit: 225°F (107.2°C)
Critical Torque Specs
− Transmission Mounting Bolts
o 85 ft-lb. (230 Nm) w/Blue Loctite
− Drive Sprocket Drive Teeth Bolts
o 105 ft-lb. (142 Nm) -Dry
− Wheel Axle Retaining Nut
o 300 ft-lb. (407 Nm)-Dry
− Drive Sprocket Lug Nut
o 129 ft-lb. (175 Nm)-Dry
− Drive Motor Mounting Bolts
o 177 ft-lbs. (480 Nm) -Dry
− Center Idler Wheel Mounting Bolts
o 105 ft-lbs. (142 Nm) -Dry
Auxiliary Pump
− Make: Haldex-Barnes #180-2061
3
− Displacement: 1.343 in
− Flow: 17.4 gpm (65.9 lpm) @ 2800 rpm (high
idle)
− Relief pressure: 3000 psi (20,684 kPa)
− Cooling/filtering: Auxiliary oil is filtered and
cooled at all times. In Auxiliary mode, the oil is
filtered after the attachment to protect the machine if the attachment motor fails or contaminants are introduced from the quick couplers.
/rev (22 cc/rev)
2-2
Chapter Overview
This chapter contains diagrams for the following
PT-50/60 systems.
• Filtering and cooling system
• Auxiliary circuit system
• Drive loop system
Figure 3-1
PT-50/60 Filtering and Cooling System
Filtering and Cooling System
The filtering and cooling system (Figure 3-1) contains
the following major components.
• Hydraulic reservoir
• Radiator/oil cooler
• Loader valve
3-001
3. System Diagrams
3-1
Auxiliary Circuit System
The auxiliary circuit system (fig. 3-2) contains the
following major components.
• Loader valve
• Pilot control manifold
• Auxiliary gear pump
• Loader control joystick
Figure 3-2
PT-50/60 Auxiliary Circuit System 3-002
3-2
Rubber Track Loader
3. System Diagrams
Self leveling (optional)
Drive Loop System
The drive loop system (fig. 3-3) contains the
following major components.
• Drive motors
• Pilot control manifold
• Drive control joystick
• Tandem pump
Figure 3-3
PT-50/60 Drive Loop System 3-003
3-3
Rubber Track Loader
3. System Diagrams
Input Portion (joystick)
Output Portion (drive motors)
tank
drive motor
brake
(PT-60 2-spd)
case drain
(PT-60 2-spd)
brake
case drain
drive motor
tandem pump
pilot generation
block
tank
Electrical Attachment Outlet
Figure 3-4 PT-50/60 Electrical Attachment Outlet
3-4
Rubber Track Loader
3. System Diagrams
Chapter Overview
This chapter contains an overview of the machine controls and instrumentation. For further information
regarding machine controls, instrumentation or operation, refer to the operation and maintenance manual
for your particular machine. Included here are illustrations of the following controls and instrumentation components and a description of their functions.
• Machine Controls
• Instrument Location and Function
• Switch Location and Function
Machine Controls (fig. 4-1)
There are three primary machine controls: lift arm control (2), drive control (1) and throttle (3).
Lift Arm Control
The lift arm control (2) is a pilot operated joystick that
allows the operator to raise or lower the loader and
dump or curl the quick attach mechanism.
Drive Control
The drive control (1) is also a pilot operated joystick. It
allows the operator to change the direction and speed
of the machine.
Throttle
The hand throttle (3) controls engine rpm.
Instrumentation
The Instruments (Figure 4-2) are positioned in the
overhead dash panel for ease of access and visibility
when seated inside the operator enclosure.
Instruments include the following components.
(1) Fuel Gauge
(2) Tachometer (optional)
(3) Engine Coolant Temp. Gauge (optional)
(4) Hour Meter
(5) Warning Indicator Display
• Engine Oil Pressure Warning Light
• Engine Temperature Warning Light
• Hydraulic Oil Temperature Warning Light
• Battery Voltage Warning Light
NOTICE
If the engine temperature, engine oil pressure or hydraulic oil
temperature lights illuminate or should the eng. coolant temp.
gauge read excessive temperatures during normal machine
operation, shut the machine down immediately (in a safe
location). Diagnose the problem and make any necessary
repairs before resuming normal operation.
NOTICE
If the battery low-voltage light should illuminate during operation, drive the machine to a suitable location and shut the
engine off. Diagnose the problem and make any needed
repairs before resuming operation.
The glow plug operation light illuminates only when the
key switch is turned to engine pre-heat, showing normal operation.
4. Machine Controls and
Instrumentation
4-1
2
3
4-1
1
4-2
1
5 4
2
3
PT-50/60 Switches
The various switches (Figure 4-3) are positioned to
provide good access and visibility. The standard and
optional switches are listed below.
(1) Work lights
(2) Heater fan (optional)
(3) Front wiper (optional)
(4) Beacon light (optional)
(5) Ignition, glow plug (pre-heat)
(6) Auxiliary hydraulics
(7) Bucket Positioning (optional)
(8) Power Quick Attach (optional)
4-2
Rubber Track Loader
4. Machine Controls and Instrumentation
4-3
1 2 3 4 5 6 7 8
5. Operator Enclosure
Disassembly and Assembly
Chapter Overview
This chapter provides disassembly and assembly
procedures for the operator enclosure assembly.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in machine damage, injury or death.
Do not attempt to perform any type of repair or maintenance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for instructions regarding proper machine operation techniques
before operating any Rubber Track Loader.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter
1 (Product Safety) for personal safety information.
Machine Preparation
Accidental machine starting can cause injury or
death to personnel working on a Rubber Track
Loader.
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to performing any service work on a Rubber Track Loader.
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is being worked on.
Operator Enclosure
Disassembly and Assembly
Procedures
Disassembly and assembly procedures are provided
for the following operator enclosure components.
• Light Bar
• Ignition Switch
• Gauges
• Lap Bar Gas Assist Spring
Note: Procedures are provided for only those operator
enclosure components listed above. However, information
for removal and installation of other operator enclosure
components can be obtained from the machine specific
parts manual.
Light Bar Removal and
Installation
The tools required for light bar console removal and
installation are listed in Table 5-1. Use manufacturer
recommended tools whenever possible.
Table 5-1
Required Tools
Combination Wrench
Light Bar Removal
Figure 5-1
1. Loosen the two cap screws that attach the light
bar to the cab frame.
5-1
Rubber Track Loader
5. Operator Enclosure Disassembly and Assembly
Figure 5-2
2. Carefully lower the light bar with the wire harness attached.
Light Bar Installation
Figure 5-5
1. Carefully position the light bar, without pinching
the wiring harness against the cab roof.
Figure 5-3
3. View of light bar interior components. Interior
components are now accessible for servicing.
Figure 5-4
4. View of dome light. If removal is required, simply
insert a lever (blade-type screw driver) at opposite end of switch in pry-pocket, and gently pry
the light assembly out of the light bar.
Figure 5-6
2. Secure the light bar to the cab roof with the two
capscrews
Ignition Switch Removal and
Installation
The tools required for ignition switch removal and
installation are listed in Table 5-2. Use manufacturer-recommended tools whenever possible.
Table 5-2
Required Tools
Combination Wrench
Ignition Switch Removal
1. Lower the light bar. Refer to Chapter 5. Light Bar
Removal procedure.
5-2
Rubber Track Loader
5. Operator Enclosure Disassembly and Assembly
Remove Nut
Figure 5-7
2. Remove the nut that secures the ignition switch
to the dash panel.
Ignition Switch Installation
Figure 5-10
1. Insert the ignition switch from the rear of the
dash panel.
Install Nut
Figure 5-8
3. Pull the ignition switch out from the rear of the
dash panel.
Figure 5-9
4. Unplug the ignition switch connector.
Figure 5-11
2. Install the nut that secures the ignition switch to
the dash panel.
Figure 5-12
3. Plug in the ignition switch connector.
5-3
Rubber Track Loader
5. Operator Enclosure Disassembly and Assembly
4. Install the light bar. Refer to Chapter 5. Light Bar
Installation procedure.
Gauge Removal and Installation
The tools required for gauge removal and installation
are listed in Table 5-3. Use manufacturerrecommended tools whenever possible.
Table 5-3
Required Tools
Combination wrench
Gauge Removal
Figure 5-15
4. Pull the gauge out from the front of the dash
panel.
1. Lower the light bar. Refer to Chapter 5. Light Bar
Removal procedure.
Figure 5-13
2. Disconnect the connector from the gauge.
Gauge Installation
Figure 5-16
1. Insert the gauge from the front of the dash panel.
Figure 5-14
3. Remove the two nuts that secure the gauge to
the retaining bracket.
Figure 5-17
2. Install the two nuts that secure the gauge to the
retaining bracket.
5-4
Rubber Track Loader
)
g
p
)
5. Operator Enclosure Disassembly and Assembly
Remove
Retainin
Cli
Figure 5-18
3. Reconnect the gauge connector.
4. Install the light bar. Refer to Chapter 5. Light Bar
Installation procedure.
Lap Bar Gas Assist Spring
Removal and Installation
The tools required for gas assist spring removal and
installation are listed in Table 5-4. Use manufacturer-recommended tools whenever possible.
Table 5-4
Required Tools
Screwdriver
Lap Bar Gas Assist Spring Removal
Figure 5-20
2. Using a small screwdriver, remove the retaining
clip from each end of the gas assist spring.
Figure 5-21
3. Remove the gas assist spring by pulling both
ends out from the ball joints.
Gas Assist
Spring
Raise Lap Bar
(Shown in Down
Position
Figure 5-19
1. Put the lap bar in the UP position to relieve tension on the lap bar gas assist spring.
Lap Bar Gas Assist Spring Installation
Gas Assist
Spring Location
Figure 5-22
1. Put the lap bar in the UP position to minimize
tension on the lap bar gas assist spring during
installation.
5-5
Raise Lap Bar
(Shown in Down
Position
Rubber Track Loader
g
p
5. Operator Enclosure Disassembly and Assembly
Install Ends on
Ball Joints
Figure 5-23
2. Install the ends of the lap bar gas assist spring
onto the ball joints.
Insert
Retainin
Cli
Figure 5-24
3. Slide the retaining clip on to each end of the gas
assist spring.
5-6
6. Seat & Fuel Sender Disassembly and Assembly
Chapter Overview
This chapter provides disassembly and assembly
procedures for the chassis assembly.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in machine damage, injury or death.
Do not attempt to perform any type of repair or maintenance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for instructions regarding proper machine operation techniques
before operating any Rubber Track Loader.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter
1 (Product Safety) for personal safety information.
Machine Preparation
Accidental machine starting can cause injury or
death to personnel working on a Rubber Track
Loader.
As a precaution, disconnect the battery cables from
the battery terminals, tape the battery clamps and
remove the key from the ignition switch prior to performing any service work on a Rubber Track Loader.
Chassis Disassembly and
Assembly Procedures
Disassembly and assembly procedures are provided
for the following chassis components.
• Seat
• Fuel Sending Unit
• Fuel Sending Unit Hose
• In-Tank Weight
Note: Procedures are provided for only those chassis
components listed above. However, information for removal and installation of other chassis compone nts can be
obtained from the exploded view illustration provided in
the Rubber Track Loader Parts manual.
Seat Removal and Installation
The tools required for seat removal and installation
are listed in Table 6-1. Use manufacturerrecommended tools whenever possible.
Table 6-1
Required Tools
Socket Wrench
Seat Removal
Place a “Do Not Operate” tag prominently on the
machine to inform personnel that the machine is being worked on.
Remove Seat Bolts
Figure 6-1
1. Remove the four nuts that fasten the seat
mounts to the frame.
6-1
Rubber Track Loader
6. Chassis Disassembly and Assembly
Unplug
Connector
Figure 6-2
2. Tilt the seat forward and reach behind the seat
to unplug the seat switch wiring harness.
Plug in the Connector
Figure 6-5
2. Tilt the seat forward and reach behind the seat
to plug in the seat switch connector
Note: The machine will not operate unless the seat switch
connector is plugged in.
Figure 6-3
3. Remove the seat. Be careful not to scratch the
control panel or sides of the cab.
Seat Installation
insert Seat Bolts
Figure 6-6
3. Position the seat so the holes in the seat mounts
are aligned with the bolts in the frame. Install the
four seat mount nuts and washers.
Fuel-Sending Unit Removal
and Installation
The tools required for fuel sending unit removal and
installation are listed in Table 6-2. Use manufacturer-recommended tools whenever possible.
Figure 6-4
1. With the seat mounts attached, place the seat in
the cab. Be careful not to scratch the control
panel or sides of the cab.
Table 6-2
Required Tools
Screwdriver
Combination Wrench
Socket Wrench
6-2
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