This is the Terex PT-50/60 service manual for the PT-50 and PT-60 rubber track loaders, powered by the Perkins 404D-22 and 404D-22 T diesel engines. Its 85 pages are organized by machine system, from safety and technical specifications through the hydraulics, undercarriage, and troubleshooting.The manual gives you specifications and torque values for both models, system diagrams for the filtering and cooling, auxiliary, and drive loop circuits, and disassembly and assembly procedures for the operator enclosure, radiator and oil cooler, hydraulic reservoir, hydrostatic and auxiliary pumps, undercarriage, and loader.Maintenance schedules cover engine oil, hydraulic fluid and filters, and the fuel and water separator. A pressure testing chapter walks through checking and adjusting charge pressure, and the troubleshooting section maps common symptoms to their likely causes. It is the workshop reference for keeping a PT-50 or PT-60 track loader working.
What's Inside This Terex PT-50, PT-60 Manual
| System | Pages | Key Topics |
|---|---|---|
| Product Safety | 5-10 | Chapter Overview |
| Technical Specifications | 11-12 | Pt-50 Specifications, Pt-60 Specifications |
| System Diagrams | 13-16 | Chapter Overview, Filtering and Cooling System, Auxiliary Circuit System, Drive Loop System, Electrical Attachment Outlet |
| Machine Controls | 17-18 | Loader Control, Drive Control, Throttle |
| Operator Enclosure | 19-24 | Light Bar, Ignition Switch, Gauges, Lap Bar Gas Assist Spring |
| Seat & Fuel Sender | 25-28 | Seat, Fuel Sending Unit, Fuel Sending Unit Hose, In-Tank Weight |
| Radiator and Oil Cooler | 29-34 | Fan Guard, Radiator/Cooler |
| Hydraulic Reservoir | 35-42 | Filter Element, Filter Assembly, Filler Cap Assembly, Access Cover Assembly, Reservoir Gauge, Suction Screen |
| Loader & Transmission Controls | 43-48 | Chapter Overview, Personal Safety, Machine Preparation, Loader/Transmission Controls Disassembly and Assembly Procedures, Joystick Removal and Installation |
| Hydrostatic & Auxiliary Pump | 49-54 | Auxiliary Gear Pump, Tandem Pump, Pump Drive Coupler |
| Undercarriage (Part 1) | 55-56 | Center Wheels, End Wheels, Sprocket Rollers, Tracks, Outboard Bearings, Drive Sprockets |
| Undercarriage (Part 2) | 57-66 | Center Wheel R&I, End Wheel R&I, Sprocket Roller R&I, Track R&I, Outboard Bearing R&I, Drive Sprocket R&I, Drive Motor R&I, Idler Wheel Hub Service |
| Loader | 67-70 | Lift Cylinders, Tilt Cylinders, Low-Flow Relief Valve |
| Maintenance | 71-76 | Chapter Overview, Maintenance Schedule, Engine Oil (Oil Change Procedures, Specifications), Hydraulic Fluid and Filter (Change Procedures), Fuel/Water Separator |
| Testing Pressure | 77-80 | Chapter Overview, Personal Safety, Machine Preparation, Hydraulic Pressure Adjustment Procedures, Charge Pressure Check, Charge Pressure Adjustment |
| Troubleshooting | 81-84 | Chapter Overview, Personal Safety, Machine Preparation, Preliminary Inspection (Visual Inspection, Troubleshooting Scenarios) |
| Back Cover | 85 | Manufacturer Information, Distributor Information, Contact Details |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| PT-50 Transmission Mounting Bolts | 85 ft-lb. w/Blue Loctite | p. 11 |
| PT-50 Drive Sprocket Drive Teeth Bolts | 88 ft-lb. -Dry | p. 11 |
| Troubleshooting - Machine starts but hydraulics will not operate | Low charge pressure | p. 82 |
| Troubleshooting - Auxiliary flow does not work. Loader works | Auxiliary hydraulic fuse blown | p. 82 |
| Track deflection (maximum) | 0.75" (1.9 cm) | p. 75 |
| Track tension adjustment range | 0.50" (1.3 cm) and 0.75" (1.9 cm) | p. 75 |
| Hydraulic filter change interval | 250 hours | p. 72 |
| PT-60 Center Idler Wheel Mounting Bolts torque | 105 ft-lbs. (142 Nm) -Dry | p. 12 |
| PT-60 Drive Sprocket Drive Teeth Bolts torque | 105 ft-lb. (142 Nm) -Dry | p. 12 |
| PT-50 Drive pumps displacement | 2.349 in³/rev (38.5 cc/rev) | p. 11 |
| PT-50 Drive pumps relief pressure | 5500 psi, 380 bar | p. 11 |
Terex PT-50, PT-60 Common Problems This Manual Covers
No drive or weak drive under load
A machine that will not move or has very weak drive usually points to the hydrostatic circuit: pump or motor wear, lost charge pressure, or internal leakage. The hydrostatic and auxiliary pump section covers the tandem pump, auxiliary gear pump, and drive coupler.
Manual Section: Hydrostatic and Auxiliary Pump p. 49Loader lifts or curls slowly
Slow, intermittent, or weak loader action comes from pump wear, low fluid, or cylinder leakage. The loader section covers the lift and tilt cylinders and the low flow relief valve so the fault can be isolated.
Manual Section: Loader p. 67Engine stalls or loses power at work
A Perkins engine that stalls, runs rough, or loses power under load is often starved by a restricted fuel path or water in the fuel. The maintenance section covers the fuel and water separator, engine oil, and the service schedule.
Manual Section: Maintenance p. 71Tracks derail or machine pulls to one side
Rubber tracks that come off, bind, or make the machine pull are typically a tension problem or worn undercarriage. The undercarriage section covers the center and end wheels, sprocket rollers, tracks, and drive sprockets.
Manual Section: Undercarriage p. 55Hydraulic oil overheats
A hot oil light or a machine that slows after extended use often means restricted cooling airflow or a dirty cooler. The radiator and oil cooler section covers the fan guard and radiator or cooler removal so the cooling path can be cleared.
Manual Section: Radiator and Oil Cooler p. 29Low hydraulic pressure symptoms
Sluggish or missing hydraulic functions can be confirmed by measuring pressure rather than guessing. The pressure testing section walks through the hydraulic pressure adjustment procedures and the charge pressure check and adjustment.
Manual Section: Testing Pressure p. 77Frequently Asked Questions
Which machines does this manual cover?
It covers the Terex PT-50 and PT-60 rubber track loaders, which use the Perkins 404D-22 and 404D-22 T diesel engines. The machines were produced from 2004 to 2010.
Does it include torque specifications?
Yes. The technical specifications section lists torque values for both models, such as the transmission mounting bolts at 85 ft-lb and the end wheel axle retaining nut at 300 ft-lb. p. 11
What are the service intervals?
The maintenance section lists a 250 hour interval for engine oil and the hydraulic filter, and a 500 hour interval for the hydraulic fluid, along with the fuel and water separator service. p. 71
Is this Service Manual a digital download?
An 85-page service manual in searchable PDF format, available the moment your checkout completes. Open it on a computer, tablet, or phone, with no shipping wait.
Am I able to print pages from this manual?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
Can I find wiring schematics in this Terex PT-50/60 manual?
Yes. The Terex PT-50/60 Service Manual includes an electrical wiring diagram covering the hydraulic and drive system circuits, as well as the electrical attachment outlet.
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