Caterpillar® Product Information

Feature Comparison
June 2005

Caterpillar ® 428E
Backhoe Loader vs
Terex 860 SX & Elite
Backhoe Loaders

®
For Dealer Sales Personnel
Summary
This document is designed to compare some of the features of the
Caterpillar 428E backhoe loader against those of the Terex 860 SX
& Elite. It is intended as a tool to be used by the Dealer when
selling against Terex, highlighting the important Caterpillar design
advantages and how they provide a solution to the wants and needs
of the increasingly demanding backhoe loader customer. The
document also highlights perceived deficiencies of the Terex 860
backhoe loader.

Chassis 3-7
■ Stabilisers

■ Tool & Battery Storage

■ Hydraulic Tank

■ Electrical System

■ Boom & Swing Transport Locks

Powertrain & Hydraulics 8 - 10

■ Engine

■ Hydraulic System

■ Wheel & Tyre Options

Loader 11 - 13
■ Lift Arms & Bucket
■ Durability
■ Visibility

Backhoe 14 - 19
■ Excavator Style Boom

■ Extendible Stick

■ Bucket Linkage

■ Hose Routing

■ Durability

■ Visibility

Cab & Operator Environment 20 - 24

■ Operator Station

■ Personal Storage

■ Controls & Operation

■ Security

■ Durability

Serviceability 25 - 28
■ Daily Checks

■ Engine Bay

■ Front Axle & Drive Shaft

■ Stabilizer Wearpads

Performance 29
■ Performance Comparison

Brief Specifications 30

2
 Chassis

Advantage: Tool & Battery Storage

The 428E is designed with large stabilizer feet which can be fitted
with bolt-on reversible two piece street pads to prevent damage to
asphalt surfaces. The stabiliser system also includes built-in lock
valves as standard.

Conclusions:
The stabiliser feet on the Terex are much smaller, which will not
spread the weight of the machine as effectively when working on
soft ground. This means that the machine will sink into the ground
more when working with the backhoe.

The shape of the Terex stabiliser foot prevents street pads from
being reversed to provide maximum component life. The
Caterpillar design is two piece and symmetrical, allowing the
operator to turn the pads or replace the section with the most wear.

The lock valve system on the 428E is incorporated into the design
and steel tubes are used throughout. The 860 system has bolt on
additional valves, which are only fitted in territories where they are
required by law.

The clean-out slot in the stabiliser leg is now included on all E-

series machines. This allows the operator to easily clean out dirt an
debris which can accumulate up inside the inner leg. The JCB leg
does not have this feature, which can lead to the trapped material
becoming packing in hard and causing damage to the stabiliser
cylinders.

428E 860

3
Chassis

Stabilisers Advantage:
The 428E has a large combined tool storage and battery box. It is
easily accessible for the operator. A heavy duty two-battery option
is available.

Conclusions:
Terex have moved the battery from the nose of their machine and
placed it in a compartment on the outside of the hydraulic tank.
There is only room for one battery.

The tool storage is now in the nose of the machine, which can
only be accessed by raising the loader arms and opening the hood.
The tool box is small, difficult to access and taking tools in and out
860 can lead to damage of the oil coolers. It is not very practical.

428E

860

428E 860 860

4
 Chassis

Advantage: Hydraulic Tank

The Hydraulic Tank in the 428E is mounted up inside the loader
tower. The tank on the Terex is a pannier tank mounted on the
LHS of the machine chassis

Conclusions:
The Caterpillar design has the hydraulic tank out of harms way. It
also provides a positive head of oil for the hydraulic pump. The
tank on the Terex is more vulnerable. The sight gauge is exposed
and could be broken by debris thrown up by the front wheel. The
lines into the tank are also exposed underneath and could be
damaged on site. Also, the steps in the hydraulic and fuel tanks are
rigidly mounted and could damage the tanks, if impacted on the
jobsite. By contrast, the E-series step are designed to bend and not
860
damage the tanks, if impacted on site.

860

428E
Chassis

Electrical System Advantage:

Electrical harnesses on the 428E are fully braided for durability
and use connectors sealed against dust and water ingress. All
electrical circuits are colour coded for easy trouble shooting and all
fuses are located neatly in one area. A 120 amp alternator is fitted
to the 428E as standard.

Conclusions:
Harnesses on the Terex are protected by plastic ribbed conduit.
This is not as durable as the fibre braided harnesses on the 428E.
The connectors are the AMP type, which do not offer the same
degree of protection provided by the Deutsch connectors used on
428E the 428E. Also, some of the fuses on the Terex are located in the
Battery compartment, which may be susceptible to dirt and
moisture and overspill oil, when filling the hydraulic tank.

The standard alternator on the 860 is only 75amp, with the option
to upgrade to 100amp. This may result in insufficient charging of
the battery when working in winter with all the worklights and cab
heater turned on.

428E

860 860

6
 Chassis

Advantage: Boom & Swing Transport Locks

The 428E has a separate lock systems for the boom and the swing.
The Terex 860 has a combined system.

Conclusions:
The boom and swing lock systems on the 428E can be controlled
independently by the operator. The boom lock cab be engaged and
dis-engaged at any swing angle. The swing lock pin is retained on
the slide frame by a lanyard, to prevent to being misplaced.

The combined system on the Terex can only be activated in on of

three positions: full swing left, full swing right or in-line with the
machine axis. This prevents the operator from safely locking the
boom up, unless in a predetermined position.

860

428E

7
Power Train & Hydraulics

Engine Advantage:
The 428E is available with a choice of engine: a 67 kW (Net)
engine is fitted as standard, while a 73 kW (Net) engine is
available as an option.

Conclusions:
The choice of engine option on the 428E allows the customer to
specify the machine to more exacting requirements. The 860 has
only one engine option, a 70.3 kW (Net) Turbocharged unit. This
results in a machine that will be over powered in some
applications, leading to increased fuel consumption and increased
operating costs, or underpowered in other applications, where the
428E will be more productive due to the higher Net power of the
top specification engine.

8
 Power Train & Hydraulics

Advantage: Hydraulic System

The hydraulic system on the 428E utilises a load sensing closed
centre system. Hydraulic power is provided by a load sensing,
variable displacement, axial piston pump. The valves are flow
sharing, which makes operating multiple functions much easier.

Conclusions:
The Caterpillar system reacts to the demand that is required by the
implements, adjusting the flow and pressure provided accordingly.
This leads to full hydraulic power at any given engine speed,
allowing delicate operations where precise modulation yet
powerful forces are required. The flow sharing valves ensure that
all services receive the oil they require and results in very smooth
modulation of multiple functions, without any one function
“stalling out”.

The load sensing system on the 428E ensures that hydraulic oil is
not constantly circulating through the hydraulic lines and filters.
This greatly reduces parasitic loads on the engine and leads to
reduced fuel consumption, improved hydraulic filter performance
and longer hydraulic oil life.

The Terex 860 makes use of a closed-centre valve, gear pump and
a complicated un-loader valve, where oil is constantly flowing
through the lines and filters. This has the effect of placing parasitic
losses on the engine and creating excess heat and noise. This will
lead to increased fuel consumption, shorter filter service life and
faster breakdown of the hydraulic oil, reducing the interval
between oil changes. This also means more wear and tear on the
engine and hydraulic pump and higher demands placed on the
cooling system.

Greater hydraulic efficiency is achieved by the Caterpillar

machine, by delivering the required flow and pressure on demand.
This also leads to more controllability, a clear advantage when
excavating in tight areas or close to services.

9
Power Train & Hydraulics

Wheel & Tyre Options Advantage:

The 428E is available with a variety of wheel and tyre options to
suit all ground conditions. 18” front wheels are available as
standard while 20” wheels are available as an option.

Conclusions:
By offering several combinations, customers can specify the 428E
with the right wheel and tyre combination for the job site.

The Terex machine is only available with 20” front wheels and a
choice of 28” or 30” rear wheels. These sizes limit the tyre choice
for the customer. The 20” front tyres also reduce the turning circle
of the machine by as much as 30%, when compared to a machine
with the standard 18” size. By comparison, the 20” option on the
428E does not compromise the turning circle, the result being that
the operator retains full manoeuvrability on site.

In some territories, it is also difficult to obtain replacement rear

tyres for the 860 with 30” rear wheels, as tyres are not a standard
size and as readily available as 26” or 28”, which are used on the
428E.

428E 860

10
 Poer Train & Hydraulics

Advantage: Lift Arms & Buckets

The 428E if fitted with a Parallel Lift Loader as standard.
Maximum bucket capacity is 1.03 m3.

Conclusions:
The Parallel lift loader design removes the need for the operator to
concentrate on bucket angle when lifting and lowering a load. The
system automatically compensates and keeps the bucket angle
constant. This is especially beneficial when working with pallet
forks. The Terex loader has a “kick out” linkage which only
adjusts bucket angle when raising the load. This system does not
operate smoothly and does not provide adjustments at all bucket
angles. When lowering the loader, it is up to the operator to adjust 428E
bucket angle manually.

860

428E 860

11
Loader

Durability Advantage:
The Caterpillar bucket features thicker bucket mounting plates,
and XT3 hoses supply pressure to the cylinders.

Conclusions:
Thicker plates contribute to a greater resistance to bending when
loading the bucket or lifting uneven weights. This contributes to a
more robust, hard wearing bucket.

The XT3 hoses and bolt on tubes throughout, improve

serviceability. Using hoses on the rear of the loader bucket reduces
the risk of leaks due to impact damage from overspill.

The Loader Bucket utilised by the 860 is a JCB copy. This design
uses thinner plates for the bucket sides and attach plates than the
Caterpillar design, which results in a less durable bucket.

428E 860

428E 860

12
 Loader

Advantage: Visibilty
The 428E offers the operator good visibility to the loader bucket.
Four front work lights are available as an option.

Conclusions:
The narrow hood on the 428E is clear of obstructions. This, along
with the divergent lift arms,a large area front windscreen and a
narrow front console results in a clear line of sight to the bucket
for the operator.
428E
On the Terex, visibility is reduced by the single tilt cylinder and
the air inlet bowl protruding from the hood surface. The
Windscreen is also divided by thick steel tubes. All of these restrict
operator visibility to the loader bucket. Visibility at night is also
reduced due to only two front work lights.

Hose routing on the Terex also reduces visibility. The MP bucket

hoses on the RHS of the machine are in the operators eye line to
the bucket and also rest against the cab glass. This will eventually 860
lead to damage on the hoses and the glass surface.

428E

860 428E

860

13
Backhoe

Excavator-Style Boom Advantage:

The 428E utilises the proven Caterpillar excavator-style boom.
Improvements with the E-series includes an excavator style nose
and a combined cylinder mount pin for improved performance.

Conclusions:
The excavator-style boom allows additional clearance when
reaching over obstacles and the ability to dig closer to the machine.
The 860 boom has a very deep and straight profile.This makes it
more difficult to dig over obstacles than with the 428E. This also
makes excavating and dumping close to the truck very difficult, as
is common on road works.

428E

860

14
 Backhoe
Advantage: Extendible Stick
The E-stick on the 428E features an outer-sliding extension, with
serrations for improved clamping incorporated into the design.

Conclusions:
The outer sliding extension keeps the wear pads and running
surfaces clean and away from the material being excavated. On the
Terex, any material being clamped in the bucket is clamped against
the sliding rails of the extension. This can result in damage to the
running surfaces and material being dragging back into the
wearpads. Both conditions will result in an increased wear rate on
the pads and reduced service life.

The serrations on the 428E E-stick also allows the operator to 428E
clamp material without the risk of damage to the stick or the need
for a thumb.

15
Backhoe

Bucket Linkage Advantage:

The 428E has a high rotation linkage which creates 205 degrees of
bucket rotation with a single pin position.The Terex 860 has only
194 degrees, with two pin positions.

A lifting eye is incorporated into the Caterpillar linkage as

standard.

Conclusions:
The high rotation linkage of the 428E allows easy bucket
clamping, longer flat bottom trenches, and deeper vertical trench
end walls. This means there is less machine repositioning with the
Cat, and no need to adjust the linkage for ‘speed’ or ‘power’
options.

Maximum bucket breakout on the Terex is only available with the

bucket pin in the “Power” position. In this case, the bucket rotation
is reduced.

The lifting eye on the 860 is a bolt on option. Any load lifted by
the machine, must be carried by the four bolts. These can come
loose and damaged during normal operation on the jobsite.

428E 860

16
 Backhoe
Advantage: Hose Routing
The hoses for the Backhoe on the 428E are routed neatly around
the slide frame and swing casting and onto the boom. Hoses are
protected where required with Kevlar sleeves.

The Hammer line quick disconnects on the 428E are mounted on

the side of the stick and are easily accessible.

Conclusions:
Hoses on the Terex 860 are bunched together in the slide frame
and swing casting. They are held in place with tie-wraps, which
will allow the hoses to rub together and wear through, leading to
leaks or hose bursts when operating.

The quick disconnects on the 860 are hidden away inside the side
plates of the stick. These are awkward to get to when connecting 860
a worktool, e.g.. Hammer, and can get caught up with the point
of the hammer, when folded into the transport position.

860

860

17
Backhoe

Durability Advantage:
The backhoe on the 428E has been designed with durability and
serviceability in mind.

The 428E has four serviceable lock cylinders on the slide frame to
provide a solid connection between the main chassis and the
backhoe. These can be replaced in minutes, should a leak occur.

Bushes are used on all pins in the swing castings

Conclusions:
The Terex 860 has a cast slide frame with the lock cylinders are
860 machined into it. As a result, they are not easily replaceable,
should they become damaged. Any repair to be carried out with
also require the full backhoe to be removed from the frame.

The Terex swing casting has no bushings on the swing cylinder

and boom foot pins. This means that when the bores wear, the
casting needs to undergo an expensive re-boring operation. By
comparison, on the 428E, the casting has bushings which can be
easily replaced when worn.

The E-stick on the 860 has smaller wearpads and no side wearpads
at all at the rear on the extension. The only rear pads run on the
inside and the outside on the top of the stick, which will eventually
wear the paint away and the surface will rust. Also, the bolt torque
on the wearpad bolts on the Terex must be checked regularly. This
is detailed by a decal on the stick. Is there a torque wrench
860 provided with the machine?

428E
860

18
 Backhoe

Advantage: Visibility
The 428E boasts superior visibility to the backhoe bucket through
large fully opening windows. Four Rear worklights are available
for working at night.

Conclusions:
The 428E boom is of a narrow fabricated design which, ensures
great visibility to the bucket throughout the operating range.

Visibility is further aided through the use of large windows, both at

the rear and on the sides of the cab. Tall side windows allow the
operator to see the area immediately adjacent to the machine.
Visibility in this area is hampered on the Terex due to shorter side
windows and wide rear fenders. 428E

Rear visibility in the Terex is poor. The rear window opening is

small and there is a lower section which cannot be removed and a
step down in to the back of the cab. Both of these limit the
operators vision when working close to the machine. Visibility is
further hampered by thick C-posts in the cab structure, the rear
wiper motor when the window is closed and the extreme curve on
the side windows. Some operators liken this to “looking through a
428E
bottle” when working in the rain.

On the 428E, two of the rear worklights are positioned on the side
of the cab. This allows the operator to see clearly thought the full
swing range, when working at night. The lights on the Terex do not
have as much side adjustment, restricting operating in the dark.

428E

860

860 860

19
Cab & Operator Environment

Operator Station Advantage:

The 428E has a large spacious cab, with wide opening doors and
windows. This, along with an Air Suspension Seat as standard and
excellent ventilation makes the Caterpillar cab a comfortable work
environment

Conclusions:
The Terex has a smaller cab then the Caterpillar, giving the
operator a feeling of being squeezed in while working. There is not
much room when spinning the seat to the backhoe working
position. Smaller rear view mirrors, extremely curved side
windows and large cab C-posts further limit the operators ability to
see the area around the machine clearly.
428E
Ventilation on the 428E is excellent: all side windows can be
opened, unlike the Terex, where only the door windows can be
opened. The rear side windows are fixed in place.

The one-piece rear window on the Terex is cumbersome to move,

difficult to latch in the open position and also limits operator
headroom, especially when wearing a helmet. When working in
the rain with the window open, the inside out mechanism allows
the inside of the window to fill up with rain water. This is then
discharged all over the operator when closing the window.

428E

860 860 860

20
 Cab & Operator Environment
Advantage: Personal Storage
The 428E cab provides ample space for the operator to store
personal possessions whilst at work.

Conclusions:
The Caterpillar machine offers lockable compartments as well as a
flask holder and a number areas for storing loose items.

The Terex cab does not have a lockable compartment of any kind.
It offers limited space for storage. The compact dimensions of the
cab do not permit large storage areas and contribute to an overall
cramped feeling by the operator. The small, difficult to access
toolbox on the machine means that the operator must also use the
cab for storage of large tools, e.g.. Backhoe Quick Coupler Release
bar. 428E

860

860 860

860

428E

21
Cab & Operator Environment

Controls & Operation Advantage:

The machine controls and switches in the 428E cab are laid out in
logical and ergonomic locations. Every switch and lever falls
easily to hand and are clearly labelled.

Conclusions:
The control layout in the Caterpillar cab results in a machine that is
easy to drive. The gauges on the LH panel cover vital machine
systems and provide more information on system health than on
860 the Terex. All the switches on the RH panel are logically placed
and well spaced.

The controls on the Terex are less intuitive to the operator. The
boom lock is next to the park brake and can be confusing to the
operator. The loader lever has a long throws, which contribute to
operator fatigue and can interfere with the operators leg when
selecting bucket rack back. The stabiliser levers are located on the
LHS of the cab, forcing the operator to lean around both sides of
the seat, when setting the machine up for Backhoe work.
860
By contrast, the stabiliser controls on the 428E are on the RHS of
the cab, just rearwards of the Loader lever and next to the boom
lock. This reduces set-up time and stops the operator from
constantly spinning in the seat.

860

428E

860

22
 Cab & Operator Environment
Advantage: Security
The 428E has an optional built-in vandal guard and optional
Machine Security System (MSS). The MSS system is compliant to
UK PTAG requirements and can provide a reduction in insurance
premiums.

All windows are secure and not accessible from the outside.

Conclusions:
The vandal guard in the 428E cab is incorporated into the design of
the console and the cover stows away neatly. The optional MSS
system operates via a separate key fob and prevents the machine
from being started and stolen. 428E
Window catches on the Terex are flimsy and can easily be forced
from the outside. Also, the door window caches are secured from
the outside with Phillips head screws. These can easily be taken
out with a screwdriver, allowing the catch to fall off inside and
grant easy access to the cab.

428E

860 860

23
Cab & Operator Environment

Durability Advantage:
The 428E has a cab designed with durability in mind. Electrical
switches are high quality, sealed and easy to read. Window latches
provide positive engagement. Plastics are scratch resistant and easy
to clean. Overall, the cab gives a strong feeling of quality.

Conclusions:
The Terex cab lacks the attention to detail found on the 428E. Side
window hold open catches are the plug-in type and require the
operator to exit the cab to close them. Electrical switches are small,
difficult to read and do not respond positively when pressed. The
Forward – Reverse selector stalk again seems flimsy in design and
does not respond as positively as that used on the 428E. Also, the
428E
gauges on the Terex are encased behind a clear plastic screen. This
can easily be scratched when cleaning, reducing the ability to read
them clearly.

860

428E

860

860 860

24
 Serviceability
Advantage: Daily Checks
All fluid levels and fill points are easy to access underneath the
hood on the 428D. All daily fluid servicing is on the left hand side
of the machine, and all filters are mounted vertically to avoid spills
and contamination.

Conclusions:
The fully opening hood on the 428E provides excellent access to
the engine bay. All fluid check and fill points are easily accessible
and colour coded, to help the operator identify the correct system.
428E
On the Terex, access to oil level check points is difficult without
first raising the loader arms. This means starting the engine, then
waiting for the oil levels to settle again to make the reading
accurate. Adding oil is impossible without first raising the arms.

The Terex transmission oil check and fill point is through a small
diameter tube (22 mm). This makes it difficult and slow to fill the
transmission oil.
860
When checking the 860 over, the operator must access both sides
of the engine bay. For example, the engine coolant bottle is on the
engine RHS. Compare this to the 428E, were all checks can be
made on the same side of the engine. Also, the fuel tank on the
Terex is on the RHS, again meaning the operator must switch sides
of the machine to complete daily checks.

860

428E 428E 860

25
Serviceability

Engine Bay Advantage:

The 428E has an accessible, clear engine bay and is equipped with
a standard fine mesh fan guard.

Conclusions:
The 428E operator can be assured that Caterpillar have safety in
mind. The engine bay on the Terex appears cluttered and has an
unguarded fan which poses a significant safety risk. Access is
awkward as the loader arms must be raised and supported. The air
pre-cleaner on the Terex also blows dust into the engine bay,
whereas the Caterpillar system has Automatic Dust Ejection and
channels it out through the exhaust.
860
On the 428E, the fuel and water separator filers have been
combined. This has lead to a 40% reduction in servicing costs, as
there is now only one filter to replace. On the Terex, there are two
filters and the water separator does not drain directly onto the
floor, resulting in the need to clean the engine, once the drain is
completed.

428E

428E

428E 860

26
 Serviceability
Advantage: Front Axle & Driveshafts
The 428E has sealed bearings and grease free king pins on the
front axle. The machine also has sealed for life driveshaft bearings.

Conclusions:
The front axle and driveshaft on the Caterpillar BHL are
maintenance free. The cuts down on the time the operator needs to
spend on daily greasing.

The Terex front axle requires regular greasing; at the main pivot
pin, the driveshaft and axle Universal joints and the axle king pins.
This means the operator must crawl under the machine regularly,
all year round, to perform this maintenance. 428E

428E

860 860

860 860

27
Servicability

Stabiliser Wearpads Advantage:

The 428E stabiliser leg wearpads have positive screw adjustment
that takes the operator only minutes to complete.

Conclusions:
The adjustment system on the 428E used a standard bolt and
locknut. Free play can be adjusted out in minutes, providing a
stable machine for backhoe operations.

To adjust the Terex, the inner leg needs to be removed and

new/thicker pads inserted. This adjustment cannot be performed in
the field and required the machine to go back to the workshop. It is
also very time consuming for the mechanic.

428E 860

28
 Performance

Backhoe Performance Performance Comparison

The 428E and Terex 860 have almost identical bucket breakout
forces. However, the Terex has to use the “Power” pin position on
the linkage to achieve this performance and this sacrifices bucket
rotation angle, by around 18%

The 428E has 18% lower stick breakout force than the 860.

The 860 can dig a 610mm wide flat bottom trench (to SAE
standards) 184mm deeper than the 428E.

Backhoe Performance
The 428E has 5% higher loader breakout force than the 860.

The 428E has 12% lower loader lift capacity than the 860.
Performance

Performance Comparison
Caterpillar 428E Terex 860
General
Net Power Std:67kW, Opt 73kW 70.3kW

Hydraulics
Pump type Axial piston Twin gear pump
Max Flow 125 l/min Main Pump: 80 l/min
Second Pump: 80 l/min
System Pressure 227 bar 225 bar

Backhoe
Breakout (Bucket) 51.1 kN 51.6 kN (Pin in “power” hole)
Breakout (Stick) 31.8 kN (Ret) 38.7 kN (Ret)
Max Dig Depth (SAE 2ft) 4248 mm (Ret) 4422 mm

Loader (MP Bucket w/forks) (MP Bucket w/forks)

Breakout 54.3kN 51.8 kN
Max Dump Height 2668mm 2662 mm
Hinge Pin Height 3340mm 3583 mm
Lift Cap to Max Height 3142kg 3593 kg
Type Parallel Lift Single Tilt

30
The information contained herein is intended for circulation only to Caterpillar and dealer employees whose duties require knowledge of such reports and is
intended exclusively for their information and training. It may contain unverified analysis and facts observed by various Caterpillar or dealer employees. However,
effort has been made to provide reliable results regarding any information comparing Caterpillar built and competitive machines. Effort has been made to use the
latest available spec sheet and other material in the full understanding that these are subject to change without notice. Any reproduction of this release without
the foregoing explanation is prohibited.

® HEKB3335
June 2005
www.CAT.com
© 2005 Caterpillar
31