Mast

erOper
ati
ons
Manual ASV PT100
posi
-track t
racked loader

TrackLoaderPar t
s
6953Covi ngtonHwy
Li
thonia,GA30058
877-857-7209 T
rac
kLo
ade
rpa
rts
.c
om
YourOneSt
opSour
cef
oral
lPar
tsASV
www. TrackLoader
Par
ts.
com
 CONTENTS

California Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Machine Labels and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operating Capacity / Attachment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Switches / Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Machine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
ROPS Canopy Tilt-up Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
WARNING
Read and understand this manual prior to operating, inspecting, or attempting to maintain the Rubber Track Loader.
Performing any of these tasks incorrectly can lead to machine damage, personal injury or even death.

1
CALIFORNIA PROPOSITION 65
California (U.S.A.) state law stipulates that manufacturers of machines operated within its borders must provide a clear warning to
customers regarding exposure to substances commonly associated with the machine that are recognized by the state as harmful.
Terex/ASV complies with this requirement by providing the following information.

CALIFORNIA CALIFORNIA
Proposition 65 Proposition 65
Warning: This product contains lead and Warning: This product contains lead, a
lead compounds, diesel engine exhaust, chemical known to the state of California
and used engine oil, chemicals known to to cause birth defects or other reproduc-
the state of California to cause cancer. tive harm.

2
 INTRODUCTION

At the time of publication, all information,

photographs, and illustrations are techni-
cally correct.

Machine Orientation
Terms like front, rear, left, and right are
used throughout this manual to describe
portions of the machine. They are to be
understood from the perspective of an
operator seated inside the cab.

WARNING
This manual contains the words
Warning, Caution and Note to empha-
size important information. The word
Thank you for purchasing an ASV There are many hazards that can be WARNING identifies personal safety
Rubber Track Loader. With this encountered during operation of an off
related information. The word CAUTION
machine, you will be able to perform highway utility vehicle such as the PT-
tasks faster and more efficiently than 100. With this in mind, it is the responsi- identifies unsafe practices that may
with any other machine its size. bility of each operator to read and fully result in machine damage. The word
understand this manual before attempt- Note: identifies supplementary informa-
The PT-100 is a rugged and agile ing to operate the machine. Machine
machine capable of working on a variety tion which requires special attention.
damage, bodily injury, or even death
of challenging terrains. It is designed to may result if the procedures and precau-
be very safe, but safe operation also tions described in this manual are not
requires caution and attentiveness on followed closely.
the part of the operator.

3
MACHINE SPECIFICATIONS

General Dimensions PT-100 Engine PT-100

Height to top of ROPS: 80 in. / 2023 mm Model: Perkins 1104C-44T
Ground clearance: 14 in. / 356 mm Type: 4-cylinder diesel
Max. lift height, at hinge pin: 125 in. / 3175 mm Displacement: 268 in.3/4.4 liter
Length of undercarriage: 90 in. / 2293 mm Gross HP @ 2300 rpm: 99.5 hp / 74 kW
Machine length, w/out bucket: 117.5 in. / 2985 mm Torque (peak): 304 ft-lb / 412 Nm
Machine length, with bucket: 148 in. / 3760 mm
Machine width: 69 in. / 1753 mm Operating Specifications
Operating capacities:
Track Specifications 35% tip load: 2,660 lb / 1207 kg
Track width: 18 in. / 457 mm 50% tip load: 3,800 lb / 1724 kg
Length of track on ground: 72.5 in. / 1842 mm Travel speed (low/high) max.: 5/10 mph / 8/16 kmh

Machine Weight Auxiliary Hydraulic Pump

Weight without bucket (shipping): 9,200 lb / 4173 kg Low flow, max.: 20 gpm / 76 lpm
Weight with bucket (operating): 10,150 lb / 4604 kg High flow, max.: 38 gpm / 144 lpm
Ground pressure: 3.5 psi / 24 kPa Pressure: 3,300 psi / 22 737 kPa
Ground contact area: 2,610 in.2 / 1.68 m2
Service Refill Capacities
Fuel tank: 26 gal / 98 L
Specifications are subject to change without notice. Hydraulic tank*: 20 gal / 76 L
Engine coolant*: 3.125 gal / 12 L
SAE J818 standards define operating capacities of rubber-tired skid steers (50% tipping
load) and tracked loaders (35% tipping load). There are no standards defining the operat- Engine oil, including filter*: 8.5 qt / 8 L
ing capacity of machines equipped with a suspended undercarriage or machines with rub-
ber tracks. * When replacing or replenishing these lubricants/fluids, it is recommended that you
specify genuine ASV products from your ASV Dealer.

4
 MACHINE LABELS AND DECALS

2040-121
Operating Guidelines
1. Warm engine prior to operating the machine.
2. Carry loads low. Load, unload and turn on level ground.
3. On inclines, travel with the heaviest end of the machine facing uphill.
4. Passengers are not permitted in or on the machine at any time.
5. Never use an attachment as a work platform.
Failure to comply with these instructions may result in machine damage, injury, or death.

Product ID Numbers
The machine PIN is located on the left
side of the firewall, next to the seat
(shown above). Always provide the PIN
when contacting the dealer about parts,
service, warranty or accessories.
Warranty claims will not be processed
unless the PIN number is provided.

5
FIRE PREVENTION

Fire Prevention With the engine off and cool, clean

The PT-100 has components that flammable debris from engine com-
operate at high temperatures. The partment, exhaust system, attach-
main heat sources are the engine and ments and other areas where there
the exhaust system. The electrical may be hot or rotating parts.
system, if damaged or improperly Check battery, fuse box, electrical
maintained, can also be a source of wiring and connections for damage
heat and sparks. Attachments (brush- or looseness.
cutters, mowers etc.) can generate
debris that can cause a fire if improp- Check fuel lines and hoses for
erly maintained. leaks or damage. Never allow open
flame near fuel or fuel system com-
Flammable debris (leaves, straw, ponents.
brush cutting debris, etc.) must be
removed from these high temperature Check hydraulic lines, hoses and
areas regularly. If flammable debris is fittings for damage or leaking fluid.
allowed to accumulate, a fire may Never use bare hands to check for
result posing a risk to the operator leaks. Pressurized fluid can pene-
and the machine. A fire can cause trate skin and cause injury or even
machine damage, severe injury, or death.
even death. Inspect for and remove
flammable debris often to avoid a fire. WARNING
Listed are a set of precautionary Do not use ether or any other aerosol
tasks that should be performed daily type starting fluid to start the engine.
or more often as needed. Repair or
Always stop the engine and allow the
replace worn/damaged components machine to cool before adding fuel. No
as required to ensure safe operation. smoking.
6
 OPERATING CAPACITY / ATTACHMENT PRECAUTIONS

Operating Capacity Exceeding the specified GVW rating will or cracking in both the host machine
The operating capacity refers to how void the warranty (see page 2). and the head itself. Vibration can also
much additional weight can be added to cause hydraulic component failure in
the standard dirt bucket's center of grav-
Mulching Type Forestry Brush items such as relief valves. Although
ity. The recommended operating capaci- Cutters these mulching type heads work
ties for these machines are listed on When using non-ASV brush cutters, extremely well on ASV machines with
page 4. The heavier the attachment, the especially mulching type forestry brush high flow hydraulics, educate yourself
less the operating capacity will be. cutters, there are many things that on the increased maintenance and
Moving the load farther from the machine should be considered. operating costs before purchasing this
will significantly reduce the operating type of attachment. ASV recommends
Mulching type brush cutters are heav- considering a rotary type brush cutter
capacity.
ier, vibrate more, and generate more as an alternative.
Note: SAE J818 standards define oper- dust and debris than rotary brush cut-
ating capacities of rubber-tired skid ters. The increased amount of dust
and debris particles can plug coolers,
CAUTION
steers (50% tipping load) and tracked
loaders (35% tipping load). There are no radiators, and air cleaners much faster, Machine damage and failure caused by uti-
standards defining the operating capacity causing overheating or even engine lizing mulching type brush cutters will not
of machines equipped with a suspended failure if left unattended. The debris is be covered by ASV warranty.
undercarriage or machines with rubber also introduced into many high temper-
tracks. ature areas and can become a fire
hazard. Debris should be cleaned fre-
quently from these areas.
Gross Vehicle Weight
The GVW (Gross Vehicle Weight) of the Mulching type brush cutters can also
PT-100 should not exceed 14,500 lbs. become unbalanced due to worn or
This weight does not include an operator, damaged blades, causing vibration. If
but does include material being carried. the attachment is operated in this con-
dition, it can cause metal fatigue and

7
MACHINE CONTROLS

Loader and Drive Controls Throttle To Increase RPM, move the lever (C)
The PT-100 has two hydraulic pilot joy- The throttle C, controls engine rpm. toward the front of the machine.
stick controls. These two joysticks are When performing delicate work that To decrease RPM, move the lever (C)
used to control machine speed, direc- requires precise movements, use a
toward the rear of the machine.
tion, lift arms and bucket or attachment. lower engine rpm. When more speed,
Joystick A is used to control the lift arms, horsepower or flow is required, use a
the bucket and float function. To engage higher engine rpm.
the float position move the joystick all
the way forward with a quick motion, the
joystick will then be held in detent. To
disengage, quickly pull back. Joystick B
controls direction and speed of the
machine.

Control Options
PT-100 machines are available with a
"Case type" control configuration. This
control option uses similar joysticks, but
with a different control pattern to direct
machine function. On these machines, A B
joystick A controls the right track as well
as bucket curl and dump functions.
Joystick B controls the left track, lift arm
up/down functions, and float position.
The float position with this configuration
C
does not have a detent position, and
must be manually held in place to acti-
vate float function.
8
 SWITCHES / INSTRUMENTATION

R S

D E F G H I J K L M N O P Q J

Dash Panel J - Fuel Level Gauge

T U
There are many switches and instru- K - Warning Indicators (3-in-one)
ments involved in the operation of PT L - Hour Meter
machines. Learn the location and func- R - High Range Indicator Light
tion of these items prior to operation. S - Glow Plug Operation Light
V
T - Oil Pressure Warning Light K
Switch Panels
U - Battery Voltage Warning Light
D - Lights, front and rear
V - Hydraulic Oil Temp. Warning Light
E - Heater Fan (optional) CAUTION
F - Front wiper (optional) If the battery voltage warning light (U)
G - Beacon (optional) illuminates, drive the machine to a suit- Should the engine temperature gauge
M - Ignition, glow plug (pre-heat) able location and shut the engine off. read excessive temperatures or
N - Low Flow Auxiliary Hydraulics Diagnose the problem and make needed should the oil pressure or hydraulic oil
O - High Flow Auxiliary Hydraulics repairs before continuing to operate. temperature lights illuminate during
P - Bucket Positioning
normal operation, shut the machine
Q - Power Quick Attach The glow plug operation light (S) will illu-
down immediately. Diagnose the prob-
Instruments minate only when the key switch is
turned to engine pre-heat, showing nor- lem and make needed repairs before
H - Tachometer
mal operation. continuing to operate.
I - Engine Temperature Gauge

9
MACHINE OPERATION

Pre-Start Checklist
Before operating the machine, perform a
pre-operation safety check. Inspect the
machine for any items that may affect
safe operation.
Check to make sure:
1. Engine compartment, chassis and
coolers are clean and free of debris.
2. Windows and lights are clean and
unobstructed.
3. Tracks are in good condition and are
properly tensioned.
A B
4. Fluids are filled to proper levels.
5. Accessory belts are in good condition
and properly tensioned. 1. Enter machine with lift arms all the 6. Run the engine at low idle for 3 to 5
6. Hyd. Hoses and fittings are in good way down. Maintain three points of minutes to warm up the engine.
condition. (no visible signs of wear) contact with the machine (photo A). 7. Set throttle to desired rpm.
7. Battery cables are in good condition 2. Fasten seat belt, and lower lap bar
Note: The parking brake is automatically
and properly fastened. into position.
engaged when the engine is turned off,
8. Joysticks and hyd. auxiliary switches 3. Starting with the throttle in the SLOW
the operator is not in the seat or the lap
are in their neutral positions. position, push the throttle 1/3 the way
bar is raised.
9. Power quick-attach is in locked posi- open.
tion. 4. Turn the ignition key to the left for 6 WARNING
Starting Procedure seconds to pre-heat the engine.
Before starting the engine, perform the While pre-heating, the glow plug Entering or exiting the vehicle under raised
pre-start checklist then proceed with the operation light will illuminate. lift arms could cause serious injury or
5. Turn the ignition key to the right to death. Never allow anyone to be under-
following procedure: neath raised, unsecured lift arms (photo B).
start the engine.
10
 MACHINE OPERATION

WARNING C
Failure to wear the seat belt could lead to
serious injury or death.

CAUTION
Do not crank the engine for more than 20
seconds. Allow the starter to cool for 2 min-
utes before cranking again.

D
WARNING To fasten an attachment, move the
power quick-attach switch to the "unlock"
Do not use aerosol type starting aids such position. Drive up to the attachment and
as ether. Such use could result in an explo- hook the top edge of the quick-attach
sion and personal injury.
into the upper lip of the attachment. Curl
Power Quick Attach the quick-attach all the way back. Move
The power quick-attach switch (C) is the power quick-attach switch to the
equipped with an orange locking device. "lock" position.
This locking device must be disengaged
before the switch can be moved to the
WARNING
unlock position. Only move the switch to Always visually verify that the quick attach
the unlock position when the lift arms are pins are fully extended and that the attach-
all the way down. The machine will not ment is securely fastened.
start unless the power quick-attach is in E
the lock position.

11
MACHINE OPERATION

Operation on Inclines
ASV Rubber Track Loaders are very sta-
WARNING
B ble on inclines. Machine weight is distrib- Failure to follow the instructions on hillside
uted evenly throughout the chassis and operation may result in machine damage,
the suspended undercarriage track sys- severe injury, or even death.
A tem provides excellent traction and
floatation on nearly all surfaces.
CAUTION
Even with these capabilities, caution
should always be exercised while oper- The engines lubrication system requires
Two Speed ating the machine on an incline. Never that the machine be kept below a maximum
The PT-100 is equipped with a two- operate the PT-100 on an incline in operation angle of 24 in order to properly
speed drive system. Low range is best supply the engine with oil. Failure to follow
excess of 18. Do not make sudden
the instructions in on hillside operation may
suited to performing strenuous work or changes in direction, move slowly, and result in engine damage or failure.
running attachments. High range is always carry loads low to maximize
intended mainly for transporting. machine stability.
Whenever the machine is turned off, the
lap bar is raised, or the operator exits When turning on an incline, back down
the seat, the machine automatically the hill while slowly turning until the
returns to low range. To shift between machine is pointed in the desired direc-
high and low ranges, push the button (A) tion. Then proceed forward.
on the front of the right joystick. When
shifting between ranges, slow the
machine to ensure a smooth transition.
The high range indicator (B) illuminates
to confirm high range operation.

12
 MACHINE OPERATION

C D

Auxiliary Hydraulics To activate auxiliary hydraulics: Note: The low flow (C) and high flow (D)
The PT-100 comes standard with a load 1. To engage the low flow hydraulics activation switches have small orange
sense, variable displacement piston intermittently, activate the toggle- locking devices that must be disengaged
pump for auxiliary hydraulics. When the type switches on the right joystick. before the switches can be moved.
low flow is engaged the variable dis- 2. To engage the low flow hydraulics These switches must be in their off (neu-
placement pump displaces 20 gpm, and continuously, activate the low flow tral) positions in order to start the
when the high flow is engaged the pump switch on the dash. engine.
displaces 38 gpm. 3. To engage the high flow hydraulics
continuously activate the high flow
switch on the dash.

13
MACHINE OPERATION

Electric Attachment Control

Attachments are controlled by various A
buttons on the drive and lift-arm control
joysticks. Most attachments are con-
trolled hydraulically but some also
require electrical input for operation. The
snow blower for instance needs both
hydraulic and electric input to function.
The 4 buttons (A) on the left joystick
send electrical current to the receptacle
(B) located on the lift arms. ASV attach-
ments that require electrical input will be
equipped with a matching receptacle to
B
ensure a proper connection to the
machine.
Note: The electrical receptacle is not
necessarily compatible with other
brands, always use ASV approved
attachments to ensure proper function.

14
 MACHINE OPERATION

WARNING
This procedure must be performed by two
people to ensure safety. Never place any
part of your body under unsecured lift arms
as personal injury or death could result!

4. Position the lift arm brace over the

fender brackets as found and install
the retaining pins to secure it there.

Lift Arm Brace 4. Have the assistant place the lift arm
When the lift arms must be left in the brace onto the top side of the cylinder
raised position, install the lift arm brace ram and install the retaining pins to
to ensure your safety. secure it there.
5. Slowly lower the lift arms until they
To install: come to rest on the brace.
1. Remove any attachments from the
machine, then park the machine on To remove:
flat, stable ground. 1. Raise the lift arms until they are clear
2. Have an assistant withdraw the of the brace.
retaining pins from the lift arm brace 2. Have an assistant remove the retain-
on the fender and remove the brace. ing pins and remove the brace.
3. Raise the lift arms to the upper limit to 3. Lower the lift arms to the lower stop.
allow for brace installation.

15
MACHINE MAINTENANCE

Engine Oil and Filter Change

Under normal conditions, the engine oil
should be changed every 500 hours or
one year; which ever comes first.
Engines which are operated under harsh
conditions should have the oil changed
every 250 hours or six months, which
ever comes first. Harsh conditions
include: continuous high load applica-
tions, operation in high temperatures, or
abnormally dusty/dirty conditions.
Engine Oil Specifications:
To change the oil and filter: ASV 10W30 Heavy Duty Engine Oil
1. Run engine for a few minutes to You may also use a quality engine oil
warm the engine oil. substitute with one of the following mini-
2. Remove the drain plug from oil pan. mum specifications:
3. Drain the oil into suitable container.
API CH-4 multigrade oil.
4. Remove engine oil filter, make sure
gasket is also removed. It may be
necessary to remove the rear skid
plate to access the filter.
5. Apply fresh oil to the new filter gasket
and install it onto the filter head.
6. Tighten the filter to the specification
found on the filter label or box.
7. Reinstall drain plug, and refill engine
to capacity with oil as specified.

16
 MACHINE MAINTENANCE

Hydraulic Fluid and Filter Change

The hydraulic fluid should be changed A
every 500 hours, and the hydraulic filter
should be changed every 250 hours.
Hydrostatic components require C
extremely clean oil in order to have a
long service life. Extreme caution must
B
be taken when changing the hydraulic
fluid. Before beginning the procedure,
make sure the machine is in a clean
working environment. Precautions
should be taken to prevent any debris
from entering the hydrostatic system.

1. Remove the middle skid-plate from

the bottom of the machine. Locate
and remove the hydraulic fluid drain D
plug (A), and drain into suitable con- E
tainer.
2. Locate the two hydraulic filters (B,C)
in the rear right-hand side of the
engine compartment.
ASV Premium All Season MV
3. Clean around the filters, and remove.
Hydraulic Oil, or approved hydraulic
4. Replace both filters with ASV
fluid such as Chevron Rykon MV. The
approved filters.
hydraulic fluid level sight gauge is
5. Replace the drain plug and skid-plate
located on the right side of the
and fill the hydraulic reservoir (D) with
machine (E).

17
MACHINE MAINTENANCE

Fuse Panel
The electrical systems in PT machines
are equipped with fuses that help to pro-
Fuel Filter and Water Separator The water separator is designed to keep tect the electrical components from dam-
The fuel filter should be changed every water out of the fuel system. The sepa- age. They are found in the fuse panel
500 hours, or as needed. A plugged fuel rator consists of a filter, a transparent which is located on the right side of the
filter can cause a loss of engine power, bowl and a drain valve. Twist the drain engine compartment.
rough running, or no start. counter clock wise to drain water from
the bowl. Drain filter daily. In the event of an electrical malfunction,
To change filter: check the fuse panel. Remove the fuse
1. Clean the outside of the filter thor- Fuel Specifications related to the component that is not
oughly. In North America, diesel fuel, distilled working properly and inspect it. If it
2. Twist the filter element housing from crude oil, that is identified as No. 1- appears damaged in any way, replace it.
counter clockwise (if looking from the D or No. 2-D in ASTM D975 generally
bottom) and remove. Push down on meet the proper specifications. CAUTION
the element and turn 90 degrees
counter clockwise and remove. Replace fuses with correct amperage fuse
3. Replace with a new element and push only. A fuse with a lower amp rating will fail
more easily whereas one of a higher rating
down and turn 90 degrees clockwise.
may cause electrical system damage.
4. Replace filter element housing.

18
 MACHINE MAINTENANCE

Undercarriages
The undercarriage assemblies typically A
operate in harsh working conditions.
They work in mud, gravel, debris and
various other abrasive materials during
operation. ASV recommends a daily C
inspection of the undercarriage assem-
blies and cleaning if necessary. B

Materials that are particularly sticky or Operation on sand, turf, or other finished To tighten the track:
abrasive like clay, mud, or gravel should surfaces may require less frequent 1. The front of the drive table is secured
be cleaned from the undercarriages cleaning, but daily inspection is still by two bolts (A). If these bolts are at
often to minimize component wear. A advised. the rear of their mounting slots they
pressure washer works well for cleaning can be used to tighten the track in
materials from the undercarriages. At Track Tension their current positions. If they are at
times when a pressure washer is not Proper track tension is necessary for the front of their slots, they need to be
available, use a bar, shovel or similar optimal undercarriage/track performance relocated. There are a series of
device to remove foreign materials. and service life. Running a track that is threaded holes in the main frame rail
too loose can cause the track to mis- to relocate these bolts as necessary.
When cleaning, pay particular attention feed, possibly causing damage. Running 2. Once these bolts are loosened or
to the drive motors/sprockets and the a track that is too tight can cause track relocated, the track may be tightened
front and rear wheels where debris is stretch, bearing failure or other preventa- by turning the turnbuckle (B).
likely to accumulate. If working in scrap ble damage. During the first 50 hours of 3. The bolts (C) do no not need to be
or debris, inspect the undercarriages operation the tracks will "break-in" and loosened. These bolts secure bush-
more often and remove foreign objects may require adjustment. ings that follow the adjustment slots
that may wrap around or lodge them- while the track is being tensioned.
selves between components causing
premature wear and damage.

19
MACHINE MAINTENANCE

Checking Track Tension To check track tension:

The tracks should be tightened only to 1. Drive the machine forward 5 feet.
the point where there is no noticeable 2. Lay a straight edge along the top of
sag in the track. Do not tighten the the track, between the sprocket and
tracks beyond this point. the front idler wheel (A). B
3. With 90 lb. of weight on the mid-point
of the track, the track should have
between 3/4 and 1 of deflection (B).

20
 MACHINE MAINTENANCE

Drive Sprocket Rollers The rollers (C) rotate on hardened steel In order to replace sprocket rollers, the
Rubber Track Loaders use rollers on pins (D), limiting wear to the inside of the drive table (E) must be pivoted out from
each drive tooth of the two drive sprock- rollers. As they wear, the rollers become under the track as required during track
ets. These rollers help minimize friction thinner, but will continue to function and removal. This will allow access to the
between lugs on the track and the perform as long as they are rotating. drive sprocket (F) and provide clearance
sprocket. Sprocket rollers should be for the removal of the retaining bolts (G)
Visually inspect rollers every 50 hours for roller replacement. For specific
treated as wear items that are inspected
and replace any that show signs of instruction regarding roller replacement,
regularly and replaced as needed.
cracking or wear-through. consult your machine specific service
manual.

C Steel Pin

D
Normal Roller Wear
New Roller
at 50% life

WARNING
Make sure the machine is turned off, the
F
key removed, and the battery discon-
E nected before performing this procedure.

21
MACHINE MAINTENANCE

Air Cleaner To clean the primary element:

The air cleaner is one of the most impor- 1. Remove loose dirt from the element
tant maintenance items on the machine. with compressed air or water hose.
Regular inspection and replacement is Compressed air: 100 PSI max. 1/8
necessary to ensure proper performance diameter nozzle at least 2 away from
and to prolong engine life. Inspect the the filter element.
air cleaner elements daily. If damaged Water: 40 PSI max. without nozzle.
or heavily soiled, clean or replace the
elements. 2. Soak the filter element in a non suds- A
ing detergent solution for at least 15
1. Open the hood, pull the yellow slide minutes moving it gently through the
lock, then twist the cover counter- solution to further clean the element.
clockwise approximately 1/8 turn and (Never soak for more than 24 hours.)
pull to remove the cover from the air
cleaner housing. 3. Rinse the filter thoroughly with a gen-
tle stream of water to remove all dirt
2. Remove the primary element (A). The and remaining detergent.
primary element can be cleaned and
reused up to five times, but should be 4. Allow the filter to dry completely
changed at least once a year. B
before reinstalling it into the machine.

3. Remove the secondary element (B). CAUTION

The secondary element is not service-
CAUTION
able or washable. The secondary ele- Do not use any heat source other than During the engine warranty period, do not
ment should be replaced every three warm air at less than 160 F to dry the filter. clean the filter elements. Instead, replace
cleanings of the primary element. the filter elements when soiled or damaged
to comply with engine warranty require-
ments.

22
 MACHINE MAINTENANCE

Grease Fittings
The illustration below shows the location of grease fittings found on the left side of the machine. An identical set of fit-
tings can be found on the right side of the machine. All fittings should be lubricated daily, prior to operation.

23
MACHINE MAINTENANCE

Radiator/oil cooler cleaning Note: Make sure water nozzle is at least

The radiator and oil cooler must be clean 12 (8 for air) from the cooler and that
to ensure proper operation. Engine and the spray is directed straight through the
hydraulic system overheating, damage cooler or the cooling fins may be dam-
and even failure can result if the radia- aged (bent over) which will decrease
tor/oil cooler is not kept clean. A pres- cooling performance.
sure washer or compressed air nozzle
work well to blow debris clear of the fins Chassis and engine cleaning
Periodic cleaning of the chassis area A
in the oil cooler and radiator.
beneath the cab and engine compart-
Note: If hydraulic oil or engine coolant ment are also necessary to maintain
temperature lights illuminate during oper- safe operation. Clean as necessary.
ation, clean coolers more often. (fig. C)

Note: In brush cutting applications check 1. Remove the belly pans on the
and clean the coolers and chassis often underside of the machine.
to avoid overheating and prevent fires.
2. Raise the hood at the rear of the
To clean radiator and oil cooler: machine. B
1. Make sure the engine is off, and 3. Pressure wash any debris from the
cool during radiator/oil cooler engine compartment and chassis
cleaning procedure. area out through the lower opening.
2. Thoroughly clean radiator/oil cooler 4. Re-install the belly pans and close
prior to operation. Direct spray the hood to complete the cleaning
forward as shown. (fig. A, B) procedure.

24
 TILT-UP ROPS

Tilt-up ROPS Service Access

The ROPS canopy tilts up for easier
service. The tilt-up canopy features a
gas spring assist and a lock-out brace.

To tilt the canopy: D

1. Remove attachment.
2. Raise the lift arms and secure with lift
arm brace.
3. Remove the four bolts that fasten the
canopy to the frame.
4. Raise the canopy and watch to make
sure the lock-out brace falls into
place.
5. Secure the canopy lock-out brace with Tilt-up ROPS (Forestry Package)
When a machine is equipped with the E
the D-latch pin (D) as shown.
forestry package, there are additional
Note: The lift arms must be raised in steps that must be taken to tilt the cab.
order to tilt the canopy. Perform these steps prior to performing
the ROPS tilting procedure on this page.

1. Remove the air pre-cleaner assembly

(E) from the machine.
2. Remove the two limb risers (F) from
the machine.
F

25
RECOMMENDED FLUIDS AND LUBRICANTS

Fluids and Lubricants The ASV fluid and lubricant product line
When replacing or replenishing the fluids includes:
and lubricants in your PT-100 Rubber
Heavy Duty Engine Oil, 10W30;
Track Loader, you can specify ASV fluids
Premium All Season MV Hydraulic Oil;
and lubricants. This assures the new flu-
Multi-Purpose EP Lithium Grease;
ids and lubricants match those originally
Long-Life 50/50 Antifreeze/Coolant;
installed when your machine left the ASV
Undercarriage Wheel Bearing
factory. ASV fluids and lubricants were
Lubricant.
developed for, tested and approved by
ASV to assure optimum life and perform-
ASV fluids and lubricants are available
ance in all ASV Rubber Track
through your ASV Dealer. If ASV prod-
Equipment, when used as recom-
ucts are not available for some reason,
mended.
use an approved equivalent, as specified
elsewhere in this manual.

26
 SERVICE LOG

Hours Service Performed Notes

27
Terex Construction Americas Brought to you by:
8800 Rostin Road ASVparts.com
5060 Fulton Industrial Blvd
Southaven, MS 38671 Atlanta, GA 30336
(888)-201-6008 877-857-7209

(662)-393-1800
www.terex.com

ASVPT100 OM (1/09)
Copyright 2009 Terex