Yes, the charge pressure on the ASV PT-80 is adjustable. To adjust it, tilt the cab to access the drive pump, remove the charge relief valve, and add or remove shims to increase or decrease the pressure until it is within the specified range of 475 ± 30 psi.

This answer is automatically generated

Jim

January 26, 2025

How do you remove the cab heater blower Asv pt80

Summary of Contents for ASV PT-80

Page 1 Service Manual PT-70/PT-80 Rubber Track Loader • Safety Overview • Technical Specifications • Circuit Diagrams • Maintenance • Controls & Instrumentation • Component Removal & Installation • Hydraulic Component Service • Hydraulic Pressure & Flow Check & Adjustment • Troubleshooting...
Page 3 PT-70/PT-80 Service Manual Printed (1-08)
Page 5: Table Of Contents
Track Removal ..... . . 4-6 Specifications (PT-80) ....2-1 Track Installation .
Page 6 Rubber Track Loader Table of Contents 6. Operator Enclosure Machine Preparation ....8-1 Chapter Overview ..... 6-1 Removal &...
Page 7 Assembly Procedure ....16-12 15” Idler Wheel (PT-80) ....13-1 Auxiliary Pump ..... 16-14 Removal Procedure .
Page 9: Product Safety
The messages are to be understood as: dure, work method or operating technique that is Attention! Your Safety Is Involved! not specifically recommended by ASV, you must satisfy yourself that it is safe for you and others. The information that follows each heading describes...
Page 10: Protective Equipment
Rubber Track Loader 1. Product Safety Protective Equipment Batteries Always wear appropriate protective equipment for Do not smoke when inspecting the battery electrolyte working conditions when working on or around a level. Never disconnect any charging unit circuit or bat- Rubber Track Loader.
Page 11: Repair
ASV jack stands work 13. Relieve hydraulic system pressure by relaxing all well to support the machine while performing hydraulic actuators prior to attempting any maintenance or repair work.
Page 12: Asbestos Information
When replacement parts are required for your machine, jects. use only genuine ASV replacement parts or parts that meet or exceed original specifications including, but not Stay clear of the cutting edges, pinching surfaces or...
Page 13: Machine Label And Decal Examples
Rubber Track Loader 1. Product Safety Machine Label and Decal Examples WARNING 2-Speed Examples of the labels and decals displayed on the (if equipped) machine are shown on this page. Entering & Exiting To engage: Maintain 3-point contact Press the button located with step and hand rails.
Page 15: Technical Specifications
Listed below are common service tools which are iden- tified and utilized in the service procedures described Model: Rexroth 08-351 in this manual. Use tools recommended by ASV when- ever possible to reduce risk of injury and or machine Auxiliary Pump damage during service.
Page 16: Specifications (Pt-70)
Listed below are common service tools which are iden- Pilot Controls (Joysticks) tified and utilized in the service procedures described in this manual. Use tools recommended by ASV when- Model: Rexroth 08-351 ever possible to reduce risk of injury and or machine damage during service.
Page 17: Circuit Diagrams
3. Circuit Diagrams Chapter Overview Hydraulic Charge Circuit This chapter contains diagrams for the following PT- 70/80 circuits: hydraulic charge circuit, hydraulic auxil- iary circuit, hydraulic drive circuit, loader valve, hydraulic pilot generation (solenoid) block and electri- cal attachment outlet. It also contains hose routing information for the control configurations for the drive and lift arm pilot controls.
Page 18: Hydraulic Auxiliary Circuit
Rubber Track Loader 3. Circuit Diagrams Hydraulic Auxiliary Circuit Figure 3-2 PT-70/80 Hydraulic Auxiliary Circuit OIL COOLER TO ATTACHMENT CASE DRAIN Q/C CHECK VALVE TO TANK (80 PSI) TO BUCKET CYL. FLOW TO TANK LOADER CONTROL TO LIFT ARM CYL. TO AUXILIARY Q/C TO LIFT ARM CYL.
Page 19: Hydraulic Drive Circuit
Rubber Track Loader 3. Circuit Diagrams Hydraulic Drive Circuit Figure 3-3 PT-70/80 Hydraulic Drive Circuit DRIVE PRESSURE RELIEF VALVES (4) 5500 PSI DRIVE CONTROL DRIVE PUMP DRIVE MOTOR DRIVE MOTOR CASE DRAIN TO COOLER TANK BRAKE 2-SPEED SHIFT (PT-80)
Page 20: Lift Arm Control Valve
Rubber Track Loader 3. Circuit Diagrams Lift Arm Control Valve Figure 3-4 PT-70/80 Lift Arm Control Valve ELIEF ALVE ETTINGS (B3) 3307 PSI (A3) 3307 PSI (B2) 3147 PSI (A2) 3669 PSI (A1) Anti-Cavitation (B1) 3640 PSI Check Valve...
Page 21: Hydraulic Pilot Generation Solenoid Block
Rubber Track Loader 3. Circuit Diagrams Hydraulic Pilot Generation Block Figure 3-5 PT-70/80 Hyd. Pilot Generation Block...
Page 22: Electrical Attachment Outlet
Rubber Track Loader 3. Circuit Diagrams Electrical Attachment Outlet Figure 3-6 PT-70/80 Electrical Attachment Outlet...
Page 23: Drive Control (Line Routing)
Rubber Track Loader 3. Circuit Diagrams Drive Control (line routing) Figure 3-7 PT-70/80 Standard Drive Control...
Page 24: Lift Arm Control (Line Routing)
Rubber Track Loader 3. Circuit Diagrams Lift Arm Control (line routing) Figure 3-8 PT-70/80 Lift Arm Control...
Page 25: Maintenance
4. Maintenance Chapter Overview Lift Arm Brace This chapter provides information on general mainte- The lift arm brace (A) is intended to keep service per- nance procedures for the PT-70/80. If there is an issue sonnel safe when it is necessary to work on a machine that requires troubleshooting, refer to Chapter 18, with the lift arms in the raised position.
Page 26: Tilt-Up Cab
4. Lower the cab completely and then fasten it to the sure it remains stable until it has reached sufficient chassis with the two bolts removed previously. height to install an ASV jack stand beneath the machine. (fig. 4-4) 6. Slide the jack stand into place making sure it is...
Page 27: Grease Fittings
Undercarriages The undercarriage assemblies in Rubber Track Loaders typically operate in harsh working conditions. They work in mud, gravel, debris and various other abrasive materials during operation. ASV recommends a daily inspection of the undercarriage assemblies and cleaning if necessary.
Page 28: Track Tension
Rubber Track Loader 4. Maintenance Track Tension (PT-70/80) Straight-Edge Proper track tension must be maintained for optimal performance and track/undercarriage life. Running a track that is too loose may cause the track to misfeed possibly causing damage to the track and or undercar- riage components.
Page 29: Drive Sprocket Rollers
Note: You may need to pry or lift the track upwards with a hoist above the drive sprocket to provide clear- ASV rubber track loaders utilize rollers on the drive ance for removal. sprockets to drive the track. These rollers help mini- 7.
Page 30: Track Removal
• ASV approved jack stands (2) • Spray lubricant • Shop vac or Pressure washer Note: The PT-80 style undercarriage is depicted in this procedure. The PT-70 undercarriage is very similar, however it has only one row of stationary inner and outer idler wheels.
Page 31 4. Maintenance 4-19 4-16 6. Remove the outer scraper plate from the suspen sion rail. (PT-80 only/fig. 4-17) 7. Remove the bolts securing the inner wheel to the hub, then remove the wheel. (PT-80 only/fig. 4-18, 4-19) 8. Use a pry bar to peel the track over the inner wheel(s) toward the outside of the machine.
Page 32: Track Installation
Rubber Track Loader 4. Maintenance Track Installation 1. Slide the track over the drive sprocket at the rear of the machine. (fig. 4-23, 4-24) 2. Slide the front of the track into position for installa tion. (fig. 4-25) 3. Lubricate the inner front wheel(s) and the inside of the front portion of the track with a spray lubricant.
Page 33 (fig. 4-31) 10. Install the scraper onto the suspension rail and tighten the bolts to secure it in place. (PT-80 only/fig. 4-32) 4-31 11. Install the outer idler wheel and secure it in place with the mounting bolts.
Page 34: Air Cleaner
Rubber Track Loader 4. Maintenance Air Cleaner The PT 70/80 are equipped with two air filter elements to remove contaminants from the air used for combus- tion. Regular inspection and replacement is necessary to ensure proper performance and to prolong engine life.
Page 35: Fuel Filter
Do not use any heat source other than warm air at less than 160°F to dry the filter. Do not clean air filter elements while engine war- ranty is in effect. During the warranty period, ASV recommends replacing air filter elements instead 4-40 of cleaning them.
Page 36: Accessory Belt Tension
Rubber Track Loader 4. Maintenance Accessory Belt Tension Drive belts typically stretch and wear during their serv- ice life. The fan and A/C belts should be checked for tension, condition and presence daily prior to operating your machine. To check fan or A/C belt tension: 1.
Page 37: Fan Belt Removal/Installation
Rubber Track Loader 4. Maintenance Fan Belt Removal & Installation Pry-bar To remove the fan belt: 1. Follow steps 1 and 2 of the belt adjustment proce dure. 2. Once loose, pivot the alternator towards the engine to increase slack. Bolt 3.
Page 38: Engine Oil/Filter Change
4. Maintenance Engine Oil/Filter Change Regular oil changes are necessary to maintain a strong running engine. ASV recommends a normal oil change interval of 250 hours or every six months. This recommendation has been made to help ensure proper lubrication during operation and to prolong engine life under typical operating conditions.
Page 39: Engine Oil Specifications
Rubber Track Loader 4. Maintenance 4-51 10. Remove the oil filler cap and fill the engine crankcase with ASV 10W-30 Heavy Duty Engine Oil (capacity: 9 U.S. quarts including filter). (fig. 4- 11. Install the oil filler cap. Full 12. Perform a visual inspection to make sure the drain plug, filter and oil filler cap are in place and tight.
Page 40: Hydraulic Fluid/Filter Change
8. Install the hydraulic system drain plug and tighten. 9. Remove the hydraulic reservoir filler cap (black) and fill the hydraulic system with ASV Premium All 4-57 Season MV Hydraulic Oil or equivalent until the full mark on the hydraulic fluid sight gauge has been reached (approx.
Page 41: Radiator/Oil Cooler (Cleaning)
Rubber Track Loader 4. Maintenance Radiator/Oil Cooler The Radiator and Oil Cooler must be kept clean to ensure proper operation. Engine and hydraulic system overheating, damage and even failure can result if the radiator/oil cooler is not kept clean. A pressure washer or compressed air nozzle work well to blow debris clear of the fins in the oil cooler and radiator.
Page 42: Case Drain Filter
Rubber Track Loader 4. Maintenance 4-62 4-63 Case Drain Filter Fuse Panel The PT machines are also equipped with a filter in the The electrical systems in the PT machines are auxiliary circuit case drain line. It protects the main equipped with fuses that protect the electrical compo- hydraulic system in the event of catastrophic failure in nents from damage.
Page 43 Rubber Track Loader 4. Maintenance Maintenance Service Service Interval Notes Item required Capacity Grease fittings Lubricate Daily Grease often. Adjust levels as Fluid levels Check Daily necessary. Fan-A/C belt Adjust tension as Check Daily tension necessary. Fan-A/C belt Replace as a pair if Inspect Daily condition...
Page 44 4-20...
Page 45: Machine Controls And Instrumentation
5. Machine Controls and Instrumentation Chapter Overview Instrumentation This chapter contains an overview of the machine con- The Instruments (Figure 5-2) are positioned in the lap trols and instrumentation. For further information bar for good visibility and when seated inside the oper- regarding machine controls, instrumentation or opera- ator enclosure.
Page 46: Switches
Rubber Track Loader 5. Machine Controls and Instrumentation Switches The various switches (Figure 5-3, 5-4, 5-5) are posi- tioned to provide good access and visibility. The stan- dard and optional switches are listed below. (1) Ignition (2) Hour Meter (3) Beacon (optional) (4) Wiper (optional) (5) Heater Fan (optional)
Page 47: Operator Enclosure
However, exploded parts dia- Do not attempt to perform any type of repair or mainte- grams exist in the PT-70 or PT-80 Parts manuals to serve as nance on a Rubber Track Loader until you have read and visual aids in the removal or installation of other operator fully understood the information in this manual.
Page 48: Removal Procedure
Rubber Track Loader 6. Operator Enclosure Pillar Switch Panels (MP-1 & MP-2) Removal (RT or LT panel) Required Tools Open or Box end Wrenches 1. Remove the 3 screws/bolts securing the pillar switch panel to the cab enclosure. (fig. 6-3) 4.
Page 49: Removal Procedure
Rubber Track Loader 6. Operator Enclosure Gauge Clusters (MP-2) Removal Required Tools Phillips Type Screwdriver Combination/Socket Wrench 6-12 3. If gauges must be removed, remove the nuts securing the backing plate to the gauge. (fig. 6-12) 6-13 6-10 1. Remove the mounting screws securing the gauge mounting plate to the lap bar gauge pod, then raise the plate to expose the wire harness connec- tors.
Page 50: Side Panels/Gauges (Mp-1)
Rubber Track Loader 6. Operator Enclosure Side Panels/Gauges (MP-1) Removal Required Tools Phillips Type Screwdriver Combination/Socket Wrenches 6-18 4. Remove the screws securing the rear side panel section to the cab enclosure. (fig. 6-18) 6-15 1. Remove the screws securing the forward side panel to the operator enclosure.
Page 51: Seat
Rubber Track Loader 6. Operator Enclosure Seat (MP-1 & MP-2) Removal Required Tools Combination/Socket Wrench 6-24 5. Disconnect the harness and then remove the seat from the machine. (fig. 6-24) 6-21 Seat Installation 1. Remove the bolts (2) securing the cab to the chas- 1.
Page 52: Removal Procedure
Rubber Track Loader 6. Operator Enclosure 6-29 2. Remove the mounting screws (6) and washers 6-27 securing the panel to the chassis. (fig. 6-29) 3. Remove the panel by lifting and twisting it over the joystick and clear of the lap bar. (fig. 6-27) Installation 1.
Page 53: Removal Procedure
Rubber Track Loader 6. Operator Enclosure Rear Interior Panel (MP-1 & 2) Lap Bar Gas Spring (MP-2) Removal Removal Required Tools Required Tools Phillips Type Screwdriver Phillips & Blade Type Screwdrivers 1. Remove the right, left and rear interior panels from the cab to access the gas spring.
Page 55: Chassis And Fuel Tank
However, exploded parts diagrams machine damage, injury or even death. exist in the PT-70 or PT-80 Parts manual to serve as visual aids in the assembly and disassembly of other chassis com- Do not attempt to perform any type of repair or mainte- ponents.
Page 56: Installation Procedure
Rubber Track Loader 7. Chassis and Fuel Tank Fuel Tank Removal Remove Screws Required Tools Screwdriver Combination/Socket Wrench 1. Raise and support the lift arms as described on page 4-1 of this manual. 2. Tilt and support the operator enclosure (cab) as described on page 4-2 of this manual.
Page 57 Rubber Track Loader 7. Chassis and Fuel Tank 7-11 6. Loosen the hose clamp securing the main fuel line 9. Remove the bolts (3) securing the fuel tank to the to the tank outlet in the front right corner of the front mounting plate.
Page 58: Footwell
Rubber Track Loader 7. Chassis & Fuel Tank Footwell Bolts Removal Required Tools Screwdriver Combination/Socket Wrench 1. Raise and support the lift arms as described on page 4-1 of this manual. (optional) 2. Tilt and support the operator enclosure (cab) as 7-16 described on page 4-2 of this manual.
Page 59: Removal Procedure
Rubber Track Loader 7. Chassis & Fuel Tank Foot Throttle Assembly Hood Assembly Removal Removal Required Tools Required Tools Screwdriver Screwdriver Combination/Socket Wrench Combination/Socket Wrench Note: The foot throttle assembly may be removed with the footwell still installed in the machine. 1.
Page 60: Installation Procedure
Rubber Track Loader 7. Chassis & Fuel Tank 7-23 3. Have an assistant help you to remove the hood assembly from the machine. (fig. 7-23) 7-24 4. Carefully set the hood assembly aside. (fig. 7-24) Installation 1. To install the hood assembly, reverse the removal procedure.
Page 61: Radiator And Oil Cooler
However, exploded parts Track Loader can be dangerous and may result in diagrams exist in the PT-70 and PT-80 Parts manuals to machine damage, injury or even death. serve as visual aids in the assembly and disassembly of other system components.
Page 62: Removal Procedure
Rubber Track Loader 8. Radiator and Oil Cooler Fan & Fan Shroud Removal Required Tools Combination Wrench Socket Wrench 1. Remove the bolts (2) securing the fuel pump/filter assembly to the radiator support and lay it aside over the bumper to allow clearance to remove the shroud and fan.
Page 63: Removal Procedure
Rubber Track Loader 8. Radiator and Oil Cooler Radiator/Oil Cooler Removal !WARNING! Personal injury can result from exposure to hot fluids and components. Allow the machine to cool thoroughly before attempting any type of service on the cooling or hydraulic systems. !WARNING! Cooling system conditioner contains alkali.
Page 64 Rubber Track Loader 8. Radiator and Oil Cooler 8-16 8-13 4. Remove the bolts (6) securing the outer shroud to the chassis, then remove the shroud. (fig. 8-13) 8-17 7. Loosen the clamps securing the upper and lower coolant hoses to the radiator, then disconnect the 8-14 hoses from the radiator.
Page 65: Hydraulic Reservoir
However, exploded parts diagrams Track Loader can be dangerous and may result in exist in the PT-70 and PT-80 Parts manuals to serve as visu- machine damage, injury or even death. al aids in the removal and installation of other system com- ponents.
Page 66 Rubber Track Loader 9. Hydraulic Reservoir 1. Remove the center and rear belly pans from the machine. 2. Drain the hydraulic fluid. Refer to page 4-16 for the hydraulic fluid and filter change procedure. 3. Remove the engine as described on page 12-5 of this manual.
Page 67 Rubber Track Loader 9. Hydraulic Reservoir 9-10 9. Gently move the hard lines out of the way to allow for reservoir removal then zip tie them to the motor mount to keep them secure. (fig. 9-7) 9-11 10. Disconnect the bucket cylinder hoses from the 12.
Page 68 Rubber Track Loader 9. Hydraulic Reservoir 9-13 9-16 16. Remove the clamps securing the auxiliary 14. Disconnect the main oil cooler line from the fitting at the filter. (fig. 9-13) hydraulic lines to the chassis. (fig. 9-16) Disconnect 9-17 9-14 9-18 9-15 17.
Page 69 Rubber Track Loader 9. Hydraulic Reservoir 9-19 9-22 fuel lines 20. Remove the auxiliary hydraulic tubes from the machine. 9-20 18. Slide the two fuel lines through the chassis open- ing and into the engine compartment so that the 9-23 aux.
Page 70 Rubber Track Loader 9. Hydraulic Reservoir 9-25 9-28 26. Remove the bolts securing the metal tank restraint 23. Remove the lower hose restraints to allow the hoses to be pulled through the chassis. (fig. 9-25) straps, them remove them from the machine. (fig.
Page 71: Removal Procedure
Rubber Track Loader 9. Hydraulic Reservoir 29. Make sure there is nothing that would visibly pre- vent the reservoir from being removed or is still attached to other components within the machine, then proceed. Reservoir Pry-bar 9-31 9-34 30. Use a long pry bar to pry the tank upward and 31.
Page 72: Installation Procedure
Rubber Track Loader 9. Hydraulic Reservoir Suction Screen Removal Suction screen Required Tools Small Pry Bar (hose removal if necessary) Socket Wrench & Extension Combination Wrenches (to remove lines) Note: The suction screen may be removed with the reservoir (tank) still in the machine. If this is necessary, remove the center belly pan and tilt and support the cab to gain access, then follow the procedure described below to remove the suction screen.
Page 73: 10. Lift-Arm/Drive Controls
However, exploded parts machine damage, injury or even death. diagrams exist in the PT-70 and PT-80 Parts manuals to serve as visual aids in the assembly and disassembly of Do not attempt to perform any type of repair or mainte- other system components.
Page 74: Joystick
Rubber Track Loader 10. Lift-Arm/Drive Controls 1. Relax all hydraulic actuators to relieve pressure in the hydraulic system prior to service. 2. Turn the ignition switch to the OFF position, remove the key and disconnect the battery to avoid accidental start. Remove (optional) 3.
Page 75: Lift Arm Float Magnet
Rubber Track Loader 10. Lift-Arm/Drive Controls Lift Arm Float Magnet Removal Required Tools Fittings Socket Wrench Combination/Open End Wrench Allen Wrench 1. Perform steps 3, 4 and 11 of the lift arm joystick control removal process. 10-7 10. Remove the fittings on the back of the joystick (lift arm control joystick only).
Page 76: Lift Arm Control Valve
Rubber Track Loader 10. Lift-Arm/Drive Controls Lift Arm Control Valve Removal Required Tools Socket Wrench Combination/Open End Wrench Screwdriver (hose clamps) 1. Perform the footwell removal procedure on page 7- 4 of this manual. 10-15 2. Drain the hydraulic system as described on page 4-15 of this manual.
Page 77: 11. Hydraulic Pumps/Motors
However, exploded parts diagrams machine damage, injury or even death. exist in the PT-70 and PT-80 Parts manuals to serve as visu- al aids in the removal and installation of other system com- Do not attempt to perform any type of repair or mainte- ponents.
Page 78 Rubber Track Loader 11. Hydraulic Pumps/Motors 1. Lower the lift arms to the ground and relax the bucket tilt/curl cylinders to relieve pressure within the hydraulic system. 2. Turn the ignition switch to the OFF position and remove the key to avoid accidental start. 3.
Page 79: Auxiliary Pump
Rubber Track Loader 11. Hydraulic Pumps/Motors Auxiliary Pump Removal Required Tools Combination Wrench Socket Wrench & Extension Pry bar Allen socket 11-6 4. Loosen the clamp securing the hose onto the barbed fitting on the right side of the pump, then disconnect it.
Page 80: Tandem Drive Pump
Rubber Track Loader 11. Hydraulic Pumps/Motors Tandem (Drive) Pump Removal Required Tools Screwdriver Combination/Open End Wrenches !WARNING! Personal injury can result from exposure to hot fluids and components. Allow the machine to cool thoroughly 11-9 before attempting any type of service on the cooling or hydraulic systems.
Page 81 Rubber Track Loader 11. Hydraulic Pumps/Motors Top & Bottom Drive Pump Hoses Oil Cooler (return) Drive Motor (RT) From Charge Filter FRONT Drive Motor (LT) LEFT RIGHT • View is from the top. REAR 11-13 11-16 • The pump is to be perceived as transparent. •...
Page 82: Drive Motor
Rubber Track Loader 11. Hydraulic Pumps/Motors Drive Motor Removal Required Tools Combination/Socket Wrench Impact Wrench 3-Jaw Puller Snap Ring Pliers Hammer/Mallet 1. Remove the track from the undercarriage by per- forming the track removal procedure on page 4-6 11-21 of this manual. 4.
Page 83 Rubber Track Loader 11. Hydraulic Pumps/Motors 11-27 11-24 10. Remove the sprocket assembly from the undercar- 7. Remove the snap ring securing the bearing riage. (fig. 11-27) assembly to the outer sprocket shaft. (fig. 11-24) 11-28 11-25 11. Remove the bolts securing the drive motor to the 8.
Page 84 Rubber Track Loader 11. Hydraulic Pumps/Motors 11-30 13. Note the orientation of the hoses as they are con- nected to the drive motor. Label them to ensure correct installation and proper orientation during reassembly. (fig. 11-30) 11-31 14. Disconnect the hoses from the drive motor making sure to cap and plug all openings to avoid contam- ination.
Page 85: 12. Engine
However, exploded parts dia- grams exist in the PT-70 and PT-80 parts manuals to serve Do not attempt to perform any type of repair or mainte- as visual aids in the assembly and disassembly of other sys- nance on a Rubber Track Loader until you have read and tem components.
Page 86: Exhaust System
Rubber Track Loader 12. Engine Exhaust System Removal Required Tools Pry Bar(s) Combination/Socket Wrench Rubber Mallot Penetrating Lubricant 12-3 !WARNING! The exhaust system is very hot at operating tem- 4. Remove the two tension (L) rods by twisting and perature. Make sure the machine is off and cool maneuvering them out of the chassis mounting before attempting to service the exhaust system.
Page 87 Rubber Track Loader 12. Engine Spring 12-8 12-11 4. Remove the tension springs that secure the middle 7. Remove the inlet pipe from the muffler. It may be pipe section to the head (upper) pipe and muffler necessary to use levers to force the inlet pipe sec- inlet (lower) pipe.
Page 88: Air Cleaner
Rubber Track Loader 12. Engine Air Cleaner Removal Required Tools Combination Wrenches Socket Wrench & Extension 12-14 10. You may now remove the tail pipes by sliding them forward within the chassis, then out. (fig, 12-14). Installation 12-15 1. To install the exhaust system, reverse the removal procedure.
Page 89: Removal Procedure
Rubber Track Loader 12. Engine Engine Removal Required Tools Combination/Socket Wrenches Angle Iron or Similar (approx. 43” long) Tie Down or Ratchet Strap Forklift/Engine Hoist Pry Bar 12-18 1. Perform the battery, air cleaner, and charge pump, removal procedures in sections 11 and 12 of this 4.
Page 90 Rubber Track Loader 12. Engine Ballstud Bolts Cable Engine 12-21 12-24 8. Disconnect the throttle cable from the engine. 11. Disconnect the case drain filter and bracket from the engine adapter plate and lay it aside. It is situ- Note: Once loose, you may want to pull the throttle ated beneath the drive pump.
Page 91 Rubber Track Loader 12. Engine 12-27 12-31 14. Lay the angle iron across the fenders (or fuel tank Note: The rear cab window is directly over the lift point if still in place) and attach one or two tie down of the engine.
Page 92 12-8...
Page 93: 13. Undercarriage
Note: Procedures are provided for only those components replacement, refer to page 4-5 of this manual. listed above. However, exploded parts diagrams exist in the PT-70 and PT-80 parts manuals to serve as visual aids in the removal and installation of other system components. Personal Safety !WARNING! 15”...
Page 94 (fig. 13-7, 13-8) 9. Repeat this procedure as necessary to remove the 15” idler wheels throughout the undercarriage. Note: To remove the 10” bogie wheels on the PT-80 undercarriages, refer to page 13-3 of this manual. Installation 1.
Page 95: Removal Procedure
Socket/impact wrench Heavy duty hydraulic jack Combination wrench ASV approved jack stands (2) Shop vac or Pressure washer 1. Perform steps 1-5 of the PT-80 15” idler wheel removal procedure on page 13-1. Remove bolts 13-11 13-9 2. Remove the bolts securing the wheel to the hub.
Page 96 Rubber Track Loader 13. Undercarriage Note: Figure 13-36 incudes an exploded parts diagram of the PT-80 undercarriage for your reference. 13-16 4. The inner and or outer bogie wheels may now be 13-13 removed with an impact wrench and allen socket as shown in fig.
Page 97 Rubber Track Loader 13. Undercarriage Sealing Surfaces Face Seal Halves 13-18 Rubber Seals 13-21 6. Once the wheels have been removed, use a press to push the axle and far side bearing out of the hub as shown. (fig. 13-20, 13-21) 7.
Page 98 Rubber Track Loader 13. Undercarriage 10. Disassemble and clean the face seals and their rubber outer seals thoroughly, then wipe them dry to ensure a good seal when assembled. 13-27A 13-27B 13-24 13. Once the seals are in place, wipe the mating sur- faces of the face seals with a clean shop cloth and alcohol in a circular motion ending in a gentle 11.
Page 99 (fig. 13-30) 21. Remove the allen plug from the center of the hub assembly and fill it with 2 ounces of ASV 10W-30 Heavy Duty Engine Oil. Then reinstall the plug. (fig. 13-33, 13-34) 22.
Page 100: Idler Hub
Required Tools Socket Wrench & Sockets (including Allen) Press & Tool Kit (PT-70: 0403-475 or PT-80: 0403-339) Snap Ring Pliers 1. Remove the hub assemblies from the undercar- riages as required first by following steps 1-7 of the track removal procedure on page 4-6.
Page 101 Rubber Track Loader 13. Undercarriage Part #: 0403-337 Rear race Part #: 0403-333 13-40 13-43 PT-70 use tool #: 0403-371 5. Remove the bearing out of the front of the hub as 7. If bearings are to be replaced, press the rear bear- shown.
Page 102 Rubber Track Loader 13. Undercarriage Note: Take care not to drop the metal face seal halves. The sealing surfaces are surface ground and have an extremely fine finish. If scratched or disfigured, the seal will not function as intended. Note: Now is a good time to inspect the components for damage or wear.
Page 103 Rubber Track Loader 13. Undercarriage Part #: 0403-335 13-52 13-55 PT-70 use tool #: 0403-374 16. Once the seals are in place, wipe the mating sur- 19. Flip the hub over, support the bearing sleeve from faces of the face seals with a clean shop cloth and the bottom with tool 0403-335 and set it onto the alcohol in a circular motion ending in a gentle press for center seal installation.
Page 104 PT-70 use tool #: 0403-372 23. Pack the bearing with ASV Multi-Purpose EP 27. Add 2 oz. (1 oz. PT-70) of ASV 10W-30 Heavy Lithium Grease and then install it onto the bearing Duty Engine Oil to the hub as shown, then reinstall sleeve using tool 0403-333.
Page 105: 14. Lift-Arm Components
However, exploded parts diagrams exist machine damage, injury or even death. in the PT-70 and PT-80 Parts manuals to serve as visual aids in the assembly and disassembly of other system com- Do not attempt to perform any type of repair or mainte- ponents.
Page 106 4. Remove the bolts securing the front and rear lift arm cylinder pivot pins to the lift arm and lift arm 1. Rest the lift arms on an ASV approved jack stand tower. (fig. 14-4) to provide clearance for lift cylinder removal. (fig.
Page 107: Bucket/Tilt Cylinder
Rubber Track Loader 14. Lift-Arm Components Bucket/Tilt Cylinder Removal Required Tools Socket Wrench Combination/Open End Wrench Hammer Punch (brass) 14-7 7. Remove the cylinder from the machine for service or inspection. (fig. 14-7) Note: At this time the pivot bushings and pivot pins are 14-8 easily accessible for replacement.
Page 108 Rubber Track Loader 14. Lift-Arm Components 14-10 14-13 4. Remove the bolt securing the lower pin to the 7. Use a pry bar to slide the lower pin out of the cylin- quick attach. (fig. 14-10) der end allowing it to be removed. (fig. 14-13) 14-11 14-14 5.
Page 109 Rubber Track Loader 14. Lift-Arm Components Quick Coupler Block PRV Removal Required Tools Combination Wrench 14-16 10. Remove the pin from the cylinder while supporting the cylinder. (fig. 14-16) 14-18 1. With the machine off and cool and with all hydraulic actuators relaxed, loosen the pressure release valve on the top of the auxiliary quick cou- pler block.
Page 110 14-6...
Page 111: 15. Quick Attach
However, exploded parts diagrams Track Loader can be dangerous and may result in exist in the PT-70 and PT-80 Parts manuals to serve as visu- machine damage, injury or even death. al aids in the assembly and disassembly of other system components.
Page 112 Rubber Track Loader 15. Quick Attach Upper guard 15-5 15-2 5. Remove the pivot link from the quick attach. (fig. 15-5) 2. Remove the bolts (3) securing the upper guard to the quick attach weldment. (fig. 15-2) Upper guard 15-6 6.
Page 113 Combination/Open End/Socket Wrenches ASV Approved Jack Stand (or equivalent) Hammer Punch (brass) 15-8 1. Rest the lift arms on an ASV approved jack stand to provide clearance for quick attach disassembly. (fig. 15-8) Remove bolt & nut Drive out 15-9 2.
Page 114 15-4...
Page 115: Hydraulic Component Service
However, exploded parts diagrams exist in the PT-70 & PT-80 parts manuals to serve as visual aids in the Do not attempt to perform any type of repair or mainte- assembly and disassembly of other system components.
Page 116 Rubber Track Loader 16. Hydraulic Component Service Cylinder Tube Weldment 16-2 16-5 4. Use an open end or pipe wrench to turn and 7. With the piston and rod removed from the cylinder, remove the end gland. (figure 16-2) inspect the cylinder bore for scratches or other damage.
Page 117 Rubber Track Loader 16. Hydraulic Component Service 16-8 16-11 13. Remove the tandem seals from the end gland pay- ing close attention to the order of removal to aid during installation of the new seals. (fig. 16-11) 16-9 16-12 11. Remove the seals and piston ring taking care not to scratch the piston.
Page 118 Rubber Track Loader 16. Hydraulic Component Service Lift Arm Control Valve 4. Remove each valve section and inspect the seals for damage, replace if necessary. (figure 16-15) Disassembly Required Tools O-ring Socket Wrench Combination Wrench Screwdriver (blade type) Low Profile Needle Nose Pliers 1.
Page 119 Rubber Track Loader 16. Hydraulic Component Service 16-22 16-19 8. Remove the spring from the spool. (fig. 16-22) Note: Figure 16-19 displays the assembly order of the spool and associated components. Spool Load Check Spring Spool 16-20 16-23 Note: The lift arm and bucket control spools are each equipped with a unique load check spool.
Page 120: Drive Motor (Brake Portion)
Rubber Track Loader 16. Hydraulic Component Service Drive Motor Assembly (brake portion) 1. Install new seals and components in place of the Disassembly originals as necessary paying close attention to Required Tools location and orientation to ensure proper function. Allen Wrench/Socket Rubber Mallot (seal removal if needed) 2.
Page 121 Rubber Track Loader 16. Hydraulic Component Service Shims Seal Bolts Spring 16-30 16-27 9. Inspect the seal for any damage. (fig. 16-30) 4. Remove the brake spring and shims. Make sure to note the order of assembly to ensure correct 10.
Page 122: Drive Motor (Motor Portion)
Rubber Track Loader 16. Hydraulic Component Service Drive Motor (motor portion) Disassembly Required Tools Allen Wrench/Socket Snap Ring Pliers Screwdriver (blade type) (seal removal if needed) Surfaces 16-36 3. Lift and remove the piston block to expose the sealing surfaces. Inspect these surfaces to ensure there is no scratching or abrasion that may affect operation.
Page 123: Drive Pump (Drive Relief Valves)
Rubber Track Loader 16. Hydraulic Component Service Drive Pump (Drive Relief Valves) Disassembly & Adjustment Required Tools Allen Wrench/Socket Combination/Socket wrench 1. With machine off and cool and with hydraulic actu- ators relaxed, remove the drive pump from the machine by following the procedure in section 11. 16-39 Ring Groove Ring...
Page 124: Posi-Power Relief Valve
Rubber Track Loader 16. Hydraulic Component Service Drive Pump Disassembly Required Tools Combination/Socket wrench Allen Wrench/Socket Rubber Mallot Screwdriver (blade type) Snap RIng Pliers 16-45 4. Flip the valve over, then tighten the nut to increase the pressure setting (CW) or loosen it to decrease the pressure setting (CCW).
Page 125 Rubber Track Loader 16. Hydraulic Component Service Bearings Swash Plate 16-49 16-52 3. Remove the valve plate and inspect it for damage or wear, specifically, scratches that can be felt with a fingernail. (fig. 16-49) Surfaces Barrel Face 16-53 5. Remove the swash plate along with the bearings 16-50 and inspect them for any damage or scratching that could affect operation.
Page 126 Rubber Track Loader 16. Hydraulic Component Service Drive Pump Assembly Required Tools Combination/Socket wrench Allen Wrench/Socket Rubber Mallot Screwdriver (blade type) Snap RIng Pliers 16-55 7. Using a rubber mallot, gently tap the shaft and bearing out of the casing for inspection or replace- ment.
Page 127 Rubber Track Loader 16. Hydraulic Component Service 16-58 16-61 4. Flip the assembly over and lay it on a table, then 7. Once the pivots are installed, check to make sure remove the pivot caps from both sides as shown. both of them are properly mated with the pins.
Page 128: Auxiliary Pump
Rubber Track Loader 16. Hydraulic Component Service Auxiliary Pump Disassembly Required Tools Allen Wrench/Socket Snap Ring Pliers O-ring 1. With machine off and cool and with hydraulic actu- ators relaxed, remove the drive pump from the machine by following the procedure in section 11. 16-67 5.
Page 129 Rubber Track Loader 16. Hydraulic Component Service Inspect Faces 16-70 8. Remove the piston/barrel assembly and inspect the slipper faces for scratches or any other dam- age that can be felt with a fingernail. (fig. 16-70) Assembly 1. To reassemble, reverse the disassembly proce- dure.
Page 130 16-16...
Page 131: Hydraulic Pressure/Flow
Cut them apart approx. halfway between the top and bottom of the filter and inspect them for debris. If contamination is suspected, contact the ASV service department at 1-800-346-4367. 17-1...
Page 132 Rubber Track Loader 17. Hydraulic Pressure & Flow 1. Attach the gauge to test port A. (fig. 17-1) Route Charge Relief the gauge so that you or an assistant can read it during testing. 2. Make sure any bystanders are clear of moving components, then start the engine.
Page 133 Rubber Track Loader 17. Hydraulic Pressure & Flow Auxiliary Pressure Check Required Tools Test Port (B) Pressure Gauges 0-1000, 0-6000 p.s.i. Auxiliary pressure is used to drive flow style attach- ments. Low auxiliary pressure can produce poor per- formance in attachments while high pressure can cause component damage/failure in the machine or the attachment being utilized.
Page 134: Lift Arm Pressure Check
Rubber Track Loader 17. Hydraulic Pressure & Flow Lift Arm Pressure Check Drive Pressure Check Required Tools Required Tools Pressure Gauge 0-6000 p.s.i. Pressure Gauge 0-6000 p.s.i. Lift arm pressure is used to lift loads or “break-out”. !WARNING! Low lift arm pressure can produce a weak lift arm func- tion while high lift arm pressure can damage lift arm This procedure should only be performed if you suspect and hydraulic components.
Page 135: Troubleshooting
Rubber Track Loader 17. Hydraulic Pressure & Flow Check your readings against that stated below. If your Posi-Power Pressure Check readings differ, relief replacement and or component Posi-power is a function of the tandem drive pump repair may be required. assembly.
Page 136: Auxiliary Flow Test
Auxiliary Flow Test the jam nut on the posi-power adjustment screw The PT-70 and PT-80 are equipped with both high and and turn it counter clockwise until it stops then low flow auxiliary circuits. If an auxiliary flow problem is retighten the jam nut.
Page 137 Rubber Track Loader 17. Hydraulic Pressure & Flow Problem 6: Flow Troubleshooting High and low flow functions only work in one If your readings differ from those listed on the charts, direction. identify the symptom you are experiencing in the list of Possible causes: possible problems below and follow the steps to identi- 1.
Page 138 17-8...
Page 139: 18. Troubleshooting
This chapter contains basic troubleshooting proce- Prior to troubleshooting, walk around the machine and dures for the PT-70 and PT-80 Rubber Track Loaders. perform an overall visual inspection. Look for missing, loose, worn or broken parts. Pay particular attention to...
Page 140 Rubber Track Loader 18. Troubleshooting Problem 2: Problem 5: Machine cranks, but will not start. Tracks are operational, but lift arms will not move. Possible causes Possible causes 1. Fuel tank empty, fuel filter plugged or fuel line 1. Continuous hydraulic flow switch activated, sending restricted.
Page 141: Engine/Machine Troubleshooting
If any of the above conditions are present, the problem lies with the machine and should be serviced by an ASV dealer. If the conditions listed above are not pres- ent, the problem lies with the engine and it should be serviced by a Perkins engine repair facility to comply with the conditions of the engine warranty.
Page 142 18-4...
Page 143: Lubricant And Fuel Specifications
When replacing or replenishing the fluids and lubri- In North America, diesel fuel, distilled from crude oil, cants in an ASV Rubber Track Loader, use ASV prod- identified as No. 1-D or No. 2-D in “ASTM D975” gen- ucts. This ensures that the new fluids and lubricants erally meet machine requirements.
Page 144 19-2...
Page 145: General Torque Specifications
20. Service Aids & Supplements General Torque Specifications Inch Fasteners Metric Fasteners Thread Size Standard Torque Thread Size Standard Torque 1/4" 9 +/- 2 lb ft 12 +/- 3 Nm 5/16" 18 +/- 4 lb ft 28 +/- 7 Nm 3/8"...
Page 146 Terex Construction Americas 8800 Rostin Road Southaven, MS 38671 (888)-201-6008 (662)-393-1800 www.terex.com...

This manual is also suitable for:

Pt-70

ASV PT-80 Service Manual

1 Product Safety

2 Technical Specifications

3 Circuit Diagrams

4 Maintenance

5 Machine Controls and Instrumentation

6 Operator Enclosure

7 Chassis and Fuel Tank

8 Radiator and Oil Cooler

Hydraulic Reservoir

10 Lift-Arm/Drive Controls

11. Hydraulic Pumps/Motors

12 Engine

13 Undercarriage

14 Lift-Arm Components

15 Quick Attach

16 Hydraulic Component Service

Hydraulic Pressure/Flow

19 Lubricant and Fuel Specifications

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