ASV PT80 Operation And Maintenance Manual
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ASV PT80 Operation And Maintenance Manual

ASV PT80 Operation And Maintenance Manual

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8/17/2016
Language:
English
Geographic Region:
All
Serial Number Range:
SN All
PT80
Operation and Maintenance
Manual
This manual is complements of
TrackLoaderParts.com
The world's best source for ASV parts.
Track Loader Parts
6543 Chupp Road
Atlanta, Georgia 30058
USA
(800)616-8156

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  • Page 1 8/17/2016 Language: English Geographic Region: Serial Number Range: SN All PT80 Operation and Maintenance Manual This manual is complements of TrackLoaderParts.com The world's best source for ASV parts. Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 (800)616-8156...
  • Page 2 I I N N T T R R O O D D U U C C T T I I O O N N Thank you for purchasing an ASV Rubber Track Loader. With this machine, you will be able to perform tasks faster and more effi- ciently than with any other machine its size.
  • Page 3 S S A A F F E E T T Y Y O O V V E E R R V V I I E E W W SAFETY SYMBOL This symbol means: Attention! Be alert! Your safety is involved! A safety message will follow this symbol describing the hazard and the precautions that need to be taken to ensure your safety.
  • Page 4 M M A A C C H H I I N N E E I I D D E E N N T T I I F F I I C C A A T T I I O O N N Serial Numbers Manual Storage Product ID Number...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction ........1 Safety Overview........ 2 Machine Identification....3 Safety ............... 6 Controls .............. 14 Operation............22 Maintenance ............. 32 Troubleshooting..........58 Machine Specifications......... 63 California Proposition 65......64 Recommended Fluids ........65 Standard Torque Guidelines ....... 66 Service Log ............
  • Page 7 S S A A F F E E T T Y Y - CONTENTS Features .............. 7 Tipping Load/Operating Cap./GVW ..9 Fire Prevention..........10 Warning Decals..........11...

  • Page 8: Safety

    SAFETY Features The PT-70/80 rubber track load- C. Operator Presence Seat ers are equipped with many Switch safety features to reduce the This switch ensures that the possibility of injury to the opera- operator is seated inside the tor during operation. machine before any motion is allowed to take place.
  • Page 9 SAFETY Features F. Power Quick-Attach Safety H. Escape Hatch Switch (if equipped) The rear window on the PT- The purpose of this switch is to 70/80 serves as an escape ensure attachments are properly hatch in an emergency situation. fastened to the machine prior to It is identified by a yellow trian- operation.

  • Page 10: Tipping Load/Operating Cap./Gvw

    G.V.W. will void the tional track loaders, or 50% of warranty. the tipping load for wheeled skid steer loaders. ASV publishes both the 35% and the 50% rat- ing for reference and compari- son. The ROC applies only to the bucket attachment.

  • Page 11: Fire Prevention

    SAFETY Fire Prevention Fire Prevention Precautionary Tasks: Rubber Track Loaders have • With the engine off and cool, components that operate at high remove any debris present in temperatures. Steps must be the engine compartment and taken to make sure that flamma- chassis area (under cab).

  • Page 12: Warning Decals

    SAFETY Warning Decals There are decals positioned throughout the machine to warn opera- tors of potential hazards. They must be observed and obeyed to avoid risks of machine damage, personal injury or even death. They are displayed here along with supplementary graphics that help to illustrate their intent and significance.
  • Page 13 SAFETY Warning Decals WARNING Keep away from tracks while machine is in motion. Serious personal injury or even death may result. CAUTION Inspect undercarriages daily for accumulation of debris. Build-up of debris may shorten component life and decrease machine performance. 2045-467 DANGER Operating Position...
  • Page 15 C C O O N N T T R R O O L L S S - CONTENTS Instrument Display ......... 15 Switch Panels............ 16 Drive & Lift Arm ..........17 Throttle/Electric Attachment...... 18 Auxiliary Hydraulic.......... 19 Two Speed/Power Quick Attach....21...

  • Page 16: Controls

    CONTROLS Instrument Display There are many instruments involved in the safe operation of your machine. Make sure to learn the location, and function of each of these items prior to operating your machine. Instrument Display The instrument display has been configured for visibility and ergonomic function.

  • Page 17: Switch Panels

    CONTROLS Switch Panels Left Right Switch Panels There are three main panels which house the switches used to control various functions throughout the machine. The switch panels include: L. Parking Brake Switch M.Headlight Switch N. Bucket Positioning Switch O. High Flow Aux. Switch P.

  • Page 18: Drive & Lift Arm

    CONTROLS Drive & Lift Arm Drive Control Lift Arm Control The PT-70/80 are equipped with The lift arm control (right joy- pilot operated joystick controls. stick) is used to control the lift The drive control (left joystick) is arms and attachment (bucket) used to control track motion.

  • Page 19: Throttle/Electric Attachment

    Note: ASV receptacle style and • To increase engine RPM, pin designation may differ from press the front (toe) of the those utilized by other manufac- foot pedal slowly towards the turers.

  • Page 20: Auxiliary Hydraulic

    CONTROLS Auxiliary Hydraulic The PT-70/80 are equipped with Note: Low and high flow circuits high and low flow auxiliary may not be used simultaneously. hydraulic circuits that allow for Low Flow Intermittent the use of hydraulic attach- The low flow auxiliary circuit can ments.
  • Page 21 Note: When connected to an overheat your hydraulic system and most likely damage your attachment, the auxiliary switch- machine/attachment. ASV rec- es have the effect of reversing ommends using only attach- flow through their respective cir-...

  • Page 22: Two Speed/Power Quick Attach

    CONTROLS Two Speed/Power Quick Attach Two Speed Power Quick Attach The PT-80 is equipped with a The PT machines are available two speed drive system with low with a power quick attach fea- and high range. ture that allows the operator to fasten and unfasten attachments •...
  • Page 23 O O P P E E R R A A T T I I O O N N - CONTENTS Pre-Operation........... 23 Starting Procedure ......... 24 Operation Techniques ........25 Attachments ............. 29...

  • Page 24: Operation

    OPERATION Pre-Operation Pre-Operation Safety Check Note: The parking brake is auto- matically activated when the Before operating the machine, operator removes the seat belt perform a pre-operation safety or leaves the operator seat. check. Inspect the machine for any items that may affect safe Note: The parking brake should operation.

  • Page 25: Starting Procedure

    OPERATION Starting Procedure Starting Procedure 6. Once running, reduce throt- tle to a low idle by pushing Upon completion of the pre- back slowly on the foot operation safety check, if all pedal with your heel. Allow items are in compliance, you are the engine to idle for 3-5 ready to start your machine.

  • Page 26: Operation Techniques

    OPERATION Operation Techniques Operating Your Machine Dirt Work Operating an ASV Rubber Track ASV Rubber Track Loaders pro- Loader is intended to be as safe vide far superior traction and and simple as possible. The floatation than traditional controls section of this manual wheeled loaders.
  • Page 27 OPERATION Operation Techniques Filling The Bucket Steps: (see illustration) 1. Lower the lift arms until they rest on the frame. 2. Tilt the bucket slowly forward until the cutting edge engages the ground. 3. Drive the machine forward until the bucket is full of material. 4.
  • Page 28 OPERATION Operation Techniques Leveling Steps: (see illustration) 1. Moving forward, raise the lift arms as you tilt the bucket slowly forward to evenly spread the material out over the ground. 2. Once the load is released, tilt the bucket forward to an angle 45°...
  • Page 29 OPERATION Operation Techniques Hill Side Operation Operation On Turf By design, Rubber Track One of the many features of a Loaders are very stable on Rubber Track Loader is the abili- inclines. Machine weight is dis- ty to work on turf and similar fin- tributed evenly throughout the ished surfaces with minimal sur- chassis and the suspended...

  • Page 30: Attachments

    OPERATION Attachments PT-70 Fastening To fasten an attachment: To unfasten an attachment: 1. Make sure the locking 1. Lower the lift arms so that levers are in their respective the attachment is just barely unlocked positions. off of the ground. 2.
  • Page 31 OPERATION Attachments PT-80 (PT-70/optional) Unfastening To fasten an attachment: To unfasten an attachment: 1. Lower the lift arms so that 1. Move the power quick-attach the attachment is just barely switch into the “unlock” posi off of the ground. tion. 2.
  • Page 33 M M A A I I N N T T E E N N A A N N C C E E - CONTENTS Precautions/Safety Warnings ..33 Lift Arm Brace Installation..... 34 Tilt-Up R.O.P.S./F.O.P.S. Cab .... 35 Jacking Procedure......36 Maintenance Schedule .........

  • Page 34: Maintenance

    Safety Warnings so by your ASV service manu- Exercise caution when perform- al. Moving engine parts pose a ing service work on the safety risk and can cause machine.

  • Page 35: Lift Arm Brace Installation

    MAINTENANCE Lift Arm Brace Installation Lift Arm Brace Installation 6. Lower the lift arms slowly until they come to rest on The lift arm brace (A) is intended the brace. to keep service personnel safe when it is necessary to work on 7.

  • Page 36: Tilt-Up R.o.p.s./F.o.p.s. Cab

    MAINTENANCE Tilt Up R.O.P.S./F.O.P.S. Cab Tilt-Up Cab The ROPS/FOPS approved cab (A) tilts up to allow easy access to components while performing maintenance. It is equipped with a gas spring assist and a brace mechanism to hold it in place while tilted.

  • Page 37: Jacking Procedure

    5. Once in place, jack the machine upward making sure it remains stable until it has reached sufficient height to install an ASV jack stand beneath the machine. (fig. 1) CAUTION Lift the machine under the tor- sion axles only! Jacking the machine in any other place may cause damage.

  • Page 38: Maintenance Schedule

    MAINTENANCE Maintenance Schedule 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 39: Grease Points

    MAINTENANCE Grease Points Grease Fitting Locations A. Lower Bucket Cylinder Pivot B. Upper Bucket Cylinder Pivot C. Front Lift Cylinder Pivot D. Lift Arm Pivot E. Rear Lift Cylinder Pivot F. Rear Axle Pivot (2) G. Front Axle Pivot (2) H.

  • Page 40: Radiator-Oil Cooler/Engine Cleaning

    MAINTENANCE Radiator/Oil Cooler & Engine Cleaning Radiator/Oil Cooler Note: Make sure water nozzle is The Radiator and Oil Cooler at least 12” (8” for air) from the must be kept clean to ensure cooler and that the spray is proper operation. Engine and directed straight through the hydraulic system overheating, cooler or the cooling fins may be...

  • Page 41: Air Cleaner

    MAINTENANCE Air Cleaner Air Cleaner The PT-70/80 are equipped with two air filter elements to remove contaminants from the air used for combustion. Regular inspec- tion and replacement is neces- sary to ensure proper perform- ance and to prolong engine life. To remove and inspect your air cleaner elements: 1.
  • Page 42 160°F to dry the filter. CAUTION Do not clean air filter ele- ments while engine warranty is in effect. During the war- ranty period, ASV recom- mends replacing air filter elements instead of cleaning them. Heavy-duty air filter manufacturers will not war- rant the air filter once it has been cleaned.

  • Page 43: Fuel Filter/Water Separator

    MAINTENANCE Fuel Filter/Water Separator Fuel Filter The fuel filter removes contami- nants from the fuel as it enters the engine for combustion. Over time the filter can become plugged and cause the engine to lose power, run roughly or fail to start.

  • Page 44: Accessory Belts

    MAINTENANCE Accessory Belts Accessory Belt Tension Drive belts typically stretch and wear during their service life. The fan and A/C belts should be Bolts checked for tension, condition Pry bar and presence daily prior to oper- ating your machine. To check fan or A/C belt tension: 1.
  • Page 45 MAINTENANCE Accessory Belts Pry bar 1/2 cage Bolt Bolts Fan Belt Removal & Installation To remove the fan belt: 1. Follow steps 1 and 2 of the belt adjustment procedure. 2. Once loose, pivot the alternator towards the engine to increase slack. Bolt 3.

  • Page 46: Engine

    Machines that are operated under harsh conditions should have their oil reservoir corner changed more frequently. ASV recommends oil change inter- vals of 250 hours or every six months for these machines. Harsh conditions may include:...
  • Page 47 47. 50 +/- 10 lb ft. 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. 6) 11. Install the oil filler cap.
  • Page 48 If the level is correct, re- install the dipstick and Engine Oil Specifications then close and latch the Use ASV 10W-30 Heavy Duty hood to complete the Engine Oil for most conditions. procedure. In the event of an alternate 7.

  • Page 49: Hydraulic System

    Introducing dirt their respective filter heads. or debris could be detrimental to Tighten filters by hand as the hydraulic system. ASV rec- instructed by the label locat ommends service intervals of ed on the filter or filter box.
  • Page 50 11. Start the machine and oper- voir filler cap (black) and fill ate all hydraulic circuits to the hydraulic system with work any trapped air out of ASV Premium All Season the system. MV Hydraulic Oil or equiva • Drive the machine forward lent until the full mark on the and backward.

  • Page 51: Electrical/Undercarriages

    They work in mud, gravel, debris are located on the fuse panel and various other abrasive behind the access cover on the materials during operation. ASV lower right side of the cab interi- recommends a daily inspection or. (fig. 6) of the undercarriage assemblies and cleaning if necessary.
  • Page 52 MAINTENANCE Undercarriages Track Tension (PT-70/80) Straight-Edge Proper track tension must be maintained for optimal perform- ance and track/undercarriage life. Running a track that is too loose may cause the track to misfeed possibly causing dam- age to the track and or under- carriage components.
  • Page 53 • Socket/impact wrench • Ratchet strap • Heavy duty hydraulic jack • Combination wrench • Long pry bar(s) • ASV approved jack stands (2) • Spray lubricant • Shop vac or Pressure washer Note: The PT-80 style undercar- PT-70 riage is depicted here. The PT-...
  • Page 54 MAINTENANCE Undercarriages 6. Remove the outer scraper plate from the suspension rail. (PT-80 only/fig. 9, 10) 7. Remove the bolts securing the inner wheel to the hub, then remove the wheel. (PT-80 only/fig. 11, 12) 8. Use a pry bar to peel the track over the inner wheel(s) toward the outside of the machine.
  • Page 55 MAINTENANCE Undercarriages Track Installation 1. Slide the track over the drive sprocket at the rear of the machine. (fig. 1) 2. Slide the front of the track into position for installation. 3. Lubricate the inner front wheel(s) and the inside of the front portion of the track with a spray lubricant.(fig.
  • Page 56 MAINTENANCE Undercarriages 9. Once the track is in position over the idler wheels, install the inner idler wheel onto the hub and secure it in place with the mounting bolts. Torque them to 90 +/- 10 Lb. Ft. (PT-80 only/fig. 6, 7, 8) Note: You may need to use a bar to keep the wheel from spin- ning as you torque the mounting...

  • Page 57: Drive Sprocket Rollers

    35% life Drive Sprocket Rollers 3. Remove the bearing cap (G) by tapping around the ASV rubber track loaders utilize bulged area of the cap with rollers on the drive sprockets to a hammer. This will relieve drive the track. These rollers...
  • Page 58 MAINTENANCE Undercarriages 8. Repeat this process as required throughout the sprocket. 9. Reinstall the sprocket by reversing steps 2-6. Note: During removal of the bearing cap (step 3) the bulged area of the cap is beaten inward. When reinstalling, orient the cap so that the domed area is facing outward.
  • Page 59 T T R R O O U U B B L L E E S S H H O O O O T T I I N N G G - CONTENTS Overview/No-Start ......... 59 Hydraulics ............60 Electrical ............. 61 Overheat.............

  • Page 60: Troubleshooting

    Troubleshooting Overview/No-Start Overview Problem The most effective way to pre- Machine cranks, but will not vent a malfunction from occur- start. ring is to closely follow the rec- Possible causes: ommended maintenance sched- 1. Fuel tank empty, fuel filter ule and instructions throughout plugged or fuel line restricted.

  • Page 61: Hydraulics

    Troubleshooting Hydraulics Problem 3. Drive control joystick (pilot Machine starts, but hydraulics control) malfunction. will not operate. 4. Low charge pressure. Possible causes: 5. Parking brake switch in on 1. Operator not in seat. position. 2. Seat belt not fastened. 6.

  • Page 62: Electrical

    Troubleshooting Hydraulics/Electrical Problem Problem Lift arms are operational, but Lift arm control joystick will not high/low flow auxiliary circuits lock into float position. are not. Possible causes: Possible causes: 1. Float magnet fuse blown. 1. Auxiliary hydraulic fuse 2. Loose, broken, or discon- blown.

  • Page 63: Overheat

    Troubleshooting Electrical/Overheat Problem Problem Battery will not charge/maintain Engine coolant temperature charge. elevated; engine overheating. Possible causes: Possible causes: 1. Loose alternator belt. 1. Low coolant level. 2. Alternator fuse blown. 2. Debris plugging radiator, lim- iting airflow. 3. Faulty alternator diode. 3.
  • Page 64 ** Bucket installed, fluid levels full, 165 lb. operator seated in cab. *** When replacing or replenishing fluids, it is recommended that you specify genuine ASV products from your ASV dealer.

  • Page 65: California Proposition 65

    Terex/ASV complies with this requirement by providing the following information. CALIFORNIA...

  • Page 66: Recommended Fluids

    ASV factory. ASV products were developed for, tested and approved by ASV to assure opti- mum life and performance in all ASV Rubber Track Equipment, when used as recommended. The ASV product line includes: •...

  • Page 67: Standard Torque Guidelines

    STANDARD TORQUE GUIDELINES Inch Fasteners Machine Specific Fasteners Thread size Standard Torque Drive Sprocket Roller 1/4" 9 +/- 2 lb ft Bolts/Nuts PT-70 & PT-80 5/16" 18 +/- 4 lb ft Torque to: 88 +/- 10 Ft./Lbs. 3/8" 35 +/- 7lb ft 7/16"...

  • Page 68: Service Log

    SERVICE LOG Hours Service Performed Notes...
  • Page 69 SERVICE LOG Hours Service Performed Notes...
  • Page 70 SERVICE LOG Hours Service Performed Notes...
  • Page 71 SERVICE LOG Hours Service Performed Notes...
  • Page 72 Terex Construction Americas 8800 Rostin Road Southaven, MS 38671 (888)-201-6008 (662)-393-1800 www.terex.com ASVPT70/80 OM (1/09) Copyright 2009 Terex...

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