8/17/2016

Operation and Maintenance

Manual

PT100 Forestry

SN All

English

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1

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

Cab Filtration / Fan Cleaning / Fluids & Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

CONTENTS

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.

WARNING

2

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

Proposition 65

Warning: This product contains lead and

lead compounds, diesel engine exhaust,

and used engine oil, chemicals known to

the state of California to cause cancer.

CALIFORNIA

Proposition 65

Warning: This product contains lead, a

chemical known to the state of California

to cause birth defects or other reproduc-

tive harm.

3

Thank you for purchasing an ASV

Rubber Track Loader. With this

machine, you will be able to perform

tasks faster and more efficiently than

with any other machine its size.

The PT-100 Forestry is a rugged and

agile machine capable of working on a

variety of challenging terrains. It is

designed to be very safe, but safe oper-

ation also requires caution and attentive-

ness on the part of the operator.

There are many hazards that can be

encountered during operation of an off

highway utility vehicle such as the PT-

100 Forestry. With this in mind, it is the

responsibility of each operator to read

and fully understand this manual before

attempting to operate the machine.

Machine damage, bodily injury, or even

death may result if the procedures and

precautions described in this manual are

not followed closely.

At the time of publication, all information,

photographs, and illustrations are techni-

cally correct.

Machine OrientationTerms 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.

This manual contains the words

Warning, Caution and Note to empha-

size important information. The word

WARNING identifies personal safety

related information. The word CAUTION

identifies unsafe practices that may

result in machine damage. The word

Note: identifies supplementary informa-

tion which requires special attention.

INTRODUCTION

WARNING

MACHINE SPECIFICATIONS

4

General Dimensions PT-100 ForestryHeight to top of ROPS: 91 in. / 2311 mm

Ground clearance: 14 in. / 356 mm

Max. lift height, at hinge pin: 125 in. / 3175 mm

Machine length, w/out bucket: 121 in. / 3073 mm

Machine length, with bucket: 151.5 in. / 3848 mm

Machine width: 69 in. / 1753 mm

Track SpecificationsTrack width: 18 in. / 457 mm

Length of track on ground: 72.5 in. / 1842 mm

Machine WeightShipping Weight: 10,400 lb / 4717 kg

Operating Weight: 11425 lb / 5182 kg

Ground pressure @ Operating Weight: 4.37 psi / 30.13 kPa

Ground contact area: 2,610 in.2 / 1.68 m2

Specifications are subject to change without notice.

SAE J818 standards define operating capacities of rubber-tired skid steers (50% tippingload) and tracked loaders (35% tipping load). There are no standards defining the operat-ing capacity of machines equipped with a suspended undercarriage or machines with rub-ber tracks.

Engine PT-100 ForestryModel: Perkins 1104C-44T

Type: 4-cylinder diesel

Displacement: 268 in.3/4.4 liter

Gross HP @ 2300 rpm: 99.9 hp / 74.5 kW

Torque (peak): 306 ft-lb / 415 Nm

Operating SpecificationsOperating capacities:

35% tip load: 2,660 lb / 1207 kg

50% tip load: 3,800 lb / 1724 kg

Travel speed (low/high) max.: 6/11.5 mph / 9.7/18.51 kmh

Auxiliary Hydraulic PumpLow flow, max.: 20 gpm / 76 lpm

High flow, max.: 40 gpm / 151.4 lpm

Pressure: 3,650 psi / 25,170 kPa

Service Refill CapacitiesFuel tank: 26 gal / 98 L

Hydraulic tank*: 20 gal / 76 L

Engine coolant*: 3.125 gal / 12 L

Engine oil, including filter*: 8.5 qt / 8 L

* When replacing or replenishing these lubricants/fluids, it is recommended that you specify genuine ASV products from your ASV Dealer.

5

Product ID Numbers

The machine PIN is located on the front

of the left joystick tower (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.

MACHINE LABELS AND DECALS

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.

Operating Guidelines2040-121

6

FIRE PREVENTION

2030-277

Fire Prevention

Brush cutting, mowing, or similar operations that generate flying debris can be a

fire hazard. Debris can accumulate inside the engine compartment, in the radiator

cooling fins, and beneath the cab in the chassis area. This debris can cause the

engine and hydraulic systems to overheat and can combust resulting in a fire. It is

important to clean these areas as often as necessary. The reversible fan feature

can help prolong cooling system cleaning intervals, however, regular inspection

and cleaning to prevent fire should still be performed. Failure to comply with these

instructions could result in machine damage, injury or even death.

With the engine off and cool and the key removed from the ignition:

1. Lift and support the hood at the rear of the machine, then lower all belly pans to

access the engine compartment and the chassis area housing the hydraulic pumps.

2. Use a pressure washer or compressed air (wear appropriate safety equipment) to

blow any debris clear of the radiator, engine compartment and chassis area.

WARNING

2040-272

Fire Prevention

The PT-100 Forestry has components

that operate at high temperatures.

The main heat sources are the

engine and the exhaust system. The

electrical system, if damaged or

improperly maintained, can also be a

source of heat and sparks.

Attachments (brushcutters, mowers

etc.) can generate debris that can

cause a fire if improperly maintained.

Flammable debris (leaves, straw,

brush cutting debris, etc.) must be

removed from these high temperature

areas regularly. If flammable debris is

allowed to accumulate, a fire may

result posing a risk to the operator

and the machine. A fire can cause

machine damage, severe injury, or

even death. Inspect for and remove

flammable debris often to avoid a fire.

Listed are a set of precautionary

tasks that should be performed daily

or more often as needed. Repair or

replace worn/damaged components

as required to ensure safe operation.

• With the engine off and cool, clean

flammable debris from engine com-

partment, exhaust system, attach-

ments and other areas where there

may be hot or rotating parts.

• Check battery, fuse box, electrical

wiring and connections for damage

or looseness.

• Check fuel lines and hoses for

leaks or damage. Never allow open

flame near fuel or fuel system com-

ponents.

• Check hydraulic lines, hoses and

fittings for damage or leaking fluid.

Never use bare hands to check for

leaks. Pressurized fluid can pene-

trate skin and cause injury or even

death.

• Do not use ether or any other aerosol

type starting fluid to start the engine.

• Always stop the engine and allow the

machine to cool before adding fuel. No

smoking.

WARNING

OPERATING CAPACITY / ATTACHMENT PRECAUTIONS

7

Operating Capacity

The operating capacity refers to how

much additional weight can be added to

the standard dirt bucket's center of grav-

ity. The recommended operating capaci-

ties for these machines are listed on

page 4. The heavier the attachment, the

less the operating capacity will be.

Moving the load farther from the machine

will significantly reduce the operating

capacity.

Note: SAE J818 standards define oper-ating capacities of rubber-tired skidsteers (50% tipping load) and trackedloaders (35% tipping load). There are nostandards defining the operating capacityof machines equipped with a suspendedundercarriage or machines with rubbertracks.

Gross Vehicle Weight

The GVW (Gross Vehicle Weight) of the

PT-100 Forestry should not exceed

13,200 lbs. Exceeding the specified

GVW rating will void the warranty (see

page 2).

Mulching Type Forestry Brush

Cutters

When using non-ASV brush cutters,

especially mulching type forestry brush

cutters, there are many things that

should be considered.

• Mulching type brush cutters generate

more dust and debris than rotary brush

cutters. The increased amount of dust

and debris particles can plug coolers,

radiators, and air cleaners much faster,

causing overheating or even engine

failure if left unattended. The debris is

also introduced into many high temper-

ature areas and can become a fire

hazard. Debris should be cleaned fre-

quently from these areas.

• Mulching type brush cutters can also

become unbalanced due to worn or

damaged “blades”, causing vibration. If

the attachment is operated in this con-

dition, it can cause metal fatigue and /

or cracking in both the host machine

and the “head” itself. Vibration can also

cause hydraulic component failure in

items such as relief valves. Although

these mulching type heads work

extremely well on ASV machines with

high flow hydraulics, educate yourself

on the increased maintenance and

operating costs before purchasing this

type of attachment.

Machine damage and failure caused by uti-

lizing non ASV mulching type brush cutters

will not be covered by ASV warranty.

CAUTION

Loader and Drive Controls

The PT-100 Forestry has two hydraulic

pilot joystick controls. These two joy-

sticks are used to control machine

speed, direction, lift arms and bucket or

attachment. Joystick A is used to control

the lift arms, the bucket and float func-

tion. To engage 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.

Throttle

The throttle C, controls engine rpm.

When performing delicate work that

requires precise movements, use a

lower engine rpm. When more speed,

horsepower or flow is required, use a

higher engine rpm.

• To Increase RPM, move the lever (C)

toward the front of the machine.

• To decrease RPM, move the lever (C)

toward the rear of the machine.

8

MACHINE CONTROLS

BA

C

Dash Panel

There are many switches and instru-

ments involved in the operation of PT

machines. Learn the location and func-

tion of these items prior to operation.

Switch PanelsD - Lights, front and rear

E - Reversible Fan (cooler cleanout)

F - Front wiper (optional)

G - Beacon (optional)

M - Ignition, glow plug (pre-heat)

N - Low Flow Auxiliary Hydraulics

O - High Flow Auxiliary Hydraulics

P - (not used)

Q - Power Quick Attach

InstrumentsH - Tachometer

I - Engine Temperature Gauge

J - Fuel Level Gauge

K - Warning Indicators (3-in-one)

L - Hour Meter

R - High Range Indicator Light

S - Glow Plug Operation Light

T - Oil Pressure Warning Light

U - Battery Voltage Warning Light

V - Hydraulic Oil Temp. Warning Light

If the battery voltage warning light (U)

illuminates, drive the machine to a suit-

able location and shut the engine off.

Diagnose the problem and make needed

repairs before continuing to operate.

The glow plug operation light (S) will illu-

minate only when the key switch is

turned to engine pre-heat, showing nor-

mal operation.

SWITCHES / INSTRUMENTATION

9

D E F G

H

Should the engine temperature gauge

read excessive temperatures or

should the oil pressure or hydraulic oil

temperature lights illuminate during

normal operation, shut the machine

down immediately. Diagnose the prob-

lem and make needed repairs before

continuing to operate.

I J

K

L M N O P Q

CAUTION

T

V

U

R S

J

K

Light

10

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.

4. Fluids are filled to proper levels.

5. Accessory belts are in good condition

and properly tensioned.

6. Hyd. Hoses and fittings are in good

condition. (no visible signs of wear)

7. Battery cables are in good condition

and properly fastened.

8. Joysticks and hyd. auxiliary switches

are in their neutral positions.

9. Power quick-attach is in locked posi-

tion.

Starting Procedure

Before starting the engine, perform the

pre-start checklist then proceed with the

following procedure:

1. Enter machine with lift arms all the

way down. Maintain three points of

contact with the machine (photo A).

2. Sit down in the operator’s seat and

fasten the seat belt.

3. Starting with the throttle in the SLOW

position, push the throttle 1/3 the way

open.

4. Turn the ignition key to the left for 6

seconds to “pre-heat” the engine.

While pre-heating, the glow plug

operation light will illuminate.

5. Turn the ignition key to the right to

start the engine.

6. Run the engine at low idle for 3 to 5

minutes to warm up the engine.

7. Set throttle to desired rpm.

Note: The parking brake is automatically

engaged when the engine is turned off,

the operator is not in the seat, or when

the seat belt is unfastened.

Entering or exiting the vehicle under raised

lift arms could cause serious injury or

death. Never allow anyone to be under-

neath raised, unsecured lift arms (photo B).

WARNING

A B

MACHINE OPERATION

11

Power Quick Attach

The power quick-attach switch (C) is

equipped with an orange locking device.

This locking device must be disengaged

before the switch can be moved to the

unlock position. Only move the switch to

the unlock position when the lift arms are

all the way down. The machine will not

start unless the power quick-attach is in

the lock position.

To fasten an attachment, move the

power quick-attach switch to the "unlock"

position. Drive up to the attachment and

hook the top edge of the quick-attach

into the upper lip of the attachment. Curl

the quick-attach all the way back. Move

the power quick-attach switch to the

"lock" position.

Failure to wear the seat belt could lead to

serious injury or death.

Do not crank the engine for more than 20

seconds. Allow the starter to cool for 2 min-

utes before cranking again.

Do not use aerosol type starting aids such

as ether. Such use could result in an explo-

sion and personal injury.

CWARNING

CAUTION

WARNING

Always visually verify that the quick attach

pins are fully extended and that the attach-

ment is securely fastened prior to use.

WARNING

D

E

12

MACHINE OPERATION

Two Speed

The PT-100 Forestry is equipped with a

two-speed drive system. Low range is

best suited to performing strenuous work

or running attachments. High range is

intended mainly for transporting.

Note: If the machine is turned off, the

seat belt is unfastened or the operator

exits the seat, the machine will automati-

cally return to low range. In order to

resume high range operation after such

an event, you must sit down in the oper-

ator seat and fasten the seat belt, then

start the engine if necessary and reacti-

vate high range as described elsewhere

on this page.

To shift between high and low ranges,

push the button (A) on the front of the

right joystick. When shifting between

ranges, slow the machine to ensure a

smooth transition. The high range indica-

tor (B) will illuminate to confirm high

range operation.

Operation on InclinesASV Rubber Track Loaders are very sta-

ble on inclines. Machine weight is distrib-

uted evenly throughout the chassis and

the suspended undercarriage track sys-

tem provides excellent traction and

floatation on nearly all surfaces.

Even with these capabilities, caution

should always be exercised while oper-

ating the machine on an incline. Never

operate the PT-100 Forestry on an

incline in excess of 18°. Do not make

sudden changes in direction, move

slowly, and always carry loads low to

maximize machine stability.

When turning on an incline, back down

the hill while slowly turning until the

machine is pointed in the desired direc-

tion. Then proceed forward.

A

B

Failure to follow the instructions regarding

operation on inclines may result in machine

damage, severe injury, or even death.

The engine’s lubrication system requires

that the machine be kept below a maximum

operation angle of 24° in order to properly

supply the engine with oil. Failure to follow

the instructions regarding operation on

inclines may result in engine damage or

failure.

WARNING

CAUTION

DO NOT remove the seat belt while the

machine is in motion. The parking brake

will automatically be applied causing the

machine to stop abruptly. Personal injury or

death may result.

WARNING

MACHINE OPERATION

13

Auxiliary Hydraulics

The PT-100 Forestry comes standard

with a load sense, variable displacement

piston pump for auxiliary hydraulics.

When the low flow is engaged the vari-

able displacement pump displaces 20

gpm, and when the high flow is engaged

the pump displaces 40 gpm.

To activate auxiliary hydraulics:

1. To engage the low flow hydraulics

intermittently, activate the toggle-

type switches on the right joystick.

2. To engage the low flow hydraulics

continuously, activate the low flow

switch on the dash.

3. To engage the high flow hydraulics

continuously activate the high flow

switch on the dash.

Note: The low flow (C) and high flow (D)

activation switches have small orange

locking devices that must be disengaged

before the switches can be moved.

These switches must be in their off (neu-

tral) positions in order to start the

engine.

C D

MACHINE OPERATION

Electric Attachment ControlAttachments are controlled by various

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

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.

Heater/AC The overhead heater/air conditioner unit

can be activated to adjust conditions

within the cab. Heat is available by turn-

ing the temperature control knob and

adjusting fan speed. To activate A/C you

must first press the AC button.

Cab PressurizationThe overhead heater/AC unit provides

cab pressurization to keep dust and

debris out of the cab during operation.

To pressurize the cab, close windows

and door, then activate the blower fan in

the overhead console. Higher fan speed

increases pressurization while lower

speed decreases pressurization.

Note: Gaskets surrounding the cab door,

windows, and those sealing the cab to

the chassis must be in good condition to

ensure pressurization. Inspect often and

replace as necessary.

Reversible FanThe fan in the PT-100 Forestry is

designed to provide reverse air flow

upon demand to aid in the cleaning of

the cooling system during operation.

The fan is timed from the factory to

reverse flow every half hour during nor-

mal operation to keep the cooler free of

debris. The fan can be activated manu-

ally by pressing the switch (C) on the

dash panel.

Note: The timed interval for the fan is

adjustable, but it is not recommended

that the interval be set to less than 15

minutes as damage to the compressor

may result. (consult dealer to adjust)

Note: Although the Reversible fan fea-

ture aids in keeping the radiator/oil

cooler clean, it is still very important that

the cleaning procedures found on page

24 be performed as recommended.

A

B

C

14

MACHINE OPERATION

Emergency Exit

There are quick release knobs and pins

located throughout the cab enclosure.

These features allow an operator to

escape or a bystander to access the cab

in an emergency.

Front Escape: (Door Exit)

Remove the two red knobs, then unlatch

the door and push it out.

Rear Escape: (Rear Window Exit)

Remove the two red knobs, pull the tri-

angular orange tag, then apply force in

the corner of the window to remove it.

Front Access: (Door Entry)

Remove the pins from the door hinges,

then remove the door to access the cab.

Rear Access: (Rear Window Entry)

Remove the silver knobs securing the

rear window grate, remove the grate,

then apply force at a corner of the win-

dow to access the cab.

Lift Arm Brace

When the lift arms must be left in the

raised position, install the lift arm brace

to ensure your safety.

To install:

1. Remove any attachments from the

machine, then park the machine on

flat, stable ground.

2. Have an assistant withdraw the

retaining pins from the lift arm brace

on the fender and remove the brace.

3. Raise the lift arms to the upper limit to

allow for brace installation.

4. Have the assistant place the lift arm

brace onto the top side of the cylinder

ram and install the retaining pins to

secure it there.

5. Slowly lower the lift arms until they

come to rest on the brace.

To remove:1. Raise the lift arms until they are clear

of the brace.

2. Have an assistant remove the retain-

ing pins and remove the brace.

3. Lower the lift arms to the lower stop.

4. Position the lift arm brace over the

fender brackets as found and install

the retaining pins to secure it there.

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!

WARNING

15

16

MACHINE MAINTENANCE

Engine Oil and Filter Change

Regular oil changes are necessary to

maintain a strong running engine. ASV

recommends a normal oil change inter-

val 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.

To change the oil and filter:

1. Run engine for a few minutes to

warm the engine oil.

2. Remove the drain plug from oil pan.

3. Drain the oil into suitable container.

4. Remove engine oil filter, make sure

gasket is also removed. It may be

necessary to lower 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.

Engine Oil Specifications:

• ASV 10W30 Heavy Duty Engine Oil

You may also use a quality engine oil

substitute with one of the following mini-

mum specifications:

• API CH-4 multigrade oil.

MACHINE MAINTENANCE

17

Hydraulic Fluid and Filter Change

The hydraulic fluid should be changed

every 500 hours, and the hydraulic filter

should be changed every 250 hours.

Hydrostatic components require

extremely clean oil in order to have a

long service life. Extreme caution must

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. Lower the forward skid plate behind

the front torsion axle. Locate and

remove the hydraulic fluid drain plug

(A), and drain into suitable container.

2. Locate the two hydraulic filters (B,C)

in the rear right-hand side of the

engine compartment.

3. Clean around the filters, and remove.

4. Replace both filters with ASV

approved filters.

5. Reinstall the drain plug and skid-plate

and fill the hydraulic reservoir (D) with

ASV Premium All Season MV

Hydraulic Oil, or approved hydraulic

fluid such as Chevron Rykon MV. The

hydraulic fluid level sight gauge is

located on the right side of the

machine (E).

B

A

C

DE

18

MACHINE MAINTENANCE

Fuel Filter and Water Separator

The fuel filter should be changed every

500 hours, or as needed. A plugged fuel

filter can cause a loss of engine power,

rough running, or no start.

To change filter:

1. Clean the outside of the filter thor-

oughly.

2. Twist the filter element housing

counter clockwise (if looking from the

bottom) and remove. Push down on

the element and turn 90 degrees

counter clockwise and remove.

3. Replace with a new element and push

down and turn 90 degrees clockwise.

4. Replace filter element housing.

The water separator is designed to keep

water out of the fuel system. The sepa-

rator consists of a filter, a transparent

bowl and a drain valve. Twist the drain

counter clock wise to drain water from

the bowl. Drain filter daily.

Fuel Specifications

In North America, diesel fuel, distilled

from crude oil, that is identified as No. 1-

D or No. 2-D in “ASTM D975” generally

meet the proper specifications.

Fuse Panel

The electrical systems in PT machines

are equipped with fuses that help to pro-

tect the electrical components from dam-

age. They are found in the fuse panel

which is located on the right side of the

engine compartment.

In the event of an electrical malfunction,

check the fuse panel. Remove the fuse

related to the component that is not

working properly and inspect it. If it

appears damaged in any way, replace it.

Replace fuses with correct amperage fuse

only. A fuse with a lower amp rating will fail

more easily whereas one of a higher rating

may cause electrical system damage.

CAUTION

MACHINE MAINTENANCE

19

UndercarriagesThe undercarriage assemblies 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 assem-

blies and cleaning if necessary.

Materials that are particularly sticky or

abrasive like clay, mud, or gravel should

be cleaned from the undercarriages

often to minimize component wear. A

pressure washer works well for cleaning

materials from the undercarriages. At

times when a pressure washer is not

available, use a bar, shovel or similar

device to remove foreign materials.

When cleaning, pay particular attention

to the drive motors/sprockets and the

front and rear wheels where debris is

likely to accumulate. If working in scrap

or debris, inspect the undercarriages

more often and remove foreign objects

that may wrap around or lodge them-

selves between components causing

premature wear and damage.

Operation on sand, turf, or other finished

surfaces may require less frequent

cleaning, but daily inspection is still

advised.

Track TensionProper track tension is necessary for

optimal undercarriage/track performance

and service life. Running a track that is

too loose can cause the track to mis-

feed, possibly causing damage. Running

a track that is too tight can cause track

stretch, bearing failure or other preventa-

ble damage. During the first 50 hours of

operation the tracks will "break-in" and

may require adjustment.

To adjust track tension:

1. The front of the drive table is secured

by two bolts (A).

Note: If the bolts (A) are at the rear of

their mounting slots they can be used to

tighten the track in their current posi-

tions. If they are at the front of their slots,

they need to be relocated. There are a

series of threaded holes in the frame rail.

The bolts can be repositioned as needed

to achieve proper tension.

2. Once the bolts (A) are loosened or

relocated, loosen the lock nut (B) on

the turnbuckle (C) and adjust by turn-

ing the turnbuckle (item C).

3. Once proper tension has been

achieved (see page 20), tighten the

locknut (B) and the two bolts (A) to

secure the drive table in place.

B CD

A

Checking Track Tension

The tracks should be tightened only to

the point where there is no noticeable

sag in the track. Do not tighten the

tracks beyond this point.

To check track tension:

1. Drive the machine forward 5 feet.

2. Lay a straight edge along the top of

the track, between the sprocket and

the front idler wheel (A).

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

A B

MACHINE MAINTENANCE

Drive Sprocket Rollers

Rubber Track Loaders use rollers on

each drive tooth of the two drive sprock-

ets. These rollers help minimize friction

between lugs on the track and the

sprocket. Sprocket rollers should be

treated as wear items that are inspected

regularly and replaced as needed.

The rollers (C) rotate on hardened steel

pins (D), limiting wear to the inside of the

rollers. As they wear, the rollers become

thinner, but will continue to function and

perform as long as they are rotating.

Visually inspect rollers every 50 hours

and replace any that show signs of

cracking or wear-through.

In order to replace sprocket rollers, the

drive table (E) must be pivoted out from

under the track as required during track

removal. This will allow access to the

drive sprocket (F) and provide clearance

for the removal of the retaining bolts (G)

for roller replacement. For specific

instruction regarding roller replacement,

consult your machine specific service

manual.

21

C Steel Pin

New RollerNormal Roller Wear

at 50% life

D

G

Make sure the machine is turned off, the

key removed, and the battery discon-

nected before performing this procedure.

WARNING

E

F

22

MACHINE MAINTENANCE

Air Cleaner

The air cleaner is one of the most impor-

tant maintenance items on the machine.

Regular inspection and replacement is

necessary to ensure proper performance

and to prolong engine life. Inspect the

air cleaner elements daily. If damaged

or heavily soiled, clean or replace the

elements.

1. Open the hood, pull the yellow slide

lock, then twist the cover counter-

clockwise approximately 1/8 turn and

pull to remove the cover from the air

cleaner housing.

2. Remove the primary element (A). The

primary element can be cleaned and

reused up to five times, but should be

changed at least once a year.

3. Remove the secondary element (B).

The secondary element is not service-

able or washable. The secondary ele-

ment should be replaced every three

cleanings of the primary element.

To clean the primary element:

1. Remove loose dirt from the element

with compressed air or water hose.

Compressed air: 100 PSI max. 1/8”

diameter nozzle at least 2” away from

the filter element.

Water: 40 PSI max. without nozzle.

2. Soak the filter element in a non suds-

ing detergent solution for at least 15

minutes moving it gently through the

solution to further clean the element.

(Never soak for more than 24 hours.)

3. Rinse the filter thoroughly with a gen-

tle stream of water to remove all dirt

and remaining detergent.

4. Allow the filter to dry completely

before reinstalling it into the machine.

A

B

Do not use any heat source other than

warm air at less than 160° F to dry the filter.

CAUTION

During the engine warranty period, do not

clean the filter elements. Instead, replace

the filter elements when soiled or damaged

to comply with engine warranty require-

ments.

CAUTION

MACHINE MAINTENANCE

23

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.

MACHINE MAINTENANCE

Radiator/oil cooler cleaning The radiator and oil cooler must be clean

to ensure proper operation. Engine and

hydraulic system overheating, damage

and even failure can result if the radia-

tor/oil cooler is not kept clean. A pres-

sure washer or compressed air nozzle

work well to blow debris clear of the fins

in the oil cooler and radiator.

Note: If hydraulic oil or engine coolant

temperature lights illuminate during oper-

ation, clean coolers more often.

Note: In brush cutting applications check

and clean the coolers and chassis often

to avoid overheating and prevent fires.

To clean radiator and oil cooler:

1. Make sure the engine is off, and

cool during radiator/oil cooler

cleaning procedure.

2. Thoroughly clean radiator/oil cooler

prior to operation. Direct spray

forward as shown. (fig. A, B)

Note: Make sure water nozzle is at least

12” (8” for air) from the cooler and that

the spray is directed straight through the

cooler or the cooling fins may be dam-

aged (bent over) which will decrease

cooling performance.

Chassis and engine cleaningPeriodic cleaning of the chassis area

beneath the cab and engine compart-

ment are also necessary to maintain

safe operation. Clean as necessary.

(fig. C)

1. Remove the belly pans on the

underside of the machine.

2. Raise the hood at the rear of the

machine.

3. Pressure wash any debris from the

engine compartment and chassis

area out through the lower opening.

4. Re-install the belly pans and close

the hood to complete the cleaning

procedure.

24

A

B

C

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:

1. Remove any attachment fastened to

the quick attach.

2. Raise the lift arms and secure with lift

arm brace.

3. Remove the bolts at the base of the

canopy that fasten it to the chassis.

4. Remove the air pre-cleaner assembly

(E) from the machine.

5. Remove the two limb risers (F) from

the machine.

6. Raise the canopy and watch to make

sure the lock-out brace falls into

place.

7. Secure the canopy lock-out brace with

the D-latch pin (D) as shown.

Note: The lift arms must be raised in

order to tilt the canopy.

TILT-UP ROPS

25

E

F

D

Cab FiltrationThe cab is equipped with two air filters,

one on each side of the cab enclosure.

They should be inspected daily and

cleaned/replaced as necessary.

To clean:

1. Remove the thumb screws securing

the side panel to the cab AC unit,

then remove the panel and filter.

2. Inspect the filter for damage. If dam-

aged, replace filter. If not damaged,

remove the filter and tap gently

along rigid edge of filter to clean. To

reinstall the filter, reverse step 1.

3. Repeat steps 1 and 2 on the oppo-

site side of the machine.

Note: Filters must be clean to maintain

cab pressure. Clean daily or as needed.

Fan CleaningThe heater/AC unit is equipped with two

fans that circulate air through the unit.

They must be cleaned daily to ensure

proper function.

To clean:

1. Remove the thumb screws securing

the lower portion of the fan guard to

the rear of the heater/AC unit.

2. Lift the guard from the bottom and

pivot it upward to expose the fans.

3. Following the guidelines on page

24, use compressed air only to blow

any dirt or debris clear of the fans.

4. Reverse steps 1 and 2 to complete

the procedure.

Fluids and LubricantsWhen replacing or replenishing the fluids

and lubricants in your PT-100 Forestry

Rubber Track Loader, you can specify

ASV fluids and lubricants. This assures

the new fluids and lubricants match

those originally installed when your

machine left the ASV factory. ASV fluids

and lubricants were developed for,

tested and approved by ASV to assure

optimum life and performance in all ASV

Rubber Track Equipment, when used as

recommended.

The ASV fluid and lubricant product line

includes:

• Heavy Duty Engine Oil, 10W30;

• Premium All Season MV Hydraulic Oil;

• Multi-Purpose EP Lithium Grease;

• Long-Life 50/50 Antifreeze/Coolant;

• Undercarriage Wheel Bearing

Lubricant.

ASV fluids and lubricants are available

through your ASV Dealer. If ASV prod-

ucts are not available, use an equivalent

product meeting the same specifications.

26

CAB FILTRATION / FAN CLEANING / FLUIDS AND LUBRICANTS

SERVICE LOG

Hours Service Performed Notes

27

Terex Construction Americas

8800 Rostin Road

Southaven, MS 38671

(888)-201-6008

(662)-393-1800

www.terex.com

ASVPT100 Forestry OM (1/09)

Copyright 2009 Terex