Rubber Track Loader. Operation and Maintenance Manual PT-100 FORESTRY

Transcription

1 Rubber Track Loader Operation and Maintenance Manual PT-100 FORESTRY

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3 CONTENTS California Proposition Introduction Specifications Machine Labels and Decals Fire Prevention Operating Capacity / Attachment Precautions Machine Controls Switches / Instrumentation Machine Operation Machine Maintenance ROPS Canopy Tilt-up Access Cab Filtration / Fan Cleaning / Fluids & Lubricants Service Log WARNING Read and understand this manual prior to operating, inspecting, or attempting to maintain the Rubber Track Loader. Performing any of these tasks incorrectly can lead to machine damage, personal injury or even death. 1

4 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 reproductive harm. 2

5 INTRODUCTION 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 operation also requires caution and attentiveness 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 technically correct. Machine Orientation Terms like front, rear, left, and right are used throughout this manual to describe portions of the machine. They are to be understood from the perspective of an operator seated inside the cab. WARNING This manual contains the words Warning, Caution and Note to emphasize 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 information which requires special attention. 3

6 MACHINE SPECIFICATIONS General Dimensions Height to top of ROPS: Ground clearance: Max. lift height, at hinge pin: Machine length, w/out bucket: Machine length, with bucket: Machine width: Track Specifications Track width: Length of track on ground: Machine Weight PT-100 Forestry 91 in. / 2311 mm 14 in. / 356 mm 125 in. / 3175 mm 121 in. / 3073 mm in. / 3848 mm 69 in. / 1753 mm 18 in. / 457 mm 72.5 in. / 1842 mm Shipping Weight: 10,400 lb / 4717 kg Operating Weight: lb / 5182 kg Ground Operating Weight: 4.37 psi / kpa Ground contact area: 2,610 in. 2 / 1.68 m 2 Specifications are subject to change without notice. SAE J818 standards define operating capacities of rubber-tired skid steers (50% tipping load) and tracked loaders (35% tipping load). There are no standards defining the operating capacity of machines equipped with a suspended undercarriage or machines with rubber tracks. Engine Model: Type: Displacement: Gross 2300 rpm: Torque (peak): Operating Specifications PT-100 Forestry Perkins 1104C-44T 4-cylinder diesel 268 in. 3 /4.4 liter 99.9 hp / 74.5 kw 306 ft-lb / 415 Nm Operating 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 Pump Low flow, max.: High flow, max.: Pressure: Service Refill Capacities Fuel tank: Hydraulic tank*: Engine coolant*: Engine oil, including filter*: 20 gpm / 76 lpm 40 gpm / lpm 3,650 psi / 25,170 kpa 26 gal / 98 L 20 gal / 76 L gal / 12 L 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. 4

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

8 FIRE PREVENTION WARNING 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 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. With the engine off and cool, clean flammable debris from engine compartment, exhaust system, attachments 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 components. Check hydraulic lines, hoses and fittings for damage or leaking fluid. Never use bare hands to check for leaks. Pressurized fluid can penetrate skin and cause injury or even death. WARNING 6 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. 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.

9 OPERATING CAPACITY / ATTACHMENT PRECAUTIONS Operating Capacity The operating capacity refers to how much additional weight can be added to the standard dirt bucket's center of gravity. The recommended operating capacities 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 operating capacities of rubber-tired skid steers (50% tipping load) and tracked loaders (35% tipping load). There are no standards defining the operating capacity of machines equipped with a suspended undercarriage or machines with rubber tracks. 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 temperature areas and can become a fire hazard. Debris should be cleaned frequently 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 condition, 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. CAUTION Machine damage and failure caused by utilizing non ASV mulching type brush cutters will not be covered by ASV warranty. 7

10 MACHINE CONTROLS Loader and Drive Controls The PT-100 Forestry has two hydraulic pilot joystick controls. These two joysticks 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 function. 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. A C B 8

11 SWITCHES / INSTRUMENTATION H K R S D E F G L I Light J M N O P Q J Dash Panel There are many switches and instruments involved in the operation of PT machines. Learn the location and function of these items prior to operation. Switch Panels D - 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 Instruments H - 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 suitable location and shut the engine off. Diagnose the problem and make needed repairs before continuing to operate. The glow plug operation light (S) will illuminate only when the key switch is turned to engine pre-heat, showing normal operation. K T V CAUTION 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 problem and make needed repairs before continuing to operate. U 9

12 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 position. Starting Procedure Before starting the engine, perform the pre-start checklist then proceed with the following procedure: 10 A 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. B 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. WARNING Entering or exiting the vehicle under raised lift arms could cause serious injury or death. Never allow anyone to be underneath raised, unsecured lift arms (photo B).

13 MACHINE OPERATION WARNING Failure to wear the seat belt could lead to serious injury or death. C CAUTION Do not crank the engine for more than 20 seconds. Allow the starter to cool for 2 minutes before cranking again. WARNING Do not use aerosol type starting aids such as ether. Such use could result in an explosion and personal injury. 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. WARNING Always visually verify that the quick attach pins are fully extended and that the attachment is securely fastened prior to use. D E 11

14 MACHINE OPERATION B 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 automatically return to low range. In order to resume high range operation after such an event, you must sit down in the operator seat and fasten the seat belt, then start the engine if necessary and reactivate high range as described elsewhere on this page. A 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 indicator (B) will illuminate to confirm high range operation. Operation on Inclines ASV Rubber Track Loaders are very stable on inclines. Machine weight is distributed evenly throughout the chassis and the suspended undercarriage track system provides excellent traction and floatation on nearly all surfaces. Even with these capabilities, caution should always be exercised while operating 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 direction. Then proceed forward. WARNING 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 Failure to follow the instructions regarding operation on inclines may result in machine damage, severe injury, or even death. CAUTION 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. 12

15 MACHINE OPERATION C D 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 variable 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 toggletype 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 (neutral) positions in order to start the engine. 13

16 MACHINE OPERATION Electric Attachment Control Attachments are controlled by various buttons on the drive and lift-arm control joysticks. Most attachments are controlled 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 attachments 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 turning the temperature control knob and adjusting fan speed. To activate A/C you must first press the AC button. 14 Cab Pressurization The 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 Fan The 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 normal operation to keep the cooler free of debris. The fan can be activated manually by pressing the switch (C) on the dash panel. A C 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 feature 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. B

17 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 triangular 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 window 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 retaining 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. WARNING This procedure must be performed by two people to ensure safety. Never place any part of your body under unsecured lift arms as personal injury or death could result! 15

18 MACHINE MAINTENANCE Engine Oil and 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. 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 minimum specifications: API CH-4 multigrade oil. 16

19 MACHINE MAINTENANCE 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. A B C 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 D 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). E 17

20 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 thoroughly. 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. 18 The water separator is designed to keep water out of the fuel system. The separator 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 protect the electrical components from damage. 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. CAUTION 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.

21 MACHINE MAINTENANCE Undercarriages The 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 assemblies and cleaning if necessary. B C A D 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 themselves 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 Tension Proper track tension is necessary for optimal undercarriage/track performance and service life. Running a track that is too loose can cause the track to misfeed, possibly causing damage. Running a track that is too tight can cause track stretch, bearing failure or other preventable 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 positions. 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 turning 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. 19

22 MACHINE MAINTENANCE A B 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

23 MACHINE MAINTENANCE Drive Sprocket Rollers Rubber Track Loaders use rollers on each drive tooth of the two drive sprockets. 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. C 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. Steel Pin G D New Roller Normal Roller Wear at 50% life WARNING F E Make sure the machine is turned off, the key removed, and the battery disconnected before performing this procedure. 21

24 MACHINE MAINTENANCE Air Cleaner The air cleaner is one of the most important 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 counterclockwise 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 serviceable or washable. The secondary element should be replaced every three cleanings of the primary element. 22 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 sudsing 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 gentle stream of water to remove all dirt and remaining detergent. 4. Allow the filter to dry completely before reinstalling it into the machine. CAUTION Do not use any heat source other than warm air at less than 160 F to dry the filter. B 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 requirements. A CAUTION

25 MACHINE MAINTENANCE Grease Fittings The illustration below shows the location of grease fittings found on the left side of the machine. An identical set of fittings can be found on the right side of the machine. All fittings should be lubricated daily, prior to operation. 23

26 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 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. Note: If hydraulic oil or engine coolant temperature lights illuminate during operation, 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) 24 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 damaged (bent over) which will decrease cooling performance. Chassis and engine cleaning Periodic cleaning of the chassis area beneath the cab and engine compartment 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. A B C

27 TILT-UP ROPS Tilt-up ROPS Service Access The ROPS canopy tilts up for easier service. The tilt-up canopy features a gas spring assist and a lock-out brace. To tilt the canopy: 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. F E D 25

28 CAB FILTRATION / FAN CLEANING / FLUIDS AND LUBRICANTS Cab Filtration The 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 damaged, replace filter. If not damaged, remove the filter and tap gently along rigid edge of filter to clean. To reinstall the filter, reverse step Repeat steps 1 and 2 on the opposite side of the machine. Note: Filters must be clean to maintain cab pressure. Clean daily or as needed. 26 Fan Cleaning The 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 Lubricants When 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 products are not available, use an equivalent product meeting the same specifications.

29 SERVICE LOG Hours Service Performed Notes 27

30 Terex Construction Americas 8800 Rostin Road Southaven, MS (888) (662) ASVPT100 Forestry OM (1/09) Copyright 2009 Terex