ASV PT-80 User manual

8/17/2016
Operation and Maintenance
Manual
PT80
SN All
English
All
Language:
Geographic Region:
Serial Number Range:
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 [phone]

IINNTTRROODDUUCCTTIIOONN
1
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.
The PT-70/80 are rugged and agile machines capable of working on
a variety of challenging terrains. They are 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-70/80. With this in
mind, it is the responsibility of each operator to read and fully under-
stand this manual before attempting to operate the machine.
Machine damage, bodily injury, or even death may result if the pro-
cedures and precautions described in this manual are not followed
closely.
Machine Orientation
Terms like front, rear, left,
and right are used through-
out this manual to describe
portions of the machine.
They are to be understood
from the perspective of an
operator seated inside the
cab.
FRONT
REAR
RIGHTLEFT

SSAAFFEETTYYOOVVEERRVVIIEEWW
2
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.
Read and understand all safety messages in order to protect your-
self and others from personal injury or death.
These safety messages are identified by the words:
DANGER, WARNING, and CAUTION.
The word “Note” is used throughout this manual to draw your
attention to specific topics or to supplement the information
provided in that section.
It is not possible to anticipate every potential hazard. The safety
messages included in this document and displayed on the machine
are not all-inclusive. They are intended to make you aware of poten-
tial risks and encourage a safe approach to operation, inspection
and maintenance of the machine. Do not operate the machine until
you are sure you have a thorough understanding of its operation,
inspection and maintenance. It is your responsibility as the operator
to exercise caution while performing these tasks to ensure your
safety and the safety of others.
!
“DANGER” refers to an imminently hazardous situation that may
result in serious injury or even death.
DANGER
“WARNING” refers to a potentially hazardous situation that may
result in serious injury or even death.
“CAUTION” refers to a potentially hazardous situation that may result
in damage to the machine or its components.
WARNING
CAUTION
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

Serial Numbers
Product ID Number
The Machine PIN is located on
the front of the cab near the
lower right corner of the door
opening. This number must be
provided when contacting your
dealer regarding parts, service,
warranty or accessories.
Warranty claims will not be
processed unless the machine
PIN is provided.
Engine Serial Number
The Engine Serial Number is
located on a metal identification
plate fastened to the engine
valve cover at the rear of the
machine.
Manual Storage
The manual storage compart-
ment is located in the lower left
portion of the cab near the oper-
ator’s left leg.
MMAACCHHIINNEEIIDDEENNTTIIFFIICCAATTIIOONN
3

TABLE OF CONTENTS
4
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........................................................ 67

5

SSAAFFEETTYY- CONTENTS
6
Features .............................................................. 7
Tipping Load/Operating Cap./GVW......... 9
Fire Prevention................................................. 10
Warning Decals................................................ 11

The PT-70/80 rubber track load-
ers are equipped with many
safety features to reduce the
possibility of injury to the opera-
tor during operation.
These features include:
A. Seat Belt
The seat belt is designed to
keep the operator securely fas-
tened in the seat should the
machine encounter uneven ter-
rain or come to a sudden stop
during operation. It is equipped
with a safety switch that is acti-
vated when the seat belt is
clicked into position around a
seated operator. This switch has
been included to ensure that the
seat belt is fastened before any
motion is allowed to take place.
Always fasten your seat belt
prior to operating the machine.
Serious injury or even death
could result if your seat belt is
left unfastened during operation.
B. Lap Bar (if equipped)
In equipped machines, the lap
bar houses the gauges to keep
the operator aware of machine
system status while operating.
C. Operator Presence Seat
Switch
This switch ensures that the
operator is seated inside the
machine before any motion is
allowed to take place. This safe-
ty switch is activated when an
operator is seated in the cab.
D. Auxiliary Hydraulic Safety
Switches
These switches have been
included to ensure that attach-
ments do not engage when the
machine is started. They must
be locked into their neutral posi-
tions in order for the machine to
start.
E. Parking Brake
The PT-70/80 are equipped with
parking brake mechanisms. The
brake effectively locks the trans-
mission when activated to pre-
vent machine movement.
Note: The lift arm control will still
function normally when the park-
ing brake is active.
Note: Switch locations D-F may
differ from the illustrations. (see
switch labels in machine)
SAFETY
Features
7
D
E
C
A
B
MP-2 configuration

SAFETY
Features
8
F. Power Quick-Attach Safety
Switch (if equipped)
The purpose of this switch is to
ensure attachments are properly
fastened to the machine prior to
operation. The engine will not
start unless this switch is in the
locked position. When installing
an attachment, always perform a
visual check to make sure it is
correctly attached and locked in
place prior to use.
Note: Items D and F are
equipped with small orange lock-
ing devices. In order to move
these switches, you must first
disengage the locking devices
by sliding them downward. The
switches may then be moved
into the desired positions.
G. Lift Arm Brace
Each machine is equipped with
a brace to ensure your safety
during service work or mainte-
nance. Prior to performing any
service or maintenance that
requires the lift arms to be in the
raised position, follow the lift arm
brace installation procedure
located on page 34.
H. Escape Hatch
The rear window on the PT-
70/80 serves as an escape
hatch in an emergency situation.
It is identified by a yellow trian-
gular tag attached to the rubber
molding surrounding the window.
To exit through this opening,
grab hold of the tag and pull to
remove the molding. This will
allow the window to be pushed
out. Then carefully crawl out of
the opening to safety.
F
G
H

Tipping Load
The tipping load is the amount
of weight that, when applied to
the bucket center of gravity,
causes the machine to begin tip-
ping forward.
The tipping load is calculated
with the machine still and on
level ground, equipped with a
standard dirt bucket that is
raised to the point in the lift arm
path where the load is posi-
tioned furthest from the
machine.
Rated Operating Capacity
The rated operating capacity
(ROC) is a percentage of the tip-
ping load. The ROC is equal to
35% of the tipping load for tradi-
tional track loaders, or 50% of
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. Pallet forks
or other attachments often move
the center of gravity further
away from the machine reducing
the ROC.
Do not exceed the rated operat-
ing capacity for your machine.
Doing so could result in serious
injury to the operator and or
damage to the machine. The
operating capacity ratings for the
PT-70/80 are located on page
63.
Note: SAE J818 standards
define operating capacity ratings
for rubber tired skid steer load-
ers (50% tipping load) and
tracked loaders (35% tipping
load). There are no standards
defining the operating capacity
of machines equipped with sus-
pended undercarriages or rub-
ber tracks.
Gross Vehicle Weight
The G.V.W. of the PT-70 and 80
machines should never exceed
11,500Lbs. for the PT-70 and
12,500 lbs. for the PT-80 during
operation. This weight excludes
an operator, but does include
any accessories, attachments or
material being moved.
Operating the machine in excess
of the the G.V.W. will void the
warranty.
SAFETY
Tipping Load/Operating Capacity/GVW
9
Load
C of G

SAFETY
Fire Prevention
10
Fire Prevention
Rubber Track Loaders have
components that operate at high
temperatures. Steps must be
taken to make sure that flamma-
ble items are kept clear of these
components during operation.
Failure to do so may result in a
fire.
The main heat sources in the
vehicle are the engine and the
exhaust system. The electrical
system could also be a source
of heat/sparks if damaged or
poorly maintained.
In some work environments,
flammable items such as leaves,
straw and brush cutting debris
may come in contact with these
sources. It is very important that
these flammable items be
removed often from areas close
to hot components. If 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.
Listed are a set of precautionary
tasks that should be performed
daily or more often if necessary.
Repair or replace worn or dam-
aged components as needed to
ensure safe machine operation.
Precautionary Tasks:
• With the engine off and cool,
remove any debris present in
the engine compartment and
chassis area (under cab).
Remove the belly pans and
pressure wash these areas
to clean them properly.
• Check the battery, fuse box,
electrical wiring and connec-
tion points for damage or
looseness.
• Check fuel lines 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 pene-
trate skin and cause injury or
even death.
• Do not use ether or any other
aerosol type starting aid to
start the engine.
• Always stop the engine and
allow the machine to cool
prior to adding fuel.
• Do not smoke or allow open
flame near the machine while
refueling.
WARNING

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.
SAFETY
Warning Decals
11
WARNING
Entering & Exiting
Maintain 3-point contact
with step and hand rails.
Engine Warm-Up
Allow the engine to
warm up prior to opera-
tion.
Carrying Loads
Carry loads low. Load,
unload and turn on level
ground.
Inclines
Travel with heaviest end
of machine facing uphill.
Riders
Riders not permitted.
Work Platform
Never use a work tool as
a work platform.
Disclaimer
Failure to observe and
comply with the warn-
ings listed above may
result in machine dam-
age, personal injury, or
even death.
Pre-Start Checklist
1. Operator seated in
cab.
2. Seat belt fastened.
3. Lap bar pivoted down.
4. Joystick controls in
neutral position.
5. Quick attach switch in
locked position.
6. High & low flow auxil-
iary switches off.
2045-469
Entering and Exiting
Carrying Loads / Inclines
Riders
Work Platform

SAFETY
Warning Decals
12
DANGER
Operating Position
Never operate the
machine with any part of
your body protruding
out of the operator
enclosure.
Failure to do so may
result in serious injury or
even death.
Prior to Operating
Read and fully under-
stand the operation and
maintenance manual
prior to operating this
machine.
2045-472
Operating Position
WARNING
Brushcutting
Brushcutting, mowing or
operations that generate
airborne debris can
cause fires.
With the engine off
and cool:
1. Inspect the engine
compartment and any
other areas containing
hot or rotating parts
2. Thoroughly clean
these areas as often
as necessary to
avoid combustion.
Failure to do so could
result in fire that may
cause machine damage,
personal injury, or even
death.
2-Speed
(if equipped)
To engage:
Press the button located
on the front of the right
joystick control.
To disengage:
Press the button a sec-
ond time.
2045-468
Keep out from under raised lift arms!
Do not go beneath raised lift arms unless the lift arm
brace has been properly installed. See operation and
maintenance manual for installation procedure.
Failure to observe or comply with warnings may result in
serious injury or even death.
DANGER
2045-466
WARNING Keep away from tracks while machine is in motion.
Serious personal injury or even death may result.
Inspect undercarriages daily for accumulation of
debris. Build-up of debris may shorten component
life and decrease machine performance.
CAUTION 2045-467

13

CCOONNTTRROOLLSS- CONTENTS
14
Instrument Display ......................................... 15
Switch Panels.................................................... 16
Drive & Lift Arm .............................................. 17
Throttle/Electric Attachment...................... 18
Auxiliary Hydraulic.......................................... 19
Two Speed/Power Quick Attach................ 21

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.
The display includes:
A. Engine Temperature Gauge
B. Oil Pressure Gauge
C. Fuel Gauge
D. Hydraulic Oil Temp. Gauge
E. Voltmeter
F. Tachometer
G. High Range Indicator
H. Glow Plug Operation Indicator
I. Low Range Indicator
J. Parking Brake Indicator
K. Hour Meter
Note: The locations of items A-U
within the operator enclosure
may differ from the illustrations.
However, they are present and
easily identified by label, form,
or by icons present on the com-
ponents.
The glow plug operation light
should illuminate only when the
ignition switch is turned to the
pre-heat position.
Pay close attention to the dis-
play during operation to ensure
that all systems are functioning
properly.
CONTROLS
Instrument Display
15
A
B C
D E F
I J
G H
K

CONTROLS
Switch Panels
16
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. Low Flow Aux. Switch
Q.Hyd. Quick Attach Switch*
R. Heater Fan Switch**
S. Windshield Wiper Switch**
T. Beacon Switch**
U. Ignition Switch
* Optional on PT-70
** Optional on PT-70/80
L
M
N
O
P
Q
R
S
T
U
Left Right

Drive Control
The PT-70/80 are equipped with
pilot operated joystick controls.
The drive control (left joystick) is
used to control track motion. The
illustration above shows the rela-
tionship between joystick and
machine movement.
Note: The machine will not
move as long as the drive con-
trol is in the neutral position.
Each joystick is equipped with a
spring return feature that auto-
matically returns it to neutral
position when released.
To stop a moving machine,
release the left joystick altogeth-
er. This will stop the machine.
Lift Arm Control
The lift arm control (right joy-
stick) is used to control the lift
arms and attachment (bucket)
movement. The illustration
above shows the relationship
between joystick and lift
arm/attachment movement.
The PT-70/80 are equipped with
a float function that allows the lift
arms and attachment (bucket) to
follow the contours of the ground
as you move with only their own
weight acting as downforce.
•To engage: push the joystick
fully forward into position.
(see illustration)
• To disengage: pull back
quickly on the joystick.
CONTROLS
Drive & Lift Arm
17

CONTROLS
Throttle/Electric Attachment
18
Throttle Controls
The throttle controls engine
RPM. When performing work
that requires delicate, precise
movements, use a lower RPM.
When more speed, horsepower,
or flow is required, use a higher
RPM.
The PT-70/80 are equipped with
foot operated throttle mecha-
nisms.
• To increase engine RPM,
press the front (toe) of the
foot pedal slowly towards the
floor until the desired rpm has
been reached.
• To decrease RPM, press the
rear (heel) of the pedal
towards the floor.
Electric Attachment Control
Most attachments for ASV
Rubber Track Loaders are con-
trolled hydraulically, but some
require electrical input as well.
When electrical input is required,
the four buttons on the drive
control (left) joystick can be uti-
lized to send electrical current to
the receptacle located on the
upper left side of the lift arms.
Note: ASV receptacle style and
pin designation may differ from
those utilized by other manufac-
turers. To ensure proper func-
tion, use only ASV approved
attachments.
Buttons
Throttle

The PT-70/80 are equipped with
high and low flow auxiliary
hydraulic circuits that allow for
the use of hydraulic attach-
ments.
The couplers for the auxiliary cir-
cuits are located on the left side
of the lift arms near the front of
the machine. They are posi-
tioned from top to bottom as
such: (see photo)
A. Case drain
B. High flow
C. High flow
D. Low flow
E. Low flow
The PT-70/80 uses a variable
displacement pump to supply oil
to the low and high flow auxiliary
circuits. This pump displaces
30gpm when the high flow
switch is activated and 20gpm
when the low flow switch is acti-
vated.
To prevent an operator from
accidentally sending 30gpm
through a low flow attachment,
the machines are equipped with
a switch mechanism that dis-
ables the high flow switch when
an attachment is connected to
the low flow quick couplers.
Note: Low and high flow circuits
may not be used simultaneously.
Low Flow Intermittent
The low flow auxiliary circuit can
be utilized intermittently or con-
tinuously. It also has the capabil-
ity of varying attachment speed
through the use of a spring cen-
tered roller switch (F) located on
the back of the right joystick.
Attachment direction is deter-
mined by rolling the switch to the
right or left or center. Attachment
speed is determined by the
amount that it is rolled in the
chosen direction. This variability
gives the operator more control
over the actuation speed of the
attachment.
To activate the low flow auxiliary
hydraulic circuit intermittently,
roll the switch left or right of cen-
ter.
• To pressurize the upper low
flow quick coupler, roll the
switch to the left of center.
• To pressurize the lower low
flow quick coupler, roll the
switch to the right of center.
• To de-activate low flow inter-
mittent operation, release the
variable switch and flow will
cease.
CONTROLS
Auxiliary Hydraulic
19
A
C
B
E
D
F