ASV pt30 User manual

8/17/2016
Operation and Maintenance
Manual
PT30
SN All
English
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1
California Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Machine Labels and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operating Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Switches/Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Machine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Recommended Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
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 (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
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-30 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-
30. With this in mind, it is the responsi-
bility of each operator to read and fully
understand this manual before attempt-
ing to operate the machine. Machine
damage, bodily injury, or even death
may result if the procedures and precau-
tions described in this manual are not
followed closely.
At the time of publication, all information,
photographs, and illustrations are techni-
cally 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.
IINNTTRROODDUUCCTTIIOONN
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.
WARNING

4
GGeenneerraallDDiimmeennssiioonnssPPTT--3300
Height to top of ROPS: 71 in./1803 mm
Ground clearance: 10 in./254 mm
Max. lift height, at hinge pin: 80.25 in./2038 mm
Length of undercarriage: 68.5 in./1740 mm
Machine length, w/out bucket: 91 in./2311 mm
Machine length, with bucket: 112 in./2844 mm
Machine width: 46.5 in./1181 mm
TTrraacckkSSppeecciiffiiccaattiioonnss
Track width: 11 in./280 mm
Length of track on ground: 55 in./1397 mm
MMaacchhiinneeWWeeiigghhtt
Weight without bucket (shipping): 2,935 lb/1331 kg
Ground pressure: 2.5 psi/17 kPa
Ground contact area: 1,183 in.2/.76 m2
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 operat-
ing capacity of machines equipped with a suspended undercarriage or machines with rub-
ber tracks.
EEnnggiinneePPTT--3300
Model: Perkins 403C-15
Type: 3-cylinder diesel
Displacement: 1.5 liter
Gross HP @ 2800 rpm: 31.5 hp/23.5 kW
Torque (peak): 64.39 lb/ft. / 87.3 Nm
OOppeerraattiinnggSSppeecciiffiiccaattiioonnss
Operating capacities:
35% tip load: 560 lb/254 kg
50% tip load: 800 lb/363 kg
Travel speed max.: 6 mph/9.7 kph
AAuuxxiilliiaarryyHHyyddrraauulliiccPPuummpp
Flow, max.: 10 gpm/37.85 Lpm
Pressure: 3,000 psi/20 684 kPa
SSeerrvviicceeRReeffiillllCCaappaacciittiieess
Fuel tank: 10 gal./37.85 L
Hydraulic tank*: 8 gal./30 L
Engine coolant*: 1.5 gal./5.68 L
Engine oil, including filter*: 1.6 gal./6.06 L
* When replacing or replenishing these lubricants/fluids, it is recommended that you spec-
ify genuine ASV products from your ASV Dealer.
MMAACCHHIINNEESSPPEECCIIFFIICCAATTIIOONNSS

5
Product ID Number
The machine PIN is located on the left
side of the firewall, next to the seat
(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.
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 Guidelines
2040-121
MMAACCHHIINNEELLAABBEELLSSAANNDDDDEECCAALLSS

6
Fire Prevention
The PT-30 has components that
operate at high temperatures. The
main heat sources are the engine
and the exhaust system. The electri-
cal system, if damaged or improperly
maintained, can also be a source of
heat and sparks. Attachments (brush-
cutters, mowers etc.) can generate
debris that can cause a fire if improp-
erly 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.
FFIIRREEPPRREEVVEENNTTIIOONN
• 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

7
Operating Capacity
The operating capacity is a percentage
of the machine’s tipping load. Tipping
load refers to the amount of weight
required to tip the machine forward when
applied to the center of gravity of the
standard dirt bucket.
This rating is calculated with the machine
on level ground and the bucket attach-
ment installed, curled and raised until at
its furthest point from the machine in the
lift arm travel path.
The Rated Operating Capacity is then
calculated as 35% of the tipping load for
traditional track loaders and 50% of the
tipping load for wheeled skid steer load-
ers. ASV publishes both figures for refer-
ence and comparison.
Note: SAE J818 standards define oper-
ating 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-30 should not exceed 4,500 lbs.
These weights do not include operator,
but do include any accessories, attach-
ments or material being carried.
Exceeding the GVW will void the war-
ranty (see page 2).
OOPPEERRAATTIINNGGCCAAPPAACCIITTYY

8
Loader and Drive Controls
The PT-30 has two hydraulic pilot joy-
stick controls. These two joysticks are
used to control machine speed, direc-
tion, 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.
Control Options
PT-30 machines are available with a
"Case type" control configuration. This
control option uses similar joysticks, but
with a different control pattern to direct
machine function. On these machines,
joystick A controls the right track as well
as bucket curl and dump functions.
Joystick B controls the left track, lift arm
up/down functions, and float position.
The float position with this configuration
does not have a detent position, and
must be manually held in place to acti-
vate float function.
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.
B
A
C
MMAACCHHIINNEECCOONNTTRROOLLSS

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 Panels
D - Lights, front and rear
E - Heater Fan (optional)
F - Front wiper (optional)
G - Beacon (optional)
K - Ignition, glow plug (pre-heat)
L - Auxiliary Hydraulics
Instruments
H -Fuel Level Gauge
I - Warning Indicators (4-in-one)
J - Hour Meter
M - (not used)
N - Glow Plug Operation Light
O - Oil Pressure Warning Light
P - Battery Voltage Warning Light
Q - Hydraulic Oil Temp. Warning Light
R - Engine Temp. Warning Light
If the battery voltage warning light (P)
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 (N) will illu-
minate only when the key switch is
turned to engine pre-heat, showing nor-
mal operation.
9
SSWWIITTCCHHEESS//IINNSSTTRRUUMMEENNTTAATTIIOONN
DE F G H I J K L
Should the engine temperature, oil
pressure, or hydraulic oil temperature
warning lights illuminate during normal
operation, shut the machine down
immediately. Diagnose the problem
and make needed repairs before con-
tinuing to operate.
CAUTION
O
Q
P
M N
J
KR

10
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 switch
are in their neutral positions.
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. Fasten seat belt, and lower lap bar
into position.
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 machine is turned off.
MACHINE OPERATION
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

11
Moving Dirt
Certain techniques can be used to
become more efficient when moving dirt
with a bucket. The following instructions
will make the machine more productive
while preventing undue stress on the
machine’s components.
The lift arms are designed to rest against
the frame while leveling or digging.
When using the lift arms in this manner
(photo C) performance will be increased
and stress will be reduced:
1. Lower the lift arms all the way
down until they rest against the
frame of the machine.
2. Tilt the bucket forward until the
cutting edge engages the ground.
3. While moving forward make slight
adjustments to the bucket tilt cylin-
ders to vary the depth you are dig
ging.
MMAACCHHIINNEEOOPPEERRAATTIIOONN
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.
WARNING
CAUTION
WARNING
C

12
Never tilt the bucket all the way forward
to use the bucket as a dozer blade
(photo A). Damage to the bucket and
bucket cylinders can result.
Never back drag as shown in photo B as
damage to the machine, especially the
bucket and tilt cylinders, can result.
Operating on turf
ASV rubber track vehicles are designed
to tread lightly and produce minimal
ground disturbance while operating on
finished surfaces like turf, however, care
should be taken while operating on these
surfaces to prevent blemishes from
occurring.
Turning poses the greatest risk of sur-
face disturbance during operation.
Moving in a straight line across turf will
cause little or no disturbance, whereas
tight cornering will most likely cause
blemishes.
While working on turf, make gradual
turns. (see item C) If space is limited,
turn gradually by moving back and forth
until facing the desired direction. (see
item D)
MMAACCHHIINNEEOOPPEERRAATTIIOONN
B
C D
A

13
Operation on Inclines
ASV 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-30 on an incline in
excess of 10°. 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 facing the desired direction.
Then proceed forward.
Fastening Attachments
With both levers on the quick-attach
interface in the “up” position, drive
towards the attachment with the quick-
attach tipped forward (photo E). Hook
the top edges of the quick attach under
the upper lip of the attachment interface.
Raise the lift arms up slightly and then
curl the quick-attach until it is fully mated
with the attachment. Turn the engine off
and exit the machine. Secure the attach-
ment by pushing the levers downward
(photo F).
To confirm engagement:
1. Raise the lift arms slightly.
2. Tilt the attachment downward.
3. Visually verify that the locking pins
can be seen through the bottom of
the mating interface.
MMAACCHHIINNEEOOPPEERRAATTIIOONN
Carry load low. Do not exceed rated oper-
ating capacity. Load, unload, turn on level
ground. Travel on inclines with heaviest
end of machine uphill. Failure to comply
with these instructions may result in
machine damage, injury or even death.
WARNING
E F

14
Auxiliary Hydraulics
The PT-30 models come equipped with
an auxiliary hydraulic system designed
to run hydraulic attachments.
To operate, connect the attachment to
the two quick couplers (photo A). To
release any pressure in the system,
press the button labeled 1 in photo A.
The auxiliary hydraulics can be engaged
intermittently or continuously depending
on the requirements of the attachment
being utilized.
To engage the hydraulic flow intermit-
tently, activate the toggle-type switch on
the top of the right joystick, photo B.
Intermittent function is ideal for attach-
ments such as grapple buckets and
dozer blades.
To engage the hydraulic flow continu-
ously, activate the 3-position switch on
the dash panel, labeled 2 in photo C.
Continuous function is ideal for attach-
ments such as snow blowers, brush cut-
ters or backhoes.
Note: Moving either switch from one
position to the other has the effect of
reversing flow through the auxiliary
hydraulic circuit.
Note: The continuous flow switch must
be in its neutral position in order to start
the engine.
Note: The continuous flow auxiliary
switch has a small orange locking switch
that must be disengaged before the
switch will activate
MMAACCHHIINNEEOOPPEERRAATTIIOONN
1
2
AB C

15
Lift Arm Brace
When the lift arms must be left in the
raised position, the lift arm brace must
be engaged.
To engage:
1. Lower the lift arms. Remove any
attachments and park the machine on
level ground.
2. Remove the pin that secures the
brace to the fender.
3. Wrap the spring around the cylinder
and attach it to the other side of the
brace (photo D).
4. Raise the lift arms until the brace con-
tacts the cylinder rod (photo E).
5. Slowly lower lift arms until the lift arms
come to rest (stop) on the brace.
6. Shut the engine off and exit the
machine.
To disengage:
1. Remove the spring from the cylinder.
2. Raise the lift arms until the brace falls
away from the cylinder rod.
3. Lower lift arms.
4. Turn the engine off.
5. It is now safe to exit the machine and
re-attach the brace to fender.
MMAACCHHIINNEEOOPPEERRAATTIIOONN
D E

16
Engine Oil
The normal oil change interval is every
500 service hours or one year, which
ever comes first. Engines which are
operated under harsh conditions should
have the oil changed every 250 service
hours or every 6 months, which ever
comes first. Harsh conditions include:
operation in high temperatures, continu-
ous high load applications, and abnor-
mally dusty/dirty conditions.
To change engine oil:
1. Run engine for a few minutes to
warm the engine oil.
2. Remove the drain plug (item 1, photo
A) from the oil pan.
3. Drain oil into suitable container.
4. Remove engine oil filter, make sure
gasket is also removed.
5. Apply fresh oil to the new filter gasket
surface and install new filter.
6. Tighten filter to specifications on filter
label or box.
7. Refill engine to capacity with oil as
specified.
Engine Oil Specifications
Due to the significant variations in the
quality and in the performance of com-
mercially available oils, ASV makes the
following recommendations:
• ASV 10W-30 Heavy Duty Engine
Oil. or
If ASV products are not available for
some reason, you may use a quality
engine oil substitution meeting the fol-
lowing minimum specification:
• API CH-4 multigrade oil
MMAACCHHIINNEEMMAAIINNTTEENNAANNCCEE
1
A

17
Hydraulic Fluid and Filter
The hydraulic fluid should be changed
every 500 service 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 pro-
cedure, make sure the machine is in a
clean working environment. Precautions
should be taken to prevent any debris
from entering the hydrostatic system.
To change hydraulic fluid and filter:
1. Locate and remove the hydraulic fluid
drain plug (item 2) through the drain
hole in the belly pan. Drain the used
fluid into a suitable container.
2. Locate the hydraulic filter behind the
operator enclosure, under the left rub-
ber plug (item 3).
3. Clean around the filter head, then
remove the three bolts securing the
cover and remove it.
4. Remove the old filter from the hous-
ing, replace it with a new one, then
reinstall the cover and rubber plug.
5. Reinstall the drain plug, then refill the
hydraulic reservoir (item 4) with ASV
Premium All Season MV Hydraulic
Oil, or an approved substitute such
as Chevron Rykon MV. Observe the
hydraulic fluid level sight gauge (5)
located on the back of the hydraulic
reservoir to ensure that the level is
correct (photo D).
6. Once full, start the engine and oper-
ate all hydraulic circuits to work any
trapped air out of the system, then
check the fluid level. If low, add fluid
as necessary until full.
MMAACCHHIINNEEMMAAIINNTTEENNAANNCCEE
B
2
4
3
C
D
5

18
Fuel Filter Change
The fuel filter should be changed every
500 service hours, or as needed. A
plugged fuel filter can cause loss of
engine power, rough running, or no start.
To change the filter:
1. Clean the outside of the filter (1) thor-
oughly (shown above).
2. Remove bolt (2) on the top of the fil-
ter assembly, then remove filter.
3. Pour diesel fuel into new filter until it
is full.
4. Reverse step 2 to install the new fuel
filter into the machine.
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.
Item Frequency Lubricant Capacity
Hydraulic fluid 500 hours ASV Premium 8 gal./30 L
MV Hydraulic Oil or
similar like Amoco Rykon MV
Hydraulic filter 250 hours
Engine oil 500 hours See p. 16 PT-30 - 1.6 gal./6.06 L
Engine Oil filter 500 hours
Fuel filter 500 hours
Coolant additive Test at 250 hours
Coolant change 1,000 hours or 2 years PT-30 - 1.5 gal
Primary air filter Check daily, clean or replace as needed (see page 22)
Secondary air filter Replace after every 3 cleanings of primary filter
All grease fittings Daily (prior to operation) ASV MP Lithium Grease
Track tension As needed (see page 20)
Note: When adding or replacing engine coolant, use ASV Long-Life Anti-Freeze/Coolant or similar
with proper SCA (supplemental cooling additive).
MMAACCHHIINNEEMMAAIINNTTEENNAANNCCEE
2
1
A

19
Water Separator
The water separator (photo B, located on
the left side of the hyd. reservoir)
removes water from the fuel supply as
the engine runs. Drain the water separa-
tor daily to maintain proper function.
To drain the water separator:
1. Loosen the twist valve on
the bottom of the separator.
2. Retighten the valve once all of the
water has been drained from the
catch bowl.
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 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.
MMAACCHHIINNEEMMAAIINNTTEENNAANNCCEE
B