ASV PT60 Operating instructions

8/17/2016
Service Repair Manual
PT60
SN 00101-03704
English
All
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i
Table of Contents
1. Product Safety
Chapter Overview ...................................................1-1
Safety Messages.....................................................1-1
Information Messages.............................................1-1
Basic Precautions ...................................................1-1
Safety Signs.......................................................1-1
Protective Equipment.........................................1-2
Mounting and Dismounting................................1-2
Lifting.................................................................1-2
Hot Fluids and Parts..........................................1-2
Corrosion Inhibitor .............................................1-2
Batteries ............................................................1-2
Pressurized Items..............................................1-2
Repair .....................................................................1-3
Attachments............................................................1-3
Asbestos Information ..............................................1-4
Machine Labels and Decals....................................1-4
Product ID Number............................................1-4
Machine Label and Decal Examples..................1-5
2. Technical Specifications
PT-50 Specifications...............................................2-1
Engine ...............................................................2-1
Transmission .....................................................2-1
Drive Motors ......................................................2-1
Control Handles.................................................2-1
Auxiliary Pump...................................................2-1
Loader Valve......................................................2-1
Cooler................................................................2-1
Critical Torque Specifications ............................2-1
PT-60 Specifications...............................................2-2
Engine ...............................................................2-2
Transmission .....................................................2-2
Drive Motors ......................................................2-2
Control Handles.................................................2-2
Auxiliary Pump...................................................2-2
Loader Valve......................................................2-2
Cooler................................................................2-2
Critical Torque Specifications ............................2-2
3. System Diagrams
Chapter Overview ...................................................3-1
Filtering and Cooling System ..................................3-1
Auxiliary Circuit System (PT-50/60) ........................3-2
Drive Loop System (PT-50/60)................................3-3
Electrical Attachment Outlet (PT-50/60)……………3-4
4. Machine Controls and Instrumentation
Chapter Overview ...................................................4-1
Machine Controls....................................................4-1
Loader Control...................................................4-1
Drive Control......................................................4-1
Throttle ..............................................................4-1
Instrumentation .......................................................4-1
Switches..................................................................4-2
5. Operator Enclosure Disassembly
and Assembly
Chapter Overview...................................................5-1
Personal Safety.......................................................5-1
Machine Preparation...............................................5-1
Preliminary Checkout..............................................5-1
Operator Enclosure Disassembly and Assembly
Procedures..............................................................5-1
Light Bar Removal and Installation .........................5-1
Light Bar Removal.............................................5-1
Light Bar Installation..........................................5-2
Ignition Switch Removal and Installation.................5-2
Ignition Switch Removal ....................................5-2
Ignition Switch Installation .................................5-3
Gauge Removal and Installation.............................5-4
Gauge Removal.................................................5-4
Gauge Installation..............................................5-4
Lap Bar Gas Assist Spring Removal
and Installation........................................................5-5
Lap Bar Gas Assist Spring Removal .................5-5
Lap Bar Gas Assist Spring Installation ..............5-5
6. Chassis Disassembly and Assembly
Chapter Overview...................................................6-1
Personal Safety.......................................................6-1
Machine Preparation...............................................6-1
Preliminary Checkout..............................................6-1
Chassis Disassembly and Assembly
Procedures..............................................................6-1
Seat Removal and Installation ................................6-1
Seat Removal....................................................6-1
Seat Installation.................................................6-2
Fuel Sending Unit Removal and Installation ...........6-2
Fuel Sending Unit Removal...............................6-3
Fuel Sending Unit Installation............................6-3
7. Radiator/Oil Cooler Disassembly
and Assembly
Chapter Overview...................................................7-1
Personal Safety.......................................................7-1
Machine Preparation...............................................7-1
Preliminary Checkout..............................................7-1
Radiator/Oil Cooler Disassembly and Assembly
Procedures..............................................................7-1
Fan Guard Removal and Installation.......................7-1
Fan Guard Removal ..........................................7-2
Fan Guard Installation .......................................7-2
Radiator/Cooler Removal and Installation...............7-2
Radiator/Cooler Removal ..................................7-2
Radiator/Cooler Installation ...............................7-4

Rubber Track Loader
Table of Contents
ii
8. Hydraulic Reservoir Disassembly
and Assembly
Chapter Overview ...................................................8-1
Personal Safety.......................................................8-1
Machine Preparation...............................................8-1
Preliminary Checkout..............................................8-1
Hydraulic Reservoir Disassembly and Assembly
Procedures..............................................................8-1
Filter Assembly Removal and Installation ...............8-1
Filter Manifold Removal.....................................8-2
Filter Manifold Installation..................................8-2
Access Cover Removal and Installation..................8-2
Access Cover Assembly Removal.....................8-2
Access Cover Assembly Installation..................8-3
Reservoir Gauge Removal and Installation.............8-3
Reservoir Gauge Removal.................................8-3
Reservoir Gauge Installation..............................8-4
Suction Screen Removal and Installation................8-4
Suction Screen Removal ...................................8-5
Suction Screen Installation ................................8-5
Hydraulic Reservoir Cleaning Procedures .............8-6
Hydraulic Reservoir Cleaning ............................8-6
9. Loader/Transmission Controls Disassembly
and Assembly
Chapter Overview ...................................................9-1
Personal Safety.......................................................9-1
Machine Preparation...............................................9-1
Preliminary Checkout..............................................9-1
Loader/Transmission Controls Disassembly and
Assembly Procedures .............................................9-1
Joystick Removal and Installation...........................9-1
Joystick Removal...............................................9-2
Joystick Installation............................................9-3
Loader Float Magnet Removal and Installation.......9-3
Loader Float Magnet Removal...........................9-3
Loader Float Magnet Installation........................9-4
Loader Valve Removal and Installation..................9-4
Loader Valve Removal ......................................9-4
Loader Valve Installation ...................................9-6
Self Level Valve Removal and Installation .............9-6
10. Transmission and Drive Disassembly
and Assembly
Chapter Overview .................................................10-1
Personal Safety.....................................................10-1
Machine Preparation.............................................10-1
Preliminary Checkout............................................10-1
Hydrostatic and Hydraulic Pump Disassembly
and Assembly Procedures ....................................10-1
Auxiliary Gear Pump Removal and Installation.....10-1
Auxiliary Gear Pump Removal.........................10-1
Tandem Pump Removal and Installation ..............10-3
Tandem Pump Removal..................................10-3
Tandem Pump Installation...............................10-4
Pump Drive Coupler Removal and Installation......10-5
Pump Drive Coupler Removal .........................10-5
Pump Drive Coupler Installation ......................10-6
11. Undercarriage Disassembly and Assembly
Chapter Overview .................................................11-1
Personal Safety.....................................................11-1
Machine Preparation.............................................11-1
Preliminary Checkout............................................11-1
Undercarriage Disassembly and Assembly
Procedures............................................................11-1
Center Wheel Removal and Installation................11-1
Wheel Removal...............................................11-2
End Wheel Removal and Installation ....................11-3
End Wheel Removal........................................11-3
End Wheel Installation.....................................11-3
Sprocket Roller Removal and Installation ............11-4
Track Removal and Installation............................11-4
Track Removal ................................................11-4
Track Installation .............................................11-4
Outboard Bearing Removal and Installationl.........11-5
Bearing Removal.............................................11-5
Bearing Installation..........................................11-5
Drive Sprocket Removal and Installation ..............11-6
Sprocket Removal ...........................................11-6
Sprocket Installation ........................................11-6
Drive Motor Removal and Installation ..................11-6
Drive Motor Removal.......................................11-6
Drive Motor Installation....................................11-6
Idler Wheel Hub Service Procedures....................11-7
Disassembly Procedure...................................11-7
Assembly Procedure .......................................11-9
12. Loader Disassembly and Assembly
Chapter Overview.................................................12-1
Personal Safety.....................................................12-1
Machine Preparation.............................................12-1
Preliminary Checkout............................................12-1
Loader Disassembly and Assembly Procedures..12-1
Lift Cylinder/Tilt Cylinder Removal
and Installation......................................................12-1
Lift Cylinder/Tilt Cylinder Removal...................12-1
Lift Cylinder/Tilt Cylinder Installation................12-3
Q/C Block Relief Valve Removal and Installation..12-3
Q/C Block Relief Valve Removal .....................12-3
Q/C Block Relief Valve Installation ..................12-4
13. Maintenance
Chapter Overview.................................................13-1
Maintenance Schedule .........................................13-1
Engine Oil .............................................................13-1
Oil Change Procedures ...................................13-1
Engine Oil Specifications.................................13-1
Hydraulic Fluid and Filter ......................................13-2
Hydraulic Fluid and Filter Change
Procedures......................................................13-2
Fuel/Water Separator............................................13-3
Fuel Filter..............................................................13-3
Fuel Filter Change Procedures........................13-3
Fuel Specifications ..........................................13-3
Air Cleaner............................................................13-3
Air Filter Change Procedures ..........................13-3
Track Tension.......................................................13-4
Track Tension Adjustment Procedures............13-4
Checking for Proper Track Adjustment............13-4
Fuse Box...............................................................13-5
Grease Fittings......................................................13-5
Bleeding the Fuel System.....................................13-6

Rubber Track Loader
Table of Contents
iii
14. Hydraulic Pressure Check & Adjustment
Chapter Overview .................................................14-1
Personal Safety.....................................................14-1
Machine Preparation.............................................14-1
Hydraulic Pressure Adjustment Procedures..........12-1
Charge Pressure check……………………………. 14-1
Charge Pressure Adjustment………………………14-2
Auxiliary Pressure Check & Adjustment…………..14-2
15. Troubleshooting
Chapter Overview .................................................15-1
Personal Safety.....................................................15-1
Machine Preparation.............................................15-1
Preliminary Checkout............................................15-1
Visual Inspection..............................................15-1
Troubleshooting Scenarios………………………...15-2

1-1
1.Product Safety
Chapter Overview
This chapter contains product safety information for
the PT-50/60 Rubber Track Loaders. Read this
chapter and understand all safety messages and
information messages before attempting to service
the machine.
Safety Messages
Safety messages are provided in this document and
on the machine. If these hazard warnings are not
heeded, bodily injury or death could occur to you or
other persons.
Hazards are identified by the Safety Alert Symbols
!DANGER!….!WARNING!….!CAUTION!.
The meaning of these safety alerts is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under a Safety Alert
Symbol explains the hazard and can be either writ-
ten or pictorially presented.
! DANGER !
This symbol is used to alert service personnel of an
imminently hazardous situation that will result in seri-
ous injury or death.
! WARNING !
This symbol is used to alert service personnel of a
potentially hazardous situation that could result in
serious injury or death.
! CAUTION !
This symbol is used to alert service personnel of an
unsafe practice that could result in injury.
Information Messages
Information messages are provided in this document
and on the machine. These messages are identified
by the labels NOTICE….Note.
NOTICE
This label is used to alert service personnel to the possibil-
ity of damaging the equipment.
Note: This label is used to provide important additional
information, comments, explanations or amplification of
the accompanying subject matter.
The person servicing the Rubber Track Loader may
be unfamiliar with many of the systems on the ma-
chine. This makes it important to use caution when
performing service work. Knowledge of the system
and/or components is important before the removal
or disassembly of any component.
It is not possible to anticipate every circum-
stance that might involve a potential hazard. The
safety messages in this document and on the
product are, therefore, not all-inclusive. If you
use a tool, procedure, work method or operating
technique that is not specifically recommended
by the manufacturer, you must satisfy yourself
that it is safe for you and for others. You should
also ensure that the product will not be damaged
or be made unsafe by the operation, lubrication,
maintenance or repair procedures that you
choose.
Basic Precautions
! WARNING !
Improper operation, lubrication, maintenance or repair
of this product can be dangerous and could result in
injury or death.
Do not operate or perform any lubrication, mainte-
nance or repair on this product until you have read
and understood the operation, lubrication, mainte-
nance and repair information.
Following is a list of basic precautions that should
always be observed.
Safety Signs
Read and understand all "Safety" signs on the prod-
uct before operating, lubricating or repairing this
product. Replace any damaged, illegible or missing
safety plates, signs or decals.

Rubber Track Loader
1. Product Safety
1-2
Protective Equipment
Always wear a hard hat, protective glasses, protec-
tive shoes and other protective equipment as re-
quired by job conditions when working around this
product. In particular, wear protective glasses when
pounding on any part of the product or its attach-
ment with a hammer or sledge. Use welders gloves,
hood/goggles, apron and other protective clothing
appropriate to the welding job being performed. Do
not wear loose clothing or jewelry that can catch on
parts of the product.
Mounting and Dismounting
Use steps and handholds when mounting or dis-
mounting a machine. Clean any mud or debris from
steps or work platforms before using them. Always
face the machine when using steps and handholds.
When it is not possible to use the designed access
system, provide ladders, scaffolds, or work platforms
to perform safe repair operations.
Lifting
Use a hoist when lifting components that weigh 23
kg (50 Ib) or more, to avoid back injury. Make sure
all chains, hooks, slings, etc., are in good condition
and are of the correct capacity. Be sure hooks are
positioned correctly and equipped with a spring
latch. Lifting eyes are not to be side loaded during a
lifting operation.
Hot Fluids and Parts
To avoid burns, be alert for hot parts on machines
that have just been stopped and hot fluids in lines,
tubes and compartments.
Be careful when removing fill caps, breathers and
plugs on the machine. Hold a rag over the cap or
plug to prevent being sprayed or splashed by liquids
under pressure. The danger is even greater if the
machine has just been stopped because fluids can
be hot.
Corrosion Inhibitor
Corrosion inhibitor contains alkali. Avoid contact with
eyes. Avoid prolonged or repeated contact with skin.
Do not take internally. In case of contact, wash skin
immediately with soap and water. For eyes, flush
with large amounts of water for at least 15 minutes.
Call Physician. Keep out of reach of children.
Batteries
Do not smoke when inspecting the battery electro-
lyte level. Never disconnect any charging unit circuit
or battery circuit cable from the battery when the
charging unit is operating. A spark can cause an
explosion from the flammable vapor mixture of hy-
drogen and oxygen that is released from the electro-
lyte through the battery outlets. Do not let electrolyte
solution make contact with skin or eyes. Electrolyte
solution is an acid. In case of contact, immediately
wash skin with soap and water. For eyes, flush with
large amounts of water for at least 15 minutes. Call
Physician. Keep out of reach of children.
Pressurized Items
1. Always use a board or a piece of cardboard
when you check for a leak. Leaking fluid under
pressure can penetrate body tissue. Fluid pene-
tration can cause serious injury and possible
death. A pinhole leak can cause severe injury. If
fluid is injected into your skin, get treatment im-
mediately. Seek treatment from a doctor that is
familiar with this type of injury.
2. Relieve all pressure in air, oil or water systems
before disconnecting or removing any lines, fit-
tings or related items. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting
any device from a system that utilizes pressure.
3. Lower the bucket, blade, or other attachment to
the ground before performing any work on the
machine. If this cannot be done, make sure the
bucket, blade, or other attachment is blocked
correctly to prevent it from dropping unexpect-
edly.
4. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not
bend or strike high-pressure lines or install ones
that have been bent or damaged. Check lines,
tubes and hoses carefully. Do not use your bare
hand to check for leaks.
5. Pressurized air or water can cause personal in-
jury. When pressurized air or water is used for
cleaning, wear a protective face shield, protec-
tive clothing, and protective shoes. The maxi-
mum air pressure for cleaning purposes must be
below 205 kPa (30 psi). When using a pressure
washer, keep in mind that nozzle pressures are
very high, generally pressures are well above
13790 kPa (2000 psi). Follow all recommended
practices provided by the pressure washer
manufacturer.

Rubber Track Loader
1. Product Safety
1-3
Repair
! WARNING !
Accidental machine starting can cause injury or death
to personnel working on the machine.
To avoid accidental machine starting, disconnect the
battery cables from the battery and tape the battery
clamps and remove the key.
Place a “Do Not Operate” tag prominently on the ma-
chine to inform personnel that the machine is being
worked on.
1. Disconnect battery and discharge any capacitor
before starting to work on the product. Attach a
Do Not Operate tag in the Operator's Compart-
ment.
2. If possible, make all repairs with the machine
parked on a level, hard surface. Block the ma-
chine to prevent it from rolling while working on
or under the machine.
3. Do not work on any machine that is supported
only by lift jacks or a hoist. Always use blocks or
jack stands to support the machine before per-
forming any service or disassembly.
4. Make sure the work area around the product is
made safe and be aware of hazardous condi-
tions that may exist. If an engine is started inside
an enclosure, make sure that the engine’s ex-
haust is properly vented.
5. Be sure all protective devices including guards
and shields are properly installed and function-
ing correctly before starting a repair. If a guard
or shield must be removed to perform the repair
work, use extra caution.
6. Always use tools that are in good condition and
be sure you understand how to use them before
performing any service work.
7. Replace all fasteners with the same part num-
ber. Do not use a lesser quality fastener if re-
placements are necessary.
8. Be prepared to stop an engine if it has been re-
cently overhauled or the fuel system has been
recently worked on. If the engine has not been
assembled correctly, or if the fuel settings are
not correct, the engine can possibly overspeed
and cause bodily injury, death or property dam-
age. Be prepared to shut off the fuel and air
supply to the engine in order to stop the engine.
9. Be careful when removing cover plates. Gradu-
ally back off the last two bolts or nuts located at
opposite ends of the cover or device. Then, pry
the cover loose to relieve any spring or other
pressure before removing the last two nuts or
bolts completely.
10. Repairs requiring welding should be performed
only with the benefit of the appropriate reference
information and by personnel adequately trained
and knowledgeable in welding procedures. De-
termine the type of metal being welded and se-
lect the correct welding procedures and
electrodes, rods or wire to provide a weld metal
equivalent at least to that of the parent weld.
11. Do not damage wiring during removal opera-
tions. Reinstall the wiring so it is not damaged
during installation or operation by contacting
sharp corners or by rubbing against some object
or hot surface.
12. Always use lift arm supports to keep lift arms
raised. Keep the attachment tilted down and as-
sure that all hydraulic pressure has been re-
lieved for maintenance or repair work that
requires the lift arms to be in the raised position.
13. Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat, vibra-
tion or rubbing against other parts during opera-
tion. Shields that protect against oil spray onto
hot exhaust components in event of a line, tube
or seal failure must be installed correctly.
14. Do not operate a machine if any rotating part is
damaged or contacts another part during opera-
tion. Any high-speed rotating component that
has been damaged or altered should be
checked for balance before reusing. Make sure
all protective devices, including guards and
shields, are properly installed and functioning
correctly before starting the engine or operating
the machine.
Attachments
Only use attachments that are recommended by the
manufacturer of the machine.
Make sure that all necessary guarding is in place on
the host machine and on the attachment.
Wear protective glasses and protective equipment
as required by conditions or as recommended in the
attachment’s operation manual.

Rubber Track Loader
1. Product Safety
1-4
Ensure that all personnel are far enough away from
the work area so they will not be struck by flying ob-
jects.
Stay clear of the cutting edges, pinching surfaces or
crushing surfaces of the attachment while perform-
ing any attachment maintenance, testing or adjust-
ments.
Asbestos Information
Equipment and replacement parts shipped from the
manufacturer are asbestos free. When replacement
parts are required, use only genuine manufacturer’s
replacement parts
Use caution when handling replacement parts from
another supplier if these parts contain asbestos.
Avoid inhaling dust that might be generated when
handling these components or when handling as-
bestos debris. Inhaling this dust can be hazardous to
your health.
The components that may contain asbestos fibers
are lining material, and some gaskets. The asbestos
that is used in these components is usually encased
in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust containing as-
bestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed.
1. Never use compressed air for cleaning. Avoid
brushing or grinding materials that contain as-
bestos. Use a wet method to clean up asbestos
debris. A vacuum that is equipped with the high-
efficiency particulate air filter (HEPA filter) can
also be used.
2. Use exhaust ventilation on permanent machin-
ing jobs.
3. Wear an approved respirator if there is no other
way to control the dust.
4. Comply with applicable rules and regulations for
the work place. In the USA, use Occupational
Safety and Health Administration requirements.
These OSHA requirements can be found in 29
CFR 1910.1001.
5. Obey environmental regulations for disposal of
asbestos.
6. Stay away from areas that might have asbestos
particles in the air.
! WARNING !
When replacement parts are required for this product,
use only genuine manufacturer’s replacement parts or
parts with equivalent specifications including, but not
limited to physical dimensions, type, strength and
material.
Failure to heed this warning can lead to premature
failures, product damage, personal injury or death.
Machine Labels and Decals
Labels and decals placed on the machine provide
safety information and operating instructions. Make
sure you know the location of these labels and un-
derstand their significance.
Product ID Number
The product ID number (PIN) is located on the left
side of the firewall (Figure 1-1). Always provide the
PIN when contacting the dealer about parts, service,
warranty or accessories. No warranty claims will be
processed unless the PIN is provided.
Figure 1-1 1-001

Rubber Track Loader
1. Product Safety
1-5
Machine Label and Decal Examples
Examples of the labels and decals placed on the
machine are shown on this page.