ASV PT60 User manual

8/17/2016
Operation and Maintenance
Manual
PT60
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English
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California Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Machine Labels and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Fire and Overheat Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operating Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Switches/Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Machine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Recommended Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
1
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
CONTENTS

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.
2
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-50/60 are rugged and agile
machines capable of working on a vari-
ety of challenging terrains. They are
designed to be very safe, but safe oper-
ation also requires caution and attentive-
ness on the part of the operator.
There are many hazards that can be
encountered during operation of an off
highway utility vehicle such as the PT-
50/60. With this in mind, it is the respon-
sibility 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--5500((PPTT--6600))
Height to top of ROPS: 77 in. / 1956 mm (77 in. / 1956 mm)
Ground clearance: 12 in. / 305 mm (12 in. / 305 mm)
Max. lift height, at hinge pin: 115 in. / 2921 mm (115 in. / 2921 mm)
Length of undercarriage: 75 in. / 1905 mm (75 in. / 1905 mm)
Machine length, w/out bucket: 100 in. / 2540 mm (100 in. / 2540 mm)
Machine length, with bucket: 128 in. / 3251 mm (128 in. / 3251 mm)
Machine width: 60 in. / 1524 mm (60 in. / 1524 mm)
TTrraacckkSSppeecciiffiiccaattiioonnss
Track width: 15 in. / 381 mm (15 in. / 381 mm)
Length of track on ground: 59 in. / 1499 mm (59 in. / 1499 mm)
MMaacchhiinneeWWeeiigghhtt
Without bucket (shipping): 5,500 lb / 2495 kg (5,500 lb / 2495 kg)
With bucket (operating): 6,200 lb / 2812 kg (6,200 lb / 2812 kg)
Ground pressure: 3.1 psi / 21.4 kPa (3.1 psi / 21.4 kPa)
Ground contact area: 1,770 in.2 / 1.14 m2 (1,770 in.2 / 1.14 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 operating
capacity of machines equipped with a suspended undercarriage or machines with rubber
tracks.
EEnnggiinneePPTT--5500((PPTT--6600))
Model: Perkins 404C-22 (Perkins 404C-22T)
Type: 4-cylinder diesel (4-cylinder turbo diesel)
Displacement: 134 in.3 / 2.2 liter (134 in.3 / 2.2 liter)
Gross HP @ 2800 rpm: 50 hp / 37.3 kW (60 hp / 44.7 kW)
Torque (peak): 105 ft-lb / 143 Nm (140 ft-lb / 190 Nm)
OOppeerraattiinnggSSppeecciiffiiccaattiioonnss
Operating capacities:
35% tip load: 1,330 lb / 603 kg (1,330 lb / 603 kg)
50% tip load: 1,900 lb / 862 kg (1,900 lb / 862 kg)
Travel speed, max.: 8 mph / 13 km (8 mph / 13 km)
AAuuxxiilliiaarryyHHyyddrraauulliiccPPuummpp
Flow, max.: 17.4 gpm / 65.9 lpm (17.4 gpm / 65.9 lpm)
Pressure: 3,000 psi / 20,670 kPa (3,000 psi / 20,670 kPa)
SSeerrvviicceeRReeffiillllCCaappaacciittiieess
Fuel tank: 15 gal / 56.8 L (15 gal / 56.8 L)
Hydraulic tank: 8 gal / 30.3 L (8 gal / 30.3 L)
Engine coolant: 2 gal / 7.5 L (2 gal / 7.5 L)
Engine oil, including filter: 2.8 gal / 10.6 L (2.8 gal / 10.6 L)
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.
MMAACCHHIINNEELLAABBEELLSSAANNDDDDEECCAALLSS
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

Fire Prevention
Rubber track loaders have components
that operate at high temperatures. The
main heat sources are the engine and
the exhaust system. The electrical sys-
tem can also be a source of heat or
sparks if damaged or improperly main-
tained.
In some work environments, flammable
items such as leaves, straw, and brush
cutting debris may come in contact with
these components. It is very important
that flammable items be removed often
from close proximity to these high tem-
perature items. 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.
Overheat Prevention
The radiator/oil cooler must be inspected
for signs of clogging and cleaned daily or
more often as needed to prevent the
engine and hydraulic system from over-
heating
Listed are a set of precautionary tasks
that should be performed daily or more
often if necessary. Repair or replace
worn or damaged components as
needed to ensure safe machine opera-
tion.
Precautionary Tasks
• With the engine off and cool, clean
dirt/debris from the radiator/oil cooler,
engine compartment, exhaust system,
attachments and other areas where
there may be hot or rotating parts.
Remove the belly pans and pressure
wash these items and all surrounding
areas until clean.
• Check battery, fuse panel, electrical
wiring and connections for damage or
looseness.
• Check fuel and hydraulic lines/hoses
for leaks or damage. Never use bare
hands to check for leaks. Pressurized
fluid can penetrate skin and cause
injury or even death.
6
1. Remove any attachment
from the machine.
2. Have an second person
remove the lift arm brace.
3. Raise the lift arms.
4. Have the second person
place the lift arm brace onto the
top side of the cylinder ram.
5. Install the retaining pins
using the holes labeled with the
arrows.
6. Slowly lower the lift arms
until they contact the brace.
7. Reverse these steps to
disengage the lift arm brace
WARNING
If instructions to safely install
lift arm brace are not followed
injury or death could result.
NEVER GO BENEATH UNSECURED LIFT ARMS
0201-752
• Never use ether or any other aerosol type starting aid to start the engine.
• Always stop the engine and allow the machine to cool before adding fuel.
• Never smoke or allow open flame near the machine while refueling.
FFIIRREEAANNDDOOVVEERRHHEEAATTPPRREEVVEENNTTIIOONN
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-50 or PT-60 should not exceed 8,500
lbs. This weight does not include an
operator, but does include any acces-
sories, attachments or material being
carried. Operating the machine in excess
of the GVW will void the warranty (see
page 2).
OOPPEERRAATTIINNGGCCAAPPAACCIITTYY

Loader and Drive Controls
The PT-50 and PT-60 have two hydraulic
pilot joystick controls. The joysticks are
used to control machine speed and
direction as well as lift arm, bucket, and
attachment functions. Joystick A (photo
right) is used to control the lift arms,
bucket, and to engage the float function.
To activate the float function, move the
joystick fully forward in a quick motion.
The joystick will then be held in detent
by the magnet attached to the joystick
base. Pull back quickly to disengage.
Joystick B controls the direction and
speed of the machine.
Control Options
Machines are available with a "Case"
style control configuration. Machines
equipped in this manner use similar joy-
sticks, but operate using a different pat-
tern to control machine function. In this
pattern, joystick A controls both the right
track and the bucket curl and dump func-
tions. Joystick B controls the left track,
lift arm, and float functions. The float
function does not have a detent position
in this configuration and must be manu-
ally held in position while operating with
float engaged.
Throttle
The throttle (C) controls engine rpm.
Use a lower rpm for work that requires
delicate operation of the machine. Use
higher rpm when faster travel speed,
higher horsepower, or more flow is
required.
• To Increase RPM, move the lever (C)
toward the front of the machine.
• To decrease RPM, move the lever (C)
toward the rear of the machine.
8
C
B
A
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)
M - Ignition, glow plug (pre-heat)
N - Continuous Flow Hydraulics
O - (not used)
P - Bucket Positioning (optional)
Q - Power Quick Attach (optional)
Instruments
H - Tachometer (optional PT-50)
I - Engine Temp. Gauge (optional PT-50)
J - Fuel Level Gauge
K - Warning Indicators (4-in-one)
L - Hour Meter
R - High Range Indicator Light (PT-60)
S - Glow Plug Operation Light
T - Oil Pressure Warning Light
U - Battery Voltage Warning Light
V - Hydraulic Oil Temp. Warning Light
W - Engine Temp. Warning Light
If the battery voltage warning light (U)
illuminates, drive the machine to a suit-
able location and shut the engine off.
Diagnose the problem and make needed
repairs before continuing to operate.
The glow plug operation light (S) will illu-
minate only when the key switch is
turned to engine pre-heat, showing nor-
mal operation.
9
SSWWIITTCCHHEESS//IINNSSTTRRUUMMEENNTTAATTIIOONN
Should the optional engine temp.
gauge read excessive temperatures
(or warning light illuminate) or should
the oil pressure or hydraulic oil temp.
lights illuminate during normal opera-
tion, shut the machine down immedi-
ately. Diagnose and make needed
repairs before resuming operation.
CAUTION
J
K
DE F G H I J K L M NOP Q
T
V
U
R S
W