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 CONTENTS

California Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Machine Labels and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operating Capacity / Attachment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Switches / Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Machine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
ROPS Canopy Tilt-up Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
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
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 CALIFORNIA
Proposition 65 Proposition 65
Warning: This product contains lead and Warning: This product contains lead, a
lead compounds, diesel engine exhaust, chemical known to the state of California
and used engine oil, chemicals known to to cause birth defects or other reproduc-
the state of California to cause cancer. tive harm.

2

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 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.
INTRODUCTION
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.
WARNING
This manual contains the words
Warning, Caution and Note to empha-
size important information. The word
There are many hazards that can be WARNING identifies personal safety
encountered during operation of an off
related information. The word CAUTION
highway utility vehicle such as the PT-
100. With this in mind, it is the responsi- identifies unsafe practices that may
bility of each operator to read and fully result in machine damage. The word
understand this manual before attempt- Note: identifies supplementary informa-
ing to operate the machine. Machine
tion which requires special attention.
damage, bodily injury, or even death
may result if the procedures and precau-
tions described in this manual are not
followed closely.
3
MACHINE SPECIFICATIONS

General Dimensions PT-100 Engine PT-100

Height to top of ROPS: 80 in. / 2023 mm Model: Perkins 1104C-44T
Ground clearance: 14 in. / 356 mm Type: 4-cylinder diesel
Max. lift height, at hinge pin: 125 in. / 3175 mm Displacement: 268 in.3/4.4 liter
Length of undercarriage: 90 in. / 2293 mm Gross HP @ 2300 rpm: 99.5 hp / 74 kW
Machine length, w/out bucket: 117.5 in. / 2985 mm Torque (peak): 304 ft-lb / 412 Nm
Machine length, with bucket: 148 in. / 3760 mm
Machine width: 69 in. / 1753 mm Operating Specifications
Operating capacities:
Track Specifications 35% tip load: 2,660 lb / 1207 kg
Track width: 18 in. / 457 mm 50% tip load: 3,800 lb / 1724 kg
Length of track on ground: 72.5 in. / 1842 mm Travel speed (low/high) max.: 5/10 mph / 8/16 kmh

Machine Weight Auxiliary Hydraulic Pump

Weight without bucket (shipping): 9,200 lb / 4173 kg Low flow, max.: 20 gpm / 76 lpm
Weight with bucket (operating): 10,150 lb / 4604 kg High flow, max.: 38 gpm / 144 lpm
Ground pressure: 3.5 psi / 24 kPa Pressure: 3,300 psi / 22 737 kPa
Ground contact area: 2,610 in.2 / 1.68 m2
Service Refill Capacities
Fuel tank: 26 gal / 98 L
Specifications are subject to change without notice. Hydraulic tank*: 20 gal / 76 L
Engine coolant*: 3.125 gal / 12 L
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- Engine oil, including filter*: 8.5 qt / 8 L
ing capacity of machines equipped with a suspended undercarriage or machines with rub-
ber tracks. * When replacing or replenishing these lubricants/fluids, it is recommended that you
specify genuine ASV products from your ASV Dealer.

4
 MACHINE LABELS AND DECALS

2040-121
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 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.

5
FIRE PREVENTION
Fire Prevention
The PT-100 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 (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.
6
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.
WARNING
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.

Operating Capacity
The operating capacity refers to how
much additional weight can be added to
the standard dirt bucket's center of grav-
ity. The recommended operating capaci-
ties 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 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-100 should not exceed 14,500 lbs.
This weight does not include an operator,
but does include material being carried.
OPERATING CAPACITY / ATTACHMENT PRECAUTIONS
Exceeding the specified GVW rating will or cracking in both the host machine
void the warranty (see page 2). and the head itself. Vibration can also
cause hydraulic component failure in
Mulching Type Forestry Brush items such as relief valves. Although
Cutters these mulching type heads work
When using non-ASV brush cutters, extremely well on ASV machines with
especially mulching type forestry brush high flow hydraulics, educate yourself
cutters, there are many things that on the increased maintenance and
should be considered. operating costs before purchasing this
type of attachment. ASV recommends
Mulching type brush cutters are heav- considering a rotary type brush cutter
ier, vibrate more, and generate more as an alternative.
dust and debris than rotary brush cut-
ters. The increased amount of dust
and debris particles can plug coolers,
CAUTION
radiators, and air cleaners much faster, Machine damage and failure caused by uti-
causing overheating or even engine lizing mulching type brush cutters will not
failure if left unattended. The debris is be covered by ASV warranty.
also introduced into many high temper-
ature areas and can become a fire
hazard. Debris should be cleaned fre-
quently 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 con-
dition, it can cause metal fatigue and
7
MACHINE CONTROLS

Loader and Drive Controls Throttle To Increase RPM, move the lever (C)
The PT-100 has two hydraulic pilot joy- The throttle C, controls engine rpm. toward the front of the machine.
stick controls. These two joysticks are When performing delicate work that To decrease RPM, move the lever (C)
used to control machine speed, direc- requires precise movements, use a
toward the rear of the machine.
tion, lift arms and bucket or attachment. lower engine rpm. When more speed,
Joystick A is used to control the lift arms, horsepower or flow is required, use a
the bucket and float function. To engage higher engine rpm.
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-100 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, A B
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
C
does not have a detent position, and
must be manually held in place to acti-
vate float function.
8

D E F G H I
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 - Low Flow Auxiliary Hydraulics
O - High Flow Auxiliary Hydraulics
P - Bucket Positioning
Q - Power Quick Attach
Instruments
H - Tachometer
I - Engine Temperature Gauge
SWITCHES / INSTRUMENTATION
R S
J K L M N O P Q J
J - Fuel Level Gauge
T U
K - Warning Indicators (3-in-one)
L - Hour Meter
R - High Range Indicator Light
S - Glow Plug Operation Light
V
T - Oil Pressure Warning Light K
U - Battery Voltage Warning Light
V - Hydraulic Oil Temp. Warning Light
CAUTION
If the battery voltage warning light (U)
illuminates, drive the machine to a suit- Should the engine temperature gauge
able location and shut the engine off. read excessive temperatures or
Diagnose the problem and make needed should the oil pressure or hydraulic oil
repairs before continuing to operate. temperature lights illuminate during
normal operation, shut the machine
The glow plug operation light (S) will illu-
down immediately. Diagnose the prob-
minate only when the key switch is
turned to engine pre-heat, showing nor- lem and make needed repairs before
mal operation. continuing to operate.
9
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.
A B
4. Fluids are filled to proper levels.
5. Accessory belts are in good condition
and properly tensioned. 1. Enter machine with lift arms all the 6. Run the engine at low idle for 3 to 5
6. Hyd. Hoses and fittings are in good way down. Maintain three points of minutes to warm up the engine.
condition. (no visible signs of wear) contact with the machine (photo A). 7. Set throttle to desired rpm.
7. Battery cables are in good condition 2. Fasten seat belt, and lower lap bar
Note: The parking brake is automatically
and properly fastened. into position.
engaged when the engine is turned off,
8. Joysticks and hyd. auxiliary switches 3. Starting with the throttle in the SLOW
the operator is not in the seat or the lap
are in their neutral positions. position, push the throttle 1/3 the way
bar is raised.
9. Power quick-attach is in locked posi- open.
tion. 4. Turn the ignition key to the left for 6 WARNING
Starting Procedure seconds to pre-heat the engine.
Before starting the engine, perform the While pre-heating, the glow plug Entering or exiting the vehicle under raised
pre-start checklist then proceed with the operation light will illuminate. lift arms could cause serious injury or
5. Turn the ignition key to the right to death. Never allow anyone to be under-
following procedure: neath raised, unsecured lift arms (photo B).
start the engine.
10

WARNING
Failure to wear the seat belt could lead to
serious injury or death.
CAUTION
Do not crank the engine for more than 20
seconds. Allow the starter to cool for 2 min-
utes before cranking again.
WARNING
Do not use aerosol type starting aids such
as ether. Such use could result in an explo-
sion 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.
MACHINE OPERATION
C
D
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 attach-
ment is securely fastened.
E
11
MACHINE OPERATION
B ble on inclines. Machine weight is distrib-
A tem provides excellent traction and
Two Speed
The PT-100 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.
Whenever the machine is turned off, the
lap bar is raised, or the operator exits
the seat, the machine automatically
returns to low range. 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) illuminates
to confirm high range operation.
12
Operation on Inclines
ASV Rubber Track Loaders are very sta-
WARNING
Failure to follow the instructions on hillside
uted evenly throughout the chassis and operation may result in machine damage,
the suspended undercarriage track sys- severe injury, or even death.
floatation on nearly all surfaces.
CAUTION
Even with these capabilities, caution
should always be exercised while oper- The engines lubrication system requires
ating the machine on an incline. Never that the machine be kept below a maximum
operate the PT-100 on an incline in operation angle of 24 in order to properly
supply the engine with oil. Failure to follow
excess of 18. Do not make sudden
the instructions in on hillside operation may
changes in direction, move slowly, and result in engine damage or failure.
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 direc-
tion. Then proceed forward.

Auxiliary Hydraulics
The PT-100 comes standard with a load
sense, variable displacement piston
pump for auxiliary hydraulics. When the
low flow is engaged the variable dis-
placement pump displaces 20 gpm, and
when the high flow is engaged the pump
displaces 38 gpm.
To activate auxiliary hydraulics:
1. To engage the low flow hydraulics
intermittently, activate the toggle-
type 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.
MACHINE OPERATION
C D
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 (neu-
tral) positions in order to start the
engine.
13
MACHINE OPERATION

Electric Attachment Control

Attachments are controlled by various A
buttons on the drive and lift-arm control
joysticks. Most attachments are con-
trolled 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 attach-
ments that require electrical input will be
equipped with a matching receptacle to
B
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.

14

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.
MACHINE OPERATION
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!
4. Position the lift arm brace over the
fender brackets as found and install
the retaining pins to secure it there.
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 retain-
ing pins and remove the brace.
3. Lower the lift arms to the lower stop.
15
MACHINE MAINTENANCE

Engine Oil and Filter Change

Under normal conditions, the engine oil
should be changed every 500 hours or
one year; which ever comes first.
Engines which are operated under harsh
conditions should have the oil changed
every 250 hours or six months, which
ever comes first. Harsh conditions
include: continuous high load applica-
tions, operation in high temperatures, or
abnormally dusty/dirty conditions.
Engine Oil Specifications:
To change the oil and filter: ASV 10W30 Heavy Duty Engine Oil
1. Run engine for a few minutes to You may also use a quality engine oil
warm the engine oil. substitute with one of the following mini-
2. Remove the drain plug from oil pan. mum specifications:
3. Drain the oil into suitable container.
API CH-4 multigrade oil.
4. Remove engine oil filter, make sure
gasket is also removed. It may be
necessary to remove 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.

16
 MACHINE MAINTENANCE

Hydraulic Fluid and Filter Change

The hydraulic fluid should be changed A
every 500 hours, and the hydraulic filter
should be changed every 250 hours.
Hydrostatic components require C
extremely clean oil in order to have a
long service life. Extreme caution must
B
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.

1. Remove the middle skid-plate from

the bottom of the machine. Locate
and remove the hydraulic fluid drain D
plug (A), and drain into suitable con- E
tainer.
2. Locate the two hydraulic filters (B,C)
in the rear right-hand side of the
engine compartment.
ASV Premium All Season MV
3. Clean around the filters, and remove.
Hydraulic Oil, or approved hydraulic
4. Replace both filters with ASV
fluid such as Chevron Rykon MV. The
approved filters.
hydraulic fluid level sight gauge is
5. Replace the drain plug and skid-plate
located on the right side of the
and fill the hydraulic reservoir (D) with
machine (E).

17
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 thor-
oughly.
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 sepa-
rator 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 pro-
tect the electrical components from dam-
age. 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.

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.
A
B
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 mis-
feed, possibly causing damage. Running
a track that is too tight can cause track
stretch, bearing failure or other preventa-
ble damage. During the first 50 hours of
operation the tracks will "break-in" and
may require adjustment.
MACHINE MAINTENANCE
C
To tighten the track:
1. The front of the drive table is secured
by two bolts (A). If these bolts 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 main frame rail
to relocate these bolts as necessary.
2. Once these bolts are loosened or
relocated, the track may be tightened
by turning the turnbuckle (B).
3. The bolts (C) do no not need to be
loosened. These bolts secure bush-
ings that follow the adjustment slots
while the track is being tensioned.
19
MACHINE MAINTENANCE
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.
20
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). B
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).

Drive Sprocket Rollers
Rubber Track Loaders use rollers on
each drive tooth of the two drive sprock-
ets. 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 Steel Pin
D
F
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.
E nected before performing this procedure.
MACHINE MAINTENANCE
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.
Normal Roller Wear
New Roller
at 50% life
WARNING
Make sure the machine is turned off, the
key removed, and the battery discon-
21
MACHINE MAINTENANCE
Air Cleaner
The air cleaner is one of the most impor-
tant 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 counter-
clockwise 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 service-
able or washable. The secondary ele-
ment 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 suds- A
ing 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 gen-
tle stream of water to remove all dirt
and remaining detergent.
4. Allow the filter to dry completely
B
before reinstalling it into the machine.
CAUTION
CAUTION
Do not use any heat source other than During the engine warranty period, do not
warm air at less than 160 F to dry the filter. clean the filter elements. Instead, replace
the filter elements when soiled or damaged
to comply with engine warranty require-
ments.
 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 fit-
tings can be found on the right side of the machine. All fittings should be lubricated daily, prior to operation.

23
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 radia-
tor/oil cooler is not kept clean. A pres-
sure 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 oper-
ation, 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 dam-
aged (bent over) which will decrease
cooling performance.
Chassis and engine cleaning
Periodic cleaning of the chassis area A
beneath the cab and engine compart-
ment 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. B
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.
 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: D

1. Remove attachment.
2. Raise the lift arms and secure with lift
arm brace.
3. Remove the four bolts that fasten the
canopy to the frame.
4. Raise the canopy and watch to make
sure the lock-out brace falls into
place.
5. Secure the canopy lock-out brace with Tilt-up ROPS (Forestry Package)
When a machine is equipped with the E
the D-latch pin (D) as shown.
forestry package, there are additional
Note: The lift arms must be raised in steps that must be taken to tilt the cab.
order to tilt the canopy. Perform these steps prior to performing
the ROPS tilting procedure on this page.

1. Remove the air pre-cleaner assembly

(E) from the machine.
2. Remove the two limb risers (F) from
the machine.
F

25
RECOMMENDED FLUIDS AND LUBRICANTS

Fluids and Lubricants The ASV fluid and lubricant product line
When replacing or replenishing the fluids includes:
and lubricants in your PT-100 Rubber
Heavy Duty Engine Oil, 10W30;
Track Loader, you can specify ASV fluids
Premium All Season MV Hydraulic Oil;
and lubricants. This assures the new flu-
Multi-Purpose EP Lithium Grease;
ids and lubricants match those originally
Long-Life 50/50 Antifreeze/Coolant;
installed when your machine left the ASV
Undercarriage Wheel Bearing
factory. ASV fluids and lubricants were
Lubricant.
developed for, tested and approved by
ASV to assure optimum life and perform-
ASV fluids and lubricants are available
ance in all ASV Rubber Track
through your ASV Dealer. If ASV prod-
Equipment, when used as recom-
ucts are not available for some reason,
mended.
use an approved equivalent, as specified
elsewhere in this manual.

26
 SERVICE LOG

Hours Service Performed Notes

27
Terex Construction Americas
8800 Rostin Road
Southaven, MS 38671
(888)-201-6008
Brought to you by:
ASVparts.com
5060 Fulton Industrial Blvd
Atlanta, GA 30336
877-857-7209

(662)-393-1800
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ASVPT100 OM (1/09)
Copyright 2009 Terex