Replacing the Starter on an ASV PT-100 Track Loader

[MikePhua]

ASV’s Compact Track Loader Legacy and the PT-100 Platform
ASV (All Season Vehicles), founded in Minnesota in 1983, carved a niche in the compact track loader market by pioneering rubber track undercarriage systems. The PT-100, introduced in the early 2000s, was one of ASV’s flagship models, designed for high-performance grading, land clearing, and forestry work. With a 99-horsepower Perkins diesel engine and a suspended undercarriage offering 18 inches of ground clearance, the PT-100 became a favorite among operators working in soft terrain and rugged environments. By 2010, ASV had sold thousands of PT-series machines across North America, with the PT-100 recognized for its traction, flotation, and hydraulic versatility.
Terminology Annotation

• Starter Motor: An electric motor that engages the engine flywheel to initiate combustion during startup.
  
• Solenoid: A magnetic switch that connects battery power to the starter motor when the ignition is activated.
  
• Ring Gear: A toothed gear mounted on the engine flywheel that meshes with the starter pinion.
  
• Perkins 1104C-E44T: A turbocharged four-cylinder diesel engine commonly used in PT-100 units.
  

Symptoms of Starter Failure
Operators of the PT-100 may encounter intermittent or complete failure to crank, especially in cold weather or after prolonged use. Common signs include:

• A single click when turning the key, with no engine turnover
  
• No response at all, even with full battery voltage
  
• Smoke or heat from the starter housing
  
• Grinding noise indicating pinion misalignment with the ring gear
  

These symptoms typically point to worn brushes, solenoid failure, or internal gear damage within the starter motor.
Accessing and Replacing the Starter
The PT-100’s starter is mounted on the right side of the engine block, tucked beneath the exhaust manifold and adjacent to the hydraulic pump. Access is tight, requiring removal of the side panel and possibly the battery tray for clearance. Replacement steps include:

• Disconnect both battery terminals to prevent arcing
  
• Remove the intake ducting and any obstructing hoses
  
• Unbolt the starter using a 9/16" socket and extension
  
• Disconnect the solenoid wire and main power cable
  
• Install the new starter, ensuring proper alignment with the ring gear
  
• Torque mounting bolts to manufacturer spec (typically 35–45 ft-lbs)
  
• Reconnect wiring and test for engagement before reassembly
  

Some operators prefer aftermarket starters for cost savings, but OEM units offer better fitment and longer service intervals.
Anecdote from a Forestry Crew
In 2018, a land clearing crew in Oregon relied on a PT-100 for slope stabilization work. After 2,400 hours, the starter began failing intermittently, especially after long idle periods. The crew replaced the unit with a high-torque aftermarket starter rated for cold-weather cranking. They also added a battery isolator switch to prevent parasitic draw during storage. The machine returned to full reliability, and the crew later standardized starter upgrades across their fleet.
Preventative Maintenance Strategies
To extend starter life and avoid premature failure:

• Inspect battery voltage monthly; low voltage increases solenoid wear
  
• Clean terminals and ground straps quarterly to ensure solid current flow
  
• Avoid excessive cranking; limit attempts to 10 seconds with cooldowns
  
• Use dielectric grease on solenoid connectors to prevent corrosion
  
• Monitor starter temperature during prolonged use in hot climates
  

Design Considerations and Future Improvements
While the PT-100’s engine compartment is compact, its starter location poses challenges for field service. Future designs could benefit from:

• Remote-mounted solenoids for easier diagnostics
  
• Quick-access panels for starter removal
  
• Integrated starter diagnostics via CAN-bus systems
  
• Heat shielding to reduce thermal stress from adjacent exhaust components
  

Conclusion
Starter replacement on the ASV PT-100 is a manageable task with proper preparation and tools. As the machine ages, electrical components like the starter become critical to uptime and reliability. By understanding the symptoms, accessing the unit carefully, and applying preventative strategies, operators can keep their PT-100 ready for demanding terrain and heavy workloads. The machine’s legacy in forestry and soft-ground operations remains strong—provided its electrical heart is maintained with care.