ASV PT100 Lifting Issue in High Flow: Troubleshooting and Solutions

[MikePhua]

The ASV PT100, a high-performance compact track loader, is widely known for its impressive lift capacity, powerful hydraulics, and reliability. However, like any piece of heavy machinery, it can occasionally experience issues that affect its performance. One such issue is when the ASV PT100 encounters lifting problems, particularly when using the high-flow hydraulic system. High-flow hydraulics are essential for operating attachments like brush cutters, augers, and high-performance grapples, and a failure to lift or operate at full capacity can create significant challenges on the job site.
This article explores the potential causes of lifting issues in the ASV PT100’s high-flow mode, along with troubleshooting tips and solutions to help operators identify and fix the problem.
Understanding High-Flow Hydraulic Systems in the ASV PT100
The ASV PT100 is equipped with a high-flow hydraulic system designed to deliver increased hydraulic power for attachments that require more pressure and flow than standard hydraulic systems. These attachments often include mulchers, hydraulic hammers, and other high-demand implements that enhance the loader’s versatility.
High-flow hydraulics typically have a flow rate of around 30-40 gallons per minute (GPM), depending on the machine. This system operates through a series of hydraulic pumps, lines, and valves that work together to transfer fluid under pressure to power the attachments. When a problem arises in the high-flow system, it can lead to underperformance, particularly with lifting functions or the operation of demanding attachments.
Common Causes of Lifting Issues in High Flow Mode

1. Hydraulic Fluid Issues
   One of the most common reasons for lifting problems in the high-flow system is inadequate hydraulic fluid or fluid contamination. Hydraulic fluid plays a crucial role in transferring power within the system, and insufficient fluid levels or contaminated fluid can cause the hydraulic pump to work inefficiently.
   • Symptoms: Slow lift, jerky movements, or an inability to lift at all when using high-flow attachments.
     
   • Solution: Always check the hydraulic fluid levels and ensure the fluid is clean and free of debris. If fluid contamination is suspected, drain and replace it with the recommended oil, and replace the hydraulic filters as well.
     
2. Faulty Hydraulic Pump
   The hydraulic pump is the heart of the system, and when it begins to fail or lose efficiency, it can cause significant problems with lifting power. A pump that’s failing may not generate enough pressure to adequately lift heavy loads, especially under high-flow conditions.
   • Symptoms: Low or inconsistent lifting power, even with the engine running at full RPM.
     
   • Solution: Inspect the hydraulic pump for signs of wear or damage. If the pump is malfunctioning, it will likely need to be replaced. Regularly servicing the pump and maintaining clean fluid will extend its lifespan.
     
3. Leaking Hydraulic Hoses or Fittings
   Leaks in the hydraulic hoses or fittings can lead to a loss of pressure, reducing the effectiveness of the high-flow hydraulic system. Even small leaks can cause significant drops in hydraulic performance, which will affect lifting capabilities.
   • Symptoms: Visible fluid leakage around the hydraulic lines or a noticeable drop in hydraulic pressure.
     
   • Solution: Inspect all hydraulic hoses and fittings for cracks, tears, or loose connections. Tighten or replace any damaged parts. Ensure that the hydraulic system is sealed properly to maintain optimal pressure.
     
4. Clogged or Damaged Hydraulic Filters
   Clogged hydraulic filters can restrict fluid flow, causing pressure issues that impact lifting and other hydraulic functions. The filters trap debris and contaminants, and when they become clogged, they can hinder the efficiency of the system.
   • Symptoms: Slow or unresponsive lifting, strange noises from the hydraulic system, or erratic hydraulic behavior.
     
   • Solution: Regularly check and replace hydraulic filters as part of routine maintenance. If the filters are heavily clogged or damaged, it’s important to replace them immediately to restore proper flow.
     
5. Solenoid Valve Malfunction
   The solenoid valve controls the flow of hydraulic fluid to various components, including the lift cylinders. A malfunctioning valve can disrupt the flow of fluid, leading to underperformance in the lifting function.
   • Symptoms: The loader may exhibit jerky or inconsistent lifting behavior, or it may not lift at all in high-flow mode.
     
   • Solution: Inspect the solenoid valve for any signs of electrical malfunction, corrosion, or damage. Solenoid valves can often be cleaned or replaced as necessary to restore smooth operation.
     
6. Improperly Calibrated Pressure Relief Valve
   The pressure relief valve prevents the system from operating at too high a pressure, which could damage components. If this valve becomes stuck or miscalibrated, it may limit the pressure in the high-flow system, reducing lifting capacity.
   • Symptoms: Limited lifting power, especially under heavy load or high-flow conditions.
     
   • Solution: Check the pressure relief valve for proper calibration and operation. If the valve is malfunctioning, recalibrate or replace it as necessary to ensure the system is running at optimal pressure.
     

Steps to Troubleshoot Lifting Problems in High Flow Mode
When lifting issues occur in high-flow mode, there are several troubleshooting steps operators can take to identify the root cause of the problem:

1. Check Hydraulic Fluid and Filter
   Start by inspecting the hydraulic fluid levels. Make sure the fluid is clean and filled to the proper level. Replace any clogged or damaged filters to ensure adequate fluid flow.
   
2. Test Hydraulic Pressure
   Measure the hydraulic pressure using a gauge to determine if the system is operating at the correct pressure. Low pressure can point to issues with the hydraulic pump, pressure relief valve, or leaking hoses.
   
3. Inspect Hydraulic Components for Leaks
   Carefully inspect all hydraulic lines, hoses, and fittings for leaks. Pay special attention to areas where hoses connect to the cylinder or pump, as these are common points of failure.
   
4. Examine the Pump and Solenoid Valve
   If no issues are found with the fluid or hoses, examine the hydraulic pump and solenoid valve. Check for any obvious signs of wear or malfunction, such as strange noises or a lack of response when operating the controls.
   
5. Test the Lifting Function Without High-Flow Attachments
   If lifting is only an issue when using high-flow attachments, disconnect these implements and test the lifting function without them. This will help determine if the issue is with the attachments themselves or with the base hydraulic system.
   

Preventative Maintenance to Avoid Future Issues
To avoid encountering lifting issues in the future, operators should follow a comprehensive preventative maintenance plan for the ASV PT100’s hydraulic system:

• Regular Fluid Changes: Follow the manufacturer’s recommended schedule for hydraulic fluid changes to prevent contamination and ensure smooth operation.
  
• Routine Inspections: Conduct regular inspections of all hydraulic components, including hoses, filters, pumps, and valves. Address any signs of wear before they lead to bigger issues.
  
• Use Recommended Attachments: Always use attachments that are compatible with the ASV PT100’s high-flow system. Using incompatible or underpowered attachments can stress the hydraulic system and lead to premature failure.
  
• Hydraulic Pressure Checks: Periodically check the hydraulic pressure to ensure that the system is operating at the correct levels. Low pressure can lead to reduced lifting capabilities.
  

Conclusion
Lifting issues in the ASV PT100, especially in high-flow mode, can significantly affect productivity on the job site. However, by understanding the potential causes of these problems, performing regular maintenance, and addressing issues as soon as they arise, operators can keep the machine running smoothly and maximize its performance. With proper care and troubleshooting, the PT100 can continue to be a reliable and versatile tool for a wide range of tasks, from construction and landscaping to material handling and excavation.