Service Manual

SR-70/SR-80
Rubber Track Loader
Safety Overview
Technical Specifications
Circuit Diagrams
Maintenance
Controls & Instrumentation
Component Removal & Installation
Hydraulic Component Service
Hydraulic Pressure & Flow Check & Adjustment
Troubleshooting
ASVSR001
Part Number: 2045-830
Printed (06/07)
SR-70/SR-80
Service Manual
Printed (06/07)
1. Product Safety
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Messages . . . . . . . . . . . . . . . . . . . . . 1-1
Information Messages . . . . . . . . . . . . . . . . . 1-1
Basic Precautions . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . 1-1
Protective Equipment . . . . . . . . . . . . . . . . 1-2
Entering and Exiting . . . . . . . . . . . . . . . . . 1-2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hot Fluids and Components . . . . . . . . . . . 1-2
Corrosion Inhibitor . . . . . . . . . . . . . . . . . . . 1-2
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Pressurized Items . . . . . . . . . . . . . . . . . . . 1-2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Work Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Asbestos Information . . . . . . . . . . . . . . . . . . 1-4
Machine Labels and Decals . . . . . . . . . . . . . 1-4
Product Identification Number . . . . . . . . . . 1-4
Engine Serial Number . . . . . . . . . . . . . . . . 1-4
Machine Label and Decal Examples . . . . . 1-5
2. Technical Specifications
Specifications (SR-80) . . . . . . . . . . . . . . . . . 2-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Transmission . . . . . . . . . . . . . . . . . . . . . . . 2-1
Drive Pumps . . . . . . . . . . . . . . . . . . . . . . 2-1
Charge Pump . . . . . . . . . . . . . . . . . . . . . 2-1
Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . 2-1
Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 2-1
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Critical Torque Specifications . . . . . . . . . . . . 2-1
Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Specifications (SR-70) . . . . . . . . . . . . . . . . . 2-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Transmission . . . . . . . . . . . . . . . . . . . . . . . 2-2
Drive Pumps . . . . . . . . . . . . . . . . . . . . . . 2-2
Charge Pump . . . . . . . . . . . . . . . . . . . . . 2-2
Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . 2-2
Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 2-2
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Critical Torque Specifications . . . . . . . . . . . . 2-2
Cycle times . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . 2-2
3. Circuit Diagrams
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 3-1
Hydraulic Charge Circuit . . . . . . . . . . . . . . . . 3-1
Hydraulic Auxiliary Circuit . . . . . . . . . . . . . . . 3-2
Hydraulic Drive Circuit . . . . . . . . . . . . . . . . . 3-3
Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 3-4
Hydraulic Pilot Generation Solenoid Block . . 3-5
Electrical Attachment Outlet . . . . . . . . . . . . . 3-6
Drive Control (line routing) . . . . . . . . . . . . . . 3-7
Lift Arm Control (line routing) . . . . . . . . . . . . 3-8
4. Maintenance
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 4-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 4-1
Lift-Arm Brace . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Tilt-up Cab . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Jacking Procedure . . . . . . . . . . . . . . . . . . . . 4-2
Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . 4-3
Undercarriages . . . . . . . . . . . . . . . . . . . . . . . 4-3
Track Tension . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Drive Sprocket Rollers . . . . . . . . . . . . . . . . . 4-5
Track Removal . . . . . . . . . . . . . . . . . . . . . . . 4-6
Track Installation . . . . . . . . . . . . . . . . . . . . . . 4-8
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Water Separator . . . . . . . . . . . . . . . . . . . . . . 4-11
Accessory Belt Tension . . . . . . . . . . . . . . . . 4-12
Fan Belt Removal/Installation . . . . . . . . . . . . 4-13
A/C Belt Removal/Installation . . . . . . . . . . . . 4-13
Engine Oil/FIlter Change . . . . . . . . . . . . . . . 4-14
Engine Oil Specifications . . . . . . . . . . . . . . . 4-15
Oil Level Check . . . . . . . . . . . . . . . . . . . . . . 4-15
Hydraulic Fluid/Filter Change . . . . . . . . . . . . 4-16
Radiator/Oil Cooler (cleaning) . . . . . . . . . . . 4-17
Engine (cleaning) . . . . . . . . . . . . . . . . . . . . . 4-17
Case Drain Filter . . . . . . . . . . . . . . . . . . . . . . 4-18
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Maintenance Schedule . . . . . . . . . . . . . . . . . 4-19
5. Machine Controls and Instrumentation
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 5-1
Machine Controls . . . . . . . . . . . . . . . . . . . . . 5-1
Loader Control . . . . . . . . . . . . . . . . . . . . . . . 5-1
Drive Control . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . 5-1
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Table of Contents
I
6. Operator Enclosure
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 6-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 6-1
Machine Preparation . . . . . . . . . . . . . . . . . . . 6-1
Removal & Installation . . . . . . . . . . . . . . . . . 6-1
Door Gas Spring . . . . . . . . . . . . . . . . . . . . 6-1
Removal Procedure . . . . . . . . . . . . . . . . 6-1
Installation Procedure . . . . . . . . . . . . . . 6-1
Pillar Switch Panels . . . . . . . . . . . . . . . . . . 6-2
Removal Procedure . . . . . . . . . . . . . . . . 6-2
Installation Procedure . . . . . . . . . . . . . . 6-2
Gauge Clusters . . . . . . . . . . . . . . . . . . . . . 6-3
Removal Procedure . . . . . . . . . . . . . . . . 6-3
Installation Procedure . . . . . . . . . . . . . . 6-3
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Removal Procedure . . . . . . . . . . . . . . . . 6-4
Installation Procedure . . . . . . . . . . . . . . 6-4
Interior Side Panel, LT . . . . . . . . . . . . . . . . 6-4
Removal Procedure . . . . . . . . . . . . . . . . 6-4
Installation Procedure . . . . . . . . . . . . . . 6-5
Interior Side Panel, RT . . . . . . . . . . . . . . . 6-5
Removal Procedure . . . . . . . . . . . . . . . . 6-5
Installation Procedure . . . . . . . . . . . . . . 6-5
Interior Panel, Rear . . . . . . . . . . . . . . . . . . 6-6
Removal Procedure . . . . . . . . . . . . . . . . 6-6
Installation Procedure . . . . . . . . . . . . . . 6-6
Lap Bar Assist Gas Spring . . . . . . . . . . . . 6-6
Removal Procedure . . . . . . . . . . . . . . . . 6-6
Installation Procedure . . . . . . . . . . . . . . 6-6
7. Chassis and Fuel Tank
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 7-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 7-1
Machine Preparation . . . . . . . . . . . . . . . . . . . 7-1
Removal & Installation . . . . . . . . . . . . . . . . . 7-1
Fuel Sending Unit . . . . . . . . . . . . . . . . . . . 7-1
Removal Procedure . . . . . . . . . . . . . . . . 7-1
Installation Procedure . . . . . . . . . . . . . . 7-2
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Removal Procedure . . . . . . . . . . . . . . . . 7-2
Installation Procedure . . . . . . . . . . . . . . 7-3
Footwell . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Removal Procedure . . . . . . . . . . . . . . . . 7-4
Installation Procedure . . . . . . . . . . . . . . 7-4
Foot Throttle Assembly . . . . . . . . . . . . . . . 7-5
Removal Procedure . . . . . . . . . . . . . . . . 7-5
Installation Procedure . . . . . . . . . . . . . . 7-5
Hood Assembly . . . . . . . . . . . . . . . . . . . . . 7-5
Removal Procedure . . . . . . . . . . . . . . . . 7-5
Installation Procedure . . . . . . . . . . . . . . 7-6
8. Radiator and Oil Cooler
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 8-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 8-1
Machine Preparation . . . . . . . . . . . . . . . . . . . 8-1
Removal & Installation . . . . . . . . . . . . . . . . . 8-1
Fan Guard . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Removal Procedure . . . . . . . . . . . . . . . . 8-1
Installation Procedure . . . . . . . . . . . . . . 8-2
Fan & Shroud . . . . . . . . . . . . . . . . . . . . . . 8-2
Removal Procedure . . . . . . . . . . . . . . . . 8-2
Installation Procedure . . . . . . . . . . . . . . 8-3
Radiator/Oil Cooler . . . . . . . . . . . . . . . . . . 8-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Installation . . . . . . . . . . . . . . . . . . . . . . . 8-4
9. Hydraulic Reservoir
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 9-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 9-1
Machine Preparation . . . . . . . . . . . . . . . . . . . 9-1
Removal & Installation . . . . . . . . . . . . . . . . . 9-1
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . 9-1
Removal Procedure . . . . . . . . . . . . . . . . 9-1
Installation Procedure . . . . . . . . . . . . . . 9-7
Suction Screen . . . . . . . . . . . . . . . . . . . . . 9-8
Removal Procedure . . . . . . . . . . . . . . . . 9-8
Installation Procedure . . . . . . . . . . . . . . 9-8
10. Lift Arm/Drive Controls
Chapter Overview . . . . . . . . . . . . . . . . . . . . .10-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . .10-1
Machine Preparation . . . . . . . . . . . . . . . . . . .10-1
Removal & Installation . . . . . . . . . . . . . . . . .10-1
Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
Removal Procedure . . . . . . . . . . . . . . . .10-1
Installation Procedure . . . . . . . . . . . . . .10-3
Lift Arm Float Magnet . . . . . . . . . . . . . . . .10-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . .10-3
Installation . . . . . . . . . . . . . . . . . . . . . . .10-3
Lift Arm Control Valve . . . . . . . . . . . . . . . .10-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . .10-4
Installation . . . . . . . . . . . . . . . . . . . . . . .10-4
11. Hydraulic Pumps/Motors
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 11-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 11-1
Machine Preparation . . . . . . . . . . . . . . . . . . . 11-1
Removal & Installation . . . . . . . . . . . . . . . . . 11-1
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Removal Procedure . . . . . . . . . . . . . . . . . . 11-1
Installation Procedure . . . . . . . . . . . . . . . . 11-2
Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . 11-3
Removal Procedure . . . . . . . . . . . . . . . . . . 11-3
Installation Procedure . . . . . . . . . . . . . . . . 11-4
Tandem Drive Pump . . . . . . . . . . . . . . . . . . . 11-4
Removal Procedure . . . . . . . . . . . . . . . . . . 11-4
Installation Procedure . . . . . . . . . . . . . . . . 11-5
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
Removal Procedure . . . . . . . . . . . . . . . . . . 11-6
Installation Procedure . . . . . . . . . . . . . . . . 11-8
Rubber Track Loader
Table of Contents
II
12. Engine
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 12-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 12-1
Removal & Installation . . . . . . . . . . . . . . . . . 12-1
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Removal Procedure . . . . . . . . . . . . . . . . 12-1
Installation Procedure . . . . . . . . . . . . . . 12-2
Exhaust System . . . . . . . . . . . . . . . . . . . . 12-2
Removal Procedure . . . . . . . . . . . . . . . . 12-2
Installation Procedure . . . . . . . . . . . . . . 12-4
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Removal Procedure . . . . . . . . . . . . . . . . 12-4
Installation Procedure . . . . . . . . . . . . . . 12-5
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Removal Procedure . . . . . . . . . . . . . . . . 12-5
Installation Procedure . . . . . . . . . . . . . . 12-7
13. Undercarriage
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 13-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 13-1
Machine Preparation . . . . . . . . . . . . . . . . . . . 13-1
Removal & Installation . . . . . . . . . . . . . . . . . 13-1
15 Idler Wheel (SR-80) . . . . . . . . . . . . . . 13-1
Removal Procedure . . . . . . . . . . . . . . . . 13-1
Installation Procedure . . . . . . . . . . . . . . 13-2
15 & 10 wheel (SR-70) . . . . . . . . . . . . . . 13-3
Removal & Installation Procedures . . . . 13-3
10 Bogie Wheel & Hub (SR-80) . . . . . . . 13-3
Removal & Service Procedure . . . . . . . . 13-3
Idler Hub . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Removal & Service Procedure . . . . . . . . 13-8
14. Lift Arm Components
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 14-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 14-1
Machine Preparation . . . . . . . . . . . . . . . . . . . 14-1
Removal & Installation . . . . . . . . . . . . . . . . . 14-1
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Removal Procedure . . . . . . . . . . . . . . . . 14-1
Installation Procedure . . . . . . . . . . . . . . 14-3
Bucket/Tilt Cylinder . . . . . . . . . . . . . . . . . . 14-3
Removal Procedure . . . . . . . . . . . . . . . . 14-3
Installation Procedure . . . . . . . . . . . . . . 14-5
Q/C Block PRV . . . . . . . . . . . . . . . . . . . . . 14-5
Removal Procedure . . . . . . . . . . . . . . . . 14-5
Installation Procedure . . . . . . . . . . . . . . 14-5
15. Quick Attach
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 15-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 15-1
Machine Preparation . . . . . . . . . . . . . . . . . . . 15-1
Removal & Installation . . . . . . . . . . . . . . . . . 15-1
Locking Pin . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Removal Procedure . . . . . . . . . . . . . . . . 15-1
Installation Procedure . . . . . . . . . . . . . . 15-2
Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
Removal Procedure . . . . . . . . . . . . . . . . 15-3
Installation Procedure . . . . . . . . . . . . . . 15-3
16. Hydraulic Component Service
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 16-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 16-1
Disassembly & Assembly . . . . . . . . . . . . . . . 16-1
Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . 16-1
Disassembly Procedure . . . . . . . . . . . . . 16-1
Assembly Procedure . . . . . . . . . . . . . . . 16-3
Lift Arm Control Valve . . . . . . . . . . . . . . . . 16-4
Disassembly Procedure . . . . . . . . . . . . . 16-4
Assembly Procedure . . . . . . . . . . . . . . . 16-6
Drive Motor (brake portion) . . . . . . . . . . . . 16-6
Disassembly Procedure . . . . . . . . . . . . . 16-6
Assembly Procedure . . . . . . . . . . . . . . . 16-7
Drive Motor (motor portion) . . . . . . . . . . . . 16-8
Disassembly Procedure . . . . . . . . . . . . . 16-8
Assembly Procedure . . . . . . . . . . . . . . . 16-9
Drive Pump (Drive Relief Valves) . . . . . . . 16-9
Disassembly & Adjustment . . . . . . . . . . 16-9
Posi-Power Relief Valve . . . . . . . . . . . . . 16-9
Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . 16-10
Disassembly Procedure . . . . . . . . . . . . . 16-10
Assembly Procedure . . . . . . . . . . . . . . . 16-12
Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . 16-14
Disassembly Procedure . . . . . . . . . . . . . 16-14
Assembly Procedure . . . . . . . . . . . . . . . 16-15
17. Hydraulic Pressure & Flow
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 17-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 17-1
Contamination Inspection . . . . . . . . . . . . . . . 17-1
Pressure/Flow Test and Troubleshooting . . . 17-1
Charge Pressure Check & Adjust . . . . . . . 17-1
Auxiliary Pressure Check & Adjust . . . . . . 17-3
Lift Arm Pressure Check . . . . . . . . . . . . . . 17-4
Drive Pressure Check . . . . . . . . . . . . . . . . 17-4
Troubleshooting . . . . . . . . . . . . . . . . . . . 17-5
Posi-Power Pressure Check & Adjust . . . . 17-5
Auxiliary Flow Test . . . . . . . . . . . . . . . . . . . 17-6
Troubleshooting . . . . . . . . . . . . . . . . . . . 17-7
18. Troubleshooting
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 18-1
Personal Safety . . . . . . . . . . . . . . . . . . . . . . 18-1
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . 18-1
General Troubleshooting Scenarios . . . . . . . 18-1
Engine/Machine Troubleshooting . . . . . . . . . 18-3
19. Lubricant and Fuel Specifications
Chapter Overview . . . . . . . . . . . . . . . . . . . . . 19-1
Fluids & Fuel Specifications . . . . . . . . . . . . . 19-1
20. Service Aids and Supplements
General Torque Specifications . . . . . . . . . . . 20-1
Electrical Schematic . . . . . . . . . . . . . . . . . . . 20-2
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . 20-3
III
Rubber Track Loader
Table of Contents
IV
Chapter Overview
This chapter contains product safety information for the
SR-70/80 Rubber Track Loaders. Read and under-
stand all product safety information before attempting
to service any Rubber Track Loader.
Safety Messages
Safety messages are included in this document to
serve as warnings of potentially dangerous conditions.
Failure to follow their instructions could result in injury
or death.
These messages are identified by the headings:
!DANGER!.!WARNING!.!CAUTION!.
The messages are to be understood as:
Attention! Your Safety Is Involved!
The information that follows each heading describes
the potential hazard and the precautions necessary to
protect yourself and others from injury. Instructions
may be written or pictorially presented.
This symbol is used to alert service personnel of an
imminently hazardous situation that will result in serious
injury or death.
This symbol is used to alert service personnel of a
potentially hazardous situation that could result in seri-
ous injury or death.
This symbol is used to alert service personnel of an
unsafe practice that could result in injury.
Information Messages
Information messages are also included in this docu-
ment to supplement the instructions and photographs
in each chapter. These messages are identified by the
labels NOTICE or Note.
NOTICE
This label is used to alert service personnel of a situation
that could lead to equipment or machine damage.
Note: This label is used to provide important additional infor-
mation, further explanation, comments or to stress the impor-
tance of a topic.
The person(s) in charge of servicing a Rubber Track
Loader may be unfamiliar with many of the systems on
the machine. This makes it especially important to use
caution when performing service tasks. Familiarize
yourself with the affected system(s) and components
before attempting any type of maintenance or service.
It is not possible to anticipate every potential haz-
ard. The safety messages included in this docu-
ment and displayed on the machine are not all-
inclusive. They are intended to make you aware of
potential risks and encourage a safe approach to
performing service work. If you use a tool, proce-
dure, work method or operating technique that is
not specifically recommended by ASV, you must
satisfy yourself that it is safe for you and others.
You must also ensure that the machine will not be
damaged or be made unsafe by the operation,
lubrication, maintenance or repair procedures that
you choose.
Basic Precautions
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Following is a list of basic precautions that should
always be observed.
Safety Labels
Safety labels are displayed in various places through-
out the machine to serve as warnings of potentially
dangerous conditions. Read and understand all
"Safety" labels on any Rubber Track Loader before
attempting to operate, maintain or repair it. Replace
any damaged, illegible or missing labels as necessary.
1. Product Safety
1-1
!WARNING!
!CAUTION!
!WARNING!
!DANGER!
Protective Equipment
Always wear appropriate protective equipment for
working conditions when working on or around a
Rubber Track Loader. Wear hard hats, protective
glasses, safety shoes and any other equipment nec-
essary to ensure your safety and the safety of others
as you work. In particular, wear protective glasses
when pounding on any part of the machine or its work
tool with a hammer or sledge. Do not wear loose cloth-
ing or jewelry that can catch on components and
cause injury. If welding is required, use welding gloves,
helmet (UV eye protection), apron, boots and any
other protective clothing necessary to ensure your
safety and the safety of others while welding. Avoid
wearing flammable or heat sensitive clothing while per-
forming tasks that involve welding.
Entering and Exiting
Always use steps and handholds when entering or
exiting a Rubber Track Loader. Clean any mud or
debris from steps or work platforms before using them.
Always face the machine when using steps and hand-
holds. When it is not possible to use the designed
entry/exit system, utilize ladders, scaffolds, or work
platforms to safely gain access to the machine.
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 posi-
tioned correctly and equipped with a spring latch.
Lifting eyes are not to be side loaded during a lifting
operation.
Hot Fluids and Components
Stay clear of hot components and system fluids of the
engine, exhaust, radiator/oil cooler and hydraulic
lines/tubes. Also, use caution 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. Be especially careful if the
machine has been operated recently, fluids may still be
hot. To ensure your safety, allow the machine to cool
before attempting any service procedure that involves
hot fluids or components.
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 electrolyte
level. Never disconnect any charging unit circuit or bat-
tery circuit cable from the battery when the charging
unit is operating. A spark can cause an explosion from
the flammable vapor mixture of hydrogen and oxygen
that is released from the electrolyte 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. Do not use hands or any other body part to check
for fluid leaks in the hydraulic system. Always use
a solid material like wood or metal to check for this
type of leak. Leaking fluid under pressure can pen-
etrate body tissue. Fluid penetration can cause
serious injury and even death. If fluid is injected
into your skin, get treatment immediately. Seek
treatment from a doctor that is familiar with this
type of injury.
2. Relieve pressure from the hydraulic system before
disconnecting or removing any lines, fittings or
related items. Do this by relaxing all hydraulic
actuators. If the lift arms are raised, make sure
they are securely braced. Be alert for possible
pressure release when disconnecting any device
from a pressurized system.
3. Lower the lift arms before performing any work on
the machine. If this cannot be done, make sure
they are securely braced to prevent them from
dropping unexpectedly during service.
4. Loose or damaged fuel, oil, 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. See item 1 for precautions on checking
for fluid leaks.
5. Pressurized air or water can also cause injury.
When pressurized air or water is used for clean-
ing, wear a protective face shield, protective cloth-
ing, and protective shoes. The recommended max-
imum air pressure for cleaning purposes is 205
kPa (30 psi). When using a pressure washer, keep
in mind that nozzle pressures are typically very
high. Generally, pressures are well above 13790
kPa (2000 psi). Follow all recommended practices
provided by the pressure washer manufacturer.
1-2
Rubber Track Loader
1. Product Safety
Repair
Accidental machine starting can cause injury or even
death to personnel working on a Rubber Track Loader.
As a precaution, disconnect the battery cables from the
battery terminals, tape the battery clamps and remove
the key from the ignition switch prior to performing any
service work on a Rubber Track Loader.
Place a Do Not Operate tag prominently on the
machine to inform personnel that the machine is being
serviced.
1. Disconnect the battery and discharge any capaci-
tor before beginning work on a machine. Attach a
Do Not Operate tag in the cab to alert any opera-
tor that service is in progress.
2. If possible, make all repairs with the machine
parked on a level, hard surface. Use blocks to pre-
vent the machine from rolling while working on or
under the machine.
3. Do not work on or under any machine that is sup-
ported only by a hydraulic jack or hoist. Always
use some sort of mechanical support to ensure
that the machine will not fall. ASV jack stands work
well to support the machine while performing
maintenance or repair work.
4. Make sure the work area around the machine is
safe and make yourself aware of any hazardous
conditions that may exist. If the engine needs to
be started inside an enclosure, make sure that the
engines exhaust is properly vented.
5. Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before beginning any service task. If a guard
or shield must be removed to perform the repair
work, use extra caution.
6. Always use the appropriate tools for the work to be
performed. Tools should be in good condition and
you should understand how to use them properly
before performing any service work.
7. When replacing fasteners, use parts of equivalent
grade and size. Do not use a lesser quality fasten-
er if replacements are necessary.
8. Be prepared to stop an engine if it has been re-
cently overhauled or the fuel system has been
recently serviced. 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 damage. 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. Gradually
back off the last two bolts or nuts located on oppo-
site sides of the cover. 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 by personnel adequately trained and knowl-
edgeable in welding procedures and with the guid-
ance of appropriate reference information.
Determine the type of metal being welded and
select the correct welding procedure and filler
material to provide a weld that is as strong or
stronger than the original weld.
11. Take precautions to avoid damaging wiring during
removal and installation operations. Carefully route
wires so that they will not contact sharp corners,
objects or hot surfaces during operation.
12. When performing service that requires the lift arms
to be in the raised position, always utilize the lift
arm brace located on the rear of the loader tower.
13. Relieve hydraulic system pressure by relaxing all
hydraulic actuators prior to attempting any
hydraulic maintenance or repair.
14. Always tighten connections to the correct torque
specification. Make sure that all shields, clamps
and guards are installed correctly to avoid exces-
sive heat, vibration or unwanted contact between
parts during operation. Shields that protect
exhaust components from oil spray in event of a
line, tube or seal failure must be correctly installed.
15. Do not operate a machine if any rotating part is
damaged or contacts other parts during operation.
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.
Work Tools (Attachments)
Only use work tools that are recommended by ASV.
Make sure that all necessary guards and protective
equipment are in place and functioning prior to operat-
ing any work tool.
1-3
Rubber Track Loader
1. Product Safety
!WARNING!
Wear protective glasses and protective equipment as
required by conditions or as recommended in the work
tools operation manual.
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 work tool while performing
any work tool maintenance, testing or adjustments.
Asbestos Information
Equipment and replacement parts shipped from the
manufacturer are asbestos free. When replacement
parts are required, use only genuine manufacturers
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 asbestos 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 asbestos 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 machining
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.
When replacement parts are required for your machine,
use only genuine ASV replacement parts or parts that
meet or exceed original specifications including, but not
limited to physical dimensions, type, strength and mate-
rial.
Installing lesser components can lead to premature fail-
ures, product damage, personal injury or death.
Machine Labels and Decals
Labels and decals placed on the machine provide
safety information and operating instructions.
Familiarize yourself with the location and significance
of these labels to ensure your safety.
Product Identification Number
The Product Identification Number (PIN) is located on
the front of the cab enclosure in the lower right corner.
(figure 1-1). Always provide the PIN when contacting
the dealer about parts, service, warranty or acces-
sories. No warranty claims will be processed unless
the PIN is provided.
Engine Serial Number
The engine serial number is located on the top of the
engine valve cover near the rear of the machine.
(figure 1-2)
1-4
Rubber Track Loader
1. Product Safety
!WARNING!
1-1
1-2
Model ID Tag
Serial # Tag
Machine Label and Decal Examples
Examples of the labels and decals displayed on the
machine are shown on this page.
1-5
Rubber Track Loader
1. Product Safety
Keep out from under raised lift arms!
Do not go beneath raised lift arms unless the lift arm
brace has been properly installed. See operation and
maintenance manual for installation procedure.
Failure to observe or comply with warnings may result in
serious injury or even death.
DANGER
2045-466
WARNING
Entering & Exiting
Maintain 3-point contact
with step and hand rails.
Engine Warm-Up
Allow the engine to
warm up prior to opera-
tion.
Carrying Loads
Carry loads low. Load,
unload and turn on level
ground.
Inclines
Travel with heaviest end
of machine facing uphill.
Riders
Riders not permitted.
Work Platform
Never use a work tool as
a work platform.
Disclaimer
Failure to observe and
comply with the warn-
ings listed above may
result in machine dam-
age, personal injury, or
even death.
Pre-Start Checklist
1. Operator seated in
cab.
2. Seat belt fastened.
3. Lap bar pivoted down.
4. Joystick controls in
neutral position.
5. Quick attach switch in
locked position.
6. High & low flow auxil-
iary switches off.
2045-469
WARNING
Brushcutting
Brushcutting, mowing or
operations that generate
airborne debris can
cause fires.
With the engine off
and cool:
1. Inspect the engine
compartment and any
other areas containing
hot or rotating parts
2. Thoroughly clean
these areas as often
as necessary to
avoid combustion.
Failure to do so could
result in fire that may
cause machine damage,
personal injury, or even
death.
2-Speed
(if equipped)
To engage:
Press the button located
on the front of the right
joystick control.
To disengage:
Press the button a sec-
ond time.
2045-468
DANGER
Operating Position
Never operate the
machine with any part of
your body protruding
out of the operator
enclosure.
Failure to do so may
result in serious injury or
even death.
Prior to Operating
Read and fully under-
stand the operation and
maintenance manual
prior to operating this
machine.
2045-472
WARNING
Keep away from tracks while machine is in motion.
Serious personal injury or even death may result.
Inspect undercarriages daily for accumulation of
debris. Build-up of debris may shorten component
life and decrease machine performance.
CAUTION
2045-467
Follow instructions closely!
Failure to install lift arm brace correctly
may result in personal injury or death.
WARNING
NEVER GO BENEATH UNSECURED LIFT ARMS
1. Remove any attachment from the machine.
2. Have an assistant remove the lift arm brace from its stowed position.
3. Start the engine and carefully raise the lift arms.
4. Have the assistant install the brace around the exposed portion of the lift cylinder rod.
5. Have the assistant secure the brace to the rod with the retaining pins, then stand clear.
6. Slowly lower the lift arms until they come to rest on the brace.
7. Shut the engine off and carefully exit the machine.
8. Reverse this procedure to lower and re-secure the lift arm brace.
2045-646
1-6
SR-80 Specifications
Engine
- Model: Perkins 804C-33T
- Displacement: 3.3 liter
- Gross horsepower: 80.5 hp (60 kW)
- Torque: 186 lb-ft. (253 Nm)
- Idle rpm: 1000 (low idle), 2600 (high idle)
- Average water /thermostat temperature: 190F,
87.8C
Transmission
- Model: Cat A22VG45 tandem (Rexroth)
Drive Pumps
- Displacement: 2.7459 in3/rev (45 cc/rev)
- Relief pressure: 5500 psi (380 bar)
- Flow: 30.91 gpm (117 lpm) @ 2600 rpm (per
pump)
Charge Pump
- Displacement: 1.373 in3/rev (22.5 cc/rev)
- Relief pressure: 475 +/- 30 psi (32.75 bar)
- Flow: 15.4 gpm (58.3 lpm) @2600 rpm
Drive Motors
- Model: Rexroth MCR 5
- Displacement: 50 in3/rev (820 cc/rev)
Pilot Controls (Joysticks)
- Model: Rexroth 08-351
Auxiliary Pump
- Make: Rexroth
- Type: Axial Piston, Variable Load Sense
- Displacement: 2.75 in3/rev (45 cc/rev)
- Max Flow: 30 gpm (113.6 lpm) @ 2600 rpm
- Relief pressure: 3000 psi (20,680 kPa)
- Marginal (Standby) Pressure: 218 psi (1,503 kPa)
- Cooling/filtering: Oil is filtered and cooled at all
times. In auxiliary mode, the oil is filtered after the
attachment to protect the machine if the attach-
ment motor fails or contaminants are introduced
from the quick couplers.
Lift Arm Control Valve
- Make: Rexroth
- Type: Load Sense
Oil Cooler
- Operating pressure: 150 psi (1034 kPa)
- Bypass relief pressure: 80 psi (689 kPa)
- Hot oil sending unit: 225F (107.2C)
- Avg. oil operating temp. 50-60F above ambient.
(High flow application 80F above ambient.)
Critical Torque Specs
- Transmission Mounting Bolts
-- 85 ft-lb. w/Blue Loctite
- Drive Sprocket Drive Teeth Bolts
-- 88 ft-lb. -Dry
- Bogie Wheel (10 Idler) Retaining Bolt
-- 180 ft-lb. - w/Red Loctite
- 15 Idler Wheel Retaining Nut
-- 350 ft-lb. -Dry
- Drive Sprocket Lug Nut
-- 206 ft-lb. -Dry
- Drive Motor Mounting Bolts
-- 206 ft-lbs. -Dry
Cycle Times
Lift-Arm up: 3.5 seconds (+/- .35 seconds)
Lift-Arm Down: 3.3 seconds (+/- .33 seconds)
Bucket Curl: 1.7 seconds (+/- .17 seconds)
Bucket Dump: 1.9 seconds (+/- .19 seconds)
Service Tools
Listed below are common service tools which are iden-
tified and utilized in the service procedures described
in this manual. Use tools recommended by ASV when-
ever possible to reduce risk of injury and or machine
damage during service.
ASV Jack Stands (2) (ASV P/N: 0402-900)
Heavy Duty Hydraulic Jack (5-ton rating)
Test Gauge Kit (ASV P/N: 0402-935)
Ratchet Strap
Long Pry Bar(s)
ASV Service Cart (0402-871)
2. Technical Specifications
& Service Tools
2-1
SR-70 Specifications
Engine
- Model: Perkins 804C-33T
- Displacement: 3.3 liter
- Gross horsepower: 71 hp (53 kW)
- Torque: 173 lb-ft. (234 Nm)
- Idle rpm: 1000 (low idle), 2600 (high idle)
- Average water /thermostat temperature: 190F,
87.8C
Transmission
- Model: Cat A22VG45 tandem (Rexroth)
Drive Pumps
- Displacement: 2.7459 in3/rev (45 cc/rev)
- Relief pressure: 5500 psi (380 bar)
- Flow: 30.91 gpm (117 lpm) @ 2600 rpm (per
pump)
Charge Pump
- Displacement: 1.373 in3/rev (22.5 cc/rev)
- Relief pressure: 475 +/- 30 psi (32.75 bar)
- Flow: 15.4 gpm (58.3 lpm) @2600 rpm
Drive Motors
- Model: Rexroth MCR 05 C
- Displacement: 37.8 in3/rev (620 cc/rev)
Pilot Controls (Joysticks)
- Model: Rexroth 08-351
Auxiliary Pump
- Make: Rexroth
- Type: Axial Piston, Variable Load Sense
- Displacement: 2.75 in3/rev (45 cc/rev)
- Max Flow: 30 gpm (113.6 lpm) @ 2600 rpm
- Relief pressure: 3000 psi (20,680 kPa)
- Marginal (Standby) Pressure: 218 psi (1,503 kPa)
- Cooling/filtering: Oil is filtered and cooled at all
times. In auxiliary mode, the oil is filtered after the
attachment to protect the machine if the attach-
ment motor fails or contaminants are introduced
from the quick couplers.
Lift Arm Control Valve
- Make: Rexroth
- Type: Load Sense
Oil Cooler
- Operating pressure: 150 psi (1034 kPa)
- Bypass relief pressure: 80 psi (689 kPa)
- Hot oil sending unit: 225F (107.2C)
- Avg. oil operating temp. 50-60F above ambient.
(High flow application 80F above ambient.)
Critical Torque Specs
- Transmission Mounting Bolts
-- 85 ft-lb. w/Blue Loctite
- Drive Sprocket Drive Teeth Bolts
-- 88 ft-lb. -Dry
- 10 Idler Wheel Retaining Nut
-- 350 ft-lb. -Dry
- 15 Idler Wheel Retaining Nut
-- 350 ft-lb. -Dry
- Drive Sprocket Lug Nut
-- 129 ft-lb. -Dry
- Drive Motor Mounting Bolts
-- 129 ft-lbs. -Dry
Cycle Times
Lift-Arm up: 3.5 seconds (+/- .35 seconds)
Lift-Arm Down: 3.3 seconds (+/- .33 seconds)
Bucket Curl: 1.7 seconds (+/- .17 seconds)
Bucket Dump: 1.9 seconds (+/- .19 seconds)
Service Tools
Listed below are common service tools which are iden-
tified and utilized in the service procedures described
in this manual. Use tools recommended by ASV when-
ever possible to reduce risk of injury and or machine
damage during service.
ASV Jack Stands (2) (ASV P/N: 0402-900)
Heavy Duty Hydraulic Jack (5-ton rating)
Test Gauge Kit (ASV P/N: 0402-935)
Ratchet Strap
Long Pry Bar(s)
ASV Service Cart (0402-871)
2-2
Rubber Track Loader
2. Technical Specifications & Service Tools
Chapter Overview
This chapter contains diagrams for the following SR-
70/80 circuits: hydraulic charge circuit, hydraulic auxil-
iary circuit, hydraulic drive circuit, loader valve,
hydraulic pilot generation (solenoid) block and electri-
cal attachment outlet. It also contains hose routing
information for the control configurations for the drive
and lift arm pilot controls.
Figure 3-1 SR-70/80 Hydraulic Charge Circuit
Hydraulic Charge Circuit
3. Circuit Diagrams
3-1
OIL COOLER
TANK
INLET
CHARGE PUMP
FLOW
PILOT GEN BLOCK
CHARGE PRESSURE
TEST PORT
(475 +/- 30 PSI)
TO HYD Q/A (OPTIONAL SR-70)
TANK
5 MICRON FILTER
TANK
CHECK VALVE
(15 PSI)
CHECK VALVE
(0 PSI)
CHARGE PRESSURE
RELIEF VALVE
(475 +/- 30 PSI)
Hydraulic Auxiliary Circuit
Figure 3-2 SR-70/80 Hydraulic Auxiliary Circuit
3-2
Rubber Track Loader
3. Circuit Diagrams
OIL COOLER
TO TANK
TO ATTACHMENT
CASE DRAIN Q/C
LOAD SENSE
TO LIFT ARM CYL.
TO AUXILIARY Q/C
TO TANK
FLOW
AUXILIARY PUMP
LOADER CONTROL
LIFT ARM VALVE
PILOT GEN. BLOCK
TO LIFT ARM CYL.
TO TANK
CHARGE PUMP INLET
TO BUCKET CYL.
CHECK VALVE
(80 PSI)
AUXILIARY PUMP INLET
Hydraulic Drive Circuit
Figure 3-3 SR-70/80 Hydraulic Drive Circuit
3-3
Rubber Track Loader
3. Circuit Diagrams
DRIVE MOTOR
DRIVE MOTOR
DRIVE PUMP
DRIVE CONTROL
TO COOLER
TANK
CASE DRAIN
BRAKE
2-SPEED SHIFT (SR-80)
DRIVE PRESSURE
RELIEF VALVES (4)
5500 PSI
Lift Arm Control Valve
Figure 3-4 SR-70/80 Lift Arm Control Valve
3-4
Rubber Track Loader
3. Circuit Diagrams
RELIEF VALVE SETTINGS
(B3) 3307 PSI
(B2) 3147 PSI
(B1) 3640 PSI
(A3) 3307 PSI
(A2) 3669 PSI
(A1) Anti-Cavitation
Check Valve
Hydraulic Pilot Generation
Block
Figure 3-5 SR-70/80 Hyd. Pilot Generation Block
3-5
Rubber Track Loader
3. Circuit Diagrams
Electrical Attachment Outlet
Figure 3-6 SR-70/80 Electrical Attachment Outlet
3-6
Rubber Track Loader
3. Circuit Diagrams
Drive Control
(line routing)
Figure 3-7 SR-70/80 Standard Drive Control
3-7
Rubber Track Loader
3. Circuit Diagrams
Lift Arm Control
(line routing)
Figure 3-8 SR-70/80 Lift Arm Control
3-8
Rubber Track Loader
3. Circuit Diagrams
Chapter Overview
This chapter provides information on general mainte-
nance procedures for the SR-70/80. If there is an issue
that requires troubleshooting, refer to Chapter 18,
Troubleshooting.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
Lift Arm Brace
The lift arm brace (A) is intended to keep service per-
sonnel safe when it is necessary to work on a machine
with the lift arms in the raised position. It is not safe to
rely on the hydraulic system to hold the lift arms in the
raised position just as it is not safe to crawl under a
machine supported only by a jack. The lift arm brace is
used to support the weight of the lift arms much like
jack stands are used to mechanically support vehicle
weight.
To install the lift arm brace:
1. Park the machine on level ground in a safe area
for performing service work.
2. Remove any attachments that may be fastened to
the quick attach.
3. Have an assistant remove the retaining pins (B)
securing the lift arm brace and remove it from the
machine.
4. Make sure bystanders are clear of the lift arms,
then raise them to the upper limit.
5. Have an assistant Install the brace around the
cylinder shaft as shown and reinstall the pins to
secure it to the cylinder.
6. Lower the lift arms slowly until they come to rest
on the brace.
7. It is now safe to shut the engine off and exit the
machine.
Do not work on or near the machine with the lift arms in
the raised position unless the lift arm brace has been
correctly installed.
To remove the lift arm brace:
1. Start the machine and raise the lift arms until they
are clear of the brace.
2. Once clear, have an assistant remove the brace
from the cylinder and stow it on the machine with
the pins.
3. Once the brace has been stowed and the assistant
is clear of the lift arms, lower the arms to the
ground and shut the engine off to complete the
procedure.
4. Maintenance
4-1
A
B
!WARNING!
!WARNING!
4-1
4-2
Tilt-Up Cab
The ROPS/FOPS approved cab (A) tilts up to allow
easier access while performing maintenance. It fea-
tures a gas spring assist and a brace mechanism to
hold it in place while tilted.
To tilt the cab:
1. Remove any attachments that may be fastened to
the machine.
2. (Optional) Raise the lift arms and secure them with
the lift arm brace. (See page 4-1.)
3. Remove the two bolts that fasten the cab to the
chassis. They are located inside the cab, one in
each of the front corners.
4. Once the bolts have been removed, tilt the cab
slowly upwards. The cab brace (B) should fall
onto the shoulder bolt (C) locking the cab in its
upright position.
The cab is now secure.
To lower the cab:
1. Raise the cab brace so that the locking channel is
clear of the shoulder bolt.
2. Hold the brace upwards and lower the cab until the
locking channel is clear of the shoulder bolt then
release the brace.
3. The cab is now free to be lowered into operating
position.
4. Lower the cab completely and then fasten it to the
chassis with the two bolts removed previously.
Jacking Procedure
Occasionally, your machine may need to be suspend-
ed off of the ground to perform maintenance. Exercise
caution when jacking the machine. Always use a jack
that is capable of lifting the machine and support its
weight with ASV approved jack stands while suspend-
ed. Never work on or under a machine supported only
by a jack.
To safely jack your machine:
1. Remove any attachments that may be fastened to
the machine and raise the lift arms.
2. Install the lift arm brace as instructed on page 4-1.
3. Once the lift arms are secured, carefully exit the
machine.
4. Roll or slide your jack under the front of the
machine and center the lifting pad directly under
the middle of the front torsion axle.
5. Once in place, jack the machine upward making
sure it remains stable until it has reached sufficient
height to install an ASV jack stand beneath the
machine. (fig. 4-4)
6. Slide the jack stand into place making sure it is
centered under the machine (left to right when
viewed from the front) and far enough back for the
machine to remain stable when the jack is lowered
and the front of the machine rests on the stand.
(fig. 4-5)
7. Once the stand is in place, slowly lower the
machine onto the stand and then remove the jack.
Repeat steps 4-7 at the rear of the machine should
both ends of the machine need to be off of the ground
for service.
4-2
Rubber Track Loader
4. Maintenance
B
C
4-3
4-4
4-5
A
Grease Fittings
The SR 70/80 are equipped with grease fittings at pivot points throughout the machine. The illustration above
shows the locations of all fittings on the left side of the machine. An identical fitting exists on the right side of the
machine for each one identified in the illustration. Lubricate all fittings DAILY or after every 10 hours of operation
to maximize component life and ensure proper machine function. (fig. 4-6)
Undercarriages
The undercarriage assemblies in Rubber Track Loaders 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 assemblies and cleaning if necessary.
Materials that are particularly sticky or abrasive like clay, mud, or gravel should be cleaned from the undercar-
riages more 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 tables, sprockets, and the front and rear wheels where
debris is likely to accumulate. If working in scrap or debris, inspect more often and remove foreign objects that
may wrap around or lodge themselves between components causing premature wear and damage.
Operation in loamy sand or on turf or other finished surfaces may require less frequent cleaning, but daily
inspection is still advised.
4-3
Rubber Track Loader
4. Maintenance
A. Lower Bucket Cylinder Pivot (2)
B. Upper Bucket Cylinder Pivot (2)
C. Front Lift Cylinder Pivot (2)
D. Lift Arm Pivot (2)
E. Rear Lift Cylinder Pivot (2)
F. Rear Axle Pivot (2)
G. Front Axle Pivot (2)
H. Lower Bucket Pivot (2)
Grease Fitting Locations
G F
D
E
H
A
B
C
4-6
Track Tension (SR-70/80)
Proper track tension must be maintained for optimal
performance and track/undercarriage life. Running a
track that is too loose may cause the track to misfeed
possibly causing damage to the track and or undercar-
riage components. Running a track that is too tight
may cause track stretch, premature bearing failure, or
other preventable damage to the machine. As a rule, a
track should only be tightened to the point where there
is no visible sag. Never tighten your tracks beyond this
point.
Note: During the first 50 hours of operation the tracks
will "break-in" and will most likely require adjustment.
To check track tension: (fig. 4-7, 4-8)
1. Drive the machine forward 5 feet to remove belt
slack from the lower and rearward portions of the
track.
2. Lay a straight edge along the top of the track
bridging the drive sprocket and front idler wheel.
3. Apply 90 lbs. of down force to the the track by
either placing weight on top or hanging it using
rope or wire midway between the drive sprocket
and front idler.
4. Measure from the bottom of the straight edge to
the lug surface (top) of the track. The deflection
should measure between 3/4" and 1".
To adjust track tension: (fig. 4-9)
1. Loosen the lock nut (A) on the turnbuckle (B) and
adjust by turning the turn buckle itself until proper
tension has been achieved.
2. Then tighten the turnbuckle lock nut to complete
the procedure.
3. Repeat the adjustment procedure on the other side
of the machine if necessary.
4-4
Rubber Track Loader
4. Maintenance
4-7
B
A
Straight-Edge
4-8
4-9
Drive Sprocket Rollers
ASV rubber track loaders utilize rollers on the drive
sprockets to drive the track. These rollers help mini-
mize friction between the track and the drive sprocket
to prolong track life.
The rollers rotate around hardened steel pins and usu-
ally wear on their inside surfaces. As they wear, the
rollers become thinner, but will continue to function as
long as they rotate freely around the pins. Sprocket
rollers should be inspected every 50 hours of operation
and replaced if cracked or worn to less than 35% of
original thickness. (.088)
To replace worn rollers:
1. Begin by performing steps 1-4 in the track removal
procedure on page 4-6 to allow the sprocket to be
removed.
2. Remove the seven bearing plate mounting bolts
(A, I), then remove the plate (B) from the drive
table.
3. Remove the bearing cap (G) by tapping around the
bulged area of the cap with a hammer. This will
relieve the outward pressure on the cap and allow
for removal.
4. Remove the external snap ring (H) from the bear
ing shaft.
5. Using a puller, remove the bearing assembly (J)
from the shaft.
6. Remove the sprocket mounting bolts (C), then
remove the sprocket.
Note: You may need to pry or lift the track upwards
with a hoist above the drive sprocket to provide clear-
ance for removal.
7. Remove one bolt (F) holding the steel pins (D) and
rollers (E) in place. Install the new rollers over
the pins, then slide the bolt back through the
sprocket and pins and secure it with the nut (K).
8. Repeat this process as required throughout the
sprocket.
9. Reinstall the sprocket by reversing steps 2-6.
Note: During removal of the bearing cap (step 3) the
bulged area of the cap is beaten inward. When rein-
stalling, orient the cap so that the domed area is facing
outward. Then tap the center of the cap with a ball
peen hammer or similar device to reset the cap. Do
this gently. Too much inward force can damage (mush-
room) the bearing shaft.
10. Repeat steps 1-9 on the other side of the machine
if necessary.
11. Perform the track tension adjustment and check
procedures on page 4-4.
Note: Replace rollers as a set to simplify inspection
and maintain proper sprocket function.
4-5
Rubber Track Loader
4. Maintenance
New Roller
Normal Wear
35% life
Steel Pin
(.088)
A
H
F
E
D
C
SR-70
D
E
F
SR-80
J
I
G
B
K
4-10
Track Removal/Installation
Tracks may need to be removed periodically to inspect
undercarriage components or for replacement if worn
or damaged. This section covers the procedure to
remove and install a track on SR 70/80 machines.
Tools required:
Socket/impact wrench
Ratchet strap
Heavy duty hydraulic jack
Combination wrench
Long pry bar(s)
ASV approved jack stands (2)
Spray lubricant
Shop vac or Pressure washer
Note: The SR-80 style undercarriage is depicted in
this procedure. The SR-70 undercarriage is very simi-
lar, however it has only one row of stationary inner and
outer idler wheels. The track removal procedure is
identical with this exception. (fig. 4-11)
Track Removal
1. Break up and remove any foreign material from the
cavity between the suspension rail and the drive
table support. (fig. 4-12)
Note: A shop vac or pressure washer will work well to
remove material from this cavity.
2. Clean the threads on the turnbuckle thoroughly
using a stiff bristle brush.
3. Loosen the lock nut on the turnbuckle and spin it
to the end of the threaded shaft to allow clearance
when the drive table is lowered.(fig. 4-13)
4. Rotate the turnbuckle and lower the drive table as
far as it will go. (fig. 4-14)
5. Remove the bolts securing the outer front wheel to
the hub. Then remove the wheel. (fig. 4-11, 4-15,
4-16)
4-6
Rubber Track Loader
4. Maintenance
4-12
4-13
4-14
4-11
SR-70
BOLTS
Cavity
4-15
6. Remove the outer scraper plate from the suspen
sion rail. (SR-80 only/fig. 4-17)
7. Remove the bolts securing the inner wheel to the
hub, then remove the wheel.
(SR-80 only/fig. 4-18, 4-19)
8. Use a pry bar to peel the track over the inner
wheel(s) toward the outside of the machine.
(fig. 4-20)
9. Once the track is off of the front wheel(s), pull the
rear of the track clear of the suspension.
(fig. 4-21, 4-22)
4-7
Rubber Track Loader
4. Maintenance
4-16
4-17
4-18
4-19
4-20
4-21
4-22
Track Installation
1. Slide the track over the drive sprocket at the rear
of the machine. (fig. 4-23, 4-24)
2. Slide the front of the track into position for installa
tion. (fig. 4-25)
3. Lubricate the inner front wheel(s) and the inside of
the front portion of the track with a spray lubricant.
(fig. 4-26)
4. Attach a ratchet strap to the upper front portion of
the track and the other end to one of the tow
hooks on the front of the machine. (fig. 4-27)
5. Tighten the strap until the track is pulled upward
slightly and in position to slide over the inner idler
wheel(s) at the front. (fig. 4-27)
6. Pull all of the slack forward and make sure the
track drive lugs are properly meshed with the
sprocket to provide as much slack as possible for
installation.
7. If you have an assistant, have them pull the track
forward while you push inward on the track. Work
the track over the wheel(s) and into place.
8. If you do not have an assistant, push the track for
ward in inward in a quick forceful motion to slide
the track into place. The ratchet strap will help to
keep the track in place while you work it over
the idler(s). (fig. 4-28)
4-8
Rubber Track Loader
4. Maintenance
4-25
4-26
4-27
4-23
4-24
4-28
9. Once the track is in position over the idler wheels,
install the inner idler wheel onto the hub and
secure it in place with the mounting bolts. Torque
them to 90 +/- 10 Lb. Ft.
(SR-80 only/fig. 4-29, 4-30, 4-31)
Note: You may need to use a bar to keep the wheel
from spinning as you torque the mounting bolts to
spec. (fig. 4-31)
10. Install the scraper onto the suspension rail and
tighten the bolts to secure it in place. (SR-80
only/fig. 4-32)
11. Install the outer idler wheel and secure it in place
with the mounting bolts. Torque them to 90 +/- 10
Lb. Ft. (fig. 4-33, 4-34)
12. Perform the track tension adjustment and check
procedures on page 4-4 to complete installation.
4-9
Rubber Track Loader
4. Maintenance
4-31
4-32
4-29
4-33
4-34
4-30
Air Cleaner
The SR 70/80 are equipped with two air filter elements
to remove contaminants from the air used for combus-
tion. Regular inspection and replacement is necessary
to ensure proper performance and to prolong engine
life.
To remove and inspect your air cleaner elements:
1. Turn the engine off.
2. Open the hood at the rear of the machine to gain
access to the engine compartment.
3. Locate the black air cleaner enclosure near the top
left of the engine compartment (when viewed from
the rear).
4. Twist the tension screw (A) counter-clockwise until
the band is loose enough to remove the cover,
then remove the cover. The primary element (B)
should be exposed.
5. Remove the primary element and inspect it. If it
appears damaged in any way, replace it. If the ele-
ment is heavily soiled, replace it. If it appears to be
in good condition, clean if necessary and re-install.
6. Once the primary element has been removed, the
secondary element (C) should be visible. Remove
and inspect it. If the element is damaged or heavily
soiled, replace it.
Note: The secondary element is not serviceable. It
should be replaced after every three cleanings of the
primary filter.
Note: The primary element may be cleaned and reused
up to five times if properly maintained, but should be
replaced at least once a year.
4-10
Rubber Track Loader
4. Maintenance
4-35
4-36
4-37
4-38
A
B
C
7. Once the inspection has been performed, install
the new secondary filter element into the enclosure
as found upon disassembly. (fig. 4-39)
8. Install the primary element by sliding it into place
in the enclosure as found upon disassembly.
9. Install and secure the cover by sliding it into place
and positioning the band over the retaining lip.
Then turn the tension screw clockwise until tight.
Gently wiggle the cover to make sure it is secure.
To clean your primary filter element:
1. Remove loose dirt from the filter element with com-
pressed air or water hose.
Compressed air: 100 P.S.I. max. 1/8" diameter
nozzle at least 2" away from filter.
Water: 40 P.S.I. max. without nozzle.
2. Soak the filter in a non-sudsing 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 gentle stream of
water to remove all dirt and remaining detergent.
4. Allow the filter to dry completely before re-installing
it into the machine.
Do not use any heat source other than warm air at
less than 160F to dry the filter.
Do not clean air filter elements while engine war-
ranty is in effect. During the warranty period, ASV
recommends replacing air filter elements instead
of cleaning them. Heavy-duty air filter manufactur-
ers will not warrant the air filter once it has been
cleaned.
Fuel Filter
The fuel filter removes contaminants from the fuel as it
enters the engine for combustion. Over time the filter
can become plugged and cause the engine to lose
power, run roughly or fail to start. The fuel filter should
be changed every 500 hours or more often if needed
to prevent these conditions from occurring.
To change the fuel filter:
1. Clean the outside of the filter assembly thoroughly
to reduce the chances of contaminants being intro
duced into the fuel system.
2. Twist the water separator catch bowl (A) counter
clockwise (when viewed from the bottom) and
remove it from the assembly. Take care not to lose
the o-ring that seals it to the filter base.
3. Twist the upper lock ring (B) counter clockwise
(when viewed from the bottom) and remove it from
the assembly.
4. Slide the filter (C) downward to remove it. Note the
position of the raised tabs on the upper portion of
the filter to simplify reassembly.
5. Install the new filter element into the assembly by
reversing steps 2-4.
Water Separator
The water separator removes water from the fuel sup-
ply as the engine runs. Drain the water separator daily
to maintain proper function.
To drain the water separator:
1. Loosen the black screw on the bottom of the
separator.
2. Re-tighten the screw after the water has been
drained from the catch bowl.
4-11
Rubber Track Loader
4. Maintenance
4-39
NOTICE
4-40
A
B
C
Accessory Belt Tension
Drive belts typically stretch and wear during their serv-
ice life. The fan and A/C belts should be checked for
tension, condition and presence daily prior to operating
your machine.
To check fan or A/C belt tension:
1. With the engine cold and off, remove the key from
the ignition to avoid accidental start.
2. Lift the hood at the rear of the machine and check
to make sure the fan and A/C belts are present
and in good condition. If they appear excessively
worn, or cracked, replace them.
3. Lay a straight edge across the alternator and crank
pulleys (crank and A/C pulleys for A/C belt) and
apply a force of 10 lbs. midway between the pul
leys. (fig. 4-41, 4-42)
4. Measure the distance from the bottom of the
straight edge to the top surface of each belt
(deflection). Fan belt deflection should meas-
ure 3/8 (7/16 A/C) if properly tensioned.
5. If the belts are loose or tight, adjust tension until
correct.
To adjust fan or A/C belt tension:
1. Make sure the engine is cold, off, and the key has
been removed from the ignition to avoid accidental
start.
2. Lift the hood at the rear of the machine and loosen
the bolts securing the alternator or A/C pump
slightly to allow the alternator or A/C pump
to pivot. (fig. 4-43, 4-44)
3. Once loose, use a small pry bar as a lever to force
the alternator or A/C pump against the belt(s) to
increase belt tension to appropriate level then
tighten bolts to specification. (fig. 4-43, 4-44)
4. Check the belt tension.
5. Adjust belt tension as necessary until correct.
4-12
Rubber Track Loader
4. Maintenance
4-41
4-42
4-43
Bolts
Pry-bar
Fan Belt Removal & Installation
To remove the fan belt:
1. Follow steps 1 and 2 of the belt adjustment proce
dure.
2. Once loose, pivot the alternator towards the
engine to increase slack.
3. Then, remove the three bolts securing the fan
cage (half) to the fan shroud. Remove that portion
of the cage. (fig. 4-45, 4-46)
4. Slip the belt off of the engine pulleys and work it
around the fan until it is clear of the blades.
To install the fan belt:
1. Reverse the steps of the removal procedure.
2. Perform the belt tension check and adjustment
procedures on page 4-12 to complete the
installation.
A/C Belt Removal & Installation
To remove the A/C belt:
1. Follow steps 1 and 2 of the belt adjustment proce
dure.
2. Once loose, pivot the A/C pump towards the
engine to increase slack.
3. Slip the belt off of the pulleys and remove
it from the machine.
To install the A/C belt:
1. Reverse the steps of the removal procedure to
reinstall the belt.
2. Perform the belt tension check and adjustment
procedures on page 4-12 to complete the
installation.
4-13
Rubber Track Loader
4. Maintenance
4-46
4-44
4-45
Bolt
Pry-bar
1/2 cage
Bolts
Bolt
Engine Oil/Filter Change
Regular oil changes are necessary to maintain a
strong running engine. The normal interval between oil
changes is 500 hours or one year. Machines that are
operated under harsh conditions should have their oil
changed more frequently. ASV recommends oil change
intervals of 250 hours or every six months for these
machines. Harsh conditions may include: continuous
high load applications, operation in high temperatures
or abnormally dusty/dirty conditions.
To change the oil and filter:
1. Start and run the engine for a few minutes to warm
the oil. Then turn the engine off before proceeding.
2. Place a suitable container under the engine oil
drain plug to catch the used oil as it drains.
3. Remove the belly pan beneath the engine.
(fig. 4-47)
4. Then remove the drain plug from the oil pan and
allow the used oil to drain completely from the
engine. Make sure to use the correct size combi
nation/socket wrench to keep the drain plug in
reusable condition. (fig. 4-48)
5. Remove the engine oil filter by hand or with strap if
necessary. (fig. 4-49)
6. Once the filter has been removed, check to make
sure the rubber gasket has come off of the filter
head with the old filter. If it is not on the old filter,
check the filter head. If it is still on the filter head,
remove it prior to installing the new filter.
(fig. 4-50)
If the old filter gasket (A) is not removed from the
filter head and the new filter is installed on top of
it, an oil leak will result when the engine is started.
If unnoticed, the engine can run itself out of oil
causing engine failure.
7. Prepare new filter for installation by rubbing fresh
oil on the exposed surface of the filter gasket.
8. Thread the new filter onto the filter head. Tighten
the filter by hand as instructed by the label located
on the filter or filter box.
9. Re-install the oil drain plug into the pan and tighten
to 50 +/- 10 lb ft.
4-14
Rubber Track Loader
4. Maintenance
4-47
4-48
4-49
4-50
NOTICE
A
10. Remove the oil filler cap and fill the engine
crankcase with ASV Posi-Lube 10W-30 Heavy
Duty Engine Oil (capacity: 9 U.S. quarts including
filter). (fig. 4-51)
11. Install the oil filler cap.
12. Perform a visual inspection to make sure the drain
plug, filter and oil filler cap are in place and tight.
13. Start the engine and watch the oil pressure gauge
located in the lap bar instrument display. The nee-
dle should rise up into the green range as soon as
oil pressure has been established. If the needle
doesnt rise above the red zone shortly after start-
up, turn the engine off immediately and look for
potential problems. If the needle does move into
the green zone as expected, oil pressure has been
achieved.
14. Once the engine is running, perform a visual
inspection to make sure there are no leaks or other
visible problems.
15. If everything looks like it should, shut the engine
down and exit the machine.
16. Re-install the belly pan.
17. Perform the oil level check procedure.
Engine Oil Specifications
ASV recommends using Posi-Lube
TM
10W-30 Heavy
Duty Engine Oil for most conditions. In the event of an
alternate working environment, the following chart may
be used as a guide to oil viscosity grades.
You may also use a quality engine oil substitute meet-
ing the following minimum specification:
API CH-4 multigrade engine oil.
Oil Level Check
To check the oil level:
1. Park the machine on level ground.
2. Open the hood to gain access to the engine com-
partment.
3. Locate and remove the engine oil dipstick from
its tube. (fig. 4-52)
4. Wipe the dipstick with a clean shop cloth and re-
insert it into the tube until it comes to rest in its
seated position.
5. Remove the dipstick once again and inspect the
end for oil on the level indicator. (fig. 4-53)
6. Oil should be present on the dipstick up to, but
not over the upper (full) level indicator notch. If
the level is correct, reinstall the dipstick and
then close and latch the hood to complete the
procedure.
7. If the level is low, add the proper grade and viscos
ity engine oil and re-check as necessary until the
proper level has been achieved. Then re-install the
dipstick and filler cap and close and latch the hood
to complete the procedure.
4-15
Rubber Track Loader
4. Maintenance
4-53
4-51
4-52
Low
Full
Hydraulic Fluid/Filter Change
Hydrostatic components require extremely clean oil in
order to have a long service life. Use extreme caution
when changing the hydraulic oil. Introducing dirt or
debris could be detrimental to the hydraulic system.
ASV recommends service intervals of 500 hours for
hydraulic fluid and 250 hours for hydraulic fluid filters.
To change the hydraulic fluid:
1. Locate the hydraulic system drain access situated
in the belly pan between the axles on the right side
of the machine. (fig. 4-54)
2. Remove the drain plug using the correct size allen
type wrench or allen socket to avoid damaging the
drain plug. (fig. 4-54, 4-55)
3. Drain the hydraulic fluid into a suitable catch con
tainer.
4. Locate the two hydraulic filters underneath the cab
on the left side of the machine. (fig. 4-56)
5. Thoroughly clean around the filters to prevent dirt
or debris from entering the system and remove the
filters by hand or with a strap as required.
6. Check to make sure the filter gaskets are still pres
ent on the old filters. If not, check the filter heads
to make sure they are free from old gasket materi
al prior to installing the new filters.
7. Prepare the new filters by rubbing a small amount
of fresh hydraulic oil onto the filter gasket surface
and then threading them onto their respective filter
heads. Tighten filters by hand as instructed by the
label located on the filter or filter box.
8. Install the hydraulic system drain plug and tighten.
9. Remove the hydraulic reservoir filler cap (black)
and fill the hydraulic system with ASV Posi-Lube
Premium All Season MV Hydraulic Oil or equiva
lent until the full mark on the hydraulic fluid sight
gauge has been reached (approx. 12.5 gal.).
(fig. 4-57,4-58)
Note: When checking or adding to the hydraulic fluid
level, do so with the lift arms in the lowered position. If
the level is checked with the lift arms in the raised
position, an inaccurate reading will result.
Note: When adding hydraulic fluid, add fluid slowly
until it is visible in the sight gauge. Once visible, add
fluid in one quart increments until the full mark has
been reached.
10. Install and secure the hydraulic reservoir filler cap.
11. Start the machine and operate all hydraulic circuits
to work any trapped air out of the system.
Drive the machine forward and backward.
Raise and lower the lift arms(unloaded).
Dump and curl bucket/quick attach.
12. Once you have purged the air from the system,
check the level on the hydraulic fluid level sight
gauge. If the level is low repeat step 9 and 10 to
complete the procedure.
4-16
Rubber Track Loader
4. Maintenance
4-54
4-56
4-57
4-58
4-55
Full
Low
Radiator/Oil Cooler
The Radiator and Oil Cooler must be kept clean to
ensure proper operation. Engine and hydraulic system
overheating, damage and even failure can result if the
radiator/oil cooler is not kept clean. A pressure 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
gauges indicate abnormally high temperatures during
operation, increase cleaning intervals.
Note: In brush cutting applications check and clean
the coolers often to avoid overheating.
To clean radiator/oil cooler:
1. Make sure the engine is off, and cool.
2. Using compressed air or a pressure washer, thor-
oughly clean radiator/oil cooler as shown.
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 damaged
(bent over) which will decrease cooling performance.
Engine
Periodic cleaning of the chassis area beneath the cab
and engine compartment are also necessary to main-
tain safe operation. Clean as required.
1. Remove the belly pans on the underside of the
machine.
2. Tilt the cab up and raise the hood at the rear of the
machine.
3. Pressure wash any debris from the engine com
part ment and chassis area out through the lower
opening.
4-17
Rubber Track Loader
4. Maintenance
4-60
4-61
4-59
Case Drain Filter
The SR machines are also equipped with a filter in the
auxiliary circuit case drain line. It protects the main
hydraulic system in the event of catastrophic failure in
an attachment. This filter is designed to last the life of
the vehicle. The only instance where this filter should
be replaced is if an attachment equipped with a case
drain has a drive motor failure during use. (fig. 4-62)
Fuse Panel
The electrical systems in the SR machines are
equipped with fuses that protect the electrical compo-
nents from damage. They are located on the fuse
panel behind the access cover on the lower right side
of the cab interior. (fig. 4-63)
In the event of an electrical malfunction, the most logi-
cal place to start is at the fuse panel. Check the fuse
related to the problem you are having and inspect it. If
the fuse appears black and burned, it needs to be
replaced. Replace fuses with the correct amperage
replacement fuse only. Replacing a fuse with one of a
lower amperage rating may lead to premature fuse fail-
ure. Replacing a fuse with one of a higher amperage
rating may burn out the electrical component the fuse
was meant to protect. See the troubleshooting section
in this manual for an additional resource to aid in track-
ing suspected electrical problems.
4-18
Rubber Track Loader
4. Maintenance
4-62 4-63
Maintenance
Item
Service
required
Interval Notes
Service
Capacity
Grease fittings Lubricate Daily Grease often.
Fluid levels Check Daily
Adjust levels as
necessary.
Fan-A/C belt
tension
Check Daily
Adjust tension as
necessary.
Fan-A/C belt
condition
Inspect Daily
Replace as a pair if
worn or damaged.
Water separator Drain Daily
Track condition Inspect Daily
Replace if severely
damaged.
Track tension Inspect Daily
Adjust tension as
necessary.
Air cleaners Inspect Daily
Replace if damaged or
heavily soiled.
Radiator/oil
cooler
Inspect Daily
Clean often
(as necessary).
Undercarriages Inspect Daily
Clean often
(as necessary).
Engine
compartment
Inspect Daily
Clean often
(as necessary).
Drive sprocket
rollers
Inspect 50 hr.
Replace if damaged or
worn. (35% min.)
Engine oil and
filter
Replace
12 Mo. or
500 hr.
Harsh conditions (6
Mo./250 hr. interval)
9 qt.
Hydraulic filters
(2)
Replace 250 hr.
Replace filters as a
pair.
Hydraulic oil Replace 500 hr.
Service refill capacity
only. (Dry: 21 gallons)
12.25 gal.
Water separator-
fuel filter
Replace 500 hr.
Replace fuel filter
element.
Radiator coolant Replace 3000 hr.
Coolant with SCA
additive required.
3.125 gal
Case drain filter
None
required
N/A
Replace if attachment
drive motor fails.
4-19
Rubber Track Loader
4. Maintenance
4-20
Chapter Overview
This chapter contains an overview of the machine con-
trols and instrumentation. For further information
regarding machine controls, instrumentation or opera-
tion, refer to the operation and maintenance manual
for the SR-70/80. Included here are illustrations of the
following controls and instrumentation components and
a description of their functions.
Machine Controls
Guage Location and Function
Switch Location and Function
Machine Controls (fig. 5-1)
There are three primary machine controls: lift arm con-
trol (1), drive control (2) and throttle (3).
Lift Arm Control
The lift arm control (1) is a pilot operated joystick that
allows the operator to raise or lower the lift arms and
dump or curl the quick attach mechanism.
Drive Control
The drive control (2) is also a pilot operated joystick. It
allows the operator to change the direction and speed
of the machine.
Throttle
The foot throttle (3) controls engine rpm.
Instrumentation
The Instruments (Figure 5-2) are positioned in the lap
bar for good visibility and when seated inside the oper-
ator enclosure. Instruments include the following com-
ponents.
(1) Engine Temperature Gauge
(2) Multi-Gauge
Oil Pressure Gauge
Hyd. Oil Temperature Gauge
Fuel Gauge
Voltmeter
(3) Tachometer
(4) Indicator Light Display
High Range Indicator
Low Range Indicator
Glow Plug Operation Indicator
Parking Brake Indicator
NOTICE
If the engine coolant temperature, engine oil pressure or
hydraulic oil temperature gauges read above normal (or
below normal for engine oil pressure) during normal machine
operation, shut the machine down immediately. Diagnose the
problem and make any necessaryrepairs before continuing to
operate the machine.
NOTICE
If the battery low-voltage light illuminates, drive the machine
to a suitable location and shut the engine off. Diagnose the
problem and make needed repairs before continuing to oper-
ate.
The glow plug operation light illuminates only when the
key switch is turned to engine pre-heat, showing nor-
mal operation.
5. Machine Controls and
Instrumentation
5-1
2
3
1
2
5-1
5-2
1
3
4
Switches
The various switches (Figure 5-3, 5-4, 5-5) are posi-
tioned to provide good access and visibility. The stan-
dard and optional switches are listed below.
(1) Ignition
(2) Hour Meter
(3) Beacon (optional)
(4) Wiper (optional)
(5) Heater Fan
(optional)
(6) Parking Brake
(7) Headlight
(8) Bucket Pos.
(9) Hight Flow Aux.
(10) Low Flow Aux.
(11) Hyd. Q/A
5-2
Rubber Track Loader
5. Machine Controls and Instrumentation
5-3 5-4
5-5
1
2
3
4
5
9
10
11
6
7
8
Chapter Overview
This chapter provides information on the assembly and
disassembly of the operator enclosure assembly. If
there is an issue that requires troubleshooting, refer to
Chapter 18, Troubleshooting.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
Machine Preparation
Accidental machine starting can cause injury or even
death to personnel working on a Rubber Track Loader.
As a precaution, disconnect the battery cables from the
battery terminals, tape the battery clamps and remove
the key from the ignition switch prior to performing any
service work on a Rubber Track Loader.
Place a Do Not Operate tag prominently on the ma-
chine to inform personnel that the machine is being
worked on.
Removal and Installation
Removal and installation procedures are provided for
the following operator enclosure components.
Cab Door Gas Spring
Forward Pillar Switch Panels
Gauge Clusters
Seat
Interior panels (right, left, and rear)
Lap Bar Gas Assist Spring
Note: Procedures are provided for only the operator enclo-
sure components listed above. However, exploded parts dia-
grams exist in the SR-70 or SR-80 Parts manuals to serve
as visual aids in the removal or installation of other operator
enclosure components.
Door Gas Spring
Removal
1. Pry the retaining clip holding the forward end of
the gas spring to the ball stud outward. (fig. 6-1)
2. Pry the gas spring off of the ball stud. (fig. 6-2)
3. Repeat this procedure on the rear of the gas
spring to remove the spring completely.
Installation
1. To reinstall, reverse the removal procedure.
6. Operator Enclosure
6-1
!WARNING!
!WARNING!
6-1
Required Tools
Blade Type Screwdriver
6-2
Retaining Clip
Pillar Switch Panels
Removal (RT or LT panel)
1. Remove the 3 screws/bolts securing the pillar
switch panel to the cab enclosure. (fig. 6-3)
2. Remove the forward end of the gas spring from
the ball stud by following steps 1-2 in the Cab
Door Gas Spring removal procedure on page 6-1.
Then remove the ball stud. (fig. 6-4)
3. Once the ball stud has been removed, begin
removing the panel by pulling back on the top to
expose the wires connected to the dome light acti-
vation switch. Carefully disconnect them from the
switch. (fig. 6-5)
4. Pivot the panel further backward to expose the
connectors on the lower switches and disconnect
them. You may then remove the panel.
(fig. 6-6, 6-7)
Note: The connectors on the harness are labeled as
are the switches in the panel. Use these labels to
properly identify (match up) and reconnect the harness
to the switches during installation.
Note: At this point in the disassembly process, the
activation switches in the panel may be removed and
replaced if necessary. (fig. 6-8)
Installation (RT or LT panel)
1. To reinstall either panel, reverse the steps of the
removal procedure.
6-2
Rubber Track Loader
6. Operator Enclosure
6-3
6-4
6-6
6-7
6-5
6-8
Required Tools
Open or Box end Wrenches
Gauge Clusters
Removal
1. Remove the mounting screws securing the gauge
mounting plate to the lap bar gauge pod, then
raise the plate to expose the wire harness connec-
tors. (fig. 6-9, 6-10)
2. Disconnect the gauges from the harness and
remove the gauge cluster. (fig. 6-11)
Note: At this point in the disassembly procedure, the
gauges may be replaced if necessary.
3. If gauges must be removed, remove the nuts
securing the backing plate to the gauge. (fig. 6-12)
4. The gauge may now be removed for repair or
replacement. (fig. 6-13, 6-14)
Installation
1. To reinstall the gauges and cluster, reverse the
removal procedure.
6-3
Rubber Track Loader
6. Operator Enclosure
6-9
6-10
6-11
6-12
6-13
6-14
Required Tools
Phillips Type Screwdriver
Combination/Socket Wrench
Seat
Removal
1. Remove the bolts (2) securing the cab to the chas-
sis. They are located inside the cab in the upper
front corners of the foot well. (fig. 6-15)
2. Raise and secure the cab as described on page 4-
2 of this manual.
3. Remove the four nuts securing the seat to the cab.
4. Remove the seat partially to expose the seat
switch harness located behind the seat. (fig. 6-17)
5. Disconnect the harness and then remove the seat
from the machine. (fig. 6-18)
Seat
Installation
1. To install the seat, reverse the removal procedure.
Interior Side Panel, LT
Removal
1. Remove the mounting screws (5) and washers
securing the panel to the chassis. (fig. 6-19)
2. Remove the cup holder mounting screws (4) and
remove the cup holder from the panel. (fig. 6-20)
6-4
Rubber Track Loader
6. Operator Enclosure
Required Tools
Combination/Socket Wrench
6-15
6-18
6-16
6-17
Required Tools
Phillips Type Screwdriver
6-19
6-20
6-5
Rubber Track Loader
6. Operator Enclosure
3. Remove the panel by lifting and twisting it over the
joystick and clear of the lap bar. (fig. 6-21)
Installation
1. To reinstall the left interior side panel, reverse the
removal procedure.
Interior Side Panel, RT
Removal
1. Remove the fuse panel access cover. (fig. 6-22)
2. Remove the mounting screws (6) and washers
securing the panel to the chassis. (fig. 6-23)
3. Disconnect the ignition switch, hour meter, and any
other switches from the cab harness. (fig. 6-24)
4. Remove the panel by lifting and twisting it over the
joystick and clear of the lap bar. (fig. 6-25)
Installation
1. To re-install the right interior side panel, reverse
the removal procedure.
6-21
Required Tools
Phillips Type Screwdriver
6-22
6-23
6-25
6-24
Rear Interior Panel
Removal
1. Remove the screws holding the rear panel to the
cab. (fig. 6-26)
2. Disconnect the rear power point from the harness,
then remove the panel from the cab. (fig. 6-27)
Installation
1. To re-install the rear interior panel, reverse the
removal procedure.
Lap Bar Gas Spring
Removal
1. Remove the right, left and rear interior panels from
the cab to access the gas spring.
2. Put the lap bar in the raised position to relieve ten-
sion on the lap bar gas spring. (fig. 6-28)
3. Using a small screwdriver, remove the retaining
clip from each end of the gas spring. (fig. 6-29)
4. Remove the gas spring by pulling both ends off of
the ball joints.
Installation
1. Reverse the removal procedure to reinstall the lap
bar gas spring.
6-6
Rubber Track Loader
6. Operator Enclosure
Required Tools
Phillips Type Screwdriver
6-26
6-27
6-28
Required Tools
Phillips & Blade Type Screwdrivers
6-29
Chapter Overview
This chapter provides information on the assembly and
disassembly of the chassis. If there is an issue that
requires troubleshooting, refer to Chapter 18,
Troubleshooting.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
Machine Preparation
Accidental machine starting can cause injury or even
death to personnel working on a Rubber Track Loader.
As a precaution, disconnect the battery cables from the
battery terminals, tape the battery clamps and remove
the key from the ignition switch prior to performing any
service work on a Rubber Track Loader.
Place a Do Not Operate tag prominently on the ma-
chine to inform personnel that the machine is being
worked on.
Removal and Installation
Removal and installation procedures are provided for
the following chassis components.
Fuel Sending Unit
Fuel Tank
Footwell
Foot Throttle Assembly
Hood Assembly
Note: Procedures are provided for only those chassis com-
ponents listed above. However, exploded parts diagrams
exist in the SR-70 or SR-80 Parts manual to serve as visual
aids in the assembly and disassembly of other chassis com-
ponents.
Fuel Sending Unit
Removal
1. Raise and support the lift arms as described on
page 4-1 of this manual.
2. Tilt and support the operator enclosure (cab) as
described on page 4-2 of this manual. (optional)
3. Locate the fuel sending unit on the left side of the
machine in the upper front corner of the fuel tank.
(fig. 7-1)
4. Remove the nuts and associated hardware secur-
ing the leads to the sending unit. (fig. 7-1)
Note: Record the order of assembly and polarity of the
leads to ensure proper function when reassembled.
7. Chassis and Fuel Tank
7-1
!WARNING!
!WARNING!
Screwdriver
Combination/Socket Wrench
Required Tools
7-1
Fuel Sending Unit
5. Remove the screws securing the fuel sending unit
to the tank. (fig. 7-2)
6. Remove the sending unit by pulling it through the
opening in the fuel tank. (fig. 7-3)
Installation
1. To install the fuel sending unit, reverse the removal
procedure. (See fig. 7-4 for terminal installation)
Fuel Tank
Removal
1. Raise and support the lift arms as described on
page 4-1 of this manual.
2. Tilt and support the operator enclosure (cab) as
described on page 4-2 of this manual. (optional)
3. Loosen the hose clamps securing the vent hoses
to the left rear tank end. (fig. 7-5)
4. Disconnect and plug the hoses. (fig. 7-6)
5. Remove the bolts securing the forward belly pan
and remove it from the machine. (fig. 7-7)
7-2
Rubber Track Loader
7. Chassis and Fuel Tank
7-2
Remove Screws
7-3
7-4
7-5
7-6
7-7
Install First
Install Last
-- Neg
+ Pos
Screwdriver
Combination/Socket Wrench
Required Tools
6. Loosen the hose clamp securing the main fuel line
to the tank outlet in the front right corner of the
machine. (fig. 7-8)
7. Disconnect this line and drain the fuel into a suit-
able catch container. (fig. 7-9)
Note: Collect and contain flammable liquids in suitable
containers. Dispose of all liquids in accordance with
local regulations and mandates.
8. Remove the bolts securing the fuel tank to the
fenders. (fig. 7-10)
9. Remove the bolts (3) securing the fuel tank to the
front mounting plate. (fig. 7-11)
10. Now that the tank is loose and empty, loosen the
hose clamp and disconnect the filler tube from the
right rear end of the tank. (fig. 7-12)
11. Lift and remove the tank from the machine.
(fig. 7-13)
Installation
1. To install the fuel tank, reverse the removal proce-
dure.
7-3
Rubber Track Loader
7. Chassis and Fuel Tank
7-8
7-9
7-10
7-11
7-12
7-13
up
out
Footwell
Removal
1. Raise and support the lift arms as described on
page 4-1 of this manual. (optional)
2. Tilt and support the operator enclosure (cab) as
described on page 4-2 of this manual.
3. Remove the bolts (4) securing the foot pedal cover
to the pedal, then remove the cover. (fig. 7-14)
4. Pry the throttle cable off of the ball stud on the foot
pedal. (fig. 7-15)
5. Remove the bolts (4) securing the footwell assem-
bly to the chassis. (fig. 7-16)
6. Remove the footwell from the chassis as shown.
(fig. 7-17)
Installation
1. To install the footwell, reverse the removal proce-
dure.
7-4
Rubber Track Loader
7. Chassis & Fuel Tank
7-14
Screwdriver
Combination/Socket Wrench
Required Tools
7-15
Pry Off
Throttle Cable
Ball Stud
7-16
7-17
Bolts
Foot Throttle Assembly
Removal
Note: The foot throttle assembly may be removed with
the footwell still installed in the machine.
1. Perform steps 3 and 4 of the footwell removal pro-
cedure on page 7-4.
2. Remove the bolts (2) and associated hardware
securing the foot throttle assembly to the footwell.
(fig. 7-18)
Note: Record the order of assembly during removal to
ensure proper operation when re-installed.
3. Remove the foot throttle from the machine.
Installation
1. To install the foot throttle assembly, reverse the
removal procedure.
Hood Assembly
Removal
1. Remove the bolts (4) securing the fluid filler tray
and hoses to the hood assembly. (fig. 7-19, 7-20)
2. Remove the bolts (6) that secure the hood to the
chassis. (fig 7-21, 7-22)
7-5
Rubber Track Loader
7. Chassis & Fuel Tank
Screwdriver
Combination/Socket Wrench
Required Tools
7-18
Pry Off
Bolts
Screwdriver
Combination/Socket Wrench
Required Tools
7-19
7-20
7-21
7-22
3. Have an assistant help you to remove the hood
assembly from the machine. (fig. 7-23)
4. Carefully set the hood assembly aside. (fig. 7-24)
Installation
1. To install the hood assembly, reverse the removal
procedure.
7-6
Rubber Track Loader
7. Chassis & Fuel Tank
7-23
7-24
Chapter Overview
This chapter provides information on the disassembly
and assembly of the radiator/oil cooler and associated
components. If there is an issue that requires trou-
bleshooting, refer to chapter 18, Troubleshooting.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Machine Preparation
Accidental machine starting can cause injury or even
death to personnel working on a Rubber Track Loader.
As a precaution, disconnect the battery cables from the
battery terminals, tape the battery clamps and remove
the key from the ignition switch prior to performing any
service work on a Rubber Track Loader.
Place a Do Not Operate tag prominently on the ma-
chine to inform personnel that the machine is being
worked on.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
Removal and Installation
Removal and installation procedures are provided for
the following radiator/oil cooler components.
Fan Guard
Fan
Fan Shroud
Radiator/Oil Cooler
Note: Procedures are provided for only those radiator/oil
cooler components listed above. However, exploded parts
diagrams exist in the SR-70 and SR-80 Parts manuals to
serve as visual aids in the assembly and disassembly of
other system components.
Note: Refer to pages 3-1and 3-2 for pictorial views of the fil-
tering and cooling system components.
Fan Guard
Removal
1. Remove the air cleaner end cap and elements to
provide clearance for guard removal. (fig. 1)
8. Radiator and Oil Cooler
8-1
!WARNING!
!WARNING!
Required Tools
Combination Wrench
Socket Wrench
Socket Wrench Extension (optional)
8-1
2. Remove bolts (5) securing the fan guard halves to
the fan shroud. (fig. 8-2, 8-3)
3. Remove both halves of the guard from the
machine. (LT side shown, fig. 8-4)
Installation
1. To install the fan guard halves, reverse the
removal procedure.
Fan & Fan Shroud
Removal
1. Remove the bolts (2) securing the fuel pump/filter
assembly to the radiator support and lay it aside
over the bumper to allow clearance to remove the
shroud and fan. (fig. 8-5)
2. Remove the bolts (6) securing the radiator and
shroud to the radiator support. (fig. 8-6)
3. Push the shroud forward to allow access the fan
mounting bolts. (fig. 8-7)
8-2
Rubber Track Loader
8. Radiator and Oil Cooler
8-2
8-3
Required Tools
Combination Wrench
Socket Wrench
8-5
8-4
8-6
8-7
4. Remove the bolts securing the fan and spacer to
the engine, then remove the fan and spacer from
between the shroud and radiator as shown.
(fig. 8-8, 8-9)
5. Remove the radiator shroud from the machine.
(fig. 8-10)
Installation
1. To install the fan and fan shroud, reverse the
removal procedure.
Radiator/Oil Cooler
Removal
Personal injury can result from exposure to hot fluids
and components. Allow the machine to cool thoroughly
before attempting any type of service on the cooling or
hydraulic systems.
Cooling system conditioner contains alkali. Avoid con-
tact with skin and eyes.
NOTICE
Collect and contain liquids in suitable containers. Dispose of
all liquids according to local regulations and mandates.
1. Perform the fan guard and fan/shroud removal pro-
cedures.
2. Remove the bolts securing the rear belly plates to
the chassis and remove them. (fig. 8-11)
3. Attach a piece of 3/8 fuel line to the drain valve,
outlet, then twist the valve control counter clock-
wise to drain the cooling system. (fig. 8-12)
8-3
Rubber Track Loader
8. Radiator and Oil Cooler
8-8
8-11
8-12
8-9
8-10
!WARNING!
!WARNING!
Required Tools
Socket Wrench
Pliers
Screwdriver
Hydraulic Caps/Plugs (various sizes)
Drain Valve
Catch Container
4. Remove the bolts (6) securing the outer shroud to
the chassis, then remove the shroud. (fig. 8-13)
5. Remove the upper hydraulic cooler hose. Cap or
plug the hose upon removal. (fig. 8-14)
6. Loosen and disconnect the lower hydraulic line
from the cooler. Cap and plug the line and cooler
opening upon disassembly. (fig. 8-15)
7. Loosen the clamps securing the upper and lower
coolant hoses to the radiator, then disconnect the
hoses from the radiator. (fig. 8-16, 8-17)
8. Tilt the radiator rearward and then remove it from
the machine. (fig. 8-18)
Installation
1. To install the radiator/oil cooler, reverse the
removal procedure.
8-4
Rubber Track Loader
8. Radiator and Oil Cooler
8-13
8-14
8-15
8-16
8-17
8-18
Chapter Overview
This chapter provides removal and installation proce-
dures for the hydraulic reservoir.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Machine Preparation
Accidental machine starting can cause injury or even
death to personnel working on a Rubber Track Loader.
As a precaution, disconnect the battery cables from the
battery terminals, tape the battery clamps and remove
the key from the ignition switch prior to performing any
service work on a Rubber Track Loader.
Place a Do Not Operate tag prominently on the ma-
chine to inform personnel that the machine is being
worked on.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
Removal and Installation
Removal and installation procedures are provided for
the following hydraulic components.
Hydraulic Reservoir (tank)
Suction Screen
Note: Procedures are provided for only those hydraulic com-
ponents listed above. However, exploded parts diagrams
exist in the SR-70 and SR-80 Parts manuals to serve as
visual aids in the removal and installation of other system
components.
Note: Refer to pages 3-1, 3-2 and 3-3 for additional
hydraulic circuit and system information.
Hydraulic Reservoir
Removal (in event of contamination)
Remove any attachment, relax all actuators and make
sure the hydraulic oil is cool before removing any com-
ponents or lines. Hot or pressurized oil can cause per-
sonal injury.
NOTICE
Collect and contain liquids in suitable containers. Dispose of
all liquids according to local regulations and mandates.
During disassembly, plug and cap all hoses and fittings to
prevent system fluid loss or contamination.
9. Hydraulic Reservoir
9-1
!WARNING!
!WARNING!
Required Tools
Screwdriver
Combination/Socket Wrench
Pry Bar(s)
!WARNING!
NOTICE
1. Remove the center and rear belly pans from the
machine.
2. Drain the hydraulic fluid. Refer to page 4-16 for the
hydraulic fluid and filter change procedure.
3. Remove the engine as described on page 12-5 of
this manual.
4. Remove the auxiliary and drive pumps (for inspec-
tion, repair, or replacement) according to the pro-
cedures in section 11 of this manual.
5. Disconnect the hoses and lines attached to the two
upright portions of the tank. (fig. 9-1, 9-2, 9-3)
6. Remove the clamps securing the quick attach hard
lines and the test port line that run from the pilot
generation block down the left side of the machine
to the engine compartment. (fig. 9-4)
7. Disconnect the quick attach hoses from the hard
lines (if equipped). (fig. 9-5)
8. Disconnect the quick attach and test port lines
from the pilot generation block. (fig. 9-6)
9-2
Rubber Track Loader
9. Hydraulic Reservoir
9-1
9-2
9-3
9-4
9-6
Disconnect
Disconnect
9-5
9. Gently move the hard lines out of the way to allow
for reservoir removal then zip tie them to the motor
mount to keep them secure. (fig. 9-7)
10. Disconnect the bucket cylinder hoses from the
hard lines in the upper right portion of the engine
compartment. Remove all line clamps. (fig. 9-8)
11. Disconnect the lift cylinder hoses from the hard
lines to allow the bucket cylinder lines to be
removed. (fig. 9-9)
12. Disconnect the bucket cylinder hard lines from the
lift arm control valve and then remove them from
the machine. (fig. 9-10, 9-11)
13. Remove the hose retainer or move it aside as
shown. (fig. 9-12)
9-3
Rubber Track Loader
9. Hydraulic Reservoir
9-7
9-8
9-9
9-10
9-11
9-12
Retainer
14. Disconnect the main oil cooler line from the fitting
at the filter. (fig. 9-13)
15. Disconnect the main oil cooler line from the junc-
tion block, then remove it from the machine.
(fig. 9-14, 9-15)
16. Remove the clamps securing the auxiliary
hydraulic lines to the chassis. (fig. 9-16)
17. Disconnect the auxiliary hydraulic lines from the lift
arm control valve and the hoses leading to the
quick coupler lines on the lift arm. (fig. 9-17, 9-18)
9-4
Rubber Track Loader
9. Hydraulic Reservoir
9-13
9-14
Disconnect
9-15
9-17
9-16
9-18
18. Slide the two fuel lines through the chassis open-
ing and into the engine compartment so that the
aux. hyd. tubes can be removed. (fig. 9-19, 9-20)
19. Disconnect the fuel sender from the main harness
at the connector.
Note: If there is anything else that is routed behind the
auxiliary hydraulic tubes that will prevent them from
being removed, disconnect or carefully remove these
items at this time to allow the tubes to be removed.
20. Remove the auxiliary hydraulic tubes from the
machine.
21. Disconnect the lower portions of the cab support
gas springs from the chassis. (fig. 9-23)
22. Label, then disconnect any control hoses coming
from the joysticks that are still attached to compo-
nents to allow them to be pulled up through the
chassis opening for clearance. (fig. 9-24)
Note: Refer to the individual hydraulic component
removal and installation procedures if additional infor-
mation is needed to properly connect hoses during
reassembly.
9-5
Rubber Track Loader
9. Hydraulic Reservoir
9-19
9-20
fuel lines
9-21
9-22
9-23
9-24
23. Remove the lower hose restraints to allow the
hoses to be pulled through the chassis. (fig. 9-25)
24. Pull the hoses up through the chassis opening and
lay them aside as shown (both sides). (fig. 9-26)
25. Disconnect the wiring running through the hose
passageway and pull it through the opening as
shown. (fig. 9-27)
26. Remove the bolts securing the metal tank restraint
straps, them remove them from the machine.
(fig. 9-28)
27. Slide the quick attach and test port tubes forward
so that they do not interfere with the reservoir
(tank) moving upwards in the chassis. (fig. 9-29)
28. Slide the various control hoses to the side of the
reservoir (tank) so that they do not interfere with
the tank moving upwards in the chassis. (fig. 9-30)
9-6
Rubber Track Loader
9. Hydraulic Reservoir
9-26
9-25
9-27
9-28
9-29
9-30
29. Make sure there is nothing that would visibly pre-
vent the reservoir from being removed or is still
attached to other components within the machine,
then proceed.
30. Use a long pry bar to pry the tank upward and
rearward from the front as shown. (fig. 9-31)
Note: You may need to pry the tank upwards within
the chassis from the rear if it isnt already to prepare
the tank to be moved in step 30.
31. Once the tank is over the axle mounts lift and
remove it from the chassis as shown. (fig. 9-32, 9-
33, 9-34)
Installation
1. To install the hydraulic reservoir, reverse the
removal procedure.
Note: The only service issue warranting the removal of
the reservoir is hydraulic system contamination. Upon
installation, the tank must be clean and free of any dirt
or debris that may contaminate the hydraulic oil. If you
are unable to successfully flush the tank clean of all
dirt or debris, replace the tank.
9-7
Rubber Track Loader
9. Hydraulic Reservoir
9-31
9-32
9-33
9-34
Pry-bar
Reservoir
Suction Screen
Removal
Note: The suction screen may be removed with the
reservoir (tank) still in the machine. If this is necessary,
remove the center belly pan and tilt and support the
cab to gain access, then follow the procedure
described below to remove the suction screen.
1. If the tank is still in the machine, drain the
hydraulic fluid as described on page 4-16 of this
manual.
2. If the tank is still in the machine, remove/discon-
nect any hoses connected to the flange weldment
that may interfere with removal.
3. Remove the bolts securing the flange to the
hydraulic reservoir. (fig. 9-35)
4. Slide the assembly out of the reservoir as shown
in fig. 9-36 and 9-37.
5. The suction screen is now accessible for inspec-
tion or replacement.
Note: If removal is necessary, thread the suction
screen off of the flange weldment and remove.
Installation
1. To install the suction screen, reverse the removal
procedure.
Note: It is important to inspect the screen for pieces of
metal or other debris that may have been generated by
a worn or defective component. If there is debris pres-
ent on the screen, the hydraulic system (including the
reservoir) must be flushed clean to remove any and all
contamination (debris). The screen should be replaced
as well as any components found to be defective.
9-8
Rubber Track Loader
9. Hydraulic Reservoir
9-35
Required Tools
Small Pry Bar (hose removal if necessary)
Socket Wrench & Extension
Combination Wrenches (to remove lines)
9-36
9-37
Suction screen
o-ring
Chapter Overview
This chapter provides removal and installation proce-
dures for the lift-arm and drive control components.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Machine Preparation
Accidental machine starting can cause injury or even
death to personnel working on a Rubber Track Loader.
As a precaution, disconnect the battery cables from the
battery terminals, tape the battery clamps and remove
the key from the ignition switch prior to performing any
service work on a Rubber Track Loader.
Place a Do Not Operate tag prominently on the ma-
chine to inform personnel that the machine is being
worked on.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
Removal and Installation
Removal and installation procedures are provided for
the following lift-arm/drive control components.
Pilot Control Joystick
Lift Arm Float Magnet
Lift Arm Control (loader) Valve
Note: Procedures are provided for only those lift-arm/drive
control components listed above. However, exploded parts
diagrams exist in the SR-70 and SR-80 Parts manuals to
serve as visual aids in the assembly and disassembly of
other system components.
Note: Refer to page 3-2 and 3-3 for pictorial views of the
hydraulic auxiliary and drive systems and components.
Pilot Control Joystick
Removal
Note: The procedures for removing and installing the right
and left joysticks are basically identical. As a result, only the
procedures for the right joystick are described in this section.
Cap and plug all fittings and hoses to prevent fluid loss
and or contamination during service work.
Remove any attachment, lower the lift arms and make
sure the hydraulic oil is cool before removing any com-
ponents or lines. Hot or pressurized oil can cause per-
sonal injury.
10. Lift-Arm/Drive Controls
10-1
!WARNING!
!WARNING!
Required Tools
Side Cutter
Combination/Open End/Socket Wrenches
Hydraulic Caps/Plugs (various sizes)
!WARNING!
NOTICE
1. Relax all hydraulic actuators to relieve pressure in
the hydraulic system prior to service.
2. Turn the ignition switch to the OFF position,
remove the key and disconnect the battery to
avoid accidental start.
3. Perform the interior side panel removal procedure
that addresses the joystick you plan to remove on
page 6-4 or 6-5 of this manual.
4. Expose and cut the zip tie securing the lower por-
tion of the boot to the joystick body, then lift it
upwards. (figure 10-1)
Note: The float magnet is now exposed as well as the
mounting bolts securing the joystick to the bracket.
(figure 10-2)
5. Label each of the hoses during the removal
process to aid in reassembly.
6. Remove the bolts (3) securing the joystick mount-
ing bracket to the cab from the outside. (fig. 10-3)
(optional)
7. Label the hydraulic hoses to aid in reassembly
(see page 3-7 or 3-8 for routing and identification).
8. Disconnect the hydraulic hoses from the various
joystick fittings and lay them aside. (fig. 10-4,10-5)
9. Disconnect all connectors coming from the joystick
harness. (fig. 10-6)
10-2
Rubber Track Loader
10. Lift-Arm/Drive Controls
10-1
10-2
10-3
10-4
Remove (optional)
10-5
10-6
Magnet
10. Remove the fittings on the back of the joystick (lift
arm control joystick only). (fig. 10-7)
11. Remove the bolts and nuts securing the joystick to
the mounting bracket. (fig. 10-8)
12. Lift the joystick through the opening in the bracket
and remove it from the machine. (fig. 10-9)
Installation
1. To install the joystick, reverse the removal proce-
dure.
Lift Arm Float Magnet
Removal
1. Perform steps 3, 4 and 11 of the lift arm joystick
control removal process.
2. Remove the allen bolt from the underside of the
magnet. (fig. 10-10)
3. Disconnect the magnet harness connector from
the machine.
4. Lift the joystick within the bracket slightly, then pull
the magnet harness and connector through the
bracket past the joystick to remove it. (fig. 10-11)
Installation
1. To install the float magnet, reverse the removal
procedure.
10-3
Rubber Track Loader
10. Lift-Arm/Drive Controls
10-7
Fittings
10-8
10-9
Required Tools
Socket Wrench
Combination/Open End Wrench
Allen Wrench
10-10
10-11
Lift Arm Control Valve
Removal
1. Perform the footwell removal procedure on page 7-
4 of this manual.
2. Drain the hydraulic system as described on page
4-15 of this manual.
3. Label all lines and hoses as necessary to aid in
reassembly. (fig. 10-12)
4. Disconnect the hose from the barb type fitting on
the auxiliary pump and the large hard line that
sweeps across the front of the pumps and con-
nects to the filter head to provide additional clear-
ance for line removal. (fig. 10-13, 10-14)
5. Disconnect all lines and hoses from the valve to
allow for removal. (figure 10-15, 10-16)
6. Remove the carriage bolts (3) securing the loader
valve to the chassis, Then remove the valve.
Note: The bolts have a square shank that mates with
a square hole in the chassis to keep them from rotat-
ing upon removal.
Installation
1. To install the lift arm control valve, reverse the
removal procedure.
10-4
Rubber Track Loader
10. Lift-Arm/Drive Controls
Required Tools
Socket Wrench
Combination/Open End Wrench
Screwdriver (hose clamps)
10-12
10-13
10-14
10-15
10-16
10-17
Chapter Overview
This chapter provides removal and installation proce-
dures for the hydraulic pumps and motors.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Machine Preparation
Accidental machine starting can cause injury or even
death to personnel working on a Rubber Track Loader.
As a precaution, disconnect the battery cables from the
battery terminals, tape the battery clamps and remove
the key from the ignition switch prior to performing any
service work on a Rubber Track Loader.
Place a Do Not Operate tag prominently on the ma-
chine to inform personnel that the machine is being
worked on.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
The hydraulic system fluid should be changed follow-
ing any hydraulic component service according
to the procedure described on page 4-16.
Removal and Installation
Removal and installation procedures are provided for
the following hydraulic components.
Charge Pump
Auxiliary Pump
Tandem (Drive) Pump
Drive Motor
Note: Procedures are provided for only those hydraulic com-
ponents listed above. However, exploded parts diagrams
exist in the SR-70 and SR-80 Parts manuals to serve as
visual aids in the removal and installation of other system
components.
Note: Refer to pages 3-1, 3-2 and 3-3 for additional motor,
pump and hydraulic system information.
Charge Pump
Removal
Remove any attachment, relax all actuators and make
sure the hydraulic oil is cool before removing any com-
ponents or lines. Hot or pressurized oil can cause per-
sonal injury.
NOTICE
Collect and contain liquids in suitable containers. Dispose of
all liquids according to local regulations and mandates.
During disassembly, plug and cap all hoses and fittings to
prevent system fluid loss or contamination.
11. Hydraulic Pumps/Motors
11-1
!WARNING!
!WARNING! Required Tools
Screwdriver
Combination Wrench
Socket Wrench
!WARNING!
NOTICE
NOTICE
1. Lower the lift arms to the ground and relax the
bucket tilt/curl cylinders to relieve pressure within
the hydraulic system.
2. Turn the ignition switch to the OFF position and
remove the key to avoid accidental start.
3. Drain the hydraulic fluid. Refer to page 4-16 for the
hydraulic fluid and filter change procedure.
4. Raise the hood at the rear of the machine.
5. Disconnect the hose from the upper charge pump
fitting. (fig. 11-1)
6. Loosen the hose clamp and disconnect the hose
from the barb type inlet tube on the underside of
the charge pump. (fig. 11-1)
7. Remove the upper and lower 12 point bolts secur-
ing the charge pump to the engine. (fig. 11-2)
8. Remove the charge pump from the engine. (fig.
11-3)
Installation
1. To install the charge pump, reverse the removal
procedure.
Note: The front bearing on the charge pump uses
engine oil for lubrication. It must be kept extremely
clean. Make sure to shield it as well as the opening to
the engine from dirt or debris while disassembled.
The gasket that seals the pump to the engine housing
should be replaced whenever the charge pump is
removed and installed to prevent oil leaks and or
dirt/debris from entering the engine during operation.
11-2
Rubber Track Loader
11. Hydraulic Pumps/Motors
11-1
11-2
11-3
Upper Hose
Lower Hose
Bolt
Gasket
Auxiliary Pump
Removal
1. Loosen the bolts securing the spilt flange clamp to
the upper front port on the aux. pump. (fig. 11-4)
2. Remove the clamp and lay the hose aside.
3. Disconnect the hose connected to the relief valve
assembly and lay it aside. (fig. 11-5)
4. Loosen the clamp securing the hose onto the
barbed fitting on the right side of the pump, then
disconnect it. (fig. 11-6)
5. Loosen the clamps securing the hoses to the inlet
weldment attached to the bottom of the pump. (fig.
11-7)
6. Loosen and remove the split flange clamp securing
the inlet weldment to the bottom of the pump simi-
larly to the one previously removed on the top of
the pump. (fig. 11-8)
11-3
Rubber Track Loader
11. Hydraulic Pumps/Motors
11-4
11-6
11-7
11-8
Required Tools
Combination Wrench
Socket Wrench & Extension
Pry bar
Allen socket
11-5
Weldment
7. Use a pry-bar to pry the inlet weldment out of the
hoses. (This can be difficult, lubricating the inlet
tubes with a penetrating lubricant may make
removal easier.) (fig. 11-9)
8. Remove the upper and lower pump mounting bolts
with an allen socket and extension. You may need
to separate the pumps slightly to remove the bolts
completely. (fig. 11-10)
9. Carefully remove the pump from the machine. (fig.
11-11)
Installation
1. To install the auxiliary pump, reverse the removal
procedure.
Tandem (Drive) Pump
Removal
Personal injury can result from exposure to hot fluids
and components. Allow the machine to cool thoroughly
before attempting any type of service on the cooling or
hydraulic systems.
NOTICE
Collect and contain liquids in a suitable container. Dispose of
all fluids according to local regulations and mandates.
During disassembly, plug and cap hoses and fittings to
prevent fluid loss and or contamination.
1. Perform the auxiliary pump removal procedure on
page 11-3 of this manual.
2. Label and disconnect all hoses from the tandem
drive pump. (fig. 11-12, 11-13, 11-14, 11-15)
Note: You may need to remove the pump mounting
bolts and twist the pump to access and disconnect
some of the hoses connected to the drive pump.
Note: Use figures 11-13, 11-14, and 11-15 to aid in
hose removal and installation and identification.
11-4
Rubber Track Loader
11. Hydraulic Pumps/Motors
11-9
!WARNING!
Required Tools
Screwdriver
Combination/Open End Wrenches
11-10
11-11
NOTICE
11-12
11-5
Rubber Track Loader
11. Hydraulic Pumps/Motors
3. Support the pump with a hoist or floor jack to pre-
vent it from falling as the mounting bolts are
removed. (fig. 11-16)
4. Remove the upper and lower mounting bolts from
the drive pump. (fig. 11-17)
5. Remove the drive pump from the machine.
Installation
1. To install the drive pump, reverse the removal pro-
cedure.
Note: Torque the tandem pump mounting bolts to 85 lb. ft.
and use blue Loc-tite or equivalent to secure the bolts in
position.
11-13
To
Oil Cooler
(return)
To
Drive Motor
(LT)
To
Drive Motor
(RT)
From
Charge
Filter
BTM BTM
BTM BTM
TOP
BTM
Top & Bottom Drive Pump Hoses
View is from the top.
The pump is to be perceived as transparent.
Ports are labeled top or bottom as they are on the pump.
REAR
FRONT
RIGHT LEFT
11-14
TOP
BTM
TOP
BTM
REAR
FRONT
RIGHT LEFT
Top & Bottom Control Hoses
E
C
F
D
View is from the top.
The pump is to be perceived as transparent.
Ports are labeled top or bottom as they are on the pump.
11-15
REAR
FRONT
RIGHT LEFT
Side Drive Pump Hoses
From
Pilot Gen
Block
To
Pilot Gen
Block
View is from the top.
11-16
11-17
Remove Bolts (2)
11-18
Drive Motor
Removal
1. Remove the track from the undercarriage by per-
forming the track removal procedure on page 4-6
of this manual.
2. Remove the three bolts securing the outer bearing
support plate to the drive table. (fig. 11-19)
3. Remove the four bolts securing the outer bearing
support plate to the bearing assembly. (fig. 11-20)
4. Remove the bearing support plate from the under-
carriage. (fig. 11-21)
5. Use a hammer to tap around the circumference of
the bearing cap which releases the outward pres-
sure holding it in place. (fig. 11-22)
6. Remove the bearing cap from the assembly. (fig.
11-23)
Rubber Track Loader
11. Hydraulic Pumps/Motors
11-6
Required Tools
Combination/Socket Wrench
Impact Wrench
3-Jaw Puller
Snap Ring Pliers
Hammer/Mallet
11-19
Remove Bolts
11-20
11-21
11-22
11-23
7. Remove the snap ring securing the bearing
assembly to the outer sprocket shaft. (fig. 11-24)
8. Use a jaw style puller and an impact wrench to
remove the bearing assembly from the sprocket
shaft. (fig. 11-25)
9. Remove the bolts securing the sprocket to the
drive motor. (fig. 11-26)
10. Remove the sprocket assembly from the undercar-
riage. (fig. 11-27)
11. Remove the bolts securing the drive motor to the
drive table. (fig. 11-28)
12. Lift the drive motor straight upward until it clears
the drive table, then forward to expose the
hydraulic hoses for removal. (fig. 11-29)
Note: There are two large bolts near the front of the
drive motor support securing it to the lower drive table
from the inside (near the chassis). Remove these bolts
prior to lifting the motor to provide additional clearance
for the hoses as you lift the motor upward. (fig. 11-29)
11-7
Rubber Track Loader
11. Hydraulic Pumps/Motors
11-24
11-25
11-26
11-27
11-28
11-29 Remove Bolts
13. Note the orientation of the hoses as they are con-
nected to the drive motor. Label them to ensure
correct installation and proper orientation during
reassembly. (fig. 11-30)
14. Disconnect the hoses from the drive motor making
sure to cap and plug all openings to avoid contam-
ination. Remove the drive motor from the under-
carriage. (fig. 11-31)
Installation
1. To install the drive motor into the undercarriage,
reverse the removal procedure.
Note: During the removal of the bearing cap, the
bulged or domed area is beaten inward. When rein-
stalling the cap, flip it around so that the domed area is
toward the outside of the machine. Then tap the center
of the cap with a ball peen hammer or similar device to
reset the cap. Do this gently, too much force can dam-
age (mushroom) the bearing shaft.
11-8
Rubber Track Loader
11. Hydraulic Pumps/Motors
11-30
11-31
Chapter Overview
This chapter provides procedures for the removal and
installation of the engine and associated components.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
Removal and Installation
Removal and installation procedures are provided for
the following engine related components.
Battery
Exhaust
Air Cleaner
Engine
Note: Procedures are provided for only those engine associ-
ated components listed above. However, exploded parts dia-
grams exist in the SR-70 and SR-80 parts manuals to serve
as visual aids in the assembly and disassembly of other sys-
tem components.
Battery
Removal
1. Open the hood at the rear of the machine.
2. Disconnect the negative and positive battery
cables from the battery terminals. (fig. 12-1)
3. Remove the wingnuts securing the battery hold
down strap. (fig. 12-2)
12. Engine
12-1
12-1
!WARNING!
12-2
4. Remove the two tension (L) rods by twisting and
maneuvering them out of the chassis mounting
holes. (fig. 12-3)
5. Lift and remove the battery from the battery tray.
(fig. 12-4)
6. If necessary, remove the battery tray by sliding it
upwards and then pulling it away from the chassis.
(fig. 12-5)
Installation
1. To install the battery, reverse the removal proce-
dure.
Exhaust System
Removal
The exhaust system is very hot at operating tem-
perature. Make sure the machine is off and cool
before attempting to service the exhaust system.
1. Perform the radiator/oil cooler removal procedure
on page 8-3 to provide access to the exhaust sys-
tem components.
2. Remove the bolts securing the rear belly pan and
remove it from the machine. (fig. 12-6)
3. Remove the nuts securing the head-pipe to the
turbo, then pull it away from the studs. (fig. 12-7)
12-2
Rubber Track Loader
12. Engine
12-4
12-5
12-6
12-7
12-3
Required Tools
Pry Bar(s)
Combination/Socket Wrench
Rubber Mallot
Penetrating Lubricant
!WARNING!
4. Remove the tension springs that secure the middle
pipe section to the head (upper) pipe and muffler
inlet (lower) pipe. (fig. 12-8)
5. Remove the upper and middle pipe sections from
the machine. (fig. 12-9)
6. Remove the clamps that secure the inlet and outlet
pipes to the muffler. (fig. 12-10)
Note: Thoroughly coat all clamped exhaust pipe joints
with a penetrating lubricant prior to attempting to
remove the pipe sections from the muffler. This will
make removal significantly easier.
7. Remove the inlet pipe from the muffler. It may be
necessary to use levers to force the inlet pipe sec-
tion out of the muffler. (fig. 12-11)
Note: Use caution not to damage the pipe or connec-
tion point during removal.
8. Remove the tail pipes from the muffler. If neces-
sary, tap the pipes lightly with a rubber mallot or
dead blow hammer to loosen the joints. (fig. 12-12)
Note: Use caution when striking the pipes with a mal-
lot. The pipes are easily damaged and may be disfig-
ured by the blows.
9. Remove the four bolts (and nuts) securing the muf-
fler to the chassis, then remove the muffler. (fig,
12-13).
12-3
Rubber Track Loader
12. Engine
12-10
12-11
12-8
Spring
12-9
12-12
12-13
10. You may now remove the tail pipes by sliding them
forward within the chassis, then out. (fig, 12-14).
Installation
1. To install the exhaust system, reverse the removal
procedure.
Air Cleaner
Removal
1. Remove the cover and the filter elements from the
air cleaner assembly. (fig. 12-15)
2. Loosen the clamp securing the intake hose to the
air cleaner housing. (fig. 12-16)
3. Remove the bolts and nuts securing the air cleaner
housing to the chassis. (fig. 12-17)
12-4
Rubber Track Loader
12. Engine
12-14
Required Tools
Combination Wrenches
Socket Wrench & Extension
12-15
12-16
12-17
4. Remove the air cleaner housing from the machine.
(fig. 12-18)
Installation
1. To install the air cleaner assembly, reverse the
removal procedure.
Engine
Removal
1. Perform the battery, air cleaner, and charge pump,
removal procedures in sections 11 and 12 of this
manual prior to starting this procedure.
2. Remove the hood assembly as described on page
7-5 of this manual.
3. Raise and support the operator enclosure (cab) as
described on page 4-2 of this manual.
4. Perform steps 2-7 of the exhaust removal proce-
dure on page 12-2 of this manual.
5. Remove the center belly pan from the machine.
6. Remove the front motor mount bolts (2) from the
machine. (fig. 12-19)
7. Remove the rear motor mount bolts (2) from the
machine. (fig. 12-20)
12-5
Rubber Track Loader
12. Engine
12-18
Required Tools
Combination/Socket Wrenches
Angle Iron or Similar (approx. 43 long)
Tie Down or Ratchet Strap
Forklift/Engine Hoist
Pry Bar
12-19
12-20
8. Disconnect the throttle cable from the engine.
Note: Once loose, you may want to pull the throttle
cable forward through the chassis to make sure it is
clear of the engine during removal.
9. Disconnect the cable restraints holding the wire
harness to the lower chassis crossmember.
(fig. 12-22)
10. Disconnect the wire harness connections in the
upper right hand portion of the engine compart-
ment. (when viewed from the rear) (fig. 12-23)
11. Disconnect the case drain filter and bracket from
the engine adapter plate and lay it aside. It is situ-
ated beneath the drive pump. (fig. 12-24)
12. Remove the two bolts securing the drive pump to
the engine adapter plate. (fig. 12-25)
13. Loosen and disconnect the fuel lines (2) from the
engine. (fig. 12-26)
12-6
Rubber Track Loader
12. Engine
12-22 Rear Axle
Restraint
Wire Harness
12-21
Cable
Ballstud
12-23
Restraint
12-24
Bolts
Engine
12-25
Bolts
12-26
14. Lay the angle iron across the fenders (or fuel tank
if still in place) and attach one or two tie down
straps to serve as a sling to hold the hydraulic
pumps up in position during engine removal. (fig.
12-27)
15. Disconnect the ground strap from the upper cross-
member. (fig. 12-28)
16. Attach a lifting chain or cable to the lift points on
the engine. (fig. 12-29)
17. Attach a device capable of safely lifting the engine
to the lifting chain as shown. (fig. 12-30) (see note)
Note: The rear cab window is directly over the lift point
of the engine. It is important to use an engine lifting
device that is low in profile and can reach forward
between the engine and chassis (as shown in fig. 12-
30) or the rear window could be damaged. (fig. 12-31)
18. Slide the engine rearward to clear the forward
motor mounts, then up and out between the radia-
tor supports. (fig. 12-32)
Installation
1. To install the engine, reverse the removal proce-
dure.
Note: When reinstalling the engine, lightly grease the
rubber motor mount surfaces to allow the engine to
slide onto them without snagging or disfiguring them.
Once the engine has been installed, make sure to
properly reconnect and install all items removed during
engine removal to ensure proper operation.
Prior to starting, make sure all fluids are at appropriate
levels and that they have not been contaminated with
dirt or debris during service. Change fluids or adjust
fluid levels as needed to ensure proper operation.
12-7
Rubber Track Loader
12. Engine
12-27
12-29
12-31
12-32
12-30
!WARNING!
12-28
12-8
Chapter Overview
This chapter provides removal and installation proce-
dures for the undercarriages.
Note: For track removal and installation procedures, refer to
pages 4-6 through 4-9 of this manual.
Note: For drive sprocket removal and roller inspection and
replacement, refer to page 4-5 of this manual.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Machine Preparation
Accidental machine starting can cause injury or even
death to personnel working on a Rubber Track Loader.
As a precaution, disconnect the battery cables from the
battery terminals, tape the battery clamps and remove
the key from the ignition switch prior to performing any
service work on a Rubber Track Loader.
Place a Do Not Operate tag prominently on the ma-
chine to inform personnel that the machine is being
worked on.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
Removal and Installation
Removal and installation procedures are provided for
the following undercarriage components.
Idler Wheels (Removal and installation)
Bogie Wheels (Removal and installation)
Hub Assembly Service Procedures
Note: Procedures are provided for only those components
listed above. However, exploded parts diagrams exist in the
SR-70 and SR-80 parts manuals to serve as visual aids in
the removal and installation of other system components.
15 Idler Wheel (SR-80)
Note: The 15 idler and 10 bogie wheels may be
removed from the SR-70 and SR-80 undercarriages
without removing the tracks.
Removal
1. Raise and support the machine by following the
jacking procedure on page 4-2.
2. Break up and remove any foreign material from the
cavity between the suspension rail and the drive
table support. (fig. 13-1)
Note: A shop vac or pressure washer will work well to
remove material from this cavity.
13. Undercarriage
13-1
!WARNING!
!WARNING!
Required Tools
Socket/impact wrench
Heavy duty hydraulic jack
Combination wrench
ASV approved jack stands (2)
Shop vac or Pressure washer
13-1
Cavity
3. Clean the threads on the turnbuckle thoroughly
using a stiff bristle brush.
4. Loosen the lock nut on the turnbuckle and spin it
to the end of the threaded shaft to allow clearance
when the drive table is lowered. (fig. 13-2)
5. Rotate the turnbuckle and lower the drive table as
far as it will go. (fig. 13-3)
6. Remove the bolts securing the outer wheel to
the hub. Then remove the wheel. (fig. 13-4, 13-5)
7. Remove the outer scraper plate from the suspen-
sion rail. (fig. 13-6)
8. Remove the bolts securing the inner wheel to the
hub, then remove the wheel. (fig. 13-7, 13-8)
9. Repeat this procedure as necessary to remove the
15 idler wheels throughout the undercarriage.
Note: To remove the 10 bogie wheels on the SR-80
undercarriages, refer to page 13-3 of this manual.
Installation
1. To install the 15 idler wheels, reverse the removal
procedure. Torque the wheel mounting bolts
upon installation to 90 +/- 10 Lb. Ft.
13-2
Rubber Track Loader
13. Undercarriage
13-2
13-3
13-4
13-5
13-6
13-7
13-8
10 & 15 Wheels (SR-70)
Note: The 15 idler and 10 bogie wheels may be
removed from the SR-70 and SR-80 undercarriages
without removing the tracks.
Removal
1. Perform steps 1-5 of the SR-80 15 idler wheel
removal procedure on page 13-1.
2. Remove the bolts securing the wheel to the hub.
(fig. 13-9)
3. Remove the wheel from the undercarriage.
(fig. 13-10)
Note: Steps 2 and 3 are accurate for the removal of
both the 10 and 15 wheels throughout the SR-70
undercarriages.
4. Repeat as necessary to remove the idler and
bogie wheels throughout the undercarriages.
Installation
1. To install the idler wheels on the SR-70, reverse
the removal procedure. Torque the 15 wheel
mounting bolts upon installation to 90 +/- 10
Lb. Ft. Torque the 10 wheel mounting bolts
upon installation to 37 +/- 5 Lb. Ft.
Bogie Wheel (SR-80 only)
Removal & Service Procedure
1. Perform steps 1-5 of the 15 idler wheel removal
procedure on page 13-1 to loosen the track and
provide clearance for bogie wheel removal.
13-3
Rubber Track Loader
13. Undercarriage
Required Tools
Socket/impact wrench
Heavy duty hydraulic jack
Combination wrench
ASV approved jack stands (2)
Shop vac or Pressure washer
13-9
13-10
Remove bolts
13-11
13-12
Required Tools
Combination/Socket Wrenches (including Allen)
Press & Various Press Tooling
Torque Wrench
Bench Vise
Note: Figure 13-36 incudes an exploded parts diagram
of the SR-80 undercarriage for your reference.
2. Remove the outer plate securing the assemblies to
the shaft. (Most plates will be a two bolt design.
The one bolt version is shown here.) (fig. 13-13)
3. Loosen and remove the 4 bolts securing the bogie
assemblies together around the mounting shaft.
(fig. 13-14, 13-15)
4. The inner and or outer bogie wheels may now be
removed with an impact wrench and allen socket
as shown in fig. 13-16. If necessary, clamp one
wheel in a vise to keep the axle from spinning
while you remove the bolts.
Note: The wheel assemblies in the SR machines use
metal face seals to keep dirt/debris out of the wheel
bearings. During wheel removal/replacement, it is nec-
essary to remove, inspect and clean all components
prior to reassembly to ensure proper function.
5. Remove both wheels from the hub. (fig. 13-17)
Note: Take care not to drop the metal face seal halves.
The sealing surfaces are surface ground and have an
extremely fine finish. If scratched or disfigured, the
seal will not function as intended.
Also, take care not to lose the keys for indexing the
wheels onto the shaft.
Note: Now is a good time to inspect the components
for damage or wear. If the bearings do not roll smooth-
ly when rotated, replace them. If the seals appear worn
or damaged, replace them. If the wheels are worn or
damaged, replace them. If the components appear to
be in good working condition, you may reuse them.
13-4
Rubber Track Loader
13. Undercarriage
13-14
Bolts
13-13
13-15
13-16
13-17
1/2 of face seal
Hub
Note: The metal face seals are a 4-piece design with
one rubber outer seal and one metal face seal fitted
into each wheel and one rubber outer seal and one
metal face seal fitted into each hub. As they are
assembled, the metal halves mate and ride against
each other on a thin layer of oil to seal out dirt and
debris. Figure 13-18 shows the various components
that make up a face seal. Figure 13-19 shows the seal
as a mated assembly.
6. Once the wheels have been removed, use a press
to push the axle and far side bearing out of the
hub as shown. (fig. 13-20, 13-21)
7. If it is necessary to remove the other bearing for
replacement, press it out as well. If not, you may
leave this bearing in the hub during cleaning.
8. Clean all parts (including wheels) thoroughly with
parts cleaning solution and dry them prior to
reassembly. Wipe the inner hub surfaces to
remove any solvent or oil residue. (fig. 13-22)
9. Reinstall the bearing and shaft into the hub as
found upon disassembly, then press the bearing
back into the hub over the shaft. (fig. 13-23)
13-5
Rubber Track Loader
13. Undercarriage
13-18
13-19
Face Seal Halves
Rubber Seals
Sealing Surfaces
13-20
13-21
13-22
13-23
10. Disassemble and clean the face seals and their
rubber outer seals thoroughly, then wipe them dry
to ensure a good seal when assembled.
11. Once the seals and hub have been thoroughly
cleaned and dried, reinstall the hub portion of the
face seal into the hub as shown. Make sure to
work the rubber seal down into place within the
hub (until it seats) to ensure a good seal.
(fig. 13-24)
12. Similarly, reinstall the wheel portion of the face
seal into the (clean) wheel. Make sure to work the
rubber seal down into place within the wheel (until
it seats) to ensure a good seal. (fig. 13-25)
13. Once the seals are in place, wipe the mating sur-
faces of the face seals with a clean shop cloth and
alcohol in a circular motion ending in a gentle
sweep from the inside to the outside of the face
until clear of the face.This will ensure a clean mat-
ing surface and a good seal. (fig. 13-26, 13-27)
14. Apply a very thin coating of fresh 10W30 engine
oil onto the seal faces (faces only) in a circular
motion to provide lubrication and help them seal.
15. Align the wheel hub and axle, then slide the wheel
back onto the axle/hub assembly as shown in fig-
ure 13-28.
16. Install the key into the opening in the axle/hub
assembly as shown. (fig. 13-29)
13-6
Rubber Track Loader
13. Undercarriage
13-24
13-25
13-26
13-27A 13-27B
13-28
Seal Surfaces
13-29
17. Apply red (high strength) thread locking compound
to the wheel retaining bolt as shown. (fig. 13-30)
18. Install the bolt and tighten it. (fig. 13-31)
19. If you havent already, repeat steps 10-18 of this
procedure on the other side of the hub/wheel
assembly to secure the second wheel in place.
20. Once the hub/wheel assembly is together as
shown, torque the wheel retaining bolts to 180 ft.
lbs. to secure them in place. (fig. 13-32)
21. Remove the allen plug from the center of the hub
assembly and fill it with 2 ounces of ASV Posi
Lube
TM
10W-30 Heavy Duty Engine Oil. Then rein-
stall the plug. (fig. 13-33, 13-34)
22. Repeat this procedure on the other half of the
bogie assembly if necessary prior to installing the
two halves back onto the undercarriage.
23. Place the rubber rods back into position on the
square shaft, then tape them in place to keep
them secure while installing the bogie assemblies
around them. (fig. 13-35)
24. Reverse steps 1-3 of this procedure to reinstall the
bogie assembly back onto the undercarriage and
complete the procedure.
25. Repeat this procedure as necessary throughout
the SR-80 undercarriage to restore proper func-
tion.
13-7
Rubber Track Loader
13. Undercarriage
13-30
13-32
13-33
13-31
13-34
13-35
Idler Hub
Service Procedure SR-70 & 80 (80 shown)
1. Remove the hub assemblies from the undercar-
riages as required first by following steps 1-7 of
the track removal procedure on page 4-6. Then
proceed to the steps below.
2. Remove the snap ring (item 22) securing the cap
(item 23) in the hub assembly. (fig. 13-36)
3. Remove the nut (item 24) and the washer (item
25), then remove the hub assembly from the axle
shaft. (fig. 13-36) (see note below)
Note: If you are removing the inner front hub assem-
bly, you will have to slide the axle (item 26) out of the
main rail weldment to remove it. (fig. 13-36, 13-37)
Note: If you are removing the outer or rear hub
assemblies you will be able to remove the hub assem-
bly once step three is complete.
4. Using a press and tool # 0403-336, press the
bearing sleeve out of the hub assembly. (fig. 13-
38, 13-39)
13-8
Rubber Track Loader
13. Undercarriage
13-36
13-37
Axle
13-38
13-39
Required Tools
Socket Wrench & Sockets (including Allen)
Press & Tool Kit (SR-70: 0403-475 or SR-80: 0403-339)
Snap Ring Pliers
Note: The hubs on SR-70 & SR-80 machines
are very similar in design. The components,
although not identical, are serviced in the same
manner. Please note any differences between
the two machines during disassembly to aid
during reassembly. (see notes in procedure)
Part #: 0403-336
SR-70 use tool #: 0403-375
Hub Tool Kits
SR-70: 0403-475
SR-80: 0403-339
5. Remove the bearing out of the front of the hub as
shown. (fig. 13-40)
6. Press the center seal and front bearing race out of
the assembly from the rear of the hub using tools
0403-337 and 0403-334. (fig. 13-41, 13-42)
Note: The center seal will be destroyed during removal
and must be replaced upon reassembly.
7. If bearings are to be replaced, press the rear bear-
ing race out of the assembly from the front of the
hub with tools 0403-337 and 0403-333. (fig. 13-43)
8. Press the bearing sleeve out of the rear bearing
using tool 0403-336. (fig. 13-44)
9. Remove the face seals and retaining ring from the
bearing sleeve for cleaning and or replacement.
(fig. 13-45)
Note: There is no retaining ring on SR-70 machines.
13-9
Rubber Track Loader
13. Undercarriage
13-40
13-41
Center seal
Front race
13-42
Center seal
Front race
13-43
Rear race
13-44
13-45
Retaining ring
Part #: 0403-337
Part #: 0403-334
Part #: 0403-337
Part #: 0403-333
Part #: 0403-336
SR-70 use tools #: 0403-372 & 0403-375
SR-70 use tool #: 0403-371
SR-70 use tool #: 0403-375
Note: Take care not to drop the metal face seal halves.
The sealing surfaces are surface ground and have an
extremely fine finish. If scratched or disfigured, the
seal will not function as intended.
Note: Now is a good time to inspect the components
for damage or wear. If the bearings do not roll smooth-
ly when rotated, replace them. If the seals appear worn
or damaged, replace them. If the wheels are worn or
damaged, replace them. If the components appear to
be in good working condition, you may reuse them.
10. Thoroughly clean all parts with parts cleaning solu-
tion and gently blow them clean with air if neces-
sary, then wipe dry.
11. Disassemble and clean the face seals and their
rubber outer seals thoroughly, then wipe them dry
to ensure a good seal when assembled.
12. Once components are clean and dry, install half of
the rear face seal into the bearing sleeve. Make
sure to work the rubber seal down into place within
the seal recess (until it seats) to ensure a good
seal. (fig. 13-46)
13. Install the other half of the rear face seal into the
retaining ring. Make sure to work the rubber seal
down into place within the ring (until it seats) to
ensure a good seal. (fig. 13-47)
14. If the rear race has been removed, press it into the
hub from the rear until properly seated with tool #:
0403-330, then install the clean, dry bearing.
(fig. 13-48)
15. Install the seal/retaining ring assembly into the rear
of the hub and press into place until seated using
the tools shown above. (fig. 13-49, 13-50)
13-10
Rubber Track Loader
13. Undercarriage
13-46
13-47
13-49
13-48
13-50
13-51
Part #: 0403-330
Part #: 0403-337
Part #: 0403-338
SR-70 use tool #: 0403-373
16. Once the seals are in place, wipe the mating sur-
faces of the face seals with a clean shop cloth and
alcohol in a circular motion ending in a gentle
sweep from the inside to the outside of the face
until clear of the face.This will ensure a clean mat-
ing surface and a good seal. (fig. 13-51, 13-52)
17. Apply a very thin coating of fresh 10W30 engine
oil onto the now clean seal faces (faces only) in a
circular motion. (fig. 13-53)
18. Press the bearing sleeve assembly (with face seal
clean, installed, and oiled) into the hub with tool
0403-336 until seated. (fig. 13-54)
19. Flip the hub over, support the bearing sleeve from
the bottom with tool 0403-335 and set it onto the
press for center seal installation. (fig. 13-55)
20. Install the center seal into the hub. Work the lip
around the bearing sleeve with your fingers prior
to pressing it into place. (fig. 13-56)
21. Install the race into the hub as shown above the
seal. When the race is pressed into place, it will
push the seal into position. (fig. 13-57)
Note: See step 22 for tool information and race instal-
lation instructions.
13-11
Rubber Track Loader
13. Undercarriage
13-52
13-53
13-54
13-55
13-56
13-57
Part #: 0403-335
SR-70 use tool #: 0403-375
SR-70 use tool #: 0403-374
22. Press the outer bearing race into the hub with tool
# 0403-330 until it seats. (fig. 13-58)
23. Pack the bearing with Posi-Lube Multi-Purpose EP
Lithium Grease and then install it onto the bearing
sleeve using tool 0403-333. (fig. 13-59)
24. Press it into the assembly until it gently seats into
the bearing race. (fig. 13-59)
25. If necessary, use a needle dispenser to fill any
places in the bearing that are not full of grease to
ensure adequate lubrication. (fig. 13-60)
26. Remove the allen plug in the center portion of the
hub. (fig. 13-61)
27. Add 2 oz. (1 oz. SR-70) of Posi-Lube 10W-30
Heavy Duty Engine Oil to the hub as shown, then
reinstall the plug and tighten. (fig. 13-62)
28. The hub assembly is now ready to be reinstalled.
To install it onto the machine, reverse steps 1-3 on
page 13-8 of this procedure. Make sure to read
the note below step 3 prior to reinstalling.
(fig. 13-63)
29. Repeat this procedure throughout the undercar-
riage as necessary to repair worn or damaged
components and restore proper function.
13-12
Rubber Track Loader
13. Undercarriage
13-58
13-59
13-60
13-61
13-62
13-63
Part #: 0403-330
Part #: 0403-333
SR-70 use tool #: 0403-373
SR-70 use tool #: 0403-372
Chapter Overview
This chapter provides removal and installation proce-
dures for the lift-arm components.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Machine Preparation
Accidental machine starting can cause injury or even
death to personnel working on a Rubber Track Loader.
As a precaution, disconnect the battery cables from the
battery terminals, tape the battery clamps and remove
the key from the ignition switch prior to performing any
service work on a Rubber Track Loader.
Place a Do Not Operate tag prominently on the ma-
chine to inform personnel that the machine is being
worked on.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
The hydraulic system fluid should be changed follow-
ing any hydraulic component service according to the
procedure described on page 4-16.
Removal and Installation
Removal and installation procedures are provided for
the following lift-arm components.
Lift Cylinder
Bucket/Tilt Cylinder
Quick Coupler Block PRV
Note: Procedures are provided for only those lift-arm compo-
nents listed above. However, exploded parts diagrams exist
in the SR-70 and SR-80 Parts manuals to serve as visual
aids in the assembly and disassembly of other system com-
ponents.
Note: Refer to page 3-1 through 3-3 for pictorial views of
the hydraulic systems and components.
Lift Cylinder
Removal
Cap and plug all fittings and hoses to prevent fluid loss
and or contamination during service work.
Remove any attachment, lower or safely support the lift
arms and make sure the hydraulic oil is cool before
removing any components or lines. Hot or pressurized
oil can cause personal injury.
14. Lift-Arm Components
14-1
!WARNING!
!WARNING!
Required Tools
Combination/Open End/Socket Wrenches
Hydraulic Caps/Plugs (various sizes)
ASV Approved Jack Stand (or equivalent)
Pin Removal Tool (ASV P/N: 2045-277)
!WARNING!
NOTICE
NOTICE
1. Rest the lift arms on an ASV approved jack stand
to provide clearance for lift cylinder removal. (fig.
14-1)
2. Disconnect the inlet and outlet hoses from the
cylinder. (fig. 14-2)
3. Label the hoses according to right and left orienta-
tion to simplify reassembly, then cap and plug the
hoses and fittings to prevent fluid loss and or sys-
tem contamination. (fig. 14-3)
4. Remove the bolts securing the front and rear lift
arm cylinder pivot pins to the lift arm and lift arm
tower. (fig. 14-4)
5. Remove the grease fitting from the pivot pins to
allow the installation of the pin removal tool. (fig.
14-5)
6. Thread the removal tool into each pin, then use
the slide hammer to extract them. (fig. 14-6)
14-2
Rubber Track Loader
14. Lift-Arm Components
14-1
14-2
14-4
14-5
14-6
14-3
7. Remove the cylinder from the machine for service
or inspection. (fig. 14-7)
Note: At this time the pivot bushings and pivot pins are
easily accessible for replacement. Inspect them for vis-
ible wear or damage and replace them as necessary .
Installation
1. To install the lift arm cylinder, reverse the removal
procedure.
Bucket/Tilt Cylinder
Removal
1. Raise the lift arms and support them with the lift
arm brace as described on page 4-1. (fig. 14-8)
2. Place a suitable catch container beneath the cylin-
der fittings, then disconnect the inlet and outlet
hoses from the cylinders. (fig. 14-9)
3. Cap and plug the hoses and fittings to prevent fluid
loss and or system contamination.
14-3
Rubber Track Loader
14. Lift-Arm Components
14-7
Required Tools
Socket Wrench
Combination/Open End Wrench
Hammer
Punch (brass)
14-8
14-9
4. Remove the bolt securing the lower pin to the
quick attach. (fig. 14-10)
5. Remove the bolt securing the upper pin to the lift
arm weldment. (fig. 14-11)
6. Disconnect the outer quick attach cylinder hose (if
equipped) to allow the lower pin to be removed.
(fig. 14-12)
7. Use a pry bar to slide the lower pin out of the cylin-
der end allowing it to be removed. (fig. 14-13)
8. Use a pry bar to pry the lower cylinder eyelet out
of the upper Q/A mount as shown. (fig. 14-14)
9. Use a hammer and a brass punch to tap the upper
pin most of the way out of the lift arm weldment.
(fig. 14-15)
Note: Make sure to support the cylinder (have an
assistant support it if necessary) while removing the
upper pin to prevent it from falling and being damaged
or from causing injury to anyone standing underneath.
14-4
Rubber Track Loader
14. Lift-Arm Components
14-10
14-11
14-12
14-13
14-14
14-15
Disconnect
10. Remove the pin from the cylinder while supporting
the cylinder. (fig. 14-16)
11. Remove the cylinder from the machine. (fig. 14-17)
Installation
1. To install a bucket/tilt cylinder, reverse the removal
procedure.
Quick Coupler Block PRV
Removal
1. With the machine off and cool and with all
hydraulic actuators relaxed, loosen the pressure
release valve on the top of the auxiliary quick cou-
pler block. (fig. 14-18)
2. Once loose, remove the valve from the block by
twisting it counter-clock-wise until free. (fig. 14-19)
Installation
1. To install the Q/C PRV, reverse the removal proce-
dure.
14-5
Rubber Track Loader
14. Lift-Arm Components
14-16
14-17
14-18
Required Tools
Combination Wrench
14-19
14-6
Chapter Overview
This chapter provides removal and installation proce-
dures for the quick attach and associated components.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Machine Preparation
Accidental machine starting can cause injury or even
death to personnel working on a Rubber Track Loader.
As a precaution, disconnect the battery cables from the
battery terminals, tape the battery clamps and remove
the key from the ignition switch prior to performing any
service work on a Rubber Track Loader.
Place a Do Not Operate tag prominently on the ma-
chine to inform personnel that the machine is being
worked on.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
Removal and Installation
Removal and installation procedures are provided for
the following quick attach components.
Quick Attach locking Pin Assemblies
Quick Attach Pivot Pins
Note: Procedures are provided for only those quick attach
components listed above. However, exploded parts diagrams
exist in the SR-70 and SR-80 Parts manuals to serve as
visual aids in the assembly and disassembly of other system
components.
Locking Pin Assembly
Removal
Remove any attachment, lower or safely support the lift
arms and make sure the hydraulic oil is cool before
removing any components or lines. Hot or pressurized
oil can cause personal injury.
1. Rest the lift arms on an ASV approved jack stand
to provide clearance for quick attach disassembly.
(fig. 15-1)
15. Quick Attach
15-1
!WARNING!
!WARNING!
Required Tools
Combination/Open End/Socket Wrenches
ASV Approved Jack Stand (or equivalent)
!WARNING!
15-1
2. Remove the bolts (3) securing the upper guard to
the quick attach weldment. (fig. 15-2)
3. Remove the upper guard from the quick attach.
(fig. 15-3)
4. Remove the bolt securing the locking pin assembly
to the locking cylinder or latch handle. (fig. 15-4)
5. Remove the pivot link from the quick attach.
(fig. 15-5)
6. Slide the locking pin assembly out of the quick
attach. (fig. 15-6)
Note: At this time the locking pin assembly compo-
nents are easily accessible for replacement. Inspect
them for visible wear or damage and replace them as
necessary .
Pay attention to the quantity and position(s) of each
component to aid during reassembly. (fig. 15-7)
Installation
1. To install the quick attach locking pin assembly,
reverse the removal procedure.
15-2
Rubber Track Loader
15. Quick Attach
15-2
15-4
15-5
15-6
15-3
Upper guard
Upper guard
15-7
Pivot Pin (quick attach)
Removal
1. Rest the lift arms on an ASV approved jack stand
to provide clearance for quick attach disassembly.
(fig. 15-8)
2. Remove the bolt securing the pivot pin to the quick
attach weldment, then drive the pin out with a
hammer and brass drift punch. (fig. 15-9)
Note: There are four pivot pins that connect the quick
attach to the lift arm and cylinders. All four pins are
removed in a similar manner.
Installation
1. To install the quick attach pivot pins, reverse the
removal procedure.
2. Repeat this process as necessary to remove and
replace worn or damaged quick attach pins.
15-3
Rubber Track Loader
15. Quick Attach
15-8
15-9
Required Tools
Combination/Open End/Socket Wrenches
ASV Approved Jack Stand (or equivalent)
Hammer
Punch (brass)
Remove bolt & nut
Drive out
15-4
Chapter Overview
This chapter provides information on inspection, disas-
sembly and assembly of major hydraulic components.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
When servicing any hydraulic component, make sure
the machine is off and cool and that all of the hydraulic
actuators are relaxed prior to disconnecting or remov-
ing any component from the system.
When servicing any hydraulic component, keep in
mind that any scratches or damage that can be felt
with a fingernail on surfaces that parts move, slide, roll
or rotate upon indicate a need for part replacement.
Hydraulic components must be kept extremely clean to
ensure proper function and service life. Do not assem-
ble any components that have not been inspected for
damage and thoroughly cleaned prior to assembly.
The hydraulic system fluid should be changed fol-
lowing any hydraulic component service according
to the procedure described on page 4-16.
Disassembly & Assembly
Disassembly and assembly procedures are provided
for the following components:
Hydraulic Cylinders
Lift Arm Control Valve
Drive motor
Drive Pump
Auxiliary Pump
Note: Procedures are provided for only those components
listed above. However, exploded parts diagrams exist in the
SR-70 & SR-80 parts manuals to serve as visual aids in the
assembly and disassembly of other system components.
Hydraulic Cylinder
Disassembly
1. With machine off and cool and with hydraulic actu-
ators relaxed, disconnect and cap hoses from the
cylinder(s) to be serviced.
Note: When servicing cylinders, the attached components
must be supported in a manner that allows the cylinders to
be safely removed and installed. (lift arms & quick attach)
2. Remove the cylinder(s) and secure it in a bench
vise to aid in disassembly. (figure 16-1)
3. Place a suitable catch container beneath the rod
end of the cylinder to catch any hydraulic oil that
may leak out upon disassembly.
16. Hydraulic Component
Service Procedures
16-1
!WARNING!
Required Tools
Bench Vise
Pipe Wrench
Socket or Impact Wrench
Screwdriver (blade type)
Rubber or Dead Blow Hammer
Small Pry Bar
16-1
NOTICE
!WARNING!
Disassembly of hydraulic components should only be performed
by factory trained personnel experienced in the disassembly
and repair of hydraulic components. Components should not be
serviced during the warranty period without written instruction
from the ASV service department. Component disassembly dur-
ing this period may void the manufacturers warranty.
NOTICE
4. Use an open end or pipe wrench to turn and
remove the end gland. (figure 16-2)
5. Use a pry bar or similar device to pull the rod and
piston from the cylinder. (figure 16-3)
6. Inspect the piston surface, seals and ring for wear
or damage. If any component appears to be dam-
aged in any way, replace it. When inspecting the
piston surface, look for scratches. If any are pres-
ent that are deep enough to catch with your finger-
nail, the piston should be replaced. (figure 16-4)
Note: Seal imperfections or scratches on the piston, bore or
rod or will cause internal/external leakage and impaired func-
tion. Defective components must be repaired or replaced.
7. With the piston and rod removed from the cylinder,
inspect the cylinder bore for scratches or other
damage. If any are present that are deep enough
to catch with your fingernail, the cylinder tube
weldment should be replaced. (figure 16-5)
8. Remove the nut from the rod end. (figure 16-6)
9. Support the piston loosely from the underside (fig-
ure 16-7), thread the nut partially on to protect the
threads and tap the rod end with a rubber or dead
blow hammer to free the piston from the rod.
10. Once loose, remove the nut and piston from the
rod.
16-2
Rubber Track Loader
16. Hydraulic Component Service
16-2
16-3
16-4
16-5
16-6
16-7
End Gland
Rod
Piston
Seals
Ring
Cylinder Tube Weldment
11. Remove the seals and piston ring taking care not
to scratch the piston. Also, pay close attention to
seal and ring orientation and position to aid when
installing new parts. (figures 16-8, 16-9)
12. Gently tap the end gland off of the cylinder rod.
(figure 16-10)
13. Remove the tandem seals from the end gland pay-
ing close attention to the order of removal to aid
during installation of the new seals. (fig. 16-11)
14. Remove the inner seal from the end gland. Pay
attention to the seal orientation upon removal to
aid during installation of the new seal. (fig. 16-12)
15. Remove the end gland outer seal from the end
gland. (figure 16-10)
16. Thoroughly clean all parts to prevent contamina-
tion of hydraulic oil when reinstalled.
Assembly
1. Install new seals and components in place of the
originals paying close attention to orientation and
location to ensure proper operation.
2. Lubricate the piston, ring, and seals with fresh
hydraulic oil prior to assembly to avoid damage.
3. Reassemble components by reversing the disas-
sembly process.
Note: During reassembly, use an impact wrench to tighten
the piston retaining lock nut. Make sure the nut is tight and
that there is no independent movement between the piston
and rod before reassembling.
16-3
Rubber Track Loader
16. Hydraulic Component Service
16-8
16-9
16-10
16-11
16-12
Outer Seal
Lift Arm Control Valve
Disassembly
1. With machine off and cool and with hydraulic actu-
ators relaxed, remove the lift arm control valve
according to the procedure on page 10-4.
2. Place the valve on a bench in a clean work area.
3. Remove the nuts holding the valve stack together.
(figure 16-13, 16-14)
4. Remove each valve section and inspect the seals
for damage, replace if necessary. (figure 16-15)
5. Remove the inlet port assemblies and inspect the
seals for damage, replace if necessary.
(figure 16-16, 16-17)
6. Once the inlet port covers have been removed
from both sides of a spool, the spool may be
removed. (fig. 16-18)
16-4
Rubber Track Loader
16. Hydraulic Component Service
Required Tools
Socket Wrench
Combination Wrench
Screwdriver (blade type)
Low Profile Needle Nose Pliers
16-13
16-15
O-ring
16-16
O-ring
16-17
16-14
16-18
Note: Figure 16-19 displays the assembly order of the
spool and associated components.
Note: The lift arm and bucket control spools are each
equipped with a unique load check spool. The load
check spools provide bucket positioning (self-Leveling).
The components can be seen above in figure 16-20.
The load check spools are similar, but they are not
identical. The main spools are also unique. All
spools must be reinstalled as found upon disas-
sembly to function properly.
7. To remove the load check spool, use a clamp to
hold the spool in place in a vice without damaging
the spool and remove the end cap with an allen
wrench. (fig. 16-21)
8. Remove the spring from the spool. (fig. 16-22)
9. Remove the load check spool with a low profile
needle nose pliers. (fig. 16-23)
Note: There is a passageway in the load check spool
that must be kept clear to ensure proper operation. It
leads from the small hole in the side of the spool to the
end of the spool. If you cannot blow air through this
passageway, it must either be cleaned or the load
check spool must be replaced to restore proper func-
tion. (fig. 16-24)
16-5
Rubber Track Loader
16. Hydraulic Component Service
16-19
16-20
16-21
Clamp
Spool
Cap
Spool Load Check
Spool
Spring Cap
16-22
16-23
16-24
Assembly
1. Install new seals and components in place of the
originals as necessary paying close attention to
location and orientation to ensure proper function.
2. Thoroughly clean all components to prevent sys-
tem contamination.
3. Reassemble components by reversing the disas-
sembly process.
Drive Motor (brake portion)
Disassembly
1. With machine off and cool and with hydraulic actu-
ators relaxed, remove the drive motor from the
undercarriage by following the procedure in sec-
tion 13.
2. Remove all but four of the allen bolts (on opposite
sides of the cover) holding the rear cover onto the
drive motor, then back the remaining four out
evenly to release the light spring pressure against
the cover. (fig. 16-25)
3. Remove the rear cover to expose the brake
assembly. (fig. 16-26)
16-6
Rubber Track Loader
16. Hydraulic Component Service
Required Tools
Allen Wrench/Socket
Rubber Mallot (seal removal if needed)
Screwdriver (blade type) (seal removal if needed)
16-26
16-25
4. Remove the brake spring and shims. Make sure to
note the order of assembly to ensure correct
reassembly. (fig. 16-27)
5. Insert an air nozzle into the port closest to the rear
of the pump as shown. (fig. 16-28)
6. Cover the opening with a shop cloth and apply
moderate pressure to the top of the brake piston to
keep it in place when air is applied. (fig. 16-28)
7. Apply air to the port and the piston should slide
upwards so that it can be removed.
Note: There is a seal around the outer edge of the pis-
ton so it may pop loose rather than gently slide out.
8. Remove the piston from the motor. Inspect the
seal for any damage. (fig. 16-29)
9. Inspect the seal for any damage. (fig. 16-30)
10. Remove the allen bolts securing the upper casting
to the drive motor. (fig. 16-30)
11. Remove the upper casting from the drive motor to
expose the clutch discs. (fig. 16-31)
12. Inspect the discs for discoloration (blueing) or for
signs of excessive wear. (fig. 16-32)
Note: If any of the individual discs measure less than
.015 replace them as a set.
Assembly
1. Replace worn or damaged components, thorough-
ly clean all parts, then reassemble the motor by
reversing the disassembly procedure.
16-7
Rubber Track Loader
16. Hydraulic Component Service
16-27
16-28
Spring
Shims
16-29
Seal
16-30
Seal
Bolts
16-31
16-32
Drive Motor (motor portion)
Disassembly
1. Mark the casing across the parting lines as shown
to ensure correct reassembly of the drive motor.
(fig. 16-33)
2. Remove the allen bolts securing the output end of
the drive motor to the main casting and remove it
from the motor as shown. (fig. 16-34, 16-35)
3. Lift and remove the piston block to expose the
sealing surfaces. Inspect these surfaces to ensure
there is no scratching or abrasion that may affect
operation. (fig. 16-36)
4. Inspect the surfaces of the cam ring and the piston
rollers for imperfections. Any damage found indi-
cates a need for component replacement.
(fig. 16-37)
5. Using a snap ring pliers, remove the snap and
retaining rings on both sides of the piston block to
allow for removal and inspection of the block, pis-
tons, piston rings, and rollers. (fig. 16-38)
16-8
Rubber Track Loader
16. Hydraulic Component Service
16-33
16-34
Required Tools
Allen Wrench/Socket
Snap Ring Pliers
Screwdriver (blade type) (seal removal if needed)
16-35
16-36
Surfaces
16-37
Surfaces
16-38
Bolts
6. Once the snap rings and retainers are removed,
slide the piston assemblies out one at a time and
inspect them for damage. (fig. 16-39, 16-40)
Note: While inspecting the piston assemblies, pay
close attention to the piston ring. Look for any signs of
damage or cracking. (fig. 16-40)
7. Inspect the rollers and sleeves as well to make
sure there are no scratches or other damage that
may affect operation.
Assembly
1. Replace worn or damaged components, thorough-
ly clean all parts, then reassemble the motor by
reversing the disassembly procedure.
Drive Pump (Drive Relief Valves)
Disassembly & Adjustment
1. With machine off and cool and with hydraulic actu-
ators relaxed, remove the drive pump from the
machine by following the procedure in section 11.
2. Remove the drive pressure relief valves as shown
in fig. 16-42 and 16-43.
3. If adjustment is needed (see drive pressure check
procedure in section 17), loosen the allen type set
screw on the valve.
16-9
Rubber Track Loader
16. Hydraulic Component Service
16-39
16-40
Ring
16-41
Ring Groove
Required Tools
Allen Wrench/Socket
Combination/Socket wrench
16-42
16-43
16-44
4. Flip the valve over, then tighten the nut to increase
the pressure setting (CW) or loosen it to decrease
the pressure setting (CCW).
Assembly & Test
1. Retighten the locking set screw and reinstall by
reversing the disassembly procedure. Retest the
pressure through the affected relief to check for
proper adjustment. If it is still not correct, repeat
the adjustment procedure until correct.
Drive Pump (Posi-Power Relief Valve)
Removal
Note: The posi-power relief valve is usually a remove
and replace item. However, If adjustment is required,
please see the posi-power relief valve adjustment pro-
cedure in section 17 of this manual.
1. Remove the valve from the drive pump as shown
in figure 16-46.
Installation
1. To install, reverse the removal procedure.
Drive Pump
Disassembly
Note: The drive pump is a tandem design where two
pumps share one housing. The disassembly and
assembly procedures are identical for both pumps.
1. Remove the allen bolts securing the end cap onto
the pump. (fig. 16-47)
2. Remove the end of the pump as an assembly
(fig. 16-48)
16-10
Rubber Track Loader
16. Hydraulic Component Service
16-45
Required Tools
Combination/Socket wrench
16-46
Required Tools
Combination/Socket wrench
Allen Wrench/Socket
Rubber Mallot
Screwdriver (blade type)
Snap RIng Pliers
16-47
16-48
3. Remove the valve plate and inspect it for damage
or wear, specifically, scratches that can be felt with
a fingernail. (fig. 16-49)
4. Inspect the end of the barrel (face) and the slipper
faces for similar scratches. (fig. 16-50, 16-51)
Note: To inspect the slipper faces, slide the barrel off
of the assembly, then slide the slippers and pistons off
of the shaft as an assembly, then inspect.
5. Remove the swash plate along with the bearings
and inspect them for any damage or scratching
that could affect operation. (fig. 16-52, 16-53)
6. Remove the snap ring holding the shaft, seal and
bearing into the casing, then remove the seal.
(fig. 16-54)
Note: If you are repairing the existing pump, you will
need to replace the outer seal as it will be destroyed
upon removal.
16-11
Rubber Track Loader
16. Hydraulic Component Service
16-49
16-50
Barrel Face
16-51
Slipper Faces
16-52
Swash Plate
16-53
Surfaces
Bearings
16-54
7. Using a rubber mallot, gently tap the shaft and
bearing out of the casing for inspection or replace-
ment. (fig. 16-55)
Drive Pump
Assembly
1. Using a rubber mallot, gently tap the shaft and
bearing into the casing until seated. (fig. 16-56)
2. Replace the seal with a new one and install taking
care not to damage it upon installation. (fig. 16-57)
3. Install the snap ring that secures the shaft, bear-
ing, and seal in place. (fig. 16-57)
16-12
Rubber Track Loader
16. Hydraulic Component Service
16-55
16-56
Required Tools
Combination/Socket wrench
Allen Wrench/Socket
Rubber Mallot
Screwdriver (blade type)
Snap RIng Pliers
16-57
4. Flip the assembly over and lay it on a table, then
remove the pivot caps from both sides as shown.
(fig. 16-58)
Note: Behind each cap is a pivot that aligns with the
two small pivot wires attached to the swash plate.
Remove these from their cavities while installing the
swash plate.
5. Assemble the bearing halves to the bottom of the
swash plate, orient the pins so that they are verti-
cal and then lower the assembly into place over
the shaft. (fig. 16-59)
6. Once installed, make sure each pin is centered in
its opening, then slide the pivot into the hole so
that it mates with the pin. (fig. 16-60)
7. Once the pivots are installed, check to make sure
both of them are properly mated with the pins.
Using a blade type screwdriver, turn the pivots
slightly to the right or left. The swash plate should
move with the pivot as each one is turned. If it
does not move, repeat step 6, then recheck. Once
correct, reinstall the caps to secure them in place
(fig. 16-61)
8. Reassemble the piston and barrel portion of the
pump as found upon disassembly, then slide it
back into the housing. (fig. 16-62, 16-63)
Note: Make sure the long end of the swash plate
alignment bar is pointing inward to ensure proper oper-
ation. (fig. 16-62)
9. Reinstall and tighten the cover bolts to secure the
cover. (fig. 16-63)
16-13
Rubber Track Loader
16. Hydraulic Component Service
16-58
16-59
Pin
16-60
Pin
16-61
16-62
Long end
16-63
Auxiliary Pump
Disassembly
1. With machine off and cool and with hydraulic actu-
ators relaxed, remove the drive pump from the
machine by following the procedure in section 11.
2. Remove the bolts securing the relief valve to the
housing. (fig. 16-64)
3. Inspect o-rings for proper shape and condition.
Replace if necessary. (fig. 16-65)
4. Remove the Allen bolts securing the cover onto the
pump. (fig. 16-66)
5. Lift the cover off to expose the pump components
and the o-ring seal. Inspect the o-ring for damage,
replace if necessary. (fig. 16-67)
6. Inspect the valve plate face (both sides) for
scratches or any other damage that can be felt
with a fingernail. (fig. 16-68)
7. Inspect the barrel face for scratches or any other
damage that can be felt with a fingernail.
(fig. 16-69)
16-14
Rubber Track Loader
16. Hydraulic Component Service
Required Tools
Allen Wrench/Socket
Snap Ring Pliers
16-64
16-65
O-rings
16-66
16-67
16-68
16-69
O-ring
Inspect Face
Inspect Face
8. Remove the piston/barrel assembly and inspect
the slipper faces for scratches or any other dam-
age that can be felt with a fingernail. (fig. 16-70)
Assembly
1. To reassemble, reverse the disassembly proce-
dure.
16-15
Rubber Track Loader
16. Hydraulic Component Service
16-70
Inspect Faces
16-16
Chapter Overview
This chapter provides hydraulic pressure and flow
check, adjustment and troubleshooting procedures.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
Hydraulic oil must be at operating temperature to
obtain accurate readings during the pressure and flow
test procedures described in this section. Start and
warm the engine and hydraulic oil prior to performing
the test and troubleshooting procedures in this section.
Contamination Inspection
The hydraulic system can become contaminated when
one or more of its dynamic components fails or begins
to wear excessively. This can introduce significant
amounts of debris into the hydraulic oil.
In the event of contamination, the defective compo-
nent(s) must be replaced, the remaining components
must be inspected and thoroughly cleaned (if found to
be reusable) and the system lines and reservoir must
be thoroughly flushed to restore original function.
The hydraulic filters remove contaminants from the oil.
Small amounts of debris found within the filters are to
be expected, but If there is significant metallic debris
found in either filter, certain components of your
hydraulic system may be contaminated. To inspect for
contamination, label the hydraulic filters by location
and remove them. Cut them apart approx. halfway
between the top and bottom of the filter and inspect
them for debris. If contamination is suspected, contact
the ASV service department at 1-800-346-4367.
Hydraulic Pressure/Flow Test &
Troubleshooting Procedures
Test and troubleshooting procedures are provided for
the following Hydraulic system components.
Charge Pressure Check & Adjustment
Auxiliary Valve Pressure Check & Adjustment
Lift Arm Pressure Check & Troubleshooting
Drive Pressure Check & Troubleshooting
Auxiliary Flow Test & Troubleshooting
When checking hydraulic system pressures, you are
essentially reading the relief valve settings of each cir-
cuit tested. If your hydraulic system and components
are functioning properly, your readings should match
those specified. If they differ, adjustment and or repair
may be required to restore proper function.
The procedures in this section are listed in the
order they are to be performed. When a pressure
issue is suspected, perform these procedures to help
diagnose and or repair the problem.
Charge Pressure Check
Charge pressure is used to prime the various circuits,
including the joysticks, with hydraulic oil for operation.
Low charge pressure could lead to sluggish operation
of any and all functions.
Note: The quick coupler (test port A) located in the engine
compartment just inside the left lift arm tower can be used for
general pressure checks and troubleshooting.
17. Hydraulic Pressure/Flow
Test & Troubleshooting
17-1
!WARNING!
Required Tools
Pressure Gauge 0-1000p.s.i.
17-1
Test Port (A)
NOTICE
1. Attach the gauge to test port A. (fig. 17-1) Route
the gauge so that you or an assistant can read it
during testing.
2. Make sure any bystanders are clear of moving
components, then start the engine.
3. Allow the engine to warm up to operating tempera-
ture, then with the engine at idle, check the charge
pressure. Record your reading. It should read 475
+/- 30 psi at this test port. If your reading differs,
adjustment is necessary.
4. If necessary, adjust the charge relief pressure.
To adjust:
a) Tilt the cab as described on page 4-2 of this
manual to access the pump.
b) Locate the charge relief valve on the top of the
drive pump. (fig. 17-2)
c) Remove the relief valve from the top of the
pump as shown in figure 17-3.
d) Add shims to increase the pressure setting, or
remove shims to decrease the setting until
within specification. (figure 17-4)
5. Retest once adjustments have been made to make
sure pressure is correct. Readjust as necessary
until correct.
17-2
Rubber Track Loader
17. Hydraulic Pressure & Flow
17-2
17-4
17-3
Charge Relief
Auxiliary Pressure Check
Auxiliary pressure is used to drive flow style attach-
ments. Low auxiliary pressure can produce poor per-
formance in attachments while high pressure can
cause component damage/failure in the machine or the
attachment being utilized.
Note: Make sure charge pressure is set correctly prior to
testing this function.
1. Tilt the cab as described on page 4-2 of this
manual to access the valve.
2. Locate the test port on the top of the lift arm con-
trol valve. (fig. 17-5)
3. Attach the 0-1000psi hydraulic gauge to test port
(B) on the top of the valve. Route the gauge so
that you or an assistant can read the gauge while
performing the test procedures. (figure 17-5, 17-6)
4. Start the machine and with the auxiliary hydraulic
switch off (no functions activated) and the engine
at idle, you should read 218 psi at test port (B).
5. Attach the 0-6000psi gauge to test port B, then
activate the low or high flow auxiliary hydraulics
with no auxiliary attachment fastened to the quick
couplers. This action will send oil over relief and
you will read the actual pressures required to acti-
vate the relief valve for each circuit. Do this for
both the high and low flow circuits in both direc-
tions. Record the pressure readings.
Check your readings against those stated below. If
your readings differ, an adjustment and or repair may
be required.
Pressures should read: (at test port B)
218 +/- 10 PSI with system relaxed (standby).
3000 +/- 100 PSI with Low Flow activated.
3000 +/- 100 PSI with High Flow activated.
6. If necessary, adjust the relief settings on the auxil-
iary standby or high pressure valves. (figure 17-7)
To adjust:
a) Remove the cap covering the affected relief
valve.
b) Using an allen wrench, turn the adjustment
screw clockwise to increase the setting or
counter-clock wise to reduce it until within
specification.
17-3
Rubber Track Loader
17. Hydraulic Pressure & Flow
Required Tools
Pressure Gauges 0-1000, 0-6000 p.s.i.
17-5
17-6
Test Port (B)
17-7
Standby
High Pressure
Lift Arm Pressure Check
Lift arm pressure is used to lift loads or break-out.
Low lift arm pressure can produce a weak lift arm func-
tion while high lift arm pressure can damage lift arm
and hydraulic components.
Note: Make sure auxiliary circuit pressures are set correctly
prior to testing this function.
1. Attach a hydraulic gauge to test port B. Route the
gauge so that you or an assistant can read the
gauge while testing these functions. (figure 17-6)
2. Raise the lift arms all the way up and continue
holding the joystick even when the lift arms stop.
Record the pressure readings. Then lower the lift
arms to the stops and continue holding the joy-
stick. Record the pressure readings. Repeat this
process with the bucket dump/curl functions.
3. Check your readings against those stated below. If
your readings differ, adjustment or repair may be
necessary. (figure 17-8)
Pressures should read: (at test port B)
3000 +/- 100 PSI when the lift arms or bucket are
in the up/curl position.
3000 +/- 100 PSI when the lift arms or bucket are
in the down/dump position.
4. If any of the readings are low, reverse the function
and recheck. If reading is within specification in
that direction, replace the opposing relief valve.
Drive Pressure Check
This procedure should only be performed if you suspect
a drive pump or drive motor is faulty. The procedure is
difficult and in performing it, you risk contaminating
your hydraulic system if your equipment and working
environment is not clean.
Make certain all couplers, fittings and hoses used during
this process are clean and free of contaminants that may
potentially cause damage to the hydraulic pump and or
system components!
Drive pressure is used to turn the drive motors that
power your tracks. Low pressure can cause decreased
drive motor performance resulting in sluggish maneu-
vering, decreased speed and or uneven forward or
reverse motion.
1. Remove the plug from the port you would like to
test and insert a quick coupler similar to the one in
port A or B.
Note: There are 4 drive pump test ports. The left side ports
are shown in figure 17-10 and the right side ports are located
to the right of the drive ports they test.
2. Attach the hydraulic gauge to the port(s) you are
trying to test and route the gauge so you or an
assistant can read the gauge during testing.
3. Position the machine so that the lift arms are rest-
ing against the chassis stops and the front edge of
the bucket is facing, centered on and in contact
with an IMMOVABLE object.
4. Move the drive control fully forward in an attempt
to drive the machine forward. This will force oil
over the relief valve and give you a reading for the
circuit you are tapped into.
5. Attach a heavy-duty chain capable of restraining
the machine securely to the bucket and an
IMMOVABLE object.
6. Move the drive control fully rearward in an attempt
to drive the machine in reverse. This will force oil
over the relief valve and give you a reading for the
circuit you are tapped into.
7. Check all four ports in this same manner and
record your readings.
Required Tools
Pressure Gauge 0-6000 p.s.i.
!WARNING!
17-4
Rubber Track Loader
17. Hydraulic Pressure & Flow
Required Tools
Pressure Gauge 0-6000 p.s.i.
17-8
Port (B)
Relief Valves
Relief Valves
Check your readings against that stated below. If your
readings differ, relief replacement and or component
repair may be required.
Pressures should read:
5500 PSI when the relief is reached in attempted
forward or reverse motion.
Drive pressure troubleshooting:
8. If one reading is low, swap the relief valve with a
similar one and recheck. If the reading improves,
replace the faulty relief valve.
9. If two readings are low, but on different circuits
(pumps), perform step 8 for both.
10. If both readings are low on one pump, disconnect
the drive hoses from the suspected ports and plug
them at the pump. Cap the hoses to prevent con-
tamination and then recheck the pressures at
those ports. If the reading improves, the drive
motor is at fault. If the reading does not improve,
one pump (in the tandem assembly) is at fault.
11. If all 4 readings are low, it is unlikely that all four
relief valves are faulty. The tandem pumps are
most likely not working properly.
Posi-Power Pressure Check
Posi-power is a function of the tandem drive pump
assembly. The posi-power control reads charge flow
(which is directly related to engine rpm) and adjusts
drive pump flow to maximize torque and prevent
engine stall during high load conditions.
This procedure should only be performed if you
suspect that the Posi-Power relief valve is faulty. In
performing this procedure you risk contaminating
your hydraulic system if your equipment and work-
ing environment is not clean.
Make certain all couplers, fittings and hoses used
during this process are clean and free of contami-
nants that may potentially cause damage to the
hydraulic pump and or system components!
To check Posi-Power pressure:
1. With the engine off and cool, disconnect and cap
the posi-power outlet hose from the port on the top
of the drive pump assembly. (figure 17-11)
2. Remove the fitting from the pump assembly and
install a quick coupler similar to the one installed in
test port A or B in its place.
3. Attach a gauge to the quick coupler and route it so
that you or an assistant can read the gauge during
operation.
4. Make sure all bystanders are clear of moving parts
and start the engine.
5. At low rpm, posi-power pressure should read 180
+/- 40 psi. (475 +/- 40 at high rpm)
17-5
Rubber Track Loader
17. Hydraulic Pressure & Flow
17-10
17-9
Test Ports
(see note)
Relief Valves
!WARNING!
17-11
Posi-Power
Adjustment
Posi-Power
Outlet
6. If your reading is low, remove the cap and loosen
the jam nut on the posi-power adjustment screw
and turn it counter clockwise until it stops then
retighten the jam nut. (figure 17-11)
a) If the screw was already turned completely
out and pressure reads lower than specified,
the posi-power relief valve is faulty and should
be replaced.
b) If you were able to turn the screw out, recheck
posi-power pressure to see if the reading is
now within specification. If it is, the system
should function properly. If it did not improve,
the posi-power relief valve is faulty and should
be replaced.
To Adjust Posi-Power:
1. Loosen the jam nut and then turn the screw to
adjust for more or less posi-power function.
(figure 17 -11)
a) Turn the screw clockwise to increase function
and limit pump flow during high load condi-
tions. (less likely to stall)
b) Turn counter-clockwise to decrease function
and maximize pump flow during high load con-
ditions. (more likely to stall)
2. Tighten the jam nut while holding the set screw in
place to keep desired setting.
Auxiliary Flow Test
The SR-70 and SR-80 are equipped with both high
and low flow auxiliary circuits. If an auxiliary flow prob-
lem is suspected, the following procedures should be
performed.
Note: If an auxiliary circuit problem is suspected, per-
form all pressure test and adjustment procedures as
necessary prior to attempting the perform the flow test
procedure. Most issues will be solved with the pres-
sure test and adjustment procedures, but if a problem
still persists after all pressures are correctly set, pro-
ceed with the flow test.
Note: The charts above give the acceptable ranges for
fluid flow when loaded to the levels indicated. The low
flow values are to be understood as acceptable if with-
in 1 gpm of the specified value. The high flow values
are acceptable if within 2 gpm of the specified value.
To test flow:
1. Attach a flow meter to the quick couplers of the cir-
cuit to be tested. (high or low flow)
2. Start the machine and activate the circuit.
3. Record and compare your readings with those of
the charts above in both directions.
17-6
Rubber Track Loader
17. Hydraulic Pressure & Flow
Low Flow Auxiliary
20
19
18
17
0
0
5
10
15
20
25
0 psi 1000 psi 2000 psi 2500 psi 3000 psi
System Load
G
P
M

(
r
e
a
d
i
n
g
s

a
r
e

+
/
-

1
)
High Flow Auxiliary
31 31
30
26
0
0
5
10
15
20
25
30
35
0 psi 1000 psi 2000 psi 2500 psi 3000 psi
System Load
G
P
M

(
r
e
a
d
i
n
g
s

a
r
e

+
/
-
2
)
Required Tools
Flow Meter (with variable loading valve)
Flow Troubleshooting
If your readings differ from those listed on the charts,
identify the symptom you are experiencing in the list of
possible problems below and follow the steps to identi-
fy and correct the problem.
Problem 1:
Both high and low flow readings are less than
specified.
Possible causes:
1. Auxiliary relief valve pressure setting incorrectly
(see page 17-3)
2. Quick coupler block pressure release valve stuck in
down (release) position.
3. Auxiliary pump malfunctioning or faulty.
4. Engine RPM too low.
Problem 2:
High flow readings are less than specified (low
flow is within specification).
Possible causes:
1. Low charge pressure.
2. Control valve spool malfunction.
Note: Make sure that the high flow reading is greater
than the low flow reading. If they are equal, the prob-
lem is most likely electrical.
Problem 3:
Flow is within specifications in one direction, but
lower than specified in the other.
Possible causes:
1. Auxiliary line relief valve in need of replacement.
(see page 17-4 for test instructions and figure 17-8
for location)
2. Control valve spool malfunction.
Problem 4:
Low flow readings are less than specified (high
flow is within specification).
To correct:
1. Turn the adjustment screw on the pilot generation
block pressure reducing valve clockwise to increase
the flow within the low flow circuit until correct.
(see page 3-5, view D, item 5 to locate)
Problem 5:
Low flow readings are higher than specified (High
flow is within specification).
To correct:
1. Turn the adjustment screw on the pilot generation
block pressure reducing valve counter clockwise to
decrease the flow within the low flow circuit until
correct. (see page 3-5, view D, item 5 to locate)
Problem 6:
High and low flow functions only work in one
direction.
Possible causes:
1. Wire broken or disconnected at the pilot generation
block.
2. Solenoid coil malfunction. (see page 3-5)
3. Solenoid spool malfunction. (see page 3-5)
4. Faulty auxiliary hydraulic switch.
Problem 7:
Low flow works as intended when using the con-
tinuous switch, but does not work when using the
variable flow thumb switch.
Possible causes:
1. Variable flow fuse blown.
2. Power wire to variable flow switch broken or dis-
connected. (BU-16 see electrical schematic)
3. Variable flow switch malfunction.
4. If the switch works in one direction, but not the
other, check the pressure reducing proportional
valves and the wires that connect them to the
wiring harness for proper condition and function.
(see page 3-5, view B item 6, view D item 4)
17-7
Rubber Track Loader
17. Hydraulic Pressure & Flow
17-8
Chapter Overview
This chapter contains basic troubleshooting proce-
dures for the SR-70 and SR-80 Rubber Track Loaders.
Additional troubleshooting aids are provided in Chapter
3 (Circuit Diagrams) and in chapters containing disas-
sembly and assembly procedures for the appropriate
component or assembly.
Personal Safety
Improper or incomplete maintenance/repair of a Rubber
Track Loader can be dangerous and may result in
machine damage, injury or even death.
Do not attempt to perform any type of repair or mainte-
nance on a Rubber Track Loader until you have read and
fully understood the information in this manual.
Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Loader.
Prior to performing any type of service work on a
Rubber Track Loader, read and understand Chapter 1
(Product Safety) for personal safety information.
Visual Inspection
Prior to troubleshooting, walk around the machine and
perform an overall visual inspection. Look for missing,
loose, worn or broken parts. Pay particular attention to
the following items:
Track tension
Fluid levels
Fan belt tension and condition
Hoses (no visible sign of wear)
Fittings (no apparent leaks)
Battery cables
Fuse panel (fuses in place and operational)
Controls (for neutral)
A simple visual inspection and operational check can
identify many problems without the need for extensive
troubleshooting. However, if these checks indicate a
problem that requires further analysis, proceed to
Troubleshooting.
General Troubleshooting
The most effective way to prevent a malfunction from
occurring is to closely follow the recommended mainte-
nance schedule and instructions throughout the life of
the machine. However, if a malfunction does occur,
finding the problem and fixing it quickly are important.
This section covers a select set of symptoms that may
occur and suggests possible causes.
Problem 1:
Machine will not crank over.
Possible causes
1. Continuous high flow switch activated.
2. Continuous low flow switch activated.
3. Power quick-attach switch in unlocked position. (if
equipped)
4. Battery cables loose or corroded.
5. Ignition fuse blown.
6. Main starter fuse blown.
7. Starter relay malfunctioning.
8. Weak or dead battery.
9. Faulty continuous hydraulic flow switch.
10.Faulty power quick attach switch.
11. Faulty ignition switch.
12.Faulty starter.
13.Loose, broken or disconnected wiring at key, relay
or starter.
14.Main power fuse (60-80 amp) blown.
18. Troubleshooting
18-1
!WARNING!
Problem 2:
Machine cranks, but will not start.
Possible causes
1. Fuel tank empty, fuel filter plugged or fuel line
restricted.
2. Battery discharged (engine rotates slowly).
3. Injection pump fuse blown.
4. Power relay (B) fuse blown (40 amp).
5. Faulty power relay (B).
6. Loose, broken or disconnected wiring at injection
pump, fuel pump or fuse.
7. Glow plugs not pre-heating (look for black smoke).
a) Main glow plug fuse blown.
b) Glow plug relay malfunctioning.
c) Loose, broken, or disconnected wiring at ignition
switch, relay or glow plug ground strip.
d) Faulty glow plugs.
8. Faulty ignition switch.
9. Loose, broken or disconnected wiring in starting cir-
cuit.
10.Loose, broken or disconnected wiring at fuel shutoff
solenoid.
11. Air in fuel system or defective fuel injection pump.
Problem 3:
Machine starts, but hydraulics will not operate.
Possible causes
1. Operator not in seat.
2. Seat belt not fastened.
3. Safety relay fuse and or or safety solenoid fuse for
seat belt or operator presence safety switches
blown.
4. Faulty operator presence safety switch.
a) Test for continuity through operator presence
and seat belt switches. Adjust or replace as neces-
sary.
5. Loose, broken or disconnected ground wires (check
ground connections behind the operator seat, from
cab to chassis and on the chassis crossmember.)
6. Faulty safety relay.
7. Faulty safety solenoid or safety solenoid spool.
8. Loose, broken or disconnected wiring at fuse, relay,
or safety solenoid.
9. Low charge pressure.
Problem 4:
Lift arm/bucket controls are operational, but tracks
will not move.
Possible causes
1. Leak in feed line to drive control joystick (pilot con-
trol).
2. Loose, broken or disconnected wire to DA control
solenoid.
3. Drive control joystick (pilot control) malfunction.
4. Low charge pressure.
5. Parking brake switch in on position.
6. Faulty parking brake switch.
Problem 5:
Tracks are operational, but lift arms will not move.
Possible causes
1. Continuous hydraulic flow switch activated, sending
oil over relief. (lift arms work, but move slowly)
If auxiliary flow hydraulics work check for:
a) Leak in feed line to lift arm control joystick (pilot
control).
b) Lift arm control joystick (pilot control) malfunc
tion.
c) Lift arm control valve assembly malfunction.
If auxiliary flow hydraulics do not work check for:
a) Main auxiliary relief malfunction.
b) Faulty auxiliary pump.
Problem 6:
Lift arms are operational, but high/low flow auxil-
iary circuits are not.
Possible causes
1. Auxiliary hydraulic fuse blown.
2. Faulty ground in at chassis crossmember.
3. Faulty auxiliary hydraulic switch.
4. Faulty auxiliary hydraulic solenoid at pilot genera-
tion block.
5. Loose, broken or disconnected wire at fuse, auxil-
iary hydraulic switch, pin connector P10.
6. Auxiliary hydraulic pilot generation spool stuck in
closed position.
7. Faulty or improperly connected quick coupler.
8. Quick coupler block pressure release stuck in down
(open) position.
Problem 7:
Multiple switches/electrical accessories are not
operational in ON or RUN position.
Possible causes
1. Power A or B fuse blown.
2. Faulty power relay (A or B).
3. Faulty ignition switch.
4. Loose, broken or disconnected wiring at ignition
switch, fuse or relay.
Problem 8:
Battery will not charge/maintain charge.
Possible causes:
1. Loose alternator belt.
2. Alternator fuse blown.
3. Faulty alternator diode.
4. Loose, broken or disconnected wiring at battery,
alternator, diode or fuse.
5. Excessive current draw with key in "off" position.
6. Faulty battery.
7. Faulty alternator.
18-2
Rubber Track Loader
18. Troubleshooting
Problem 9:
Lift arm control joystick will not lock into float
position.
Possible causes
1. Float magnet fuse blown.
2. Loose, broken, or disconnected wiring at fuse, float
detent magnet, or pin connector P8.
3. Faulty float detent magnet.
Problem 10:
Lift arms will not float, engine labors and lift arms
create down pressure when float is engaged.
Possible causes
1. Engine RPM too low.
2. Low charge pressure.
3. Lift arm control joystick malfunction (pilot control).
4. Lift arm control valve malfunctioning.
Problem 11:
Hydraulic oil temperature elevated; hydraulic sys-
tem overheating.
Possible causes
1. Debris plugging oil cooler, limiting airflow.
2. Low hydraulic oil level.
3. Loose or missing fan belt.
4. Damaged or missing cooling fan blades.
5. Incompatible attachment.
a) Attachment must match machine flow capabili
ties.
b) Attachment hose inside diameter must be at
least " for low flow and " for high flow.
c) Low flow attachment coupled to high flow circuit.
6. Faulty hydraulic oil temperature sending unit.
7. Faulty quick coupler.
8. Cooler bypass relief open.
Note: Cooler bypass should open at 80 PSI.
Problem 12:
Engine coolant temperature elevated; engine over-
heating.
Possible causes:
1. Low coolant level.
2. Debris plugging radiator, limiting airflow.
3. Damaged or missing cooling fan blades.
4. Loose or missing fan belt.
5. Faulty engine coolant temperature gauge.
Engine/Machine Troubleshooting
When a problem occurs that effects engine perform-
ance or function, it is important to determine whether
or not the problem lies with the machine itself, or with
the engine. A machine problem should be repaired by
an ASV dealer, while an engine specific problem
should only be repaired by a representative of the
engine manufacturer. Making this determination will
ensure timely and appropriate service to help minimize
down-time.
Problem:
Hard starting
check for:
1. 12V power to glow plugs. (With test light or multi-
meter, measure voltage at green glow plug com-
mon power lead.)
a) If power is not present, see problem 1, step 7.
2. Water in fuel.
3. Proper grade and quality fuel.
Problem:
Low power
check for:
1. Dirty, clogged, or restricted fuel filter.
2. Adequate supply of fuel to engine (fuel lines).
3. Water in fuel.
4. Proper grade and quality fuel.
Problem:
No start
check for:
1. 12V power at fuel shutoff solenoid. (With test light
or multi-meter, measure voltage at white power
lead entering the solenoid.)
a) If no power is present, see problem 1, step 3-6)
2. Ensure 12V power to fuel pump. (With test light or
multi-meter, measure voltage at white power lead
entering the electronic fuel pump.)
3. Low fuel.
4. Out of fuel. (ensure proper gauge/sending unit
function. Inspect tank for fuel)
5. Blocked or restricted fuel line. (try alternate/remote
fuel supply to pump.)
6. Water in fuel.
7. Proper grade and quality fuel.
If any of the above conditions are present, the problem
lies with the machine and should be serviced by an
ASV dealer. If the conditions listed above are not pres-
ent, the problem lies with the engine and it should be
serviced by a Perkins engine repair facility to comply
with the conditions of the engine warranty.
18-3
Rubber Track Loader
18. Troubleshooting
18-4
Chapter Overview
When replacing or replenishing the fluids and lubri-
cants in an ASV Rubber Track Loader, use ASV Posi-
Lube products. This ensures that the new fluids and
lubricants match those originally installed when the
machine left the ASV factory. Posi-Lube products were
developed for, tested and approved by ASV to assure
optimum life and performance in all ASV Rubber Track
Equipment, when used as recommended.
Fluids
Engine Oil
ASV Posi-Lube Heavy Duty Engine Oil, 10W-30
Capacity: 9 U.S. quarts (including filter)
P/N: 0300-767 1 quart
P/N: 0402-838 12 quarts
P/N: 0402-839 1 gallon
P/N: 0402-840 6 gallons
Engine Anti-freeze/Coolant
ASV Posi-Lube Long-Life 50/50
Antifreeze/Coolant
Capacity: 3.125 U.S. gallons
P/N: 0300-766 1 gallon
P/N: 0402-841 6 gallons
Hydraulic Oil
ASV Posi-Lube Premium All Season MV
Hydraulic Oil
Capacity: 20 U.S. gallons (including filters)
P/N: 0400-253 5 gallons
P/N: 0402-833 55 gallons
Grease (general-use)
ASV Posi-Lube Multi-Purpose EP Lithium
Grease
P/N: 0300-769 1 tube
P/N: 0402-844 10 tubes
P/N: 0402-834 40 tubes
If Posi-Lube products are not available, use high
quality substitutions that meet or exceed factory
installed fluid specifications.
Fuel Specifications
In North America, diesel fuel, distilled from crude oil,
identified as No. 1-D or No. 2-D in ASTM D975 gen-
erally meet machine requirements.
19. Lubricant & Fuel
Specifications
19-1
19-2
20. Service Aids &
Supplements
20-1
General Torque Specifications
Inch Fasteners Metric Fasteners
Thread Size Standard Torque
1/4" 9 +/- 2 lb ft
5/16" 18 +/- 4 lb ft
3/8" 35 +/- 7lb ft
7/16" 50 +/- 11 lb ft
1/2" 75 +/- 15 lb ft
9/16" 120 +/- 22 lb ft
5/8" 160 +/- 30 lb ft
3/4" 275 +/- 37 lb ft
7/8" 460 +/- 60 lb ft
1" 660 +/- 75 lb ft
1-1/8" 960 +/- 110 lb ft
1-1/4" 1320 +/- 150 lb ft
1-3/8" 1780 +/- 220 lb ft
1-1/2" 2280 +/- 260 lb ft
Thread Size Standard Torque
M6 12 +/- 3 Nm
M8 28 +/- 7 Nm
M10 55 +/- 10 Nm
M12 100 +/- 20 Nm
M14 160 +/- 30 Nm
M16 240 +/- 40 Nm
M20 460 +/- 60 Nm
M24 800 +/- 100 Nm
M30 1600 +/- 200 Nm
M36 2700 +/- 300 Nm
Terex Construction Americas
8800 Rostin Road
Southaven, MS 38671
(888)-201-6008
(662)-393-1800
www.terex.com