Table of Contents
Summary of Contents for ASV RC-100
- Page 1 Service Manual RC-100 Rubber Track Loader Safety Overview Technical Specifications System Diagrams Disassembly and Assembly Instructions Troubleshooting Maintenance Hydraulic Pressure Check & Adjustment ASVSP003 (07/04) Part Number: 0201-669...
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Page 3: Table Of Contents
Table of Contents 1. Product Safety Light Bar Removal ..........5-1 Ignition Switch Removal and Installation ....5-2 Chapter Overview........... 1-1 Ignition Switch Removal........5-2 Safety Messages ............ 1-1 Ignition Switch Installation......... 5-3 Information Messages ..........1-1 Console Gauge/Warning Panel Removal and Basic Precautions........... - Page 4 Rubber Track Loader Table of Contents 9. Transmission and Drive Disassembly 13. Troubleshooting and Assembly Chapter Overview..........13-1 Personal Safety ............ 13-1 Chapter Overview........... 9-1 Machine Preparation ..........13-1 Personal Safety ............9-1 Preliminary Checkout ........... 13-1 Machine Preparation ..........9-1 Visual Inspection..........
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Page 5: Product Safety
Note: This label is used to provide important additional This chapter contains product safety information for information, comments, explanations or amplification of the RC-100 Rubber Track Loaders. Read this chap- the accompanying subject matter. ter and understand all safety messages and informa-... -
Page 6: Protective Equipment
Rubber Track Loader 1. Product Safety Protective Equipment Batteries Always wear a hard hat, protective glasses, protec- Do not smoke when inspecting the battery electro- tive shoes and other protective equipment as re- lyte level. Never disconnect any charging unit circuit quired by job conditions when working around this or battery circuit cable from the battery when the product. -
Page 7: Repair
Rubber Track Loader 1. Product Safety 9. Be careful when removing cover plates. Gradu- Repair ally back off the last two bolts or nuts located at ! WARNING ! opposite ends of the cover or device. Then, pry the cover loose to relieve any spring or other Accidental machine starting can cause injury or death pressure before removing the last two nuts or to personnel working on the machine. -
Page 8: Asbestos Information
Rubber Track Loader 1. Product Safety Ensure that all personnel are far enough away from the work area so they will not be struck by flying ob- ! WARNING ! jects. When replacement parts are required for this product, Stay clear of the cutting edges, pinching surfaces or use only genuine manufacturer’s replacement parts or crushing surfaces of the work tool while performing parts with equivalent specifications including, but not... -
Page 9: Machine Label And Decal Examples
Rubber Track Loader 1. Product Safety Machine Label and Decal Examples Examples of the labels and decals placed on the machine are shown on this page. -
Page 11: Technical Specifications
2. Technical Specifications Loader Valve RC-100 Specifications − Make: Husko − Type: Load Sense Engine − Model: Cat 3054CT (Turbo) Cooler − Displacement: 4.4 liter − Operating pressure: 150 psi (1034 kPa) − Gross horsepower: 99.5 hp (74 kW) − Bypass relief pressure: 80 psi (689 kPa) −... -
Page 13: System Diagrams
This chapter contains diagrams for the following RC- 100 systems: hydraulic charge system, auxiliary cir- cuit system, drive loop system, loader valve, sole- noid block, and electrical attachment outlet Figure 3-1 RC-100 Hydraulic Charge System 15 LB. RELIEF VALVE RETURN TO TANK... -
Page 14: Auxiliary Circuit System
Rubber Track Loader 3. System Diagrams Auxiliary Circuit System Figure 3-2 RC-100 Auxiliary Circuit System... -
Page 15: Drive Loop System
Rubber Track Loader 3. System Diagrams Drive Loop System Figure 3-3 RC-100 Drive Loop System... -
Page 16: Loader Valve
Rubber Track Loader 3. Systems Diagrams Loader Valve Figure 3-4 RC-100 Loader Valve... -
Page 17: Solenoid Block
Rubber Track Loader 3. Systems Diagrams Solenoid Block Figure 3-5 RC-100 Solenoid Block OPERATOR PRESENCE DRIVE FUNCTION POWER QUICK-ATTACH OPERATOR PRESENCE LOADER FUNCTIONS... -
Page 18: Electrical Attachment Outlet
Rubber Track Loader 3. Systems Diagrams Electrical Attachment Outlet Figure 3-6 RC-100 Electrical Attachment Outlet LEFT HAND CONTROLLER... -
Page 19: Machine Controls And Instrumentation
4. Machine Controls and Instrumentation Chapter Overview Drive Control The drive control (2) allows the operator to change This chapter contains an overview of the machine directions and speed using a simple, pilot-operated controls and instrumentation. It includes an illustra- joystick. -
Page 20: Gauge/Warning Light Panel
Rubber Track Loader 4. Machine Controls and Instrumentation Gauge/Warning Light Panel The gauge/warning light panel (Figure 4-4) includes the following indicator lights. (1) Engine coolant temperature warning (2) Glow plug operation (3) Engine oil pressure warning (4) Hydraulic oil temperature warning (5) Battery low-voltage warning (6) Fuel gauge (7) Service hour meter... -
Page 21: Dash & Lap Bar Disassembly
5. Dash & Lap Bar Disassembly and Assembly Operator Enclosure Chapter Overview Disassembly and Assembly This chapter provides disassembly and assembly Procedures procedures for the operator enclosure assembly. Disassembly and assembly procedures are provided for the following operator enclosure components. Personal Safety •... -
Page 22: Ignition Switch Removal And Installation
Rubber Track Loader 5. Operator Enclosure Disassembly and Assembly 1. Remove the two bolts that attach the light bar to the cab frame. It may be necessary to remove a side window if equipped with an enclosed cab. Two Speed Inicator Figure 5-4 4. -
Page 23: Ignition Switch Installation
Rubber Track Loader 5. Operator Enclosure Disassembly and Assembly Ignition Switch Installation Remove Nut Figure 5-6 Figure 5-9 2. Remove the nut that secures the ignition switch 1. Insert the ignition switch from the rear of the to the dash panel. dash panel. -
Page 24: Console Gauge/Warning Panel Removal And Installation
Rubber Track Loader 5. Operator Enclosure Disassembly and Assembly Console Gauge/Warning Panel Removal and Installation The tools required for console gauge/warning panel removal and installation are listed in Table 5-3. Use manufacturer-recommended tools whenever possi- ble. Table 5-3 Required Tools Combination wrench Figure 5-14 Console Gauge Removal... -
Page 25: Lap Bar Gas Assist Spring Removal And Installation
Rubber Track Loader 5. Operator Enclosure Disassembly and Assembly Plug in Connectors Remove Retaining Clip Figure 5-17 Figure 5-19 3. Plug in the console gauge connectors. 2. Using a small screwdriver, remove the retaining clip from each end of the gas assist spring. 4. - Page 26 Rubber Track Loader 5. Operator Enclosure Disassembly and Assembly Install Ends on Ball Joints Figure 5-22 2. Install the ends of the lap bar gas assist spring onto the ball joints. Insert Retaining Clip Figure 5-23 3. Slide the retaining clip on to each end of the gas assist spring.
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Page 27: Fuel Tank Disassembly And Assembly
6. Fuel Tank Disassembly and Assembly Chapter Overview Disassembly and Assembly Procedures This chapter provides disassembly and assembly procedures for the chassis assembly. Disassembly and assembly procedures are provided for the following chassis components. Personal Safety • Fuel Sending Unit ! WARNING ! •... -
Page 28: Fuel Tank Removal
Remove fuel/water separator Figure 6-4 Fuel Tank Removal The RC-100 has two fuel tanks that are connected by a cross over tube, the procedure is basically the Figure 6-2 same for each tank. 3. Remove the fuel sending unit. Be careful not to damage the float mechanism when pulling it 1. - Page 29 Rubber Track Loader 6. Chassis Disassembly and Assembly 4. Remove wire to fuel sending unit on right side Remove Exhaust tank. Pipe 5. Remove fuel tank mounting bolts, vent and return hoses on each tank, use floor jack to secure fuel tanks.
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Page 31: Radiator/Oil Cooler Disassembly
7. Radiator/Oil Cooler Disassembly and Assembly Chapter Overview Preliminary Checkout This chapter provides disassembly and assembly If troubleshooting is required prior to disassembly or procedures for the radiator/oil cooler assembly. assembly, refer to Chapter 13. Troubleshooting. Personal Safety Radiator/Oil Cooler ! WARNING ! Disassembly and Assembly Procedures... -
Page 32: Fan Guard Removal
Rubber Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Fan Guard Removal Figure 7-2 1. Remove the 4 bolts that secure the condenser to Figure 7-1 the fan shroud. 2. Lift straight up while moving the condenser from 1. Remove the bolts that secure the fan guard to side to side. -
Page 33: Fan Removal
Rubber Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Figure 7-4 Figure 7-6 Fan Removal The tools required for radiator/cooler removal and installations are listed below. Use manufacturer- recommended tools whenever possible. Required Tools Combination Wrench Socket Wrench Screwdriver Figure 7-7 Radiator/Cooler Removal ! WARNING ! Hot oil can cause personal injury. - Page 34 Rubber Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly Remove the filler cap slowly to relieve pressure only when the engine is stopped and the radiator cap is cool enough to touch with your bare hand. Do not attempt to tighten the hose connections when the coolant is hot.
- Page 35 Rubber Track Loader 7. Radiator/Oil Cooler Disassembly and Assembly 5. Remove rear engine skid plate from the ma- chine. This will give you access to the bottom radiator hose and bottom hydraulic hoses. Figure 7-14 8. Remove the three bolts on each side of the Ra- diator/Cooler, which fasten it to the frame.
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Page 37: Loader/Transmission Controls Disassembly
8. Loader/Transmission Controls Disassembly and Assembly Chapter Overview Loader/Transmission Controls Disassembly and Assembly This chapter provides disassembly and assembly procedures for the loader/transmission controls as- Procedures sembly. Disassembly and assembly procedures are provided for the following loader/transmission control compo- Personal Safety nents. - Page 38 Rubber Track Loader 8. Loader/Transmission Controls Disassembly and Assembly ! WARNING ! Lower all attachments and make sure the oil is cool before removing any components or lines. Hot oil can cause personal injury. 1. Lower the lift arms to the ground. 2.
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Page 39: Loader Float Magnet Removal And Installation
Rubber Track Loader 8. Loader/Transmission Controls Disassembly and Assembly 5. Make sure the hoses are labeled before remov- ing to aid in reinstalling. Remove the hoses and disconnect the wiring harness from the joystick 6. Unbolt the joystick from the joystick tower and remove. -
Page 40: Loader Float Magnet Installation
Rubber Track Loader 8. Loader/Transmission Controls Disassembly and Assembly Loader Float Magnet Installation Position Magnet Loader Float Magnet Figure 8-14 Figure 8-12 3. With the loader float magnet installed, the con- 1. Position the loader float magnet at the front of trol is ready to mount in the console. -
Page 41: Chapter Overview
9. Hydrostatic and Aux. Pump Disassembly and Assembly Chapter Overview Hydrostatic and Hydraulic Pump Disassembly and As- This chapter provides disassembly and assembly procedures for the hydrostatic and auxiliary pump. sembly Procedures Disassembly and assembly procedures are provided Personal Safety for the following transmission and drive components. - Page 42 Rubber Track Loader 9. Transmission and Drive Disassembly and Assembly 6. Remove the heel plate directly under the seat. NOTICE Collect and contain liquids in a suitable container. Dispose of all liquids according to local regulations and mandates. Note: During disassembly, cap all hoses and fittings to prevent fluid loss and contamination of the system fluids.
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Page 43: Auxiliary Pump Removal
Rubber Track Loader 9. Transmission and Drive Disassembly and Assembly 8. Remove hoses attached to charge pump. Auxiliary Pump Removal 1. Remove all hoses from auxiliary pump. Remove split flange Figure 9-6 Figure 9-8 9. Remove the split flange in order for the charge pump clear. -
Page 44: Tandem Pump Removal
Rubber Track Loader 9. Transmission and Drive Disassembly and Assembly Remove Bolt Figure 9-10 Figure 9-11 3. Secure pump by chain or floor jack to prevent it Tandem Pump Removal from falling once mounting bolts are removed. The tools required for tandem pump removal and installation are listed in Table 0-2. -
Page 45: Tandem Pump Installation
Rubber Track Loader 9. Transmission and Drive Disassembly and Assembly 2. Install the hoses and tubes on the tandem pump. Pump shaft Hydraulic Reservoir Clean-out If there has been a pump failure it is necessary to clean out the hydraulic reservoir, as well has hoses, tubes and hydraulic lines. -
Page 47: Undercarriage Disassembly And Assembly
10. Undercarriage Disassembly and Assembly Chapter Overview Preliminary Checkout This chapter provides disassembly and assembly If troubleshooting is required prior to disassembly or procedures for the undercarriage assemblies. assembly, refer to Chapter 13. Troubleshooting. Personal Safety Undercarriage Disassembly ! WARNING ! and Assembly Procedures Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in... - Page 48 Rubber Track Loader 10. Undercarriage Disassembly and Assembly Figure 10-4 2. Remove tensioning turnbuckle by removing front Figure 10-1 and rear nuts and bolts, fig. 10-4. 1. Remove the 2 bolts that fasten the drive 3. Using a chain and chain binder, pull the drive sprocket table to the frame rail, fig.
- Page 49 Rubber Track Loader 10. Undercarriage Disassembly and Assembly ! WARNING ! To remove the tracks, the machine must be jacked up and placed on jack stands sturdy enough to support the weight of the machine. The manufacturer-approved jack stands are recommended. Long bolt Pivot Bracket Figure 10-7...
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Page 50: Track Installation
Rubber Track Loader 10. Undercarriage Disassembly and Assembly 3. After the track is off of the 14" wheels, the rest of the track will easily come off of the undercarriage. 3. Install the track tool pivot base as shown in Figure 10-14 using the longer capscrews supplied with the pivot base. -
Page 51: Sprocket Removal
Rubber Track Loader 10. Undercarriage Disassembly and Assembly 2. The steel pin that the roller pivots on is hardened steel, and may not need to be replaced at the same time as the roller. Sprocket Removal and Installation The tools required for sprocket removal and installation are listed in Table 0-1. - Page 52 Rubber Track Loader 10. Undercarriage Disassembly and Assembly Figure 10-22 Figure 10-19 2. Pry the bearing plate off. Figure 10-23 4. Using a puller, remove the bearing and bearing housing from the shaft. Figure 10-20 Figure 10-21 Figure 10-24 3. Remove the soft plug from the end of bearing 5.
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Page 53: Drive Motor Removal
Rubber Track Loader 10. Undercarriage Disassembly and Assembly Figure 10-25 Figure 10-28 Figure 10-26 Figure 10-29 Drive Motor Removal 1. Drain the hydraulic fluid, see chapter 11. Remove the bolts which fasten the drive motor to the drive table. Figure 10-30 Figure 10-27 2. - Page 54 Rubber Track Loader 10. Undercarriage Disassembly and Assembly Figure 10-33 Figure 10-31 3. Pull the drive motor free from the drive table housing. 3. Unbolt the wheels from the tube and replace,the center wheel is split for easy removal and installation Wheel Replacement 1.
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Page 55: 14" Wheel Keeper Plates
Rubber Track Loader 10. Undercarriage Disassembly and Assembly 14" Wheel Keeper Plates The 14" Wheels on each end can be spaced out 1/4" each for a total of 1/2". This can be done if the track has stretched to the point where the standard adjustment holes are not enough. -
Page 57: 11. Maintenance
• Grease fittings • Track tension Item Frequency Lubricant Capacity Hydraulic Fluid 500 hrs ASV Posi-Lube 20 gal/75.7 l • Engine oil • Air cleaner Hydraulic Oil, • Hydraulic fluid and filter or Rykon MV • Fuel separator and filter... -
Page 58: Oil Change Procedures
Hydraulic Fluid Drain Plug Engine Oil Specifications Due to the significant variations in the quality and performance of commercially available oils, ASV Heavy-Duty Diesel Engine Oil – 10W30 is recom- mended. If Posi-Lube is not available, use of the following: •... -
Page 59: Fuel Filter
Rubber Track Loader 11. Maintenance Fuel-Water Separator Hydraulic Filters Figure 11-2 2. Clean the area around the hydraulic filters. Figure 11-5 1. Twist the drain counter-clockwise to drain water from the bowl. Drain Case Drain Filter, change only if an attachment with a case drain has a drive motor failure. -
Page 60: Fuel Filter Change Procedures
Rubber Track Loader 11. Maintenance Fuel Filter Change Procedures Air Cleaner The air cleaner is one of the most important mainte- nance items on the machine. A poorly maintained air cleaner can seriously shorten the life of the engine. Air Filter Change Procedures NOTICE When working in dusty conditions, the air cleaner ele- ments should be checked and changed more frequently... -
Page 61: Track Tension
Rubber Track Loader 11. Maintenance Safety Element Tension adjustment turnbuckle Figure 11-10 3. Remove the safety element. This element is not Figure 11-12 serviceable or washable. It should be replaced with every three cleanings of the primary ele- 3. Retighten or replace the two bolts on the drive ment. -
Page 62: Checking For Proper Track Adjustment
Rubber Track Loader 11. Maintenance Checking for Proper Track Adjustment 1. Drive the machine forward five feet. 2. Lay a straightedge along the top of the track be- tween the sprocket and the front idler wheel. 3. Using a rope or wire, put 90 pounds of down force on the track at the midpoint of the straight- edge. -
Page 63: Hydraulic Pressure Check & Adjustment
12. Hydraulic Pressure Check & Adjustment Chapter Overview Hydraulic Pressure This chapter provides an overview of checking and Adjustment Procedures setting pressures. It is important to contact the manufacturer for assistance before beginning these Adjustment and test procedures are provided for the procedures. - Page 64 Rubber Track Loader 12. Hydraulic Pressure Check & Adjustment Table 12-2 Required Tools Pressure Gauge Attach Gauge Figure 12-2 1. Attach the gauge to the charge pressure test port, located next to the hydraulic filters. 2. Start the engine. Figure 12-4 1.
- Page 65 13. Troubleshooting Chapter Overview Preliminary Checkout This chapter contains basic troubleshooting proce- A simple visual inspection and operational check dures for the Rubber Track Loader. can identify many problems without the need for ex- tensive troubleshooting. If these checks indicate a Additional troubleshooting aids are provided in problem that requires further analysis, proceed to Chapter 3.
- Page 66 Rubber Track Loader 13. Troubleshooting Faulty safety solenoid or safety solenoid spool. Troubleshooting Poor wire connections on fuse, relay, or safety sole- This section identifies selected problems and sug- noid. gests probable causes. Low charge pressure. Problem 4 Lift arms operate but tracks will not move. Problem 1 Probable cause Machine will not crank over.
- Page 67 Rubber Track Loader 13. Troubleshooting Problem 8 Problem 12 Battery will not charge and/or battery goes dead. Hot coolant light illuminates; engine operating hot. Probable cause Probable cause Alternator fuse blown. 1. Low coolant level. Alternator diode bad. 2. Debris plugging radiator, limiting airflow. Alternator resistor behind fuse panel bad.
- Page 68 Terex Construction Americas 8800 Rostin Road Southaven, MS 38671 (888)-201-6008 (662)-393-1800 www.terex.com...
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Fuel filter location