Terex ASV SR70 Service & Repair Manual
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Terex ASV SR70 Service & Repair Manual

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8/17/2016
Language:
English
Geographic Region:
All
Serial Number Range:
SN All
SR70
Service Repair Manual
This manual is complements of
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The world's best source for ASV parts.
Track Loader Parts
6543 Chupp Road
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Atlanta, Georgia 30058
USA
(800)616-8156

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Summary of Contents for Terex ASV SR70

  • Page 1 8/17/2016 Language: English Geographic Region: Serial Number Range: SN All SR70 Service Repair Manual This manual is complements of TrackLoaderParts.com The world's best source for ASV parts. Track Loader Parts 6543 Chupp Road https://tractormanualz.com/ Atlanta, Georgia 30058 (800)616-8156...

  • Page 2: Table Of Contents

    Table of Contents 1. Product Safety 3. Circuit Diagrams Chapter Overview ..... 1-1 Chapter Overview ..... 3-1 Safety Messages .
  • Page 3 Rubber Track Loader Table of Contents 6. Operator Enclosure Removal Procedure ....8-1 Chapter Overview ..... 6-1 Installation Procedure .
  • Page 4 Rubber Track Loader Table of Contents 12. Engine 16. Hydraulic Component Service Chapter Overview ..... 12-1 Chapter Overview ..... 16-1 Personal Safety .
  • Page 5 https://tractormanualz.com/...

  • Page 6: Product Safety

    1. Product Safety Note: This label is used to provide important additional infor- Chapter Overview mation, further explanation, comments or to stress the impor- This chapter contains product safety information for the tance of a topic. SR-70/80 Rubber Track Loaders. Read and under- stand all product safety information before attempting The person(s) in charge of servicing a Rubber Track to service any Rubber Track Loader.

  • Page 7: Protective Equipment

    Rubber Track Loader 1. Product Safety Protective Equipment Batteries Always wear appropriate protective equipment for Do not smoke when inspecting the battery electrolyte working conditions when working on or around a level. Never disconnect any charging unit circuit or bat- Rubber Track Loader.

  • Page 8: Repair

    Rubber Track Loader 1. Product Safety Repair cause bodily injury, death or property damage. Be prepared to shut off the fuel and air supply to the !WARNING! engine in order to stop the engine. Accidental machine starting can cause injury or even 9.

  • Page 9: Asbestos Information

    Rubber Track Loader 1. Product Safety Wear protective glasses and protective equipment as 6. Stay away from areas that might have asbestos required by conditions or as recommended in the work particles in the air. tool’s operation manual. Ensure that all personnel are far enough away from !WARNING! the work area so they will not be struck by flying ob- When replacement parts are required for your machine,...

  • Page 10: Machine Label And Decal Examples

    Rubber Track Loader 1. Product Safety Machine Label and Decal Examples WARNING 2-Speed Examples of the labels and decals displayed on the (if equipped) machine are shown on this page. Entering & Exiting To engage: Maintain 3-point contact Press the button located with step and hand rails.
  • Page 11 https://tractormanualz.com/...

  • Page 12: Technical Specifications

    2. Technical Specifications & Service Tools SR-80 Specifications Oil Cooler Operating pressure: 150 psi (1034 kPa) Engine Bypass relief pressure: 80 psi (689 kPa) Hot oil sending unit: 225°F (107.2°C) Model: Perkins 804C-33T Avg. oil operating temp. 50-60°F above ambient. Displacement: 3.3 liter (High flow application 80°F above ambient.) Gross horsepower: 80.5 hp (60 kW)

  • Page 13: Specifications (Sr-70)

    Rubber Track Loader 2. Technical Specifications & Service Tools SR-70 Specifications Oil Cooler Operating pressure: 150 psi (1034 kPa) Engine Bypass relief pressure: 80 psi (689 kPa) Hot oil sending unit: 225°F (107.2°C) Model: Perkins 804C-33T Avg. oil operating temp. 50-60°F above ambient. Displacement: 3.3 liter (High flow application 80°F above ambient.) Gross horsepower: 71 hp (53 kW)

  • Page 14: Circuit Diagrams

    3. Circuit Diagrams Chapter Overview Hydraulic Charge Circuit 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.

  • Page 15: Hydraulic Auxiliary Circuit

    Rubber Track Loader 3. Circuit Diagrams Hydraulic Auxiliary Circuit Figure 3-2 SR-70/80 Hydraulic Auxiliary Circuit OIL COOLER TO ATTACHMENT CASE DRAIN Q/C CHECK VALVE TO TANK (80 PSI) TO BUCKET CYL. FLOW TO TANK LOADER CONTROL TO LIFT ARM CYL. TO AUXILIARY Q/C TO LIFT ARM CYL.

  • Page 16: Hydraulic Drive Circuit

    Rubber Track Loader 3. Circuit Diagrams Hydraulic Drive Circuit Figure 3-3 SR-70/80 Hydraulic Drive Circuit DRIVE PRESSURE RELIEF VALVES (4) 5500 PSI DRIVE CONTROL DRIVE PUMP DRIVE MOTOR DRIVE MOTOR CASE DRAIN TO COOLER TANK BRAKE 2-SPEED SHIFT (SR-80) https://tractormanualz.com/...

  • Page 17: Lift Arm Control Valve

    Rubber Track Loader 3. Circuit Diagrams Lift Arm Control Valve Figure 3-4 SR-70/80 Lift Arm Control Valve ELIEF ALVE ETTINGS (B3) 3307 PSI (A3) 3307 PSI (B2) 3147 PSI (A2) 3669 PSI (A1) Anti-Cavitation (B1) 3640 PSI Check Valve https://tractormanualz.com/...

  • Page 18: Hydraulic Pilot Generation Solenoid Block

    Rubber Track Loader 3. Circuit Diagrams Hydraulic Pilot Generation Block Figure 3-5 SR-70/80 Hyd. Pilot Generation Block https://tractormanualz.com/...

  • Page 19: Electrical Attachment Outlet

    Rubber Track Loader 3. Circuit Diagrams Electrical Attachment Outlet Figure 3-6 SR-70/80 Electrical Attachment Outlet https://tractormanualz.com/...

  • Page 20: Drive Control (Line Routing)

    Rubber Track Loader 3. Circuit Diagrams Drive Control (line routing) Figure 3-7 SR-70/80 Standard Drive Control https://tractormanualz.com/...

  • Page 21: Lift Arm Control (Line Routing)

    Rubber Track Loader 3. Circuit Diagrams Lift Arm Control (line routing) Figure 3-8 SR-70/80 Lift Arm Control https://tractormanualz.com/...

  • Page 22: Maintenance

    4. Maintenance Chapter Overview Lift Arm Brace This chapter provides information on general mainte- The lift arm brace (A) is intended to keep service per- nance procedures for the SR-70/80. If there is an issue sonnel safe when it is necessary to work on a machine that requires troubleshooting, refer to Chapter 18, with the lift arms in the raised position.

  • Page 23: Tilt-Up Cab

    Rubber Track Loader 4. Maintenance 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.

  • Page 24: Grease Fittings

    Rubber Track Loader 4. Maintenance Grease Fitting Locations 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.

  • Page 25: Track Tension

    Rubber Track Loader 4. Maintenance Track Tension (SR-70/80) Straight-Edge 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.

  • Page 26: Drive Sprocket Rollers

    Rubber Track Loader 4. Maintenance SR-70 SR-80 Steel Pin (.088”) New Roller Normal Wear 4-10 35% life Drive Sprocket Rollers Note: You may need to pry or lift the track upwards with a hoist above the drive sprocket to provide clear- ASV rubber track loaders utilize rollers on the drive ance for removal.

  • Page 27: Track Removal

    Rubber Track Loader 4. Maintenance 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: Cavity •...
  • Page 28 Rubber Track Loader 4. Maintenance 4-19 4-16 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.

  • Page 29: Track Installation

    Rubber Track Loader 4. Maintenance 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.
  • Page 30 Rubber Track Loader 4. Maintenance 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.

  • Page 31: Air Cleaner

    Rubber Track Loader 4. Maintenance 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.

  • Page 32: Fuel Filter

    Rubber Track Loader 4. Maintenance 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.

  • Page 33: Accessory Belt Tension

    Rubber Track Loader 4. Maintenance 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.

  • Page 34: Fan Belt Removal/Installation

    Rubber Track Loader 4. Maintenance Fan Belt Removal & Installation Pry-bar 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. Bolt 3.

  • Page 35: Engine Oil/Filter Change

    Rubber Track Loader 4. Maintenance 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.

  • Page 36: Engine Oil Specifications

    Rubber Track Loader 4. Maintenance 4-51 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. Full 12.

  • Page 37: Hydraulic Fluid/Filter Change

    Rubber Track Loader 4. Maintenance 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.

  • Page 38: Radiator/Oil Cooler (Cleaning)

    Rubber Track Loader 4. Maintenance 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.

  • Page 39: Case Drain Filter

    Rubber Track Loader 4. Maintenance 4-62 4-63 Case Drain Filter Fuse Panel The SR machines are also equipped with a filter in the The electrical systems in the SR machines are auxiliary circuit case drain line. It protects the main equipped with fuses that protect the electrical compo- hydraulic system in the event of catastrophic failure in nents from damage.
  • Page 40 Rubber Track Loader 4. Maintenance Maintenance Service Service Interval Notes Item required Capacity Grease fittings Lubricate Daily Grease often. Adjust levels as Fluid levels Check Daily necessary. Fan-A/C belt Adjust tension as Check Daily tension necessary. Fan-A/C belt Replace as a pair if Inspect Daily condition...
  • Page 41 4-20 https://tractormanualz.com/...

  • Page 42: Machine Controls And Instrumentation

    5. Machine Controls and Instrumentation Chapter Overview Instrumentation This chapter contains an overview of the machine con- The Instruments (Figure 5-2) are positioned in the lap trols and instrumentation. For further information bar for good visibility and when seated inside the oper- regarding machine controls, instrumentation or opera- ator enclosure.

  • Page 43: Switches

    Rubber Track Loader 5. Machine Controls and Instrumentation 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)

  • Page 44: Operator Enclosure

    6. Operator Enclosure Chapter Overview Removal and Installation This chapter provides information on the assembly and Removal and installation procedures are provided for disassembly of the operator enclosure assembly. If the following operator enclosure components. there is an issue that requires troubleshooting, refer to •...

  • Page 45: Removal Procedure

    Rubber Track Loader 6. Operator Enclosure Pillar Switch Panels Removal (RT or LT panel) Required Tools Open or Box end Wrenches 1. Remove the 3 screws/bolts securing the pillar switch panel to the cab enclosure. (fig. 6-3) 4. Pivot the panel further backward to expose the connectors on the lower switches and disconnect them.

  • Page 46: Removal Procedure

    Rubber Track Loader 6. Operator Enclosure Gauge Clusters Removal Required Tools Phillips Type Screwdriver Combination/Socket Wrench 6-12 3. If gauges must be removed, remove the nuts securing the backing plate to the gauge. (fig. 6-12) 6-13 6-10 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.

  • Page 47: Seat

    Rubber Track Loader 6. Operator Enclosure Seat Removal Required Tools Combination/Socket Wrench 6-18 5. Disconnect the harness and then remove the seat from the machine. (fig. 6-18) 6-15 Seat Installation 1. Remove the bolts (2) securing the cab to the chas- 1.

  • Page 48: Removal Procedure

    Rubber Track Loader 6. Operator Enclosure 6-23 2. Remove the mounting screws (6) and washers 6-21 securing the panel to the chassis. (fig. 6-23) 3. Remove the panel by lifting and twisting it over the joystick and clear of the lap bar. (fig. 6-21) Installation 1.

  • Page 49: Removal Procedure

    Rubber Track Loader 6. Operator Enclosure Rear Interior Panel Lap Bar Gas Spring Removal Removal Required Tools Required Tools Phillips Type Screwdriver Phillips & Blade Type Screwdrivers 1. Remove the right, left and rear interior panels from the cab to access the gas spring. 6-26 1.

  • Page 50: Chassis And Fuel Tank

    7. Chassis and Fuel Tank Chapter Overview Removal and Installation This chapter provides information on the assembly and Removal and installation procedures are provided for disassembly of the chassis. If there is an issue that the following chassis components. requires troubleshooting, refer to Chapter 18, •...

  • Page 51: Fuel Tank

    Rubber Track Loader 7. Chassis and Fuel Tank Fuel Tank Removal Remove Screws Required Tools Screwdriver Combination/Socket Wrench 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.
  • Page 52 Rubber Track Loader 7. Chassis and Fuel Tank 7-11 6. Loosen the hose clamp securing the main fuel line 9. Remove the bolts (3) securing the fuel tank to the to the tank outlet in the front right corner of the front mounting plate.

  • Page 53: Footwell

    Rubber Track Loader 7. Chassis & Fuel Tank Footwell Bolts Removal Required Tools Screwdriver Combination/Socket Wrench 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 7-16 described on page 4-2 of this manual.

  • Page 54: Removal Procedure

    Rubber Track Loader 7. Chassis & Fuel Tank Foot Throttle Assembly Hood Assembly Removal Removal Required Tools Required Tools Screwdriver Screwdriver Combination/Socket Wrench Combination/Socket Wrench Note: The foot throttle assembly may be removed with the footwell still installed in the machine. 1.

  • Page 55: Installation Procedure

    Rubber Track Loader 7. Chassis & Fuel Tank 7-23 3. Have an assistant help you to remove the hood assembly from the machine. (fig. 7-23) 7-24 4. Carefully set the hood assembly aside. (fig. 7-24) Installation 1. To install the hood assembly, reverse the removal procedure.

  • Page 56: Radiator And Oil Cooler

    8. Radiator and Oil Cooler Chapter Overview Removal and Installation This chapter provides information on the disassembly Removal and installation procedures are provided for and assembly of the radiator/oil cooler and associated the following radiator/oil cooler components. components. If there is an issue that requires trou- bleshooting, refer to chapter 18, Troubleshooting.

  • Page 57: Removal Procedure

    Rubber Track Loader 8. Radiator and Oil Cooler Fan & Fan Shroud Removal Required Tools Combination Wrench Socket Wrench 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.

  • Page 58: Removal Procedure

    Rubber Track Loader 8. Radiator and Oil Cooler Radiator/Oil Cooler Removal !WARNING! 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. !WARNING! Cooling system conditioner contains alkali.
  • Page 59 Rubber Track Loader 8. Radiator and Oil Cooler 8-16 8-13 4. Remove the bolts (6) securing the outer shroud to the chassis, then remove the shroud. (fig. 8-13) 8-17 7. Loosen the clamps securing the upper and lower coolant hoses to the radiator, then disconnect the 8-14 hoses from the radiator.

  • Page 60: Hydraulic Reservoir

    9. Hydraulic Reservoir Chapter Overview Removal and Installation This chapter provides removal and installation proce- Removal and installation procedures are provided for dures for the hydraulic reservoir. the following hydraulic components. Personal Safety • Hydraulic Reservoir (tank) • Suction Screen !WARNING! Note: Procedures are provided for only those hydraulic com- Improper or incomplete maintenance/repair of a Rubber...
  • Page 61 Rubber Track Loader 9. Hydraulic Reservoir 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.
  • Page 62 Rubber Track Loader 9. Hydraulic Reservoir 9-10 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) 9-11 10. Disconnect the bucket cylinder hoses from the 12.
  • Page 63 Rubber Track Loader 9. Hydraulic Reservoir 9-13 9-16 14. Disconnect the main oil cooler line from the fitting 16. Remove the clamps securing the auxiliary at the filter. (fig. 9-13) hydraulic lines to the chassis. (fig. 9-16) Disconnect 9-17 9-14 9-18 9-15 17.
  • Page 64 Rubber Track Loader 9. Hydraulic Reservoir 9-19 9-22 fuel lines 20. Remove the auxiliary hydraulic tubes from the machine. 9-20 18. Slide the two fuel lines through the chassis open- ing and into the engine compartment so that the 9-23 aux.
  • Page 65 Rubber Track Loader 9. Hydraulic Reservoir 9-25 9-28 23. Remove the lower hose restraints to allow the 26. Remove the bolts securing the metal tank restraint hoses to be pulled through the chassis. (fig. 9-25) straps, them remove them from the machine. (fig.

  • Page 66: Removal Procedure

    Rubber Track Loader 9. Hydraulic Reservoir 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. Reservoir Pry-bar 9-31 9-34 30. Use a long pry bar to pry the tank upward and 31.

  • Page 67: Installation Procedure

    Rubber Track Loader 9. Hydraulic Reservoir Suction Screen Removal Suction screen Required Tools Small Pry Bar (hose removal if necessary) Socket Wrench & Extension Combination Wrenches (to remove lines) 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.

  • Page 68: 10. Lift-Arm/Drive Controls

    10. Lift-Arm/Drive Controls Chapter Overview Removal and Installation This chapter provides removal and installation proce- Removal and installation procedures are provided for dures for the lift-arm and drive control components. the following lift-arm/drive control components. Personal Safety • Pilot Control Joystick •...

  • Page 69: Joystick

    Rubber Track Loader 10. Lift-Arm/Drive Controls 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. Remove (optional) 3.

  • Page 70: Lift Arm Float Magnet

    Rubber Track Loader 10. Lift-Arm/Drive Controls Lift Arm Float Magnet Removal Required Tools Fittings Socket Wrench Combination/Open End Wrench Allen Wrench 1. Perform steps 3, 4 and 11 of the lift arm joystick control removal process. 10-7 10. Remove the fittings on the back of the joystick (lift arm control joystick only).

  • Page 71: Lift Arm Control Valve

    Rubber Track Loader 10. Lift-Arm/Drive Controls Lift Arm Control Valve Removal Required Tools Socket Wrench Combination/Open End Wrench Screwdriver (hose clamps) 1. Perform the footwell removal procedure on page 7- 4 of this manual. 10-15 2. Drain the hydraulic system as described on page 4-15 of this manual.

  • Page 72: 11. Hydraulic Pumps/Motors

    11. Hydraulic Pumps/Motors Chapter Overview Removal and Installation This chapter provides removal and installation proce- Removal and installation procedures are provided for dures for the hydraulic pumps and motors. the following hydraulic components. • Charge Pump Personal Safety • Auxiliary Pump •...
  • Page 73 Rubber Track Loader 11. Hydraulic Pumps/Motors 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.

  • Page 74: Auxiliary Pump

    Rubber Track Loader 11. Hydraulic Pumps/Motors Auxiliary Pump Removal Required Tools Combination Wrench Socket Wrench & Extension Pry bar Allen socket 11-6 4. Loosen the clamp securing the hose onto the barbed fitting on the right side of the pump, then disconnect it.

  • Page 75: Tandem Drive Pump

    Rubber Track Loader 11. Hydraulic Pumps/Motors Tandem (Drive) Pump Removal Required Tools Screwdriver Combination/Open End Wrenches !WARNING! Personal injury can result from exposure to hot fluids and components. Allow the machine to cool thoroughly 11-9 before attempting any type of service on the cooling or hydraulic systems.
  • Page 76 Rubber Track Loader 11. Hydraulic Pumps/Motors Top & Bottom Drive Pump Hoses Oil Cooler (return) Drive Motor (RT) From Charge Filter FRONT Drive Motor (LT) RIGHT LEFT • View is from the top. REAR 11-13 11-16 • The pump is to be perceived as transparent. •...

  • Page 77: Drive Motor

    Rubber Track Loader 11. Hydraulic Pumps/Motors Drive Motor Removal Required Tools Combination/Socket Wrench Impact Wrench 3-Jaw Puller Snap Ring Pliers Hammer/Mallet 1. Remove the track from the undercarriage by per- forming the track removal procedure on page 4-6 11-21 of this manual. 4.
  • Page 78 Rubber Track Loader 11. Hydraulic Pumps/Motors 11-27 11-24 7. Remove the snap ring securing the bearing 10. Remove the sprocket assembly from the undercar- riage. (fig. 11-27) assembly to the outer sprocket shaft. (fig. 11-24) 11-28 11-25 11. Remove the bolts securing the drive motor to the 8.
  • Page 79 Rubber Track Loader 11. Hydraulic Pumps/Motors 11-30 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) 11-31 14. Disconnect the hoses from the drive motor making sure to cap and plug all openings to avoid contam- ination.

  • Page 80: 12. Engine

    12. Engine Chapter Overview Removal and Installation This chapter provides procedures for the removal and Removal and installation procedures are provided for installation of the engine and associated components. the following engine related components. • Battery Personal Safety • Exhaust !WARNING! •...

  • Page 81: Exhaust System

    Rubber Track Loader 12. Engine Exhaust System Removal Required Tools Pry Bar(s) Combination/Socket Wrench Rubber Mallot Penetrating Lubricant 12-3 !WARNING! The exhaust system is very hot at operating tem- 4. Remove the two tension (L) rods by twisting and perature. Make sure the machine is off and cool maneuvering them out of the chassis mounting before attempting to service the exhaust system.
  • Page 82 Rubber Track Loader 12. Engine Spring 12-8 12-11 4. Remove the tension springs that secure the middle 7. Remove the inlet pipe from the muffler. It may be pipe section to the head (upper) pipe and muffler necessary to use levers to force the inlet pipe sec- inlet (lower) pipe.

  • Page 83: Air Cleaner

    Rubber Track Loader 12. Engine Air Cleaner Removal Required Tools Combination Wrenches Socket Wrench & Extension 12-14 10. You may now remove the tail pipes by sliding them forward within the chassis, then out. (fig, 12-14). Installation 12-15 1. To install the exhaust system, reverse the removal procedure.

  • Page 84: Removal Procedure

    Rubber Track Loader 12. Engine Engine Removal Required Tools Combination/Socket Wrenches Angle Iron or Similar (approx. 43” long) Tie Down or Ratchet Strap Forklift/Engine Hoist Pry Bar 12-18 1. Perform the battery, air cleaner, and charge pump, removal procedures in sections 11 and 12 of this 4.
  • Page 85 Rubber Track Loader 12. Engine Ballstud Bolts Cable Engine 12-21 12-24 8. Disconnect the throttle cable from the engine. 11. Disconnect the case drain filter and bracket from the engine adapter plate and lay it aside. It is situ- Note: Once loose, you may want to pull the throttle ated beneath the drive pump.
  • Page 86 Rubber Track Loader 12. Engine 12-27 12-31 14. Lay the angle iron across the fenders (or fuel tank Note: The rear cab window is directly over the lift point if still in place) and attach one or two tie down of the engine.
  • Page 87 12-8 https://tractormanualz.com/...

  • Page 88: 13. Undercarriage

    13. Undercarriage Chapter Overview Removal and Installation This chapter provides removal and installation proce- Removal and installation procedures are provided for dures for the undercarriages. the following undercarriage components. • Idler Wheels (Removal and installation) Note: For track removal and installation procedures, refer to •...
  • Page 89 Rubber Track Loader 13. Undercarriage 3. Clean the threads on the turnbuckle thoroughly using a stiff bristle brush. 13-2 13-6 7. Remove the outer scraper plate from the suspen- sion rail. (fig. 13-6) 13-3 13-7 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.

  • Page 90: Removal Procedure

    Rubber Track Loader 13. Undercarriage 10” & 15” Wheels 4. Repeat as necessary to remove the idler and (SR-70) bogie wheels throughout the undercarriages. Note: The 15” idler and 10” bogie wheels may be Installation removed from the SR-70 and SR-80 undercarriages 1.
  • Page 91 Rubber Track Loader 13. Undercarriage Note: Figure 13-36 incudes an exploded parts diagram of the SR-80 undercarriage for your reference. 13-16 4. The inner and or outer bogie wheels may now be 13-13 removed with an impact wrench and allen socket as shown in fig.
  • Page 92 Rubber Track Loader 13. Undercarriage Sealing Surfaces Face Seal Halves 13-18 Rubber Seals 13-21 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.
  • Page 93 Rubber Track Loader 13. Undercarriage 10. Disassemble and clean the face seals and their rubber outer seals thoroughly, then wipe them dry to ensure a good seal when assembled. 13-27A 13-27B 13-24 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 11.
  • Page 94 Rubber Track Loader 13. Undercarriage 13-30 13-34 17. Apply red (high strength) thread locking compound to the wheel retaining bolt as shown. (fig. 13-30) 21. Remove the allen plug from the center of the hub assembly and fill it with 2 ounces of ASV Posi Lube 10W-30 Heavy Duty Engine Oil.

  • Page 95: Idler Hub

    Rubber Track Loader 13. Undercarriage 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.
  • Page 96 Rubber Track Loader 13. Undercarriage Part #: 0403-337 Rear race Part #: 0403-333 13-40 13-43 SR-70 use tool #: 0403-371 5. Remove the bearing out of the front of the hub as 7. If bearings are to be replaced, press the rear bear- shown.
  • Page 97 Rubber Track Loader 13. Undercarriage 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.
  • Page 98 Rubber Track Loader 13. Undercarriage Part #: 0403-335 13-52 13-55 SR-70 use tool #: 0403-374 16. Once the seals are in place, wipe the mating sur- 19. Flip the hub over, support the bearing sleeve from faces of the face seals with a clean shop cloth and the bottom with tool 0403-335 and set it onto the alcohol in a circular motion ending in a gentle press for center seal installation.
  • Page 99 Rubber Track Loader 13. Undercarriage Part #: 0403-330 13-58 13-61 SR-70 use tool #: 0403-373 22. Press the outer bearing race into the hub with tool 26. Remove the allen plug in the center portion of the # 0403-330 until it seats. (fig. 13-58) hub.

  • Page 100: 14. Lift-Arm Components

    14. Lift-Arm Components Chapter Overview Removal and Installation This chapter provides removal and installation proce- Removal and installation procedures are provided for dures for the lift-arm components. the following lift-arm components. Personal Safety • Lift Cylinder • Bucket/Tilt Cylinder !WARNING! •...
  • Page 101 Rubber Track Loader 14. Lift-Arm Components 14-4 14-1 4. Remove the bolts securing the front and rear lift arm cylinder pivot pins to the lift arm and lift arm 1. Rest the lift arms on an ASV approved jack stand tower.

  • Page 102: Bucket/Tilt Cylinder

    Rubber Track Loader 14. Lift-Arm Components Bucket/Tilt Cylinder Removal Required Tools Socket Wrench Combination/Open End Wrench Hammer Punch (brass) 14-7 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 14-8 easily accessible for replacement.
  • Page 103 Rubber Track Loader 14. Lift-Arm Components 14-10 14-13 4. Remove the bolt securing the lower pin to the 7. Use a pry bar to slide the lower pin out of the cylin- der end allowing it to be removed. (fig. 14-13) quick attach.
  • Page 104 Rubber Track Loader 14. Lift-Arm Components Quick Coupler Block PRV Removal Required Tools Combination Wrench 14-16 10. Remove the pin from the cylinder while supporting the cylinder. (fig. 14-16) 14-18 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.
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  • Page 106: 15. Quick Attach

    15. Quick Attach Chapter Overview Removal and Installation This chapter provides removal and installation proce- Removal and installation procedures are provided for dures for the quick attach and associated components. the following quick attach components. Personal Safety • Quick Attach locking Pin Assemblies •...
  • Page 107 Rubber Track Loader 15. Quick Attach Upper guard 15-5 15-2 5. Remove the pivot link from the quick attach. (fig. 15-5) 2. Remove the bolts (3) securing the upper guard to the quick attach weldment. (fig. 15-2) Upper guard 15-6 6.

  • Page 108: Removal Procedure

    Rubber Track Loader 15. Quick Attach Pivot Pin (quick attach) Removal Required Tools Combination/Open End/Socket Wrenches ASV Approved Jack Stand (or equivalent) Hammer Punch (brass) 15-8 1. Rest the lift arms on an ASV approved jack stand to provide clearance for quick attach disassembly. (fig.
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  • Page 110: Hydraulic Component Service

    NOTICE 16. Hydraulic Component Disassembly of hydraulic components should only be performed by factory trained personnel experienced in the disassembly Service Procedures 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 manufacturer’s warranty.
  • Page 111 Rubber Track Loader 16. Hydraulic Component Service Cylinder Tube Weldment 16-2 16-5 4. Use an open end or pipe wrench to turn and 7. With the piston and rod removed from the cylinder, remove the end gland. (figure 16-2) inspect the cylinder bore for scratches or other damage.
  • Page 112 Rubber Track Loader 16. Hydraulic Component Service 16-8 16-11 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) 16-9 16-12 11. Remove the seals and piston ring taking care not to scratch the piston.
  • Page 113 Rubber Track Loader 16. Hydraulic Component Service Lift Arm Control Valve 4. Remove each valve section and inspect the seals for damage, replace if necessary. (figure 16-15) Disassembly Required Tools O-ring Socket Wrench Combination Wrench Screwdriver (blade type) Low Profile Needle Nose Pliers 1.
  • Page 114 Rubber Track Loader 16. Hydraulic Component Service 16-22 16-19 8. Remove the spring from the spool. (fig. 16-22) Note: Figure 16-19 displays the assembly order of the spool and associated components. Spool Load Check Spring Spool 16-20 16-23 Note: The lift arm and bucket control spools are each equipped with a unique load check spool.

  • Page 115: Drive Motor (Brake Portion)

    Rubber Track Loader 16. Hydraulic Component Service Drive Motor Assembly (brake portion) 1. Install new seals and components in place of the Disassembly originals as necessary paying close attention to Required Tools location and orientation to ensure proper function. Allen Wrench/Socket Rubber Mallot (seal removal if needed) 2.
  • Page 116 Rubber Track Loader 16. Hydraulic Component Service Shims Seal Bolts Spring 16-30 16-27 9. Inspect the seal for any damage. (fig. 16-30) 4. Remove the brake spring and shims. Make sure to note the order of assembly to ensure correct 10.

  • Page 117: Drive Motor (Motor Portion)

    Rubber Track Loader 16. Hydraulic Component Service Drive Motor (motor portion) Disassembly Required Tools Allen Wrench/Socket Snap Ring Pliers Screwdriver (blade type) (seal removal if needed) Surfaces 16-36 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.

  • Page 118: Drive Pump (Drive Relief Valves)

    Rubber Track Loader 16. Hydraulic Component Service Drive Pump (Drive Relief Valves) Disassembly & Adjustment Required Tools Allen Wrench/Socket Combination/Socket wrench 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. 16-39 Ring Groove Ring...

  • Page 119: Posi-Power Relief Valve

    Rubber Track Loader 16. Hydraulic Component Service Drive Pump Disassembly Required Tools Combination/Socket wrench Allen Wrench/Socket Rubber Mallot Screwdriver (blade type) Snap RIng Pliers 16-45 4. Flip the valve over, then tighten the nut to increase the pressure setting (CW) or loosen it to decrease the pressure setting (CCW).
  • Page 120 Rubber Track Loader 16. Hydraulic Component Service Bearings Swash Plate 16-49 16-52 3. Remove the valve plate and inspect it for damage or wear, specifically, scratches that can be felt with a fingernail. (fig. 16-49) Surfaces Barrel Face 16-53 5. Remove the swash plate along with the bearings 16-50 and inspect them for any damage or scratching that could affect operation.
  • Page 121 Rubber Track Loader 16. Hydraulic Component Service Drive Pump Assembly Required Tools Combination/Socket wrench Allen Wrench/Socket Rubber Mallot Screwdriver (blade type) Snap RIng Pliers 16-55 7. Using a rubber mallot, gently tap the shaft and bearing out of the casing for inspection or replace- ment.
  • Page 122 Rubber Track Loader 16. Hydraulic Component Service 16-58 16-61 4. Flip the assembly over and lay it on a table, then 7. Once the pivots are installed, check to make sure remove the pivot caps from both sides as shown. both of them are properly mated with the pins.

  • Page 123: Auxiliary Pump

    Rubber Track Loader 16. Hydraulic Component Service Auxiliary Pump Disassembly Required Tools Allen Wrench/Socket Snap Ring Pliers O-ring 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. 16-67 5.
  • Page 124 Rubber Track Loader 16. Hydraulic Component Service Inspect Faces 16-70 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.
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  • Page 126: Hydraulic Pressure/Flow

    17. Hydraulic Pressure/Flow Test & Troubleshooting Chapter Overview Hydraulic Pressure/Flow Test & This chapter provides hydraulic pressure and flow Troubleshooting Procedures check, adjustment and troubleshooting procedures. Test and troubleshooting procedures are provided for the following Hydraulic system components. Personal Safety •...
  • Page 127 Rubber Track Loader 17. Hydraulic Pressure & Flow 1. Attach the gauge to test port A. (fig. 17-1) Route Charge Relief 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.
  • Page 128 Rubber Track Loader 17. Hydraulic Pressure & Flow Auxiliary Pressure Check Required Tools Test Port (B) Pressure Gauges 0-1000, 0-6000 p.s.i. 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.

  • Page 129: Lift Arm Pressure Check

    Rubber Track Loader 17. Hydraulic Pressure & Flow Lift Arm Pressure Check Drive Pressure Check Required Tools Required Tools Pressure Gauge 0-6000 p.s.i. Pressure Gauge 0-6000 p.s.i. Lift arm pressure is used to lift loads or “break-out”. !WARNING! Low lift arm pressure can produce a weak lift arm func- tion while high lift arm pressure can damage lift arm This procedure should only be performed if you suspect and hydraulic components.

  • Page 130: Troubleshooting

    Rubber Track Loader 17. Hydraulic Pressure & Flow Check your readings against that stated below. If your Posi-Power Pressure Check readings differ, relief replacement and or component Posi-power is a function of the tandem drive pump repair may be required. assembly.

  • Page 131: Auxiliary Flow Test

    Rubber Track Loader 17. Hydraulic Pressure & Flow 6. If your reading is low, remove the cap and loosen Auxiliary Flow Test the jam nut on the posi-power adjustment screw The SR-70 and SR-80 are equipped with both high and turn it counter clockwise until it stops then and low flow auxiliary circuits.
  • Page 132 Rubber Track Loader 17. Hydraulic Pressure & Flow Problem 6: Flow Troubleshooting High and low flow functions only work in one If your readings differ from those listed on the charts, direction. identify the symptom you are experiencing in the list of Possible causes: possible problems below and follow the steps to identi- 1.
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  • Page 134: 18. Troubleshooting

    18. Troubleshooting Chapter Overview Visual Inspection This chapter contains basic troubleshooting proce- Prior to troubleshooting, walk around the machine and dures for the SR-70 and SR-80 Rubber Track Loaders. perform an overall visual inspection. Look for missing, loose, worn or broken parts. Pay particular attention to Additional troubleshooting aids are provided in Chapter the following items: 3 (Circuit Diagrams) and in chapters containing disas-...
  • Page 135 Rubber Track Loader 18. Troubleshooting Problem 2: Problem 5: Machine cranks, but will not start. Tracks are operational, but lift arms will not move. Possible causes Possible causes 1. Fuel tank empty, fuel filter plugged or fuel line 1. Continuous hydraulic flow switch activated, sending restricted.

  • Page 136: Engine/Machine Troubleshooting

    Rubber Track Loader 18. Troubleshooting Problem 9: Engine/Machine Troubleshooting Lift arm control joystick will not lock into float When a problem occurs that effects engine perform- position. ance or function, it is important to determine whether Possible causes or not the problem lies with the machine itself, or with 1.
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  • Page 138: Lubricant And Fuel Specifications

    19. Lubricant & Fuel Specifications Chapter Overview Fuel Specifications When replacing or replenishing the fluids and lubri- In North America, diesel fuel, distilled from crude oil, cants in an ASV Rubber Track Loader, use ASV Posi- identified as No. 1-D or No. 2-D in “ASTM D975” gen- Lube products.
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  • Page 140: Service Aids And Supplements

    20. Service Aids & Supplements General Torque Specifications Inch Fasteners Metric Fasteners Thread Size Standard Torque Thread Size Standard Torque 1/4" 9 +/- 2 lb ft 12 +/- 3 Nm 5/16" 18 +/- 4 lb ft 28 +/- 7 Nm 3/8"...
  • Page 141 Terex Construction Americas 8800 Rostin Road Southaven, MS 38671 (888)-201-6008 (662)-393-1800 www.terex.com https://tractormanualz.com/...

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