ASV RC30 Service & Repair Manual
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ASV RC30 Service & Repair Manual

By tlp
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8/17/2016
Language:
English
Geographic Region:
All
Serial Number Range:
SN All
RC30
Service Repair Manual
This manual is complements of
TrackLoaderParts.com
The world's best source for ASV parts.
Track Loader Parts
https://www.tractormanualpdf.info/
6543 Chupp Road
Atlanta, Georgia 30058
USA
(800)616-8156

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Summary of Contents for ASV RC30

  • Page 1 8/17/2016 Language: English Geographic Region: Serial Number Range: SN All RC30 Service Repair Manual This manual is complements of TrackLoaderParts.com The world's best source for ASV parts. Track Loader Parts https://www.tractormanualpdf.info/ 6543 Chupp Road Atlanta, Georgia 30058 (800)616-8156...

  • Page 2: Table Of Contents

    Table of Contents Ignition Switch Removal ........5-2 1. Product Safety Ignition Switch Installation .........5-3 Console Gauge/Warning Panel Removal and Chapter Overview ...........1-1 Installation...............5-4 Safety Messages.............1-1 Console Gauge Removal........5-4 Information Messages..........1-1 Console Gauge Installation........5-4 Basic Precautions ...........1-1 Lap Bar Gas Assist Spring Removal Safety Signs............1-1 and Installation............5-5 Protective Equipment.........1-2...
  • Page 3 Rubber Track Loader Table of Contents Filter Assembly Removal and Installation ....8-1 11. Engine Components Disassembly and As- Filter Assembly Removal ........8-2 sembly Filter Assembly Installation ........8-3 Chapter Overview ..........11-1 Filler Cap Assembly Removal and Installation ..8-4 Personal Safety.............11-1 Filler Cap Assembly Removal......8-4 Machine Preparation..........11-1 Filler Cap Assembly Installation......8-5 Preliminary Checkout ..........11-1...
  • Page 4 Rubber Track Loader Table of Contents Low-Flow Relief Valve Removal and Installation ..13-5 Low-Flow Relief Valve Removal ......13-5 Low-Flow Relief Valve Installation ....13-6 14. Quick Attach Disassembly and Assembly Chapter Overview ..........14-1 Personal Safety.............14-1 Machine Preparation ..........14-1 Preliminary Checkout ..........14-1 Quick Attach Disassembly and Assembly Procedures............14-1 Latch Pin Assembly Removal and Installation ..14-1...
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  • Page 6: Product Safety

    1. Product Safety Chapter Overview Note: This label is used to provide important additional This chapter contains product safety information for information, comments, explanations or amplification of the Rubber Track Loader. Read this chapter and the accompanying subject matter. understand all safety messages and information messages before attempting to service the machine.

  • Page 7: 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 8: 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 9: 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 10: 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. https://www.tractormanualpdf.info/...
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  • Page 12: Technical Specifications

    2. Technical Specifications Auxiliary Pump Specifications − Model: Rexroth − Displacement: 0.87 in /rev (114.3 cc/rev) Engine − Flow: 10 gpm (37.8 lpm) @ 2800 rpm (high − Model: Cat 3013 idle) − Displacement: 1.5 liter − Relief pressure: 3000 psi (20,684 kPa) −...
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  • Page 14: System Diagrams

    3. System Diagrams Chapter Overview Filtering and Cooling System This chapter contains diagrams for the following The filtering and cooling system (Figure 3-1) con- Rubber Track Loader systems. tains the following major components. • • Filtering and cooling system Hydraulic reservoir •...

  • Page 15: Auxiliary Circuit System

    Rubber Track Loader 3. System Diagrams Auxiliary Circuit System The auxiliary circuit system (Figure 3-2) contains the following major components. • Loader valve • Pilot control manifold • Auxiliary gear pump • Loader control joystick Figure 3-2 Auxiliary Circuit System 3-002 To Cooler Then to Tank...

  • Page 16: Drive Loop System

    Rubber Track Loader 3. System Diagrams Drive Loop System The drive loop system (Figure 3-3) contains the fol- lowing major components. • Tandem pump • Drive motors • Pilot control manifold • Brake cylinders • Drive control joystick Figure 3-3 Drive Loop System 3-003 To Implement...
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  • Page 18: Machine Controls And Instrumentation

    4. Machine Controls and Instrumentation Chapter Overview Drive Control The drive control allows the operator to change di- This chapter contains an overview of the machine rections and speed using a simple, pilot-operated controls and instrumentation. It includes an illustra- joystick.

  • Page 19: Gauge/Warning Light Panel

    Rubber Track Loader 4. Machine Controls and Instrumentation Gauge/Warning Light Panel The gauge/warning light panel (Figure 4-3) 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 20: Operator Enclosure Disassembly

    5. Operator Enclosure 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 21: Light Bar Installation

    All Surface Loader 5. Operator Enclosure Disassembly and Assembly Light Bar Installation Figure 5-2 5-002 2. Carefully lower the light bar with the wire har- Figure 5-5 5-005 ness attached. 1. Carefully position the light bar, without pinching the wiring harness against the cab frame. Light Switch Hyd.

  • Page 22: Ignition Switch Installation

    All Surface Loader 5. Operator Enclosure Disassembly and Assembly Ignition Switch Installation Remove Nut Figure 5-7 5-007 Figure 5-10 5-010 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 23: Console Gauge/Warning Panel Removal And Installation

    All Surface Loader 5. Operator Enclosure Disassembly and Assembly 4. Install the light bar. Refer to Chapter 5. Light Bar Installation procedure. 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.

  • Page 24: Lap Bar Gas Assist Spring Removal And Installation

    All Surface Loader 5. Operator Enclosure Disassembly and Assembly Plug in Connectors Remove Retaining Clip Figure 5-18 5-018 Figure 5-20 5-020 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 25 All Surface Loader 5. Operator Enclosure Disassembly and Assembly Install Ends on Ball Joints Figure 5-23 5-023 2. Install the ends of the lap bar gas assist spring onto the ball joints. Insert Retaining Clip Figure 5-24 5-024 3. Slide the retaining clip on to each end of the gas assist spring.

  • Page 26: Chassis Disassembly And Assembly

    6. Chassis Disassembly and Assembly Chapter Overview Chassis 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 • Seat ! WARNING ! •...

  • Page 27: Seat Installation

    Rubber Track Loader 6. Chassis Disassembly and Assembly Unplug Connector Plug in the Connector Figure 6-2 6-002 Figure 6-5 6-002 2. Tilt the seat forward and reach behind the seat to unplug the seat switch wiring harness. 2. Tilt the seat forward and reach behind the seat to plug in the seat switch connector Note: The machine will not operate unless the seat switch connector is plugged in.

  • Page 28: Fuel Sending Unit Installation

    Rubber Track Loader 6. Chassis Disassembly and Assembly Fuel Sending Unit Removal 1. Remove the seat. Refer to Chapter 6. Seat Re- moval procedure. 2. Pump fuel from the tank until there is no fuel remaining above the sending unit. NOTICE Collect and contain liquids in a suitable container.

  • Page 29: Fuel Tank Removal And Installation

    Rubber Track Loader 6. Chassis Disassembly and Assembly Fuel Tank Removal and Installation The tools required for fuel tank removal and installa- tion are listed in Table 6-3. Use manufacturer- recommended tools whenever possible. Table 6-3 Required Tools Screwdriver Combination Wrench Socket Wrench Figure 6-11 6-005...
  • Page 30 Rubber Track Loader 6. Chassis Disassembly and Assembly Remove Floor Pan Bolts Remove Filler Piece Figure 6-14 6-007 Figure 6-17 6-009 4. Remove the four bolts that hold the floor pan to 7. Remove the steel filler piece behind the fuel the frame.

  • Page 31: Fuel Tank Installation

    Rubber Track Loader 6. Chassis Disassembly and Assembly Attach Remove Filler Hose Filler Hose Figure 6-20 6-012 Figure 6-23 6-012 10. Remove the rubber filler hose from the back end 2. Attach the filler hose to the rear of the tank. or the tank.
  • Page 32 Rubber Track Loader 6. Chassis Disassembly and Assembly Install Floor Pan Bolts and Washers Insert Filler Piece Figure 6-29 6-007 Figure 6-26 6-009 8. Install the four floor pan bolts and washers. 5. Insert the steel filler piece behind the fuel tank. 9.
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  • Page 34: 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. Ad- assembly, refer to Chapter 15. Troubleshooting. justment procedures are also included for selected radiator/oil cooler components.

  • Page 35: Fan Guard Removal

    All Surface Loader 7. Radiator/Oil Cooler Disassembly and Assembly Fan Guard Removal Fan and Fan Shroud Removal and Installation The tools required for fan and fan shroud removal and installation are listed in Table 7-2. Use manufac- turer-recommended tools whenever possible. Table 7-2 Required Tools Guard...

  • Page 36: Fan And Fan Shroud Installation

    All Surface Loader 7. Radiator/Oil Cooler Disassembly and Assembly Remove Bolts Figure 7-7 7-006 Figure 7-4 7-003 6. Remove the shroud from the engine compart- 3. Remove the three bolts from each side of the ment. fan shroud that secure the shroud to the radia- tor/cooler.

  • Page 37: Radiator/Cooler Removal And Installation

    All Surface Loader 7. Radiator/Oil Cooler Disassembly and Assembly Radiator/Cooler Removal and Installation The tools required for radiator/cooler removal and installation are listed in Table 7-3. Use manufac- turer-recommended tools whenever possible. Table 7-3 Install Bolts Required Tools Combination Wrench Figure 7-10 7-004 Socket Wrench...
  • Page 38 All Surface Loader 7. Radiator/Oil Cooler Disassembly and Assembly Remove Hose Figure 7-13 7-008 Figure 7-16 7-002 3. Remove the bolts from the lower engine com- 6. Remove the upper hose from the oil cooler sec- partment screen. tion. Cap the hose and fitting. Drain Coolant Figure 7-14...

  • Page 39: Radiator/Cooler Installation

    All Surface Loader 7. Radiator/Oil Cooler Disassembly and Assembly Install Remove Bolts Bolts Figure 7-19 7-003 Figure 7-22 7-003 9. Remove the three mounting bolts on each side 2. With the radiator/cooler in position, install the of the radiator/cooler. three mounting bolts on each side of the radia- tor/cooler.

  • Page 40: Radiator/Oil Cooler Adjustment Procedures

    All Surface Loader 7. Radiator/Oil Cooler Disassembly and Assembly 8. Fill the radiator with coolant and the hydraulic reservoir with oil. Install Hose Radiator/Oil Cooler Adjustment Procedures Adjustment procedures are provided for the follow- ing radiator/oil cooler components. • Fan Shroud •...

  • Page 41: Fan Guard Adjustment

    All Surface Loader 7. Radiator/Oil Cooler Disassembly and Assembly Fan Guard Adjustment The tools required for fan guard adjustment are listed in Table 7-5. Use manufacturer-recommended tools whenever possible. Table 7-5 Tool Name Combination Wrench Loosen Capscrews to Adjust Figure 7-29 7-002 1.

  • Page 42: Hydraulic Reservoir Disassembly

    8. Hydraulic Reservoir Disassembly and Assembly Chapter Overview Hydraulic Reservoir Disassembly and Assembly This chapter provides disassembly and assembly procedures for the hydraulic reservoir assembly. Procedures Cleaning procedures are also included for the hy- draulic reservoir. Disassembly and assembly procedures are provided for the following hydraulic reservoir components.

  • Page 43: Filter Assembly Removal

    Rubber Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Filter Assembly Removal ! WARNING ! Hot oil can cause personal injury. Make sure the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand.

  • Page 44: Filter Assembly Installation

    Rubber Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Figure 8-9 8-004 Figure 8-6 8-006 3. Install the two bolts that secure the filter assem- 6. Remove the filter assembly gasket from the res- bly to the reservoir. ervoir. Filter Assembly Installation Figure 8-10 8-003 Figure 8-7...

  • Page 45: Filler Cap Assembly Removal And Installation

    Rubber Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Figure 8-13 8-007 Figure 8-12 8-001 1. Pull the filler cap off and remove the six screws 6. Install the hose on the left side of the filter as- from around the base of the filler cap flange. sembly.

  • Page 46: Filler Cap Assembly Installation

    Rubber Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Figure 8-16 8-010 Figure 8-19 8-008 4. Remove the filler cap gasket from the reservoir. 3. Place the filler cap flange on the gasket with the mounting holes aligned. Filler Cap Assembly Installation Figure 8-20 8-007 Figure 8-17...

  • Page 47: Access Cover Assembly Removal

    Rubber Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Access Cover Assembly Removal Access Cover Assembly Installation ! WARNING ! Hot oil can cause personal injury. Make sure the oil is cool before removing any components or lines. Clamping Remove the oil filler cap only when the engine is Disk stopped and the filler cap is cool enough to touch with your bare hand.

  • Page 48: Reservoir Gauge Removal And Installation

    Rubber Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Reservoir Gauge Removal and Installation The tools required for reservoir gauge removal and installation are listed in Table 8-4. Use manufac- turer-recommended tools whenever possible. Table 8-4 Required Tools Combination Wrench Figure 8-25 8-016 Reservoir Gauge Removal...

  • Page 49: Reservoir Gauge Installation

    Rubber Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Reservoir Gauge Installation Suction Screen Removal ! WARNING ! Insert Reser- Hot oil can cause personal injury. Make sure the oil is voir Gauge cool before removing any components or lines. with Mounting Bolts/Washers Remove the oil filler cap only when the engine is...

  • Page 50: Suction Screen Installation

    Rubber Track Loader 8. Hydraulic Reservoir Disassembly and Assembly Hydraulic Reservoir Cleaning Procedures Cleaning procedures are provided for the following hydraulic reservoir components. • Hydraulic Reservoir Hydraulic Reservoir Cleaning The tools required for hydraulic reservoir cleaning are listed in Table 8-6. Use manufacturer- recommended tools whenever possible.
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  • Page 52: Loader/Transmission Controls Disassembly

    9. 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 53: Loader Control Joystick/Drive Control Joystick Removal

    Rubber Track Loader 9. Loader/Transmission Controls Disassembly and Assembly Loader Control Joystick Operation – The right- hand joystick controls the loader arm and the at- tachment tilt cylinder. It allows the operator to raise, lower and pivot the attachment. The joystick oper- ates on hydraulic charge pressure.

  • Page 54: Loader Control Joystick/Drive Control Joystick Installation

    Rubber Track Loader 9. Loader/Transmission Controls Disassembly and Assembly Loader Control Joystick/Drive Control Joystick Installation Note: Since the procedures for installing both joystick con- trols are identical, only the loader control joystick proce- dure is described below. Figure 9-4 9-004 Hose and 7.

  • Page 55: Loader Float Magnet Removal And Installation

    Rubber Track Loader 9. Loader/Transmission Controls Disassembly and Assembly Install Screws Figure 9-12 9-001 Figure 9-9 9-004 7. Install the four retaining screws in the side 4. With the mounting plate, wiring harness and cover. hoses installed, the control is ready to mount in the console.
  • Page 56 Rubber Track Loader 9. Loader/Transmission Controls Disassembly and Assembly Remove Side Cover Loader Float Magnet Figure 9-14 9-002 Figure 9-17 9-008 2. Remove the joystick side cover. 5. Remove the control from the console and locate the loader float magnet at the front of the con- trol.

  • Page 57: Loader Float Magnet Installation

    Rubber Track Loader 9. Loader/Transmission Controls Disassembly and Assembly Loader Float Magnet Installation Pull the Boot Down Position Magnet Figure 9-23 9-007 Figure 9-20 9-010 4. Position the control on the console and pull the 1. Position the loader float magnet at the front of rubber boot down over the base of the joystick.

  • Page 58: Loader Valve Removal And Installation

    Rubber Track Loader 9. Loader/Transmission Controls Disassembly and Assembly 1. Lower the lift arms to the ground. 2. Turn the engine start switch to the OFF position. 3. Relieve hydraulic pressure from the auxiliary circuit. Install Screws 4. Drain the hydraulic fluid. Refer to Chapter 16. Hydraulic Fluid and Filter Change.
  • Page 59 Rubber Track Loader 9. Loader/Transmission Controls Disassembly and Assembly Remove Tubes Remove Nuts Figure 9-32 9-016 Figure 9-29 9-013 10. Remove the nuts from the four bolts that secure 7. Remove the tubes from the side of the loader the loader valve to the hydraulic reservoir. valve.

  • Page 60: Loader Valve Installation

    Rubber Track Loader 9. Loader/Transmission Controls Disassembly and Assembly Loader Valve Installation Install Tubes Figure 9-37 9-014 Figure 9-34 9-017 4. Install the tubes on the bottom of the loader 1. Position the loader valve against the hydraulic valve. reservoir. Install Tubes Install...
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  • Page 62: Transmission And Drive Disassembly

    10. Transmission and Drive Disassembly and Assembly Chapter Overview Transmission and Drive Disassembly and Assembly This chapter provides disassembly and assembly procedures for the transmission and drive assembly. Procedures Disassembly and assembly procedures are provided Personal Safety for the following transmission and drive components. ! WARNING ! •...

  • Page 63: Auxiliary Gear Pump Removal And Installation

    Rubber Track Loader 10. Transmission and Drive Disassembly and Assembly Auxiliary Gear Pump Removal and Installation The tools required for auxiliary gear pump removal and installation are listed in Table 10-1. Use manu- facturer-recommended tools whenever possible. Table 10-1 Auxiliary Gear Required Tools Pump...

  • Page 64: Auxiliary Gear Pump Installation

    Rubber Track Loader 10. Transmission and Drive Disassembly and Assembly Note: It is not necessary to separate the lower manifold tube from the gear pump: this can be done after the pump is removed, if necessary. Remove Bolt Auxiliary Gear Pump Installation Tandem Pump Auxiliary...

  • Page 65: Tandem Pump Removal And Installation

    Rubber Track Loader 10. Transmission and Drive Disassembly and Assembly Tandem Pump Removal and Installation Install The tools required for tandem pump removal and Bolt installation are listed in Table 10-2. Use manufac- turer-recommended tools whenever possible. Table 10-2 Required Tools Screwdriver Combination Wrench Socket Wrench...

  • Page 66: Tandem Pump Installation

    Rubber Track Loader 10. Transmission and Drive Disassembly and Assembly Pump Drive Coupler Remove Pump Hoses and Mounting Tubes Plate Figure 10-11 10-007 Figure 10-14 10-010 8. Remove all hoses and tubes from the tandem 11. Remove the tandem pump (with pump drive pump.

  • Page 67: Pump Drive Coupler Removal And Installation

    Rubber Track Loader 10. Transmission and Drive Disassembly and Assembly 5. Install the auxiliary gear pump. Refer to Chapter 10. Auxiliary Gear Pump Installation. Install Bolt 6. Install the fuel tank. Refer to Chapter 6. Fuel Tank Installation. 7. Install the seat. Refer to Chapter 6. Seat Installation.

  • Page 68: Pump Drive Coupler Installation

    Rubber Track Loader 10. Transmission and Drive Disassembly and Assembly Pump Drive Coupler Installation 4. Drain the hydraulic fluid. Refer to Chapter 16. Hydraulic Fluid and Filter Change. Tandem Pump Drive Shaft 5. Remove the seat. Refer to Chapter 6. Seat Re- moval.
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  • Page 70: Engine Components Disassembly And As

    11. Engine Components Disassembly and Assembly Chapter Overview Engine Components Disassembly and Assembly This chapter provides disassembly and assembly procedures for the engine components. Procedures Disassembly and assembly procedures are provided Personal Safety for the following engine components. ! WARNING ! •...

  • Page 71: Muffler Removal And Installation

    Rubber Track Loader 11. Engine Components Disassembly and Assembly 2. Using the channel lock, slide the flex pipe off the Muffler Removal and muffler. Installation The tools required for muffler removal and installa- NOTICE tion are listed in Table 11-1. Use manufacturer- Do not kink or twist the exhaust pipe.

  • Page 72: Exhaust Pipe Removal And Installation

    Rubber Track Loader 11. Engine Components Disassembly and Assembly Tighten Bolts Install Bolts Figure 11-5 11-003 Figure 11-7 11-001 2. From underneath the machine, install the four 4. Tighten the bolts on the muffler clamp. muffler mounting bolts, making sure all, if any, shims are in place.

  • Page 73: Exhaust Pipe Installation

    Rubber Track Loader 11. Engine Components Disassembly and Assembly Remove Bolts Figure 11-11 11-005 Figure 11-9 11-004 4. Remove the exhaust flex pipe gasket from the exhaust manifold. 2. Remove the four bolts that secure the exhaust flex pipe to the exhaust manifold. Note: The gasket may come off with the exhaust pipe.

  • Page 74: Battery Removal

    Rubber Track Loader 11. Engine Components Disassembly and Assembly Battery Removal and Installa- tion The tools required for battery removal and installa- tion are listed in Table 11-3. Use manufacturer- recommended tools whenever possible. Table 11-3 Required Tools Combination Wrench Socket Wrench Figure 11-13 11-005...

  • Page 75: Battery Installation

    Rubber Track Loader 11. Engine Components Disassembly and Assembly Battery Installation Disconnect Positive Cable Figure 11-18 11-008 3. Disconnect the battery cable from the positive Figure 11-21 11-011 battery terminal. 1. Place the battery in position in the engine com- partment.

  • Page 76: Bleeding The Fuel System

    Rubber Track Loader 11. Engine Components Disassembly and Assembly 3. Turn-over the engine from the operators com- Connect partment until fuel is flowing from the bleed Negative screw without any air bubbles. Cable 4. Tighten the bleed screw. 5. Engine should now start within 10 seconds. For serial numbers 1358 and higher.
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  • Page 78: Undercarriage Disassembly And Assembly

    12. 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 following undercarriage assem- assembly, refer to Chapter 15. Troubleshooting. blies. • Track • Suspension Undercarriage Disassembly and Assembly Procedures Personal Safety...

  • Page 79: Wheel Removal

    Rubber Track Loader 12. Undercarriage Disassembly and Assembly Wheel Removal O-Ring Figure 12-1 12-004 Figure 12-4 12-007 1. Locate the wheels marked A, B, and C. If the 4. Remove the o-ring from inside the wheel. track is to be removed, wheels A, B, and the wheel to the inside of B must be removed.

  • Page 80: Wheel Installation

    Rubber Track Loader 12. Undercarriage Disassembly and Assembly Figure 12-10 12-051 Figure 12-7 12-010 3. Insert the o-ring into the wheel, seating it against 7. With wheels removed, inspect the axle for wear the outside bearing race. Make sure there is or damage.

  • Page 81: Sprocket Roller Removal

    Rubber Track Loader 12. Undercarriage Disassembly and Assembly Sprocket Roller Removal Sprocket Roller Installation Position Drive Sprocket to Access Roller Figure 12-11 12-057 Figure 12-14 12-059 1. Rotate the drive sprocket to allow access to the 1. With the drive sprocket rotated to the desired sprocket roller bolt.

  • Page 82: Brake Removal

    Rubber Track Loader 12. Undercarriage Disassembly and Assembly Brake Removal Figure 12-16 12-004 Figure 12-19 12-022 1. Locate the wheel marked C located directly be- 4. Move the brake cylinder out from the sprocket. If hind the drive sprocket. If the brake is to be re- replacing the brake cylinder, clean and discon- placed, this wheel must also be removed.

  • Page 83: Track Removal And Installation

    Rubber Track Loader 12. Undercarriage Disassembly and Assembly Figure 12-22 12-004 1. Locate the wheels marked A and B. If the track Figure 12-21 12-021 is to be removed, these wheels and the wheel to the inside of B must also be removed. 2.
  • Page 84 Rubber Track Loader 12. Undercarriage Disassembly and Assembly Figure 12-25 12-012 Figure 12-28 12-015 4. Using the wrench, turn the track tensioner until 7. Pry the drive sprocket assembly away from the tensioner and pivot the tensioner out of the way. the track has significant slack.

  • Page 85: Track Installation

    Rubber Track Loader 12. Undercarriage Disassembly and Assembly Track Installation ! WARNING ! To install the tracks, the machine must be jacked up and placed on jack stands sturdy enough to support the weight of the machine. The manufacturer-supplied jack stands are recommended.

  • Page 86: Sprocket Bearing Plate Removal And Installation

    Rubber Track Loader 12. Undercarriage Disassembly and Assembly Table 12-5 Required Tools Socket Wrench Allen Wrench Combination Wrench Torque Wrench Steel Punch Sprocket Bearing Plate Removal 1. Remove the track. Refer to Chapter 12. Track Removal. Figure 12-36 12-054 2. Move the brake away from the sprocket. Refer 6.
  • Page 87 Rubber Track Loader 12. Undercarriage Disassembly and Assembly Figure 12-40 12-025 Figure 12-42 12-027 5. Loosen the allen bolt from the lock collar. Using 7. Remove the bearing plate from the sprocket a steel punch, rotate the lock collar in the direc- shaft.

  • Page 88: Sprocket Bearing Plate Installation

    Rubber Track Loader 12. Undercarriage Disassembly and Assembly Sprocket Bearing Plate Installation Figure 12-48 12-041 Figure 12-45 12-028 4. Slide the lock collar all the way unto the shaft until it stops. Rotate the lock collar in the direc- 1. If the bearing flanges were split to inspect the tion opposite to which it was loosened.

  • Page 89: Sprocket Installation

    Rubber Track Loader 12. Undercarriage Disassembly and Assembly 1. Remove the bearing plate as described above. Remove the bolt from the center of the sprocket shaft. Figure 12-52 12-033 4. Remove the sprocket. Be careful not to lose the key that fits into the drive motor shaft. Figure 12-50 12-031 Sprocket Installation...

  • Page 90: Drive Motor Removal And Installation

    Rubber Track Loader 12. Undercarriage Disassembly and Assembly ing compound is very important; it fills in small Required Tools inconsistencies in the shaft and creates a better Socket Wrench bond between the shaft and the sprocket.. Crows Foot Attachment Drive Motor Removal Figure 12-55 12-034 3.

  • Page 91: Drive Motor Installation

    Rubber Track Loader 12. Undercarriage Disassembly and Assembly Drive Motor Installation Position the drive motor so the hydraulic fittings exit in the correct location. Install the drive motor bolts. Clean and inspect the drive motor shaft. Reinstall all hoses and fittings. Reinstall drive sprocket as outlined above.

  • Page 92: Loader Disassembly And Assembly Procedures

    13. Loader Disassembly and Assembly • Chapter Overview Lift Cylinders • Tilt Cylinders This chapter provides disassembly and assembly procedures for the loader assembly. • Pressure Release Valve Personal Safety Note: Procedures are provided for only those loader com- ponents listed above. However, information for removal ! WARNING ! and installation of other loader components can be ob- tained from the Rubber Track Loader Parts List manual.
  • Page 93 Rubber Track Loader 13. Loader Disassembly and Assembly Note: During disassembly, cap all hoses and fittings to Lift prevent fluid loss and contamination of the system fluids. Cylinder 1. Lower the loader arms onto a jackstand with the arms resting about 6 inches off the ground. 2.

  • Page 94: Lift Cylinder/Tilt Cylinder Installation

    Rubber Track Loader 13. Loader Disassembly and Assembly Remove Quick-Coupler Block / Pres- sure Release Valve Removal and Installation The tools required for low-flow relief valve removal and installation are listed in Table 13-2. Use manu- facturer-recommended tools whenever possible. Table 13-2 Required Tools Figure 13-6...
  • Page 95 Rubber Track Loader 13. Loader Disassembly and Assembly Quick Coupler Block / Pressure Release Valve Installation Install Bolts Figure 13-8 13-008 3. Press the button on top of the valve to release hydraulic pressure. Figure 13-11 13-009 1. Install the four bolts that secure the low-flow re- lief valve to the loader frame.

  • Page 96: Quick Attach Disassembly And Assembly

    14. Quick Attach Disassembly and Assembly Chapter Overview Preliminary Checkout This chapter provides disassembly and assembly If troubleshooting is required prior to disassembly or procedures for the quick attach assembly. assembly, refer to Chapter 15. Troubleshooting. Personal Safety Quick Attach Disassembly and ! WARNING ! Assembly Procedures Improper operation, lubrication, maintenance or repair...

  • Page 97: Latch Pin Assembly Installation

    Rubber Track Loader 14. Quick Attach Disassembly and Assembly Latch Pin Assembly Installation Handle Latch Pin Handle Cotter Pin Spring Mechanism Pivot Pin Shaft Clevis Figure 14-1 14-001 3. With a steel punch, remove the spring pin that Figure 14-4 14-004 fastens the handle to the pivot pin shaft.

  • Page 98: Quick Attach Assembly Removal And Installation

    Rubber Track Loader 14. Quick Attach Disassembly and Assembly Quick Attach Assembly Removal 1. With no work tool attached and suitable blocks Latch in place, tilt the quick attach assembly forward and lower the lift arms until the quick attach as- sembly rests securely on the blocks about 6 Clevis inches off the ground.

  • Page 99: Quick Attach Assembly Installation

    Rubber Track Loader 14. Quick Attach Disassembly and Assembly Install Remove Bolt Bolt Insert Remove Figure 14-10 14-002 Figure 14-12 14-002 4. Remove the bolt and push out the pin that se- 3. Insert the pin and install the bolt that secures cures each end of the quick attach assembly to each end of the quick attach assembly to the tilt the loader frame.

  • Page 100: 15. Troubleshooting

    15. 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 101: Troubleshooting

    Rubber Track Loader 15. Troubleshooting Poor wire connections on fuse, relay, or safety sole- Troubleshooting noid. This section identifies selected problems and sug- Low charge pressure. gests probable causes. Problem 4 Loader operates but tracks will not move. Probable cause Problem 1 Leak in feed line to pilot control.
  • Page 102 Rubber Track Loader 15. Troubleshooting Problem 8 Problem 13 Auxiliary hydraulic full-time direction switch operates but Loader will not float; labors engine and has down pressure part-time thumb switch will not operate. when detented into float. Probable cause Probable cause Auxiliary hydraulic mode switch in wrong position or Engine RPM too low.
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  • Page 104: 16. Maintenance

    Posi-Lube Lithium Grease Track Tension As needed Due to the variations in the quality and performance of commercially available oils, ASV Posi-Lube Heavy Duty Diesel Engine Oil – 10W30 is recom- NOTICE mended. If Posi-Lube is not available, use one of the...

  • Page 105: Hydraulic Fluid And Filter

    All Surface Loader 16. Maintenance Hydraulic Fluid and Filter The hydraulic fluid should be changed every 500 service hours, and the hydraulic filter should be changed every 250 hours. Hydrostatic components require extremely clean oil for long service life. Hydraulic Fluid and Filter Change Procedures ! WARNING ! Filter...

  • Page 106: Fuel Filter Change Procedures

    All Surface Loader 16. Maintenance Fuel Filter Change Procedures Primary Element Figure 16-6 16-010 2. Remove the primary element. The primary ele- ment can be cleaned and reused up to five Figure 16-5 16-004 times, but it should be changed at least once a year.

  • Page 107: Track Tension Adjustment Procedures

    All Surface Loader 16. Maintenance 3. After loosening the jam nut, turn the track ten- Track Tension Adjustment Procedures sioner until the track tension is within specifica- tions. 4. Once proper tension is achieved, retighten the jam nut Checking for Proper Track Adjustment 1.

  • Page 108: Fuse Box

    All Surface Loader 16. Maintenance Fuse Box Grease Fittings Figure 16-14 16-013 The locations of the grease fittings for the left side of Figure 16-13 16-012 the machine are shown above. An identical set of fittings is located on the right side of the machine. The fuse box is located on the left side of the engine compartment.
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  • Page 110: Hydraulic Pressure Check & Adjustment

    17. Hydraulic Pressure Check & Adjustment Chapter Overview Hydraulic Pressure This chapter provides a 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 111 Rubber Track Loader 17. Hydraulic Pressure Check & Adjustment ! WARNING ! Hot oil can cause personal injury. Lower all attach- ments and make sure the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped and the filler cap is cool enough to touch with your hands.
  • Page 112 Rubber Track Loader 17. Hydraulic Pressure Check & Adjustment 2. Remove the hose coupling from the tandem Repeat procedure on remaining charge pres- pump T-adapter to allow access to the front charge sure relief valve. The charge pressure relief pressure relief valve locking screw. valves must have the same number of shims.

  • Page 113: Auxiliary Pressure Check & Adjustment

    Rubber Track Loader 17. Hydraulic Pressure Check & Adjustment 6. Extract the high-pressure relief valve collar, valve spring, spring loading nut and pressure spring from the valve cavity. 7. Adjust the drive pressure by turning the spring loading nut. Turning Clockwise will increase pressure.
  • Page 114 Rubber Track Loader 17. Hydraulic Pressure Check & Adjustment Jam Nut Adjustment Screw Figure 13 10-113 4. Loosen the jam nut and turn the adjustment Figure 11 10-111 screw in with an allen wrench to increase pres- 2. Make sure the auxiliary mode switch is in the sure and turn screw out to decrease pressure.
  • Page 115 https://www.tractormanualpdf.info/...
  • Page 116 Index Loader Float Magnet Removal and Installation......9-4 Loader Valve Removal and Installation ........9-7 Loader/Transmission Controls Disassembly and Assembly ..9-1 Access Cover Removal and Installation........8-5 Low-Flow Relief Valve Removal and Installation .....13-5 Air Filter Change Procedures........... 16-3 Asbestos Information ..............1-4 Auxiliary Circuit System .............
  • Page 117 Terex Construction Americas 8800 Rostin Road Southaven, MS 38671 (888)-201-6008 (662)-393-1800 www.terex.com https://www.tractormanualpdf.info/...

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