ASV Posi-Track SR80 Track Loader Service Repair Manual

Service Manual SR-70/SR-80 Rubber Track Loader • Safety Overview • Technical Specifications • Circuit Diagrams • Maintenance • Controls & Instrumentation • Component Removal & Installation • Hydraulic Component Service • Hydraulic Pressure & Flow Check & Adjustment • Troubleshooting ASVSR001 Part Number: 2045-830 Printed (06/07)

SR-70/SR-80 Service Manual Printed (06/07)

1. Product Safety Chapter Overview . . . . . . . . . . . . . . . . . . . . . 1-1 Safety Messages . . . . . . . . . . . . . . . . . . . . . 1-1 Information Messages . . . . . . . . . . . . . . . . . 1-1 Basic Precautions . . . . . . . . . . . . . . . . . . . . . 1-1 Safety Labels . . . . . . . . . . . . . . . . . . . . . . . 1-1 Protective Equipment . . . . . . . . . . . . . . . . 1-2 Entering and Exiting . . . . . . . . . . . . . . . . . 1-2 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Hot Fluids and Components . . . . . . . . . . . 1-2 Corrosion Inhibitor . . . . . . . . . . . . . . . . . . . 1-2 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Pressurized Items . . . . . . . . . . . . . . . . . . . 1-2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Work Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Asbestos Information . . . . . . . . . . . . . . . . . . 1-4 Machine Labels and Decals . . . . . . . . . . . . . 1-4 Product Identification Number . . . . . . . . . . 1-4 Engine Serial Number . . . . . . . . . . . . . . . . 1-4 Machine Label and Decal Examples . . . . . 1-5 2. Technical Specifications Specifications (SR-80) . . . . . . . . . . . . . . . . . 2-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Transmission . . . . . . . . . . . . . . . . . . . . . . . 2-1 Drive Pumps . . . . . . . . . . . . . . . . . . . . . . 2-1 Charge Pump . . . . . . . . . . . . . . . . . . . . . 2-1 Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . 2-1 Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 2-1 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Critical Torque Specifications . . . . . . . . . . . . 2-1 Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Service Tools . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Specifications (SR-70) . . . . . . . . . . . . . . . . . 2-2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Transmission . . . . . . . . . . . . . . . . . . . . . . . 2-2 Drive Pumps . . . . . . . . . . . . . . . . . . . . . . 2-2 Charge Pump . . . . . . . . . . . . . . . . . . . . . 2-2 Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . 2-2 Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 2-2 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Critical Torque Specifications . . . . . . . . . . . . 2-2 Cycle times . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Service Tools . . . . . . . . . . . . . . . . . . . . . . . . 2-2 3. Circuit Diagrams Chapter Overview . . . . . . . . . . . . . . . . . . . . . 3-1 Hydraulic Charge Circuit . . . . . . . . . . . . . . . . 3-1 Hydraulic Auxiliary Circuit . . . . . . . . . . . . . . . 3-2 Hydraulic Drive Circuit . . . . . . . . . . . . . . . . . 3-3 Lift Arm Control Valve . . . . . . . . . . . . . . . . . . 3-4 Hydraulic Pilot Generation Solenoid Block . . 3-5 Electrical Attachment Outlet . . . . . . . . . . . . . 3-6 Drive Control (line routing) . . . . . . . . . . . . . . 3-7 Lift Arm Control (line routing) . . . . . . . . . . . . 3-8 4. Maintenance Chapter Overview . . . . . . . . . . . . . . . . . . . . . 4-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 4-1 Lift-Arm Brace . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Tilt-up Cab . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Jacking Procedure . . . . . . . . . . . . . . . . . . . . 4-2 Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . 4-3 Undercarriages . . . . . . . . . . . . . . . . . . . . . . . 4-3 Track Tension . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Drive Sprocket Rollers . . . . . . . . . . . . . . . . . 4-5 Track Removal . . . . . . . . . . . . . . . . . . . . . . . 4-6 Track Installation . . . . . . . . . . . . . . . . . . . . . . 4-8 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Water Separator . . . . . . . . . . . . . . . . . . . . . . 4-11 Accessory Belt Tension . . . . . . . . . . . . . . . . 4-12 Fan Belt Removal/Installation . . . . . . . . . . . . 4-13 A/C Belt Removal/Installation . . . . . . . . . . . . 4-13 Engine Oil/FIlter Change . . . . . . . . . . . . . . . 4-14 Engine Oil Specifications . . . . . . . . . . . . . . . 4-15 Oil Level Check . . . . . . . . . . . . . . . . . . . . . . 4-15 Hydraulic Fluid/Filter Change . . . . . . . . . . . . 4-16 Radiator/Oil Cooler (cleaning) . . . . . . . . . . . 4-17 Engine (cleaning) . . . . . . . . . . . . . . . . . . . . . 4-17 Case Drain Filter . . . . . . . . . . . . . . . . . . . . . . 4-18 Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Maintenance Schedule . . . . . . . . . . . . . . . . . 4-19 5. Machine Controls and Instrumentation Chapter Overview . . . . . . . . . . . . . . . . . . . . . 5-1 Machine Controls . . . . . . . . . . . . . . . . . . . . . 5-1 Loader Control . . . . . . . . . . . . . . . . . . . . . . . 5-1 Drive Control . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . 5-1 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Table of Contents I

6. Operator Enclosure Chapter Overview . . . . . . . . . . . . . . . . . . . . . 6-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 6-1 Machine Preparation . . . . . . . . . . . . . . . . . . . 6-1 Removal & Installation . . . . . . . . . . . . . . . . . 6-1 Door Gas Spring . . . . . . . . . . . . . . . . . . . . 6-1 Removal Procedure . . . . . . . . . . . . . . . . 6-1 Installation Procedure . . . . . . . . . . . . . . 6-1 Pillar Switch Panels . . . . . . . . . . . . . . . . . . 6-2 Removal Procedure . . . . . . . . . . . . . . . . 6-2 Installation Procedure . . . . . . . . . . . . . . 6-2 Gauge Clusters . . . . . . . . . . . . . . . . . . . . . 6-3 Removal Procedure . . . . . . . . . . . . . . . . 6-3 Installation Procedure . . . . . . . . . . . . . . 6-3 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Removal Procedure . . . . . . . . . . . . . . . . 6-4 Installation Procedure . . . . . . . . . . . . . . 6-4 Interior Side Panel, LT . . . . . . . . . . . . . . . . 6-4 Removal Procedure . . . . . . . . . . . . . . . . 6-4 Installation Procedure . . . . . . . . . . . . . . 6-5 Interior Side Panel, RT . . . . . . . . . . . . . . . 6-5 Removal Procedure . . . . . . . . . . . . . . . . 6-5 Installation Procedure . . . . . . . . . . . . . . 6-5 Interior Panel, Rear . . . . . . . . . . . . . . . . . . 6-6 Removal Procedure . . . . . . . . . . . . . . . . 6-6 Installation Procedure . . . . . . . . . . . . . . 6-6 Lap Bar Assist Gas Spring . . . . . . . . . . . . 6-6 Removal Procedure . . . . . . . . . . . . . . . . 6-6 Installation Procedure . . . . . . . . . . . . . . 6-6 7. Chassis and Fuel Tank Chapter Overview . . . . . . . . . . . . . . . . . . . . . 7-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 7-1 Machine Preparation . . . . . . . . . . . . . . . . . . . 7-1 Removal & Installation . . . . . . . . . . . . . . . . . 7-1 Fuel Sending Unit . . . . . . . . . . . . . . . . . . . 7-1 Removal Procedure . . . . . . . . . . . . . . . . 7-1 Installation Procedure . . . . . . . . . . . . . . 7-2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Removal Procedure . . . . . . . . . . . . . . . . 7-2 Installation Procedure . . . . . . . . . . . . . . 7-3 Footwell . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Removal Procedure . . . . . . . . . . . . . . . . 7-4 Installation Procedure . . . . . . . . . . . . . . 7-4 Foot Throttle Assembly . . . . . . . . . . . . . . . 7-5 Removal Procedure . . . . . . . . . . . . . . . . 7-5 Installation Procedure . . . . . . . . . . . . . . 7-5 Hood Assembly . . . . . . . . . . . . . . . . . . . . . 7-5 Removal Procedure . . . . . . . . . . . . . . . . 7-5 Installation Procedure . . . . . . . . . . . . . . 7-6 8. Radiator and Oil Cooler Chapter Overview . . . . . . . . . . . . . . . . . . . . . 8-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 8-1 Machine Preparation . . . . . . . . . . . . . . . . . . . 8-1 Removal & Installation . . . . . . . . . . . . . . . . . 8-1 Fan Guard . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Removal Procedure . . . . . . . . . . . . . . . . 8-1 Installation Procedure . . . . . . . . . . . . . . 8-2 Fan & Shroud . . . . . . . . . . . . . . . . . . . . . . 8-2 Removal Procedure . . . . . . . . . . . . . . . . 8-2 Installation Procedure . . . . . . . . . . . . . . 8-3 Radiator/Oil Cooler . . . . . . . . . . . . . . . . . . 8-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Installation . . . . . . . . . . . . . . . . . . . . . . . 8-4 9. Hydraulic Reservoir Chapter Overview . . . . . . . . . . . . . . . . . . . . . 9-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 9-1 Machine Preparation . . . . . . . . . . . . . . . . . . . 9-1 Removal & Installation . . . . . . . . . . . . . . . . . 9-1 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . 9-1 Removal Procedure . . . . . . . . . . . . . . . . 9-1 Installation Procedure . . . . . . . . . . . . . . 9-7 Suction Screen . . . . . . . . . . . . . . . . . . . . . 9-8 Removal Procedure . . . . . . . . . . . . . . . . 9-8 Installation Procedure . . . . . . . . . . . . . . 9-8 10. Lift Arm/Drive Controls Chapter Overview . . . . . . . . . . . . . . . . . . . . .10-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . .10-1 Machine Preparation . . . . . . . . . . . . . . . . . . .10-1 Removal & Installation . . . . . . . . . . . . . . . . .10-1 Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1 Removal Procedure . . . . . . . . . . . . . . . .10-1 Installation Procedure . . . . . . . . . . . . . .10-3 Lift Arm Float Magnet . . . . . . . . . . . . . . . .10-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . .10-3 Installation . . . . . . . . . . . . . . . . . . . . . . .10-3 Lift Arm Control Valve . . . . . . . . . . . . . . . .10-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . .10-4 Installation . . . . . . . . . . . . . . . . . . . . . . .10-4 11. Hydraulic Pumps/Motors Chapter Overview . . . . . . . . . . . . . . . . . . . . . 11-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 11-1 Machine Preparation . . . . . . . . . . . . . . . . . . . 11-1 Removal & Installation . . . . . . . . . . . . . . . . . 11-1 Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Removal Procedure . . . . . . . . . . . . . . . . . . 11-1 Installation Procedure . . . . . . . . . . . . . . . . 11-2 Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . 11-3 Removal Procedure . . . . . . . . . . . . . . . . . . 11-3 Installation Procedure . . . . . . . . . . . . . . . . 11-4 Tandem Drive Pump . . . . . . . . . . . . . . . . . . . 11-4 Removal Procedure . . . . . . . . . . . . . . . . . . 11-4 Installation Procedure . . . . . . . . . . . . . . . . 11-5 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 Removal Procedure . . . . . . . . . . . . . . . . . . 11-6 Installation Procedure . . . . . . . . . . . . . . . . 11-8 Rubber Track Loader Table of Contents II

12. Engine Chapter Overview . . . . . . . . . . . . . . . . . . . . . 12-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 12-1 Removal & Installation . . . . . . . . . . . . . . . . . 12-1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Removal Procedure . . . . . . . . . . . . . . . . 12-1 Installation Procedure . . . . . . . . . . . . . . 12-2 Exhaust System . . . . . . . . . . . . . . . . . . . . 12-2 Removal Procedure . . . . . . . . . . . . . . . . 12-2 Installation Procedure . . . . . . . . . . . . . . 12-4 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Removal Procedure . . . . . . . . . . . . . . . . 12-4 Installation Procedure . . . . . . . . . . . . . . 12-5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 Removal Procedure . . . . . . . . . . . . . . . . 12-5 Installation Procedure . . . . . . . . . . . . . . 12-7 13. Undercarriage Chapter Overview . . . . . . . . . . . . . . . . . . . . . 13-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 13-1 Machine Preparation . . . . . . . . . . . . . . . . . . . 13-1 Removal & Installation . . . . . . . . . . . . . . . . . 13-1 15” Idler Wheel (SR-80) . . . . . . . . . . . . . . 13-1 Removal Procedure . . . . . . . . . . . . . . . . 13-1 Installation Procedure . . . . . . . . . . . . . . 13-2 15” & 10” wheel (SR-70) . . . . . . . . . . . . . . 13-3 Removal & Installation Procedures . . . . 13-3 10” Bogie Wheel & Hub (SR-80) . . . . . . . 13-3 Removal & Service Procedure . . . . . . . . 13-3 Idler Hub . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8 Removal & Service Procedure . . . . . . . . 13-8 14. Lift Arm Components Chapter Overview . . . . . . . . . . . . . . . . . . . . . 14-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 14-1 Machine Preparation . . . . . . . . . . . . . . . . . . . 14-1 Removal & Installation . . . . . . . . . . . . . . . . . 14-1 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 14-1 Removal Procedure . . . . . . . . . . . . . . . . 14-1 Installation Procedure . . . . . . . . . . . . . . 14-3 Bucket/Tilt Cylinder . . . . . . . . . . . . . . . . . . 14-3 Removal Procedure . . . . . . . . . . . . . . . . 14-3 Installation Procedure . . . . . . . . . . . . . . 14-5 Q/C Block PRV . . . . . . . . . . . . . . . . . . . . . 14-5 Removal Procedure . . . . . . . . . . . . . . . . 14-5 Installation Procedure . . . . . . . . . . . . . . 14-5 15. Quick Attach Chapter Overview . . . . . . . . . . . . . . . . . . . . . 15-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 15-1 Machine Preparation . . . . . . . . . . . . . . . . . . . 15-1 Removal & Installation . . . . . . . . . . . . . . . . . 15-1 Locking Pin . . . . . . . . . . . . . . . . . . . . . . . . 15-1 Removal Procedure . . . . . . . . . . . . . . . . 15-1 Installation Procedure . . . . . . . . . . . . . . 15-2 Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3 Removal Procedure . . . . . . . . . . . . . . . . 15-3 Installation Procedure . . . . . . . . . . . . . . 15-3 16. Hydraulic Component Service Chapter Overview . . . . . . . . . . . . . . . . . . . . . 16-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 16-1 Disassembly & Assembly . . . . . . . . . . . . . . . 16-1 Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . 16-1 Disassembly Procedure . . . . . . . . . . . . . 16-1 Assembly Procedure . . . . . . . . . . . . . . . 16-3 Lift Arm Control Valve . . . . . . . . . . . . . . . . 16-4 Disassembly Procedure . . . . . . . . . . . . . 16-4 Assembly Procedure . . . . . . . . . . . . . . . 16-6 Drive Motor (brake portion) . . . . . . . . . . . . 16-6 Disassembly Procedure . . . . . . . . . . . . . 16-6 Assembly Procedure . . . . . . . . . . . . . . . 16-7 Drive Motor (motor portion) . . . . . . . . . . . . 16-8 Disassembly Procedure . . . . . . . . . . . . . 16-8 Assembly Procedure . . . . . . . . . . . . . . . 16-9 Drive Pump (Drive Relief Valves) . . . . . . . 16-9 Disassembly & Adjustment . . . . . . . . . . 16-9 Posi-Power Relief Valve . . . . . . . . . . . . . 16-9 Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . 16-10 Disassembly Procedure . . . . . . . . . . . . . 16-10 Assembly Procedure . . . . . . . . . . . . . . . 16-12 Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . 16-14 Disassembly Procedure . . . . . . . . . . . . . 16-14 Assembly Procedure . . . . . . . . . . . . . . . 16-15 17. Hydraulic Pressure & Flow Chapter Overview . . . . . . . . . . . . . . . . . . . . . 17-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 17-1 Contamination Inspection . . . . . . . . . . . . . . . 17-1 Pressure/Flow Test and Troubleshooting . . . 17-1 Charge Pressure Check & Adjust . . . . . . . 17-1 Auxiliary Pressure Check & Adjust . . . . . . 17-3 Lift Arm Pressure Check . . . . . . . . . . . . . . 17-4 Drive Pressure Check . . . . . . . . . . . . . . . . 17-4 Troubleshooting . . . . . . . . . . . . . . . . . . . 17-5 Posi-Power Pressure Check & Adjust . . . . 17-5 Auxiliary Flow Test . . . . . . . . . . . . . . . . . . . 17-6 Troubleshooting . . . . . . . . . . . . . . . . . . . 17-7 18. Troubleshooting Chapter Overview . . . . . . . . . . . . . . . . . . . . . 18-1 Personal Safety . . . . . . . . . . . . . . . . . . . . . . 18-1 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . 18-1 General Troubleshooting Scenarios . . . . . . . 18-1 Engine/Machine Troubleshooting . . . . . . . . . 18-3 19. Lubricant and Fuel Specifications Chapter Overview . . . . . . . . . . . . . . . . . . . . . 19-1 Fluids & Fuel Specifications . . . . . . . . . . . . . 19-1 20. Service Aids and Supplements General Torque Specifications . . . . . . . . . . . 20-1 Electrical Schematic . . . . . . . . . . . . . . . . . . . 20-2 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . 20-3 III Rubber Track Loader Table of Contents

Chapter Overview This chapter contains product safety information for the SR-70/80 Rubber Track Loaders. Read and understand all product safety information before attempting to service any Rubber Track Loader. Safety Messages Safety messages are included in this document to serve as warnings of potentially dangerous conditions. Failure to follow their instructions could result in injury or death. These messages are identified by the headings: !DANGER!….!WARNING!….!CAUTION!. The messages are to be understood as: Attention! Your Safety Is Involved! The information that follows each heading describes the potential hazard and the precautions necessary to protect yourself and others from injury. Instructions may be written or pictorially presented. This symbol is used to alert service personnel of an imminently hazardous situation that will result in serious injury or death. This symbol is used to alert service personnel of a potentially hazardous situation that could result in serious injury or death. This symbol is used to alert service personnel of an unsafe practice that could result in injury. Information Messages Information messages are also included in this document to supplement the instructions and photographs in each chapter. These messages are identified by the labels NOTICE or Note. NOTICE This label is used to alert service personnel of a situation that could lead to equipment or machine damage. Note: This label is used to provide important additional information, further explanation, comments or to stress the impor- tance of a topic. The person(s) in charge of servicing a Rubber Track Loader may be unfamiliar with many of the systems on the machine. This makes it especially important to use caution when performing service tasks. Familiarize yourself with the affected system(s) and components before attempting any type of maintenance or service. It is not possible to anticipate every potential hazard. The safety messages included in this document and displayed on the machine are not all- inclusive. They are intended to make you aware of potential risks and encourage a safe approach to performing service work. If you use a tool, procedure, work method or operating technique that is not specifically recommended by ASV, you must satisfy yourself that it is safe for you and others. You must also ensure that the machine will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. Basic Precautions Improper or incomplete maintenance/repair of a Rubber Track Loader can be dangerous and may result in machine damage, injury or even death. Do not attempt to perform any type of repair or maintenance on a Rubber Track Loader until you have read and fully understood the information in this manual. Refer to the Operation and Maintenance manual for instructions regarding proper machine operation tech- niques before operating any Rubber Track Loader. Following is a list of basic precautions that should always be observed. Safety Labels Safety labels are displayed in various places through- out the machine to serve as warnings of potentially dangerous conditions. Read and understand all "Safety" labels on any Rubber Track Loader before attempting to operate, maintain or repair it. Replace any damaged, illegible or missing labels as necessary. 1. Product Safety 1-1 !WARNING! !CAUTION! !WARNING! !DANGER!

Protective Equipment Always wear appropriate protective equipment for working conditions when working on or around a Rubber Track Loader. Wear hard hats, protective glasses, safety shoes and any other equipment necessary to ensure your safety and the safety of others as you work. In particular, wear protective glasses when pounding on any part of the machine or its work tool with a hammer or sledge. Do not wear loose clothing or jewelry that can catch on components and cause injury. If welding is required, use welding gloves, helmet (UV eye protection), apron, boots and any other protective clothing necessary to ensure your safety and the safety of others while welding. Avoid wearing flammable or heat sensitive clothing while performing tasks that involve welding. Entering and Exiting Always use steps and handholds when entering or exiting a Rubber Track Loader. Clean any mud or debris from steps or work platforms before using them. Always face the machine when using steps and handholds. When it is not possible to use the designed entry/exit system, utilize ladders, scaffolds, or work platforms to safely gain access to the machine. Lifting Use a hoist when lifting components that weigh 23 kg (50 Ib) or more, to avoid back injury. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are posi- tioned correctly and equipped with a spring latch. Lifting eyes are not to be side loaded during a lifting operation. Hot Fluids and Components Stay clear of hot components and system fluids of the engine, exhaust, radiator/oil cooler and hydraulic lines/tubes. Also, use caution when removing fill caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. Be especially careful if the machine has been operated recently, fluids may still be hot. To ensure your safety, allow the machine to cool before attempting any service procedure that involves hot fluids or components. Corrosion Inhibitor Corrosion inhibitor contains alkali. Avoid contact with eyes. Avoid prolonged or repeated contact with skin. Do not take internally. In case of contact, wash skin immediately with soap and water. For eyes, flush with large amounts of water for at least 15 minutes. Call Physician. Keep out of reach of children. Batteries Do not smoke when inspecting the battery electrolyte level. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Do not let electrolyte solution make contact with skin or eyes. Electrolyte solution is an acid. In case of contact, immediately wash skin with soap and water. For eyes, flush with large amounts of water for at least 15 minutes. Call Physician. Keep out of reach of children. Pressurized Items 1. Do not use hands or any other body part to check for fluid leaks in the hydraulic system. Always use a solid material like wood or metal to check for this type of leak. Leaking fluid under pressure can pen- etrate body tissue. Fluid penetration can cause serious injury and even death. If fluid is injected into your skin, get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury. 2. Relieve pressure from the hydraulic system before disconnecting or removing any lines, fittings or related items. Do this by relaxing all hydraulic actuators. If the lift arms are raised, make sure they are securely braced. Be alert for possible pressure release when disconnecting any device from a pressurized system. 3. Lower the lift arms before performing any work on the machine. If this cannot be done, make sure they are securely braced to prevent them from dropping unexpectedly during service. 4. Loose or damaged fuel, oil, hydraulic, lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones that have been bent or damaged. Check lines, tubes and hoses carefully. See item 1 for precautions on checking for fluid leaks. 5. Pressurized air or water can also cause injury. When pressurized air or water is used for cleaning, wear a protective face shield, protective clothing, and protective shoes. The recommended max- imum air pressure for cleaning purposes is 205 kPa (30 psi). When using a pressure washer, keep in mind that nozzle pressures are typically very high. Generally, pressures are well above 13790 kPa (2000 psi). Follow all recommended practices provided by the pressure washer manufacturer. 1-2 Rubber Track Loader 1. Product Safety

ASV Posi-Track SR80 Track Loader Service Repair Manual

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