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Disassembly and - Cutting Edge Machinery

1. 8 2 Access Cover Assembly Removal 0006 8 2 Access Cover Assembly Installation 8 3 Reservoir Gauge Removal and Installation 8 3 Reservoir Gauge Removal cceeeeeeeeseeee 8 3 Reservoir Gauge Installation 0eceeeeee 8 4 Rubber Track Loader 10 11 12 Suction Screen Removal and Installation 8 4 Suction Screen Removal 8 5 Suction Screen Installation cc cee 8 5 Hydraulic Reservoir Cleaning Procedures 8 6 Hydraulic Reservoir Cleaning cccccceseeeeees 8 6 Loader Transmission Controls Disassembly and Assembly Chapter OVErVieW ssssssseeeeeeeeeeeeeaaaessseeeeeees 9 1 Personal Satety acae e odes 9 1 Machine Preparation suntvsurseeievieweeiuvert terse yroeeehaxee 9 1 Preliminary Checkout c ccseeeeeeeeeeeeeeeeeeeeeeeeaes 9 1 Loader Transmission Controls Disassembly and Assembly ProCedures ccccccsseeeeeeeeeeeeaanseeeees 9 1 Joystick Removal and Installation e 9 1 Joystick Removal ccccccccseeeeeesaeeeeeeeseeeeeeeeas 9 1 Joystick Installation ccccccecceessssseeeeeeeeeeeeeees 9 3 Loader Float Magnet Removal and Installation 9 4 Loader Float Magnet Removal c 008 9 4 Loader Float Magnet Installation 0 9 6 Loader Valve Removal and Installation 9 7 Loader Valve REMmoval
2. 0 eee 11 3 Track REMOVAL ccccccsseeeesseeeceeeeeseeeeeeseees 11 4 Track Installation ccccsccccsseeeesseeeeeseeeessees 11 5 Sprocket Bearing REMOVAI ccccccccecssssseeeeeeees 11 6 Sprocket Bearing Plate Removal 11 6 Sprocket Removal and Installation 0008 11 7 Sprocket REMOVAL cccccccssssseeeeeeeeeeseeeeees 11 7 Drive Motor Removal and Installation 11 8 Loader Disassembly and Assembly Chapter OVErVieW ccccccccssssseeeeeeeeeeaeeeeeeeeeeaaas 12 1 Personal Safely soa a cicn Siem A 12 1 13 14 15 Table of Contents Machine Preparation ccccccccccssseeecseeeeeneeeeenees 12 1 Preliminary Checkout c0ccccesseeeeeeeeeeeeeeeeaeees 12 1 Loader Disassembly and Assembly Procedures 12 1 Lift Cylinder Tilt Cylinder Removal ANG INStANAUON siceraria e decal 12 1 Lift Cylinder Tilt Cylinder Removal 0 12 1 Lift Cylinder Tilt Cylinder Installation 12 3 Low Flow Relief Valve Removal and Installation 12 3 Low Flow Relief Valve Removal 008 12 3 Low Flow Relief Valve Installation 12 6 Maintenance Chapter OVErVieW cccccccccccssssessesseeeeeeeeeeeeeeaaeees 13 1 Maintenance SChedule ccccccsseeeeeeeeeeeeeeees 13 1 ENGINE Olllsiece seccnceren inch 2s ioia pi Cartauni N 13 1 Oil Change Procedures ssssssesseeeeee
3. c ccsccecseeeeeseeeeeaees 9 7 Loader Valve Installation cccccccccssseeeeeeeees 9 9 Transmission and Drive Disassembly and Assembly Chapter OVErVieW csssseeeeeeeeeeeeeeeeessseeeeeess 10 1 Personal Safety 2 e cenvecicbadci crea ecieilcks 10 1 Machine Preparation ccccccssseeeeceesseeeeeeeeeeees 10 1 Preliminary Checkout cccccccssseseeeeeeeaeesseeeeees 10 1 Transmission and Drive Disassembly and Assembly Procedures ceeeeeeeeeeees 10 1 Auxiliary Gear Pump Removal and Installation 10 1 Auxiliary Gear Pump Removal 00s0008 10 1 Tandem Pump Removal and Installation 10 3 Tandem Pump Removal sses 10 3 Tandem Pump Installation 0 eee 10 4 Pump Drive Coupler Removal and Installation 10 5 Pump Drive Coupler Removal 006 10 5 Pump Drive Coupler Installation 06 10 6 Undercarriage Disassembly and Assembly Chapter OVErVieW ssssseeceeeeeeeeeeeeaesssneeeeees 11 1 Personal Salety eann E AE 11 1 Machine Preparation ccccsssecesseeeeeeeeeeeeeeeens 11 1 Preliminary Checkout cccccseeeeeceeeeeeeeeeeeeeeees 11 1 Undercarriage Disassembly and Assembly Procedure Sse a a EINE 11 1 WheelRemoval is iekaros E ER ee 11 1 Wheel REMOval ccccsseeccsseeeceeseeeseeseeeeees 11 2 Sprocket Roller Removal and Installation 11 3 Track Removal and Installation
4. 6 001 Figure 6 1 1 Remove the four nuts that fasten the seat mounts to the frame Rubber Track Loader 6 Chassis Disassembly and Assembly g i Connector Unplu Figure 6 2 6 002 2 Tilt the seat forward and reach behind the seat to unplug the seat switch wiring harness 6 003 Figure 6 3 3 Remove the seat Be careful not to scratch the control panel or sides of the cab Seat Installation 6 003 Figure 6 4 1 With the seat mounts attached place the seat in the cab Be careful not to scratch the control panel or sides of the cab 6 2 Figure 6 5 6 002 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 connecior is plugged in insert Seat Bolts avi Figure 6 6 6 001 3 Position the seat so the holes in the seat mounts are aligned with the bolts in the frame Install the four seat mount nuts and washers Fuel Sending Unit Removal and installation The tools required for fuel sending unit removal and installation are listed in Table 6 2 Use manufac turer recommended tools whenever possible Table 6 2 Required Tools Screwdriver Combination Wrench Socket Wrench 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 NOT
5. gt Side Cover a Figure 9 25 9 002 6 Place the side cover in position on the console Rubber Track Loader 9 Loader Transmission Controls Disassembly and Assembly Install Screws Figure 9 26 9 001 7 Install the four retaining screws in the side cover Loader Valve Removal and Installation The tools required for loader valve removal and in stallation are listed in Table 9 2 Use manufacturer recommended tools whenever possible Table 9 2 Required Tools Combination Wrench Loader Valve Removal I 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 NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids 9 7 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 4 Drain the hydraulic fluid Refer to Chapter 16 Hydraulic Fluid and Filter Change Figure 9 27 9 011 5 Locate the loader valve which is mounted on the side of the hydraulic reservoir 9 012 Figure 9 28 6 Remove the
6. 00sseeeeees 6 3 Fuel Sending Unit Installation ceeeeeee 6 3 Radiator Oil Cooler Disassembly and Assembly Chapter OVErVieW cccccccceescseeeeeeeeeeseeeeeeeeeeenaas 7 1 Personal Safely ictevdiecatatie et soo eed ccc asse aliases 7 1 Machine Preparation cccccccsssecceseeeeceeeeeseeees 7 1 Preliminary Checkout ccccccccseseeeeseeeeeeeeeeeees 7 1 Radiator Oil Cooler Disassembly and Assembly PHOCEOULES E a ae ican eee 7 1 Fan Guard Removal and Installation 0 7 1 Fan Guard Removal ccccscceececceeceseeeeaeeeees 7 2 Fan Guard Installation cccccceeceeeceeeeeeeeeeees 7 2 Radiator Cooler Removal and Installation 7 2 Radiator Cooler Removal ccccseseeecseeeeeeeees 7 2 Radiator Cooler Installation 7 4 Hydraulic Reservoir Disassembly and Assembly Chapter OVerViW cccccccccccceessssseseeeeeeeeeeeeeeeaaaees 8 1 Personal Safety ssssssssseeeeeeeeeeeeeeeeeeaeaeeeeeeees 8 1 Machine Preparation wxesiscdesdccats dasversedczesetidiiacewenne 8 1 Preliminary Checkout cccccceeceeeeseeeeeeeeeeeeeeees 8 1 Hydraulic Reservoir Disassembly and Assembly PROCC CUI CS sessed eao i eer 8 1 Filter Assembly Removal and Installation 8 1 Filter Manifold Removal cc sccceseeeeeeeeeees 8 2 Filter Manifold Installation cceeeeeceeeeeees 8 2 Access Cover Removal and Installation
7. Drive Motor Removal and Installation Use manufacturer recommended tools whenever possible Figure 0 22 12 035 1 Using a pressure washer or compressed air clean all hydraulic fittings on the drive motor thoroughly before removing any hoses Dry the fittings Remove the hoses and cap immediately Figure 0 23 12 036 2 Remove the 8 bolts that mount the Drive motor to the drive table Reverse the procedure to install the drive motor and torque the drive motor mounting bolts to 160 ft lbs Chapter Overview This chapter provides disassembly and assembly procedures for the loader assembly Personal Safety I WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Before starting any disassembly or assembly procedures refer to Chapter 2 Product Safety Basic Precautions for personal safety information Machine Preparation I WARNING Accidental machine starting can cause injury or death to personnel working on the machine To avoid accidental machine starting disconnect the battery cables from the battery and tape the battery clamps and remove the key Place a Do Not Operate tag prominently on the machine to inform personnel
8. RC 60 amp RC 60 Turf Edition Rubber Track Loaders Safety Overview Technical Specifications System Diagrams Disassembly and Assembly Instructions Troubleshooting Maintenance Hydraulic Pressure Check amp Adjustment ASVSP005 07 04 Part Number 2030 184 Product Safety Chapter OVErVieW cccccccsssseeeeeeeeeeaeeeeeeseesaaeeeees 1 1 Safety Messages cccceccesesseeeeeeeeeeseeeeeeeeeeeeeeaas 1 1 Information Messages ccccseeeeeeeeeeeeeeeeeseeeeeens 1 1 Basic Precaution tcoxiec baie cctetovecwla nce ee E 1 1 Salely SIONS xe cessation aaah ete eeeeseeeeseeds 1 1 Protective EQuIDMent ccccsssseesseseeeeeeeeess 1 2 Mounting and Dismounting 0 ceeeeeeeeeeeeees 1 2 CUNO ia haben teel tate EA 1 2 Hot FluidsS andiP ats eoiccctcdaeesee ee tothe tans 1 2 Gorrosion MADIO cise eo eee 1 2 Banerne eee ene ee en te nes em ee Te 1 2 Pressurized Items ccceceeeceececeececceeeeceeeeeees 1 2 REDA orir creer es ese eee Aa eee 1 3 WOK TOOS eee a east e deigein tne mia lh ehranes 1 3 Asbestos INformation cccecceceeeeeceeceeeeeeeeeeeeeees 1 4 Machine Labels and Decals c cccccecceese eee eeee 1 4 Product ID Number cccceeeeceeceeeeceeeeeeeeees 1 4 Machine Label and Decal Examples 1 5 Technical Specifications Ghapler OVGWVICW sorsia 2 1 SDECIICATIONS eeen e A e E 2 1 ENGINE senita er eerie tie Gecrreetner e
9. Repair I WARNING Accidental machine starting can cause injury or death to personnel working on the machine To avoid accidental machine starting disconnect the battery cables from the battery and tape the battery clamps and remove the key Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on 1 Disconnect battery and discharge any capacitor before starting to work on the product Attach a Do Not Operate tag in the Operator s Compart ment 2 If possible make all repairs with the machine parked on a level hard surface Block the ma chine to prevent it from rolling while working on or under the machine 3 Do not work on any machine that is supported only by lift jacks or a hoist Always use blocks or jack stands to support the machine before per forming any service or disassembly 4 Make sure the work area around the product is made safe and be aware of hazardous condi tions that may exist If an engine is started inside an enclosure make sure that the engine s ex haust is properly vented 5 Be sure all protective devices including guards and shields are properly installed and function ing correctly before starting a repair If a guard or shield must be removed to perform the repair work use extra caution 6 Always use tools that are in good condition and be sure you understand how to use them before performing any service work 7 Re
10. Attachment must be rated at a minimum of 16 3 gallons per minute and 3000 PSI b Attachment hose size must be a minimum of 1 2 inch 7 Faulty hot oil sending unit a Hot oil light should illuminate at 225 F 8 Faulty quick coupler 9 Cooler bypass relief a Cooler bypass relief should open at 80 PSI Problem 15 Track makes popping noise Probable cause 1 2 3 Track too loose Refer to track adjustment section Worn or stuck drive teeth Outer roller should pivot as lug comes into sprocket Loose or worn sprocket Worn track lugs ASV Inc 840 Lily lane P O Box 5160 Grand Rapids MN 55744 ASV Parts amp Service Phone 800 346 4367 ASV Parts amp Service Fax 218 327 2297 www asvi com ASVSP005 07 04 Copyright 2004 ASV Inc Printed in U S A
11. 2 Product Safety Repair for machine preparation information 7 1 7 Radiator Oil Cooler Disassembly and Assembly Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting Radiator Oil Cooler Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following radiator oil cooler components e Fan Guard e Radiator Cooler Note Procedures are provided for only those radiator oil cooler components listed above However information for removal and installation of other radiator oil cooler compo nents can be obtained from the Rubber Track Loader Parts List manual Note Refer to Figure 3 1 for an overview of the filtering and cooling system Fan Guard Removal and In Stallation The tools required for fan guard removal and instal lations are listed in JTable 7 1 Use manufacturer recommended tools whenever possible Table 7 1 Required Tools Combination Wrench Rubber Track Loader 7 Radiator Oil Cooler Disassembly and Assembly Fan Guard Removal 7 001 Figure 7 1 1 Remove the bolts that secure the fan guard to the fan shroud 2 Remove the fan guard from the engine com partment Fan Guard Installation 1 Position the fan guard over the fan and against the fan shroud 2 Install the capscrews that secure the fan guard to the fan guard mounts 7 2 Radiator Cooler Removal and In
12. 7 010 6 Remove the hose and fitting caps and install the lower hose on the oil cooler section 7 Close the petcock and fill the radiator with cool ant and the hydraulic reservoir with oil reas Rubber Track Loader 7 Radiator Oil Cooler Disassembly and Assembly Chapter Overview This chapter provides disassembly and assembly procedures for the hydraulic reservoir assembly Cleaning procedures are also included for the hydraulic reservoir Personal Safety I WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Before starting any disassembly or assembly procedures refer to Chapter 2 Product Safety Basic Precautions for personal safety information Machine Preparation I WARNING Accidental machine starting can cause injury or death to personnel working on the machine To avoid accidental machine starting disconnect the battery cables from the battery and tape the battery clamps and remove the key Place a Do Not Operate tag prominently on the machine to inform personnel that the machine is being worked on Before starting any disassembly or assembly procedures refer to Chapter 2 Product Safety Repair for machine preparation in
13. ccccee eee eeaees 15 2 Chapter Overview This chapter contains product safety information for the RC 60 Rubber Track Loader Read this chapter and understand all safety messages and information messages before attempting to service the machine Safety Messages Safety messages are provided in this document and on the machine If these hazard warnings are not heeded bodily injury or death could occur to you or other persons Hazards are identified by the Safety Alert Symbols The meaning of these safety alerts is as follows Attention Become Alert Your Safety is Involved The message that appears under a Safety Alert Symbol explains the hazard and can be either writ ten or pictorially presented DANGER This symbol is used to alert service personnel of an imminently hazardous situation that will result in seri ous injury or death WARNING This symbol is used to alert service personnel of a potentially hazardous situation that could result in serious injury or death CAUTION This symbol is used to alert service personnel of an unsafe practice that could result in injury Information Messages Information messages are provided in this document and on the machine These messages are identified by the labels NOTICE Note NOTICE This label is used to alert service personnel to the possibil ity of damaging the equipment 5 1 Product Safety Note This label is used to provide important
14. in the seat with the lap bar down for the flow to work 4 Pressure should be approximately 3000 psi All Surface Loader 14 Hydraulic Pressure Check amp Adjustment Jam Nut d 3 i Adjustment B Scren I i q i a pe 7 ae a I TE LES E i e h om T L rf l wo 7 i f i il b F aia P b S mie te LETI E l L B E i z i hh 7 m i 1 i 1 i Y 1 i L d Figure 13 10 113 ae 5 To adjust the auxiliary pressure loosen the jam nut and turn the adjustment screw in with an al len wrench to increase pressure and turn screw out to decrease pressure Tighten jam nut when after adjustment has been made DO NOT ex ceed 3 000 psi 14 3 Chapter Overview This chapter contains basic troubleshooting proce dures for the Rubber Track Loader Additional troubleshooting aids are provided in Chapter 3 System Diagrams and in those chapters containing disassembly and assembly procedures for the appropriate component or assembly Personal Safety WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication mainte nance or repair on this product until you have read and understood the operation lubrication mainte nance and repair information Before starting any troubleshooting procedures re fer to Chapter 2 Product Safety Basic Precautio
15. machine To avoid accidental machine starting disconnect the battery cables from the battery and tape the battery clamps and remove the key Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Before starting any disassembly or assembly proce dures refer to Chapter 2 Product Safety Repair for machine preparation information Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting 9 1 Disassembly and Assembly Loader Transmission Controls Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following loader transmission control compo nents e Left Control Joystick e Right Control Joystick e Loader Float Magnet e Loader Valve Note Procedures are provided for only those loader transmission control components listed above However information for removal and installation of other loader transmission control components can be obtained from the Rubber Track Loader Parts List manual Note Refer to Chapter 3 for an overview of the auxiliary circuit system and drive loop system Joystick Removal and Installa tion There are two joysticks that control the operation of the machine Required Tools Screwdriver Open End Wrench Right Joystick Removal Note Since the procedures for removing both joystick controls are identical
16. problem and make needed repairs before continuing to operate NOTICE If the battery low voltage light illuminates drive the ma chine to a suitable location and shut the engine off Diag nose the problem and make needed repairs before continuing to operate The glow plug operation light illuminates only when the key switch is turned to engine pre heat showing normal operation Figure 4 2 4 003 4 2 Chapter Overview This chapter provides disassembly and assembly procedures for the operator enclosure assembly Personal Safety I WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication mainte nance or repair on this product until you have read and understood the operation lubrication mainte nance and repair information Before starting any disassembly or assembly proce dures refer to Chapter 2 Product Safety Basic Precautions for personal safety information Machine Preparation I WARNING Accidental machine starting can cause injury or death to personnel working on the machine To avoid accidental machine starting disconnect the battery cables from the battery and tape the battery clamps and remove the key Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Before starting any disassembly or assembly
17. s Ne Remove AS a Retaining Clip i i zy F Figure 5 20 5 020 2 Using a small screwdriver remove the retaining clip from each end of the gas assist spring Figure 5 21 5 021 3 Remove the gas assist spring by pulling both ends out from the ball joints Rubber Track Loader 5 Operator Enclosure Disassembly and Assembly Lap Bar Gas Assist Spring Installation Gas Assist Spring Location ace eee eed w3 ASE yE i o7 R9 SSD n A f be a r gt 1 td i r 3 f Figure 5 22 5 022 1 Put the lap bar in the UP position to minimize tension on the lap bar gas assist spring during installation 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 Figure 5 24 5 024 3 Slide the retaining clip on to each end of the gas assist spring 5 6 Chapter Overview This chapter provides disassembly and assembly procedures for the chassis assembly Personal Safety I WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication mainte nance or repair on this product until you have read and understood the operation lubrication mainte nance and repair information Before starting any disassembly or assembly proce dures refer to Chapter 2 Product Safety Basic Precautio
18. screws that fasten the unit to the tank Note Be careful not to cross the wires or hoses If the fuel sending unit wires are crossed the fuel gauge will not work If the hoses are crossed the engine will not run 4 Install the seat Refer to Chapter 6 Seat Instal lation procedure 6 4 Chapter Overview This chapter provides disassembly and assembly procedures for the radiator oil cooler assembly Ad justment procedures are also included for selected radiator oil cooler components Personal Safety I WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication mainte nance or repair on this product until you have read and understood the operation lubrication mainte nance and repair information Before starting any disassembly or assembly proce dures refer to Chapter 2 Product Safety Basic Precautions for personal safety information Machine Preparation I WARNING Accidental machine starting can cause injury or death to personnel working on the machine To avoid accidental machine starting disconnect the battery cables from the battery and tape the battery clamps and remove the key Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Before starting any disassembly or assembly proce dures refer to Chapter
19. that the machine is being worked on Before starting any disassembly or assembly procedures refer to Chapter 2 Product Safety Repair for machine preparation information Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting 12 1 12 Loader Disassembly and Assembly Loader Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following loader components e Lift Cylinders e Tilt Cylinders e Low Flow Relief Valve Note Procedures are provided for only those loader components listed above However information for removal and installation of other loader components can be obtained from the Rubber Track Loader Parts List manual Lift Cylinder Tilt Cylinder Removal and Installation The tools required for lift cylinder removal and installation are listed in Use manufacturer recommended tools whenever possible Table 0 1 Required Tools Combination Wrench Socket Wrench Lift Cylinder Tilt Cylinder Removal Note Since the procedures for removing the lift cylinders and tilt cylinders are identical only the lift cylinder procedure is described below I WARNING Hot oil can cause personal injury Lower all attachments 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
20. the bulb primer with your hand until fuel flows from the bleed screw without any air bub bles 4 Tighten the bleed screw 13 6 Chapter Overview This chapter provides a overview of checking and setting pressures It is important to contact the manufacturer for assistance before beginning these procedures Personal Safety I WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication mainte nance or repair on this product until you have read and understood the operation lubrication mainte nance and repair information Before starting any disassembly or assembly proce dures refer to Chapter 2 Product Safety Basic Precautions for personal safety information Machine Preparation I WARNING Accidental machine starting can cause injury or death to personnel working on the machine To avoid accidental machine starting disconnect the battery cables from the battery and tape the battery clamps and remove the key Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Before starting any disassembly or assembly proce dures refer to Chapter 2 Product Safety Repair for machine preparation information 14 Hydraulic Pressure Check amp Adjustment Hydraulic Pressure Adjustment Procedures Adjustment and test proc
21. the engine for a few minutes to warm the engine oil 16 001 Figure 16 1 2 Remove the drain plug from the bottom of the engine Drain oil into suitable container Remove engine oil filter making sure the gasket is also removed 5 Put some fresh oil on the new filter gasket and install new filter Tighten filter to specifications on filter label 7 Refill engine to capacity with oil as specified Engine Oil Specifications Due to the significant variations in the quality and performance of commercially available oils ASV Posi Lube Heavy Duty Diesel Engine Oil 10W30 is recommended If Posi Lube is not available use one of the the following e Caterpillar Diesel Engine Oil 10W30 Engine Oil 15W40 4 F to 104 F 5 F to 122 F Use only use commercial oils that meet the following classifications Caterpillar Diesel e EMALRG 1 e API CG 4 multigrade oil multigrade oil e API CH 4 e API CF 4 multigrade oil multigrade oil Rubber Track Loader 13 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 I 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 en
22. the tandem pump Cap the hoses and tubes Tandem Pump Installation Pump Drive Remove Bolt Se Mounting Plate Figure 10 7 10 008 i Figure 10 10 10 010 9 Remove the mounting bolt with spring lock washer and flat washer from the right hand side of the tandem pump 11 Install the mounting bolt with spring lock washer and flat washer on the left hand side of the tan dem pump at 85 ft lb with blue loctite 2 fA Figure 10 8 10 009 10 Remove the mounting bolt with spring lock washer and flat washer from the left hand side of the tandem pump Mounting oe _ Plate ii Figure 10 12 10 008 Figure 10 9 10 4 12 Install the mounting bolt with spring lock washer and flat washer on the right hand side of the tandem pump at 85 ft lb with blue loctite 13 Install the hoses and tubes on the tandem pump 14 Install the auxiliary gear pump Refer to Chapter 10 Auxiliary Gear Pump Installation 15 Install the access cover and seat Refer to Chapter 6 Seat Installation 16 Add fuel and manufacturer approved hydraulic fluid Pump Drive Coupler Removal and Installation The tools required for pump drive coupler removal and installation are listed in Table 10 3 Use manu facturer recommended tools whenever possible Table 10 3 Required Tools Screwdriver Combination Wrench Socket Wrench Pump Drive Coupler Removal I WARNING Hot oil can cause personal i
23. to personnel working on the machine To avoid accidental machine starting disconnect the battery cables from the battery and tape the battery clamps and remove the key Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Before starting any disassembly or assembly proce dures refer to Chapter 2 Product Safety Repair for machine preparation information Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting 10 1 Disassembly and Assembly Hydrostatic and Hydraulic Pump Disassembly and As sembly Procedures Disassembly and assembly procedures are provided for the following transmission and drive components e Auxiliary Gear Pump e Tandem Pump e Pump Drive Coupler Note Procedures are provided for only those transmission and drive components listed above However information for removal and installation of other transmission and drive components can be obtained from the Rubber Track Loader Parts Manual Note Refer to Figure 3 2 for an overview of the auxiliary circuit system and Figure 3 3 for an overview of the drive loop system Auxiliary Gear Pump Removal and Installation The tools required for auxiliary gear pump removal and installation are listed in Use manu facturer recommended tools whenever possible Table 10 1 Required Tools Screwdriver Combination Wrenc
24. ICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Figure 6 7 6 004 3 Remove the hoses and wires from the fuel sending unit then remove the screws that fasten the unit to the tank Mark the wires and hoses Note If the fuel sending unit wires are crossed the fuel gauge will not work If the hoses are crossed the engine will not run Figure 6 8 6 005 6 3 Rubber Track Loader 6 Chassis Disassembly and Assembly 4 Remove the fuel sending unit Be careful not to damage the float mechanism when pulling it through the opening in the fuel tank Figure 6 9 6 006 5 The fuel pickup line will also come out with the fuel sending unit Fuel Sending Unit Installation Figure 6 10 6 006 1 Insert the fuel pickup line into the fuel tank open ing The pickup line is attached to the fuel sending unit Note The weight on the end of the fuel pickup line must rest on the bottom of the tank for proper operation 2 Insert the fuel sending unit float mechanism into the fuel tank opening Be careful not to damage the float when pushing it through the opening Rubber Track Loader 6 Chassis Disassembly and Assembly Note Make sure that the wire on the sending unit is not bent and the fuel pickup line does not interfere with the movement of the float 3 Connect the hoses and wires to the fuel sending unit and then install the
25. Loader 3 Systems Diagrams Drive Loop System The drive loop system Figure 3 3 contains the following major components e Tandem pump e Drive motors e Pilot control manifold e Drive control joysticks Figure 3 5 Drive Loop System I0 RESERYOIR B ee i a Li La 7 1 I J H 1 a s 1 H s Ld i w a t H E i 1 cae ay TO RESERVOIR 3 5 Rubber Track Loader 3 Systems Diagrams Electrical Attachment Outlet Figure 3 6 RC 60 Electrical Attachment Outlet CONNECTOR ON LEFT HAND CONTROLER L i L SEAT SWITCH OF MACHINE BUCKET EWN 3 6 Chapter Overview This chapter contains an overview of the machine controls and instrumentation It includes an illustra tion of the following controls and instrumentation components and a description of their functions e Machine controls e Dash panel e Gauge warning light panel Machine Controls There are three primary machine controls loader amp drive control 1 amp 2 and throttle 3 Loader Control RC 60 The loader control 1 allows the operator to raise lower and pivot the attachment using a simple pilot operated joystick sh W ree Bah i dig oe Ga a p a Figure 4 1 4 001 4 1 4 Machine Controls and Instrumentation Loader Control w optional Case control The loader and bucket are controlled by the side ways motion of the controls 1 amp 2 The right joystick operates the bucket and t
26. P BAR LOWERED BEFORE s y 7 LOWER WORK TOOL TO GROUND f m 3 STOP ENGINE AND REMOVE IGNITION KEY MACHINE WILL OPERATE J __ _ 4 REMOVE SEAT BELT PARKING BRAKE IS APPLIED AUTOMATICALLY 0310 122 ALWAYS WEAR YO U R SEAT B E LT FAILURE TO FOLLOW INSTRUCTIONS OR HEED WARNINGS COULD RESULT IN INJURY OR DEATH SEE THE OPERATORS MANUAL FOR DETAILED INSTRUCTIONS 0304 302 WARNING LOADER LIFT ARM BRACE MUST BE IN PLACE WHEN WORKING UNDER LIFT ARMS TO ENGAGE TO DISENGAGE 1 REMOVE WORK TOOL PARK MACHINE 1 REMOVE SPRING FROM CYLINDER ON LEVEL GROUND LOWER LIFT ARMS 2 RAISE LIFT ARMS UNTIL BRACE D A N E E R I 2 RELEASE PIN THAT SECURES BRACE TO FALLS AWAY FROM CYLINDER ROD J FENDER 3 LOWER LIFT ARMS ALL THE WAY 3 WRAP SPRING AROUND CYLINDER AND DOWN ATTACH TO OTHER SIDE OF BRACE 4 SHUT OFF ENGINE AND EXIT 4 RAISE LIFT ARMS UNTIL BRACE RESTS MACHINE ON CYLINDER ROD 5 REATTACH BRACE TO FENDER 5 SLOWLY LOWER LIFT ARMS UNTIL BRACE STOPS MOVEMENT 6 SHUT OFF ENGINE AND EXIT MACHINE FAILURE TO FOLLOW INSTRUCTIONS OR HEED WARNINGS COULD RESULT IN INJURY OR DEATH BREP VGA WHF PRENE OPERATI ARELES WAORH WATS THR ARM FEET C2 LEGS BTA OFRRATOR STATES hi HE FALURE TO FOLLORS IS Tee TE OF HEED WAARME GAN SERAT IH SERRAR HUET OF OATH CARRY LOAD LOW DO NOT EXCEED RATED OPERATING CAPACITY TRAVEL UP AND DOWN LOAD UNLOAD TURN HILL WITH HEAVIEST DANGER ON LE
27. VEL GROUND END OF LOADER UPHILL FAILURE TO FOLLOW INSTRUCTIONS OR HEED WARNINGS COULD RESULT IN INJURY OR DEATH KEEP OUT OF THIS AREA LOADER LIFT ARM MUST BE RESTING ON LOADER STOPS WHEN WORKING UNDER RAISED LIFT ARM 0310 139 FAILURE TO FOLLOW INSTRUCTIONS OR HEED WARNINGS COULD RESULT IN DEATH OR SERIOUS INJURY 1 5 RC 60 Specifications Engi ne Model Cat 3024CT Displacement 2 2 liter Gross horsepower 60 hp 44 7 kW Torque 140 Ib ft 190 Nm Idle rom 2800 high idle 1175 low idle Average water thermostat temperature 190 F 87 8 C Transmission Model Cat AA2Z0VG45T tandem Rexroth Drive pumps Displacement 2 7459 in rev 45 cc rev Relief pressure 5500 psi 380 bar Flow 33 2 gpm 125 Ipm 2800 rpm high idle Charge pump Displacement 1 098 in rev 18 cc rev Relief pressure 400 450 psi Drive Motors Model Rexroth MCR 05C Displacement 37 8 in rev 620 cc rev Control Handles Model CAT 4TH6 Auxiliary Pump Make Haldex Barnes 1 80 2061 Displacement 1 343 in rev 22 cc rev Flow 16 27 gpm 61 85 Ipm 2800 rpm high idle Relief pressure 3000 psi 20 684 kPa Cooling filtering Auxiliary oil is filtered and cooled at all times In Auxiliary mode the oil is filtered after the attachment to protect the ma chine if the attachment motor fails or contami nants are introduced from the quick couplers 2 1 2 Technical Specifications Loader Val
28. ack Loader components e Engine oil e Air cleaner e Hydraulic fluid and filter e Fuse box e Fuel separator and filter e Grease fittings e Track tension e Fuel bleeding The general maintenance schedule for the Rubber Track Loader is listed in the table below Item Frequency Lubricant Capacity Hydraulic Fluid 500 hrs ASV Posi Lube 8 gal 30 Hydraulic Oil or Rykon MV Hydraulic Filter 250 hrs Engine Oil 250 hrs Posi Lube HD 2 6 gal 9 8 Diesel Engine Engine Filter 250 hrs Fuel Filter S00 hrs gt lt gt Primary Air Check daily clean and reuse as needed Filter up to 5 times change at least once per year Secondary Air Every 3 cleanings Filter of primary filter Grease Fittings 10 hrs Posi Lube Lithium Grease Track Tension As needed o o o Coolant Test for coolant additive at 250 hrs Change at 1000 hrs or two years NOTICE When replacing engine coolant use Posi Lube Long Life 50 50 Antifreeze Coolant Caterpillar Extended Life Cool ant or equivalent antifreeze with the proper SCA Supplemental Cooling Additive Engine Oil The normal oil change interval is every 250 service hours or six months whichever comes first Engines that are operated under severe conditions may need the oil changed every 100 service hours or every 3 months whichever comes first Severe operating conditions include high temperatures continuous high loads and dusty conditions 13 1 13 Maintenance Oil Change Procedures 1 Run
29. additional information comments explanations or amplification of the accompanying subject matter The person servicing the Rubber Track Loader may be unfamiliar with many of the systems on the ma chine This makes it important to use caution when performing service work Knowledge of the system and or components is important before the removal or disassembly of any component It is not possible to anticipate every circum stance that might involve a potential hazard The safety messages in this document and on the product are therefore not all inclusive If you use a tool procedure work method or operating technique that is not specifically recommended by the manufacturer you must satisfy yourself that it is safe for you and for others You should also ensure that the product will not be damaged or be made unsafe by the operation lubrication maintenance or repair procedures that you choose Basic Precautions I WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication mainte nance or repair on this product until you have read and understood the operation lubrication mainte nance and repair information Following is a list of basic precautions that should always be observed Safety Signs Read and understand all Safety signs on the prod uct before operating lubricating or repairing thi
30. ansmission and remove the pump Figure 10 6 10 006 Rubber Track Loader 10 Transmission and Drive Disassembly and Assembly 10 3 Tandem Pump Removal and Installation The tools required for tandem pump removal and installation are listed in Use manufac turer recommended tools whenever possible Table 10 2 Required Tools Screwdriver Combination Wrench Socket Wrench Tandem Pump Removal I 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 NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids 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 4 Drain the hydraulic fluid Refer to Chapter 16 Hydraulic Fluid and Filter Change 5 Remove the seat Refer to Chapter 6 Seat Re moval 6 Remove the auxiliary gear pump Refer to Chap ter 10 Auxiliary Gear Pump Removal 7 Remove the belly pan Rubber Track Loader 10 Transmission and Drive Disassembly and Assembly 8 Remove all hoses and tubes from
31. cleaned and reused up to five times but it should be changed at least once a year j Safety Element 16 011 Figure 16 7 3 Remove the safety element The safety element is not serviceable or washable It should be re placed with every three cleanings of the primary element Track Tension Proper track tension is very important for optimum performance and long track life Tracks that are run too loose can cause misfeeding and ratcheting pos sibly causing damage to the track During the first 50 hours of operation the tracks will oreak in and will most likely require adjustment 13 4 Track Tension Adjustment Procedures Figure 16 8 16 005 1 Locate the jam nut on the track tensioner and clean the threads thoroughly before proceeding 2 Loosen the jam nut You can use the wrench supplied with the machine but a standard wrench is preferred for shop use Figure 16 9 3 After loosening the jam nut turn the track ten 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 Drive the machine forward five feet Figure 16 10 16 008 2 Lay a straightedge along the top of the track be tween the sprocket and the front idler wheel 3 Using a rope or wire put 50 pounds of down force on the track at the midpoint of the straight edge 16 009 Figure 16 11 4 Using aruler measur
32. dd manufacturer approved hydraulic fluid Rubber Track Loader 9 Loader Transmission Controls Disassembly and Assembly Leveling Valve Removal and Installation Leveling valve installation Fig 9 40 1 Remove tube connections and unplug the wiring harness Fig 9 41 2 Remove capscrews holding the valve to the frame Place plastic caps on all fittings if avail able Fig 9 42 3 Remove the valve 9 10 Fig 9 43 1 Place the leveling valve against the tower and secure in place with the two 4 20 capscrews in the pretapped holes in the tower b x Fig 9 44 2 Tighten capscrews securely Fig 9 45 3 Reconnect hydraulic tubes and plug in the wiring harness 10 Hydrostatic and Aux Pump Chapter Overview This chapter provides disassembly and assembly procedures for the hydrostatic and auxiliary pump Personal Safety I WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication mainte nance or repair on this product until you have read and understood the operation lubrication mainte nance and repair information Before starting any disassembly or assembly proce dures refer to Chapter 2 Product Safety Basic Precautions for personal safety information Machine Preparation I WARNING Accidental machine starting can cause injury or death
33. draulic Fluid and Filter Change 2 Remove the access cover assembly Refer to Chapter 8 Access Cover Assembly Removal Figure 8 12 8 014 3 With a magnet centered in an absorbent rag thoroughly clean the interior of the reservoir to prevent any debris from entering the system when you remove the suction filter 8 5 Rubber Track Loader 8 Hydraulic Reservoir Disassembly and Assembly Figure 8 13 4 Reach inside the reservoir and unscrew the suction screen Remove the suction screen from the reservoir Suction Screen Installation Figure 8 14 8 015 1 Insert the suction screen in the reservoir through the access cover opening 2 Reach inside the reservoir and screw the suction screen into the bottom of the reservoir 3 Install the access cover assembly Refer to Chapter 8 Access Cover Assembly Installation 4 Add manufacturer approved hydraulic fluid Rubber Track Loader 8 Hydraulic Reservoir Disassembly and Assembly Hydraulic Reservoir Cleaning Procedures Cleaning procedures are provided for the following hydraulic reservoir components e Hydraulic Reservoir Hydraulic Reservoir Cleaning The tools required for hydraulic reservoir cleaning are listed in Table 8 5 Use manufacturer recommended tools whenever possible Table 8 5 Tool Name Combination Wrench I WARNING Hot oil can cause personal injury Make sure the oil is cool before removing any components or lin
34. e Removal and Installation The tools required for low flow relief valve removal and installation are listed in Table 0 2 Use manufacturer recommended tools whenever possible Table 0 2 Required Tools Combination Wrench Socket Wrench Pressure Release Valve Removal I WARNING Hot oil can cause personal injury Lower all attachments and make sure the oil is cool before removing any components or lines NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids 1 Lower the lift arms to the ground 2 Turn the engine start switch to the OFF position Rubber Track Loader 12 Loader Disassembly and Assembly Figure 0 8 13 008 3 Press the button on top of the valve to release hydraulic pressure Figure 0 9 13 009 4 Remove and cap all hoses 13 009 Figure 0 10 5 Remove the four bolts that secure the low flow relief valve to the loader frame and remove the valve 12 4 Quick Coupler Block Pressure Release Valve Installation Figure 0 11 13 009 1 Install the four bolts that secure the low flow relief valve to the loader frame 13 009 Figure 0 12 2 Install all hoses Chapter Overview This chapter contains maintenance requirements and procedures for the following Rubber Tr
35. e Cover Figure 9 14 9 002 2 Remove the joystick side cover E Screws Figure 9 15 9 003 3 Remove the four retaining screws from the top cover ae TE Pull the 9 007 Figure 9 16 4 Remove the rubber boot from the base of the joystick and pull the boot up 9 5 Figure 9 17 9 008 5 Remove the control from the console and locate the loader float magnet at the front of the con trol So aaa iby Dir hel Figure 9 18 9 009 6 The loader float magnet is held in place by an allen screw at the bottom of the magnet Re move this screw 9 010 Figure 9 19 7 Remove the loader float magnet Rubber Track Loader 9 Loader Transmission Controls Disassembly and Assembly Loader Float Magnet Installation Position Figure 9 20 9 010 1 Position the loader float magnet at the front of the control i A H 3 aS ae it ee b E a Figure 9 21 9 009 2 The loader float magnet is held in place by an allen screw at the bottom of the magnet Install this screw Figure 9 22 9 008 3 With the loader float magnet installed the con trol is ready to mount in the console Pull the Boot Down F Figure 9 23 9 007 4 Position the control on the console and pull the rubber boot down over the base of the joystick Install 1 aA i Screws Figure 9 24 9 003 5 Install the four retaining screws in the top cover Position the
36. e procedures for installing both joystick con trols are identical only the right control joystick procedure is described below Hose and Control Labels Figure 9 7 9 006 1 Match the factory labels on the hoses and the control 2 Connect the hoses TE Connect the Wiring Harness Figure 9 8 9 005 3 Connect the joystick wiring harness Rubber Track Loader 9 Loader Transmission Controls Disassembly and Assembly Install Screws Figure 9 9 9 004 4 With the mounting plate wiring harness and hoses installed the control is ready to mount in the console Install 1 aAA l Screws ai 9 003 Figure 9 10 5 Position the control on top of the console and install the four retaining screws in the top cover Position the gt Side Cover Figure 9 11 9 002 6 Place the side cover in position on the console 9 4 Figure 9 12 9 001 7 Install the four retaining screws in the side cover Loader Float Magnet Removal and Installation The tools required for loader float magnet removal and installations are listed n rabie 9 1 Use manufacturer recommended tools whenever ossible able 9 1 Required Tools Screwdriver Open End Wrench Allen Wrench Loader Float Magnet Removal 9 001 Figure 9 13 1 Remove the four retaining screws from the side cover Rubber Track Loader 9 Loader Transmission Controls Disassembly and Assembly Remove Wid Sid
37. e the distance between the straightedge and track The track should not de flect more than 0 75 between the top of the track and the straightedge 5 If the track deflects more than 0 75 tighten the track between 0 50 and 0 75 13 5 Rubber Track Loader 13 Maintenance Fuse Box 16 012 Figure 16 12 The fuse box is located on the left side of the engine compartment The machine should never be oper ated with the fuse box cover removed Grease Fittings a sn SELNES T LE EEE EET EL Shahin 2 2 2 TTE oct Coo a Kiirt a P PE ke T Gil 2 as T ne as es aS Lo Figure 16 13 16 013 The locations of the grease fittings for the left side of the machine are shown above An identical set of fittings is located on the right side of the machine These fitting should be lubricated at least after every 10 hours of operation using Posi Lube Multi Pur pose EP Lithium Grease Rubber Track Loader 13 Maintenance Bleeding the Fuel System The tools required for bleeding the fuel system are listed below Use manufacturer recommended tools whenever possible Table 16 1 Required Tools Combination Wrench If the machine has been run out of fuel it may be necessary to bleed the fuel system Figure 11 25 11 006 1 Locate the bleed screw directly above the fuel injection pump 2 Loosen the bleed screw two full turns Figure 11 27 11 004 3 Pump
38. eal protector over the front wheel shaft 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 Figure 12 14A Figure 0 13 12 047 1 Place the track around the back wheels and on top of the drive sprocket Make sure the track drive lugs mesh with the sprocket Figure 0 15 12 049 Rubber Track Loader 11 Undercarriage Disassembly and Assembly Install the track tool as shown in Figure 0 15 Install the track tool s collar over the 14 wheel hub make sure the collars hinge bolt is closest to the wheel hub See figure 12 16 Figure 0 18 12 055 8 Tighten the track by turning the track tensioner a T n When proper track tension has been achieved ae SSS ee tighten the jam nut on the track tensioner Figure 0 16 ioe 9 Check for proper track tension Refer to Chapter 16 Maintenance Checking for Proper Track he wheel h ide guide 6 Place the wheel between the outside guide lugs Adjustment and the inside drive lugs then pry the wheel along with the track using the track tool Line up the wheel with the shaft and slide the wheel on lt is very important to use the bullet shaped thread seal protector during this procedure Sprocket Bearing Removal and Installation The tools required for sprocket bearing plate removal and installation are listed in Use man
39. edures are provided for the following transmission and drive components e Charge Pressure Check amp Adjustment e Auxiliary Valve Pressure Check amp Adjustment Charge Pressure Check The service tools required for the charge pressure check are listed in Table 0 1 Use manufacturer recommended tools whenever possible Table 0 1 eo Fest Port Figure 0 1 10 101 All Surface Loader 14 Hydraulic Pressure Check amp Adjustment _ Attach Gau Figure 0 2 10 102 1 Attach the gauge to the charge pressure test port located next to the fuel filter 2 Start the engine 3 Check the pressure with the engine at wide open throttle Make sure the engine is properly warmed up before running wide open Charge pressure should be between 400 and 450 psi 4 Turn the engine start switch to the OFF position Remove the gauge from the test port Install the floor pan Auxiliary Pressure Check amp Adjustment The service tools required for the auxiliary pressure check and adjustment are listed in Table 0 1 Use manufacturer recommended tools whenever possi ble Table 0 2 Required Tools Pressure Gauge Allen Wrench 14 2 Figure 10 1 Insert the hydraulic gauge into one of the at tachment quick couplers 10 111 Figure 11 2 Engage the continuous flow switch next to the key switch Make sure it is in the direction that sends flow to the gage 3 There must be an operator
40. ee eee 2 1 WRENS IMIS SIO Mics xc roeaes sacczecclvcscs cope tcssensuecnzsseseeseceeas 2 1 Drive MOtors c ccccccsececeeeeceeeeeceeeceeeeseeeeseeeees 2 1 C nirolHandle S rnei nadine 2 1 A xiliaty PUMP eeii eeecese aes Sia 2 1 Loader Vae ssaceanie Aae a sora 2 1 CODE e E 2 1 System Diagrams Chapter Overvie W ciie 3 1 Filtering and Cooling SyStem cceceeeeeeertee 3 1 Auxiliary Circuit System RC 60 cceeeeeeees 3 2 Drive Loop System RC 60 ceeeeeeeeeeeeee 3 3 Auxiliary Circuit System R 60 ceceeeeeeees 3 4 Drive Loop System R 60 ceeeeeeeeeeeeees 3 5 Machine Controls and Instrumentation Chapter OVErVieW cccccccssseseeeeeeeeeeseeeeeeseeaeaaeees 4 1 Machine Controls cccccccccccsssecceecessecesseeeseeeeeeas 4 1 Loader Control citcs ais tnotcesshesdeevtapsdsaisnargecvaebdeors 4 1 EEIWE COMI O chien vicnieewigee E sawn 4 1 MALOO ete tangnae Masha tol cq ctetaadacanasen tender acaad 4 1 DAS AIP ANC esas vecevcscteue see vecdentre es ioatcrenanetnsseeeeseeage 4 1 Gauge Warning Light Panel ccccccceeeeeeeeeeee 4 2 Operator Enclosure Disassembly and Assembly Chapter OVErVieW scssssseeeeeeeeeeeeeeseaeesssseeeees 5 1 Personal Safety cccccccccccccceessseseeeeeeeeeeeeeeeeeeaeaes 5 1 Machine Preparation cccccssseeeeeeeseeeeeeeseeeeeees 5 1 Preliminary Checkout ccsseeeeeeeeeeeeeseeee
41. eeeeeaes 5 1 Operator Enclosure Disassembly and Assembly Procede S earn e AA 5 1 Light Bar Removal and Installation 000 5 1 Light Bar EMOV Al atnceitdalvscncn eaten aeitheowiaiwetie 5 1 Table of Contents Light Bar Installation cccccccsseeeeesseeeeeeeees 5 2 Ignition Switch Removal and Installation 5 2 Ignition Switch Removal ccccssseeeeeeeseeeeees 5 2 Ignition Switch Installation cccccsseeeeeeeeees 5 3 Console Gauge Warning Panel Removal and NAS TANTO ices lt lt itasatedasictotuhasdude soaseodatncnacceaessueceatesas 5 4 Console Gauge ReEmoval cccccccsssssseeeeeeeeees 5 4 Console Gauge Installation eeeee 5 4 Lap Bar Gas Assist Spring Removal ANG IMIStANATON ssas toe EE 5 5 Lap Bar Gas Assist Spring Removal 5 5 Lap Bar Gas Assist Spring Installation 5 5 Chassis Disassembly and Assembly Chapter Ove view sceet veer sercsnczsvneests ice seeccocnerteeteotvves 6 1 PEI SOMMali SAlCly icradan e E Malate 6 1 Machine Preparation cccceeeeeeeeeeeeeeeeeees 6 1 Preliminary GHECKOUV arrus 6 1 Chassis Disassembly and Assembly Procedures araea ae e oe 6 1 Seat Removal and Installation ccccccsseeeeeeeees 6 1 Seat REMOVAL nsari ana 6 1 Seat Installation cccceeeccccceeesseeseeeeeeeeeeeeeees 6 2 Fuel Sending Unit Removal and Installation 6 2 Fuel Sending Unit Removal
42. eeees 13 1 Engine Oil Specifications ccccsseeeeeeeeees 13 1 Hydraulic Fluid and Filter ccccccceeeeeeeeeeeeeeee 13 2 Hydraulic Fluid and Filter Change PIOCCOURES cin nenon h a NE Aa ARTE 13 2 Fuel FIET 22 3228 sen ctsaecdascecteunieadeasdacodeentesdeedeeaeceaoes 13 3 Fuel Filter Change Procedures 0006 13 3 Fuel Specifications csini na 13 3 Air NOUN G Wiehe orto ches to i aerate e 13 3 Air Filter Change Procedures 13 3 Tack MOMSION estes teeters e a veoats 13 4 Track Tension Adjustment Procedures 13 4 Checking for Proper Track Adjustment 13 4 FUSE BOX bc vncieshsancah recat a 13 4 Grease Fittings x22 asa ksenstedecdcocacusass ieseetnddeesesbeoedes 13 5 Hydraulic Pressure Check amp Adjustment Charge Pressur check ccic sic sedc canteen axtiesacsecnes 14 1 Charge Pressure Adjustment c0sceeeeees 14 2 Drive Pressure Adjustment ccceeeeeeeees 14 3 Auxiliary Pressure Check amp Adjustment 14 4 Troubleshooting Chapter OVErVieW cccccccccccsssssseseeeeeeeeeeeeeeeeaaees 15 1 Personal Safety ssssssseeeeeeeeeeeeeeeeeeseaeeeeeeees 15 1 Machine Preparation cccccccsssseeeeeeeneeeeeeaees 15 1 Preliminary Checkout cccccceeeeesseeeeeeeeeeeeeees 15 1 Visual INS pectic tae 15 1 Operational Checks ccccceeeeseeeeeeeeeeeaeeeees 15 1 Troubleshooting SCenariOS
43. eep the work tool tilted down and as sure that all hydraulic pressure has been re lieved for maintenance or repair work that requires the lift arms to be in the raised position 13 Tighten connections to the correct torque Make sure that all heat shields clamps and guards are installed correctly to avoid excessive heat vibra tion or rubbing against other parts during opera tion Shields that protect against oil spray onto hot exhaust components in event of a line tube or seal failure must be installed correctly 14 Do not operate a machine if any rotating part is damaged or contacts another part during opera tion Any high speed rotating component that has been damaged or altered should be checked for balance before reusing Make sure all protective devices including guards and shields are properly installed and functioning correctly before starting the engine or operating the machine Work Tools Only use work tools that are recommended by the manufacturer of the machine Make sure that all necessary guarding is in place on the host machine and on the work tool Wear protective glasses and protective equipment as required by conditions or as recommended in the work tool s operation manual 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 jects Stay clear of the cutting edges pinching surfaces or crushing surfaces o
44. emove the upper hose from the radiator sec tion Cap the hose and fitting 2 Drain the coolant using the petcock on the bot tom of the radiator ESS TAS tai 5 i ai I ra Pt Figure 7 6 7 012 Figure 7 3 7 010 6 Remove the lower hose from the radiator sec 3 Remove the lower hose from the oil cooler sec tion Cap the hose and fitting tion Cap the hose and fitting Figure 7 4 7 002 4 Remove the upper hose from the oil cooler sec tion Cap the hose and fitting Figure 7 7 7 003 7 3 Rubber Track Loader 7 Radiator Oil Cooler Disassembly and Assembly 7 Remove the three mounting bolts on each side of the radiator cooler Figure 7 8 7 013 8 Remove the radiator cooler from the engine compartment Radiator Cooler Installation Figure 7 9 7 013 1 Install the engine shroud and position the radia tor cooler in the engine compartment Figure 7 10 7 003 2 With the radiator cooler in position install the three mounting bolts on each side of the radia tor cooler a it i Figure 7 11 7 012 3 Remove the hose and fitting caps and install the lower hose on the radiator section Figure 7 12 7 011 4 Remove the hose and fitting caps and install the upper hose on the radiator section E x Install AN Hose Figure 7 13 7 002 5 Remove the hose and fitting caps and install the upper hose on the oil cooler section Figure 7 14
45. equired for track removal and installation are listed in Table 0 3 Use manufacturer recommended tools whenever possible Table 0 3 Required Tools Socket Wrench Floor Jack Track Tool Combination Wrench Thread Seal protector Rubber Track Loader 11 Undercarriage Disassembly and Assembly Track Removal I WARNING To remove the tracks the machine must be jacked up and placed on jack stands sturdy enough to support the weight of the machine The manufacturer supplied jack stands are recommended Figure 0 10 12 011 3 Using the wheel extractor loosen the front wheel and remove the outside roller bearing The outside guide lugs will prevent you from removing the front 14 outside wheel without the track coming off at the same time Figure 0 9 12 016 1 Loosen the track completely by loosen the track jack with an 1 7 8 wrench 2 Remove the front wheel s wheel cap and install the thread seal protector bullet shaped piece over the end of the shaft TE Figure 0 11 12 012 4 Remove the 14 wheel The front 14 outside wheel and the front of the track will come off together Figure 12 9 Rubber Track Loader 11 Undercarriage Disassembly and Assembly Figure 0 12 12 013 Figure 0 14 12 048 2 Using soap lubricate the front inside wheel Pull Track Installation the track into the position shown in figure 12 15 I WARNING 3 Install the bullet shaped thread s
46. es Remove the oil filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates 1 Drain the hydraulic fluid Refer to Chapter 16 Hydraulic Fluid and Filter Change 2 Remove the access cover assembly Refer to Chapter 8 Access Cover Assembly Removal 3 Thoroughly wipe out the interior of the hydraulic reservoir with a magnet and a clean rag 4 Install the access cover assembly Refer to Chapter 8 Access Cover Assembly Installation 5 Add manufacturer approved hydraulic fluid 8 6 9 Loader Transmission Controls Chapter Overview This chapter provides disassembly and assembly procedures for the loader transmission controls as sembly Personal Safety I WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication mainte nance or repair on this product until you have read and understood the operation lubrication mainte nance and repair information Before starting any disassembly or assembly proce dures refer to Chapter 2 Product Safety Basic Precautions for personal safety information Machine Preparation I WARNING Accidental machine starting can cause injury or death to personnel working on the
47. f the work tool while performing any work tool maintenance testing or adjustments Asbestos Information Equipment and replacement parts shipped from the manufacturer are asbestos free When replacement parts are required use only genuine manufacturer s replacement parts Use caution when handling replacement parts from another supplier if these parts contain asbestos Avoid inhaling dust that might be generated when handling these components or when handling as bestos debris Inhaling this dust can be hazardous to your health The components that may contain asbestos fibers are lining material and some gaskets The asbestos that is used in these components is usually encased in a resin or sealed in some way Normal handling is not hazardous unless airborne dust containing as bestos is generated If dust that may contain asbestos is present there are several guidelines that should be followed 1 Never use compressed air for cleaning Avoid brushing or grinding materials that contain as bestos Use a wet method to clean up asbestos debris A vacuum that is equipped with the high efficiency particulate air filter HEPA filter can also be used 2 Use exhaust ventilation on permanent machin ing jobs 3 Wear an approved respirator if there is no other way to control the dust 4 Comply with applicable rules and regulations for the work place In the USA use Occupational Safety and Health Administration requirements T
48. formation Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting 8 1 8 Hydraulic Reservoir Disassembly and Assembly Hydraulic Reservoir Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following hydraulic reservoir components e Filter Assembly e Access Cover Assembly e Reservoir Gauge e Suction Screen Note Procedures are provided for only those hydraulic reservoir components listed above However information for removal and installation of other hydraulic reservoir components can be obtained from the Rubber Track Loader Parts List manual Note Refer to Figure 3 1 for an overview of the filtering and cooling system Filter Manifold Assembly Removal and Installation The tools required for filter assembly removal and installation are listed in Table 8 1 Use manufacturer recommended tools whenever possible Table 8 1 Required Tools Combination Wrench Note Refer to Chapter 14 Maintenance for procedures on changing the hydraulic filter element Rubber Track Loader 8 Hydraulic Reservoir Disassembly and Assembly Filter Manifold Assembly Removal 3 Remove the filter manifold assembly Reverse Steps for intstallation I WARNING Hot oil can cause personal injury Make sure the oil is Access Cover Removal and cool before removing any components or lines Remove the oil fille
49. gh the opening in the top of the reservoir and into the tank 8 3 Rubber Track Loader 8 Hydraulic Reservoir Disassembly and Assembly Figure 8 6 8 012 2 Tighten the access cover bolt Reservoir Gauge Removal and Installation The tools required for reservoir gauge removal and installation are listed in Table 8 3 Use manufacturer recommended tools whenever possible Table 8 3 Required Tools Combination Wrench Reservoir Gauge Removal I 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 NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids 1 Drain the hydraulic fluid Refer to Chapter 14 Maintenance 2 Remove the filter manifold Refer to Chapter 8 Filter Assembly Removal Rubber Track Loader 8 Hydraulic Reservoir Disassembly and Assembly Figure 8 7 8 016 3 View of hydraulic reservoir with filter assembly removed Figure 8 8 8 017 4 Reach inside the reservoir and remove the two nuts that fasten the reservoir gauge to the reservoir Remove Reservoir Gauge with Mounting Figure 8 9 8 018 5 Pull the
50. ght a SR WE Level Light Gauge Figure 5 4 5 004 4 View of light bar interior to operator s left when seated 5 2 Light Bar Installation Figure 5 5 5 005 1 Carefully position the light bar without pinching the wiring harness against the cab frame 5 006 Figure 5 6 2 Secure the light bar to the cab frame with the two bolts Ignition Switch Removal and Installation The tools required for ignition switch removal and installation are listed in Table 5 2 Use manufac turer recommended tools whenever possible Table 5 2 Required Tools Combination Wrench Rubber Track Loader 5 Operator Enclosure Disassembly and Assembly Ignition Switch Removal J ee 1 Lower the light bar Refer to Chapter 5 Light Bar 4 Unplug the ignition switch connector Removal procedure Ignition Switch Installation ee Remove Nut Figure 5 7 5 007 2 Remove the nut that secures the ignition switch Figure 5 10 p 5 010 to the dash panel 1 Insert the ignition switch from the rear of the dash panel Install Nut Figure 5 8 5 008 Figure 5 11 5 011 3 Pull the ignition switch out from the rear of the dash panel 2 Install the nut that secures the ignition switch to the dash panel 5 3 Rubber Track Loader 5 Operator Enclosure Disassembly and Assembly Figure 5 12 5 012 3 Plug in the ignition switch connector 4 Install the light bar Refer to Chapter 5 Light Bar Instal
51. gine is stopped and the filler cap is cool enough to touch with your bare hand NOTICE Extreme care must be taken when changing the hydraulic fluid Before starting the procedure make sure the ma chine is in a clean working environment Precautions should be taken to prevent any debris from entering the hydrostatic system NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Hydraulic Fluid Drain Plug Figure 16 2 16 002 1 Locate and remove the hydraulic fluid drain plug and drain the fluid into a suitable container 13 2 Figure 16 3 16 015 2 Clean the area around the filter assembly which is located on the top of the hydraulic reservoir 16 003 Figure 16 4 3 Turn the hydraulic filter counter clockwise and remove the filter 4 Change the filter element and replace the filter in the tank 5 Fill with manufacturer approved hydraulic fluid Fuel Water Separator 1 Turn the fuel shut off valve up to close the fuel supply 2 Remove the retaining ring from the fuel water separator Remove the bowl float spring and screen Dump any water from the bowl and make sure the screen is clean 5 Reinstall components and reopen the fuel shut off valve by turning to the down position Fuel Filter The fuel filter should be changed every 500 service hours or as needed A plugged fuel filter can cause loss of engi
52. h Socket Wrench Auxiliary Gear Pump Removal I WARNING Hot oil can cause personal injury Lower all attach ments and make sure the oil is cool before removing any components or lines Rubber Track Loader 10 Transmission and Drive Disassembly and Assembly Remove the oil filler cap only when the engine is stopped and the filler cap is cool enough to touch with your hands NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids 1 Lower the lift arms to the ground 2 Turn the engine start switch to the OFF position Figure 10 2 10 002 3 Relieve hydraulic pressure from the auxiliary 7 Remove the access cover beneath the seat circuit 4 Drain the hydraulic fluid Refer to Chapter 76 Hydraulic Fluid and Filter Change 5 Remove the seat Refer to Chapter 6 Seat Re wat I B A fi moval we S E Bi KF a ON j AVE Figure 10 3 10 003 8 Disconnect the 4 bolt split flange fitting ae ie _ i TE pas cs j 7 E pe z ANA i a i eae as i r SIM I a p i i 3 a Figure 10 1 10 001 6 View with seat removed Figure 10 4 10 004 10 2 9 Remove the other split flange fitting and the re maining fitting Figure 10 5 10 005 10 Remove the 2 bolts that mount the pump to the hydrostatic tr
53. he left joystick operates the loader boom Drive Control RC 60 The drive control 2 allows the operator to change directions and speed using a simple pilot operated joystick Drive Control w optional Case control The forward and reverse motion of each track is con trolled by the forward and back motion of the con trols 1 amp 2 The right joystick operates the right track and the left joystick operates the left track Throttle The throttle controls engine rpm Dash Panel The dash panel Error Reference source not is positioned for easy visibility in the heads up position inside the operator s enclosure The dash panel includes the following components 1 Interior light 1 2 Slope indicator 3 Self level Switch 4 5 4 Ignition switch 5 Gauge warning light panel Figure 4 2 O Rubber Track Loader 4 Machine Controls and Instrumentation Gauge Warning Light Panel The gauge warning light panel Figure 4 2 includes the following indicator lights 1 Engine coolant temperature warning 2 3 4 5 6 7 Glow plug operation Engine oil pressure warning Hydraulic oil temperature warning Battery low voltage warning Fuel gauge mm em A AAR gt a A a a Service hour meter NOTICE If the engine coolant temperature engine oil pressure or hydraulic oil temperature lights illuminate during normal machine operation shut the machine down immediately Diagnose the
54. heel cap Figure 0 3 12 007 j i iii 79 i ot j aS a d i E aW Figure 0 4 12 008 4 Using a socket remove the nut that fastens the wheel to the shaft Remove the wheel with the wheel extractor Figure 0 5 12 009 5 To remove an inside wheel slide under the machine and repeat the wheel removal procedure Figure 0 6 12 010 6 With wheels removed inspect the bearings and axle for wear or damage Sprocket Roller Removal and Installation The tools required for sprocket roller removal and installation are listed in Use manufacturer recommended tools whenever possible Table 0 2 Note The rollers should be inspected every 25 hours for rotation and wear through The rollers on the drive sprocket are easily replaceable The track DOES NOT need to be removed to replace these rollers Roll as Drive Sprocket Steel Pin Sprocket Roller Bolt y Rubber Track Loader 11 Undercarriage Disassembly and Assembly Figure 0 7 12 057 1 Rotate the drive sprocket to allow access to the sprocket roller bolt Remove the bolt 2 Remove the roller and steel pin from the drive sprocket Steel em aX 18 Steel Pin gt Figure 0 8 12 019 3 Inspect the rollers for wear and replace as necessary The inner steel pin will normally not need replacing unless the roller has worn completely away and the steel pin is worn Track Removal and Installation The tools r
55. hese OSHA requirements can be found in 29 CFR 1910 1001 5 Obey environmental regulations for disposal of asbestos 6 Stay away from areas that might have asbestos particles in the air 1 4 I WARNING When replacement parts are required for this product use only genuine manufacturer s replacement parts or parts with equivalent specifications including but not limited to physical dimensions type strength and material Failure to heed this warning can lead to premature failures product damage personal injury or death Machine Labels and Decals Labels and decals placed on the machine provide safety information and operating instructions Make sure you know the location of these labels and un derstand their significance Product ID Number The product ID number PIN is located on the left side of the firewall Figure 1 1 Always provide the PIN when contacting the dealer about parts service warranty or accessories No warranty claims will be processed unless the PIN is provided Figure 1 1 1 001 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 WARNING MOUNTING AND DISMOUNTING OPERATING INSTRUCTIONS a MAINTAIN he 2 FEET AND 1 HAND OR 1 FOOT AND 2 HANDS WITH STEPS AND HAND HOLDS OPERATOR MUST BE IN SEAT JA WHEN LEAVING LOADER 1 PARK MACHINE ON LEVEL GROUND WITH LA
56. lation 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 Table 5 3 Required Tools Combination wrench Console Gauge Removal 1 Lower the light bar Refer to Chapter 5 Light Bar Removal procedure Figure 5 13 2 Remove the connectors from the console gauge Figure 5 14 5 014 3 Remove the two nuts that secure the console gauge to the retaining clip Figure 5 15 5 015 4 Pull the console gauge out from the front of the dash panel Console Gauge Installation Figure 5 16 5 016 1 Insert the console gauge from the front of the dash panel Figure 5 17 5 017 2 Install the two nuts that secure the console gauge to the retaining clip Figure 5 18 3 Plug in the console gauge connectors 4 Install the light bar Refer to Chapter 5 Light Bar Installation procedure Lap Bar Gas Assist Spring Removal and Installation The tools required for gas assist spring removal and installation are listed in Table 5 4 Use manufac turer recommended tools whenever possible Table 5 4 Required Tools 5 5 Rubber Track Loader 5 Operator Enclosure Disassembly and Assembly Lap Bar Gas Assist Spring Removal Figure 5 19 1 Putthe lap bar in the UP position to relieve ten sion on the lap bar gas assist spring
57. ne power rough running or no start NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates 13 3 Rubber Track Loader 13 Maintenance Fuel Filter Change Procedures Figure 16 5 1 Clean the outside of the filter thoroughly 2 Remove the spin on filter and dispose of prop erly Pour diesel fuel into the new filter until it is full Spin the new filter into place and tighten Fuel Specifications In North America diesel fuel distilled from crude oil and identified as NO 1 D or No 2 D in ASTM D975 generally meets the proper specifications Air Cleaner The air cleaner is one of the most important mainte nance items on the machine A poorly maintained air cleaner can seriously shorten the life of the engine Air Filter Change Procedures NOTICE When working in dusty conditions the air cleaner ele ments should be checked and changed more frequently than when working under normal conditions NOTICE Do not clean the primary air cleaner element by bumping and tapping This could damage the seals Do not use elements with damaged pleat gaskets or seals 1 Open the hood release the latches on either side of the air cleaner and then remove the cover Rubber Track Loader 13 Maintenance Primar Elgme as 1 3 i Y Fet ae Eo A Figure 16 6 16 010 2 Remove the primary element The primary ele ment can be
58. nections on fuse relay or safety sole noid 8 Low charge pressure Problem 4 Loader operates but tracks will not move Probable cause 1 Leak in feed line to pilot control 2 Pilot control malfunctioning 3 Low pilot pressure Problem 5 Tracks operate but loader will not operate Probable cause 1 Continuous hyd flow switch activated sending oil over relief 2 Check to see if auxiliary flow works If auxiliary flow works skip to number 5 3 Main auxiliary relief malfunction 4 Auxillary pump bad 5 Leak in feed line to loader control pilot 6 Loader control pilot malfunctioning 7 Loader valve malfunctioning Problem 6 Auxiliary flow does not work Loader works Probable cause 1 Auxiliary hydraulic fuse blown 2 Faulty ground wire a Clean ground connections on left rear side of hydraulic tank 3 Auxiliary hydraulic switch failure 4 Poor wire connections at fuse auxiliary hyd switch or pin connector P17 5 Auxiliary hydraulic pilot generation spool stuck 6 Bad or not fully connected Quick Coupler Problem 9 Auxiliary hydraulics will only flow one way Try both con tinuous flow and intermittent thumb switch Probable cause 1 Auxiliary hydraulic relay 1 or 2 failure 2 Auxiliary hydraulic pilot generation coil faulty 3 Auxiliary hydraulic pilot generation spool faulty 4 Poor wire connections at relay pilot generation so lenoid pin connector P16 or P21 5 L
59. njury 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 NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids 1 Lower the lift arms to the ground 2 Turn the engine start switch to the OFF position Rubber Track Loader 10 Transmission and Drive Disassembly and Assembly 3 Relieve hydraulic pressure from the auxiliary circuit 4 Drain the hydraulic fluid Refer to Chapter 16 Hydraulic Fluid and Filter Change 5 Remove the seat Refer to Chapter 6 Seat Re moval 6 Remove the auxiliary gear pump Refer to Chap ter 10 Auxiliary Gear Pump Removal 7 Remove the tandem pump Refer to Chapter 10 Tandem Pump Removal Loosen Locking Pump X Drive E Coupler i Tandem Pump Figure 10 13 10 011 8 Loosen the locking screw that secures the pump drive coupler to the drive shaft extending from the end of the tandem pump Tandem Pump Drive Shaft Pump Drive Coupler Figure 10 14 10 012 9 Slide the pump drive coupler off the tandem pump drive shaft Rubber Track Loader 10 Transmission and Drive Disassembly and Assembly Pump Drive Coupler Ins
60. ns for personal safety information Machine Preparation I WARNING Accidental machine starting can cause injury or death to personnel working on the machine To avoid accidental machine starting disconnect the battery cables from the battery and tape the battery clamps and remove the key Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Before starting any troubleshooting procedures re fer to Chapter 2 Product Safety Repair for ma chine preparation information 15 1 15 Troubleshooting Preliminary Checkout A simple visual inspection and operational check can identify many problems without the need for ex tensive troubleshooting If these checks indicate a problem that requires further analysis proceed to Troubleshooting in this section Visual Inspection Prior to troubleshooting do a walk around and per form a visual inspection of the machine Look for missing loose or worn parts Perform the following visual checks e Track tension e Fluid levels e Fan belt tension and condition e Hoses no visible sign of wear e Fittings no leaks e Battery cables e Fuse box fuses in place and operational e Controls for neutral Rubber Track Loader 15 Troubleshooting Troubleshooting Th is section identifies selected problems and sug gests probable causes Problem 1 Machine will not crank over Probable cau
61. ns for personal safety information Machine Preparation I WARNING Accidental machine starting can cause injury or death to personnel working on the machine To avoid accidental machine starting disconnect the battery cables from the battery and tape the battery clamps and remove the key Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Before starting any disassembly or assembly proce dures refer to Chapter 2 Product Safety Repair for machine preparation information Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting 6 Seat amp Fuel Sender Dis 6 1 assembly and Assembly Chassis Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following chassis components e Seat e Fuel Sending Unit e Fuel Sending Unit Hose e In Tank Weight Note Procedures are provided for only those chassis components listed above However information for re moval and installation of other chassis components can be obtained from the exploded view illustration provided in the Rubber Track Loader Parts List manual Seat Removal and Installation The tools required for seat removal and installation are listed in Table 6 11 Use manufacturer recommended tools whenever possible Table 6 1 Required Tools Socket Wrench Seat Removal
62. oader 3 System Diagrams Auxiliary Circuit System RC 60 The auxiliary circuit system Figure 3 2 contains the following major components e Loader valve e Pilot control manifold e Auxiliary gear pump e Loader control joystick Figure 3 2 RC 60 Auxiliary Circuit System KU 60 AUX TO BUCKET CYLINDER HT i TO RESERVOIR CHARGE TO TRANSMISSION 3 2 f TO IMPLEMENT 3 002 TO LOADER CYLINDER p HU LUADER ee li TO COOLER RELIEF a Q N Rubber Track Loader 3 System Diagrams Drive Loop System RC 60 The drive loop system Figure 3 3 contains the fol lowing major components e Drive motors e Pilot control manifold e Drive control joystick e Tandem Pump Figure 3 3 RC 60 Drive Loop System 3 003 3 3 Rubber Track Loader 3 Systems Diagrams Auxiliary Circuit System RC 60 with optional Case controls The auxiliary circuit system Figure 3 2 contains the following major components e Loader valve e Pilot control manifold e Auxiliary gear pump e Loader control joysticks Figure 3 4 Auxiliary Circuit System TO BUCKET CYLINDER TO LOADER CYLINDER _ TU LOADER ge OS TO COOLER RELIEF 0 IMPLEMENT TO RESERVOIR y D Z o Ma Sor gt YY i PAS CHARGE TO TRANSMISSION 3 4 Rubber Track
63. oader valve malfunction Problem 10 No power to numerous auxiliary functions or accessories in ON or RUN position Probable cause 1 Main power relay A or B fuse blown 2 Main relay A or B faulty 3 Ignition switch malfunction 4 Poor wire connections at ignition switch fuse or re lay Problem 11 Battery will not charge and or battery goes dead Probable cause 1 Alternator fuse blown 2 Alternator diode bad 3 Poor wire connections at battery alternator diode or fuse 4 Excessive draw in off position a Fuel gauge and hour meter should draw only 0 01 amps in off position 5 Bad battery 6 Bad alternator Problem 12 Loader control will not lock in float position Probable cause 1 2 3 Float magnet fuse blown Poor wire connections at fuse float detent magnet or pin connector P18 Faulty float detent magnet 15 3 Rubber Track Loader 15 Troubleshooting Problem 13 Loader will not float labors engine and has down pressure when detented into float Probable cause 1 Engine RPM too low 2 Low charge pressure 3 Pilot control malfunction 4 Loader valve malfunction Problem 14 Hot oil light illuminates hydraulic system operating hot Probable cause 1 Auxiliary hydraulic switch activated sending oil over relief 2 Low oil level 3 Debris plugging oil cooler limiting airflow 4 Broken fan blades 5 Loose fan belt 6 Improper attachment a
64. only the right control joystick proce dure is described below Rubber Track Loader 9 Loader Transmission Controls Disassembly and Assembly Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids I WARNING Lower all attachments and make sure the oil is cool before removing any components or lines Hot oil can cause personal injury 1 Lower the lift arms to the ground 2 Turn the engine switch to the OFF position and disconnect the battery 3 Relieve hydraulic pressure from the auxiliary circuit 9 2 Figure 9 1 9 001 4 Remove the four retaining screws from the side Cover SS r m i m a r E j Remove gt 5 Side Cover 9 002 Figure 9 2 5 Remove the joystick side cover E i Screws 9 003 Figure 9 3 6 Remove the four retaining screws from the top cover Rubber Track Loader 9 Loader Transmission Controls Disassembly and Assembly Figure 9 4 9 004 7 Pull the joystick out of the console The mount ing plate wiring harness and hoses will stay connected to the joystick lt fl i Disconnect the Wiring Harness Figure 9 5 9 005 8 Disconnect the joystick wiring harness Hose and Control Labels Figure 9 6 9 006 9 The hoses and the control are labeled at the factory Make sure the labels are still legible 10 Remove the hoses Joystick Installation Note Since th
65. place all fasteners with the same part num ber Do not use a lesser quality fastener if re placements are necessary 8 Be prepared to stop an engine if it has been re cently overhauled or the fuel system has been recently worked on If the engine has not been assembled correctly or if the fuel settings are not correct the engine can possibly overspeed and cause bodily injury death or property dam age Be prepared to shut off the fuel and air supply to the engine in order to stop the engine 1 3 Rubber Track Loader 1 Product Safety 9 Becareful when removing cover plates Gradu ally back off the last two bolts or nuts located at opposite ends of the cover or device Then pry the cover loose to relieve any spring or other pressure before removing the last two nuts or bolts completely 10 Repairs requiring welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures De termine the type of metal being welded and se lect the correct welding procedures and electrodes rods or wire to provide a weld metal equivalent at least to that of the parent weld 11 Do not damage wiring during removal opera tions Reinstall the wiring so it is not damaged during installation or operation by contacting sharp corners or by rubbing against some object or hot surface 12 Always use lift arm supports to keep lift arms raised K
66. proce dures refer to Chapter 2 Product Safety Repair for machine preparation information Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting 5 1 5 Operator Enclosure Disassembly and Assembly Operator Enclosure Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following operator enclosure components e Light Bar e Ignition Switch e Console Gauge Warning Panel e Lap Bar Gas Assist Spring Note Procedures are provided for only those operator enclosure components listed above However information for removal and installation of other operator enclosure components can be obtained from the Rubber Track Loader Parts List manual Light Bar Removal and Installation The tools required for light bar console removal and installation are listed in Table 5 1 Use manufac turer recommended tools whenever possible Table 5 1 Required Tools Combination Wrench Light Bar Removal 5 001 Figure 5 1 1 Remove the two bolts that attach the light bar to the cab frame Rubber Track Loader 5 Operator Enclosure Disassembly and Assembly Figure 5 2 5 002 2 Carefully lower the light bar with the wire har ness attached Ignition Switch Figure 5 3 5 003 3 View of light bar interior to operator s right when seated Interior components are now accessible for servicing Headli
67. r cap only when the engine is Installation stopped and the filler cap is cool enough to touch with The tools required for access cover removal and your bare hand installation are listed in Table 8 2 Use manufacturer recommended tools whenever possible Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids Table 8 2 Required Tools Combination Wrench Access Cover Assembly Removal I 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 Figure 8 1 8 001 1 Remove the hose from the filter manifold assembly Cap hose and fitting Figure 8 3 8 012 1 Slightly loosen the access cover bolt to separate the upper cap from the oval shaped clamping disk on the underside of the assembly This will allow the assembly to be removed Do not remove the bolt entirely or the oval shaped clamp will fall into the reservoir Figure 8 2 8 002 2 Remove the four bolts which fasten the filter manifold to the hydraulic reservoir 8 2 Clamping eN Figure 8 4 8 013 2 Remove the access cover assembly from the reservoir Access Cover Assembly Installation Clamping Figure 8 5 8 013 1 Insert the access cover assembly with the clamping disk extending completely throu
68. reservoir gauge and the two mounting bolts washers off the reservoir DO NOT misplace the rubber washers or the reservoir will leak 8 4 Reservoir Gauge Installation Insert Reservoir Gauge with Mounting Ew T be Figure 8 10 8 018 1 Install the reservoir gauge in the reservoir using the two mounting bolts washers 8 017 Figure 8 11 2 Reach inside the reservoir and install the two nuts that secure the reservoir gauge to the reservoir 3 Install the filter assembly Refer to Chapter 8 Filter Assembly Installation 4 Add manufacturer approved hydraulic fluid Suction Screen Removal and Installation The tools required for suction screen removal and installation are listed in Table 8 4 Use manufacturer recommended tools whenever possible Table 8 4 Required Tools Combination Wrench Suction Screen Removal I 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 NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Note It is normally not necessary to replace the suction screen unless there has been a catastrophic failure and there is debris in the reservoir 1 Drain the hydraulic fluid Refer to Chapter 16 Hy
69. s product Replace any damaged illegible or missing safety plates signs or decals Rubber Track Loader 1 Product Safety Protective Equipment Always wear a hard hat protective glasses protec tive shoes and other protective equipment as re quired by job conditions when working around this product In particular wear protective glasses when pounding on any part of the product or its work tool with a hammer or sledge Use welders gloves hood goggles apron and other protective clothing appropriate to the welding job being performed Do not wear loose clothing or jewelry that can catch on parts of the product Mounting and Dismounting Use steps and handholds when mounting or dis mounting a machine 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 access system provide ladders scaffolds or work platforms to perform safe repair operations 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 positioned correctly and equipped with a spring latch Lifting eyes are not to be side loaded during a lifting operation Hot Fluids and Parts To avoid burns be alert for hot parts on machines that have just been stopped and hot fluids in lines tube
70. s and compartments Be careful 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 The danger is even greater if the machine has just been stopped because fluids can be hot 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 1 2 Batteries Do not smoke when inspecting the battery electro lyte 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 hy drogen and oxygen that is released from the electro lyte 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 Always use a board or a piece of cardboard when you check for a leak Leaking fluid under pressure can penetrate body tissue Fluid pene tration can Cause serious injury and possible dea
71. se 1 2 3 4 5 6 T 8 9 1 Continuous hyd flow switch activated Weak or dead battery Faulty continuous hyd flow switch Battery cables loose or corroded Ignition fuse blown Main starter fuse blown Starter relay malfunctioning Bad ignition switch Bad starter 0 Poor wire connections at key relay or starter Problem 2 Machine cranks but will not start Probable cause 1 Injection pump fuse blown 2 Main power fuse B blown 3 Main power relay B not activating 4 Poor wire connection at injection pump or fuse 5 Glow plugs not heating Will see black smoke a Main glow plug fuse blown b Glow plug relay not activating c Poor wire connections at ignition switch relay or glow plug strip d Failed glow plugs e Bad ignition switch Problem 3 Machine starts but hydraulics will not operate Probable cause 1 Lap bar must be in down position operator must be seated in seat and front door if installed must be closed Safety fuse blown Faulty operator presence switch a Test continuity through seat lap bar and door switch Adjust or replace as necessary Lap bar and door switch are magnetic switches and should be adjusted to approximately 1 16 inch away from steel pickup bracket Poor ground check ground wires on bottom left rear side of hydraulic reservoir Safety relay is not activating Faulty safety solenoid or safety solenoid spool 15 2 7 Poor wire con
72. stallation The tools required for radiator cooler removal and installations are listed in Table 7 2 Use manufac turer recommended tools whenever possible Table 7 2 Required Tools Combination Wrench Socket Wrench Screwdriver Radiator Cooler Removal I 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 I WARNING Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to the heat ers and the engine contain hot coolant and steam Contact can cause severe burns Remove the filler cap slowly to relieve pressure only when the engine is stopped and the radiator cap is cool enough to touch with your bare hand Do not attempt to tighten the hose connections when the coolant is hot The hose can come off and cause burns Cooling system conditioner contains alkali Avoid contact with skin and eyes NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates 1 Drain the hydraulic fluid Refer to Chapter 16 Hydraulic Fluid and Filter Change Rubber Track Loader 7 Radiator Oil Cooler Disassembly and Assembly ee Figure 7 5 7 011 Figure 7 2 7 008 5 R
73. tallation Tandem Pump Drive Shaft Drive Coupler Figure 10 15 10 012 1 Slide the pump drive coupler all the way onto the tandem pump drive shaft Tighten Locking Screw Pump Drive Coupler Figure 10 16 10 011 2 Tighten the locking screw that secures the pump drive coupler to the tandem pump drive shaft 3 Install the tandem pump Refer to Chapter 10 Tandem Pump Installation 4 Install the auxiliary gear pump Refer to Chapter 10 Auxiliary Gear Pump Installation 5 Install the seat Refer to Chapter 6 Seat Installation 6 Add fuel and manufacturer approved hydraulic fluid 10 6 Chapter Overview This chapter provides disassembly and assembly procedures for the undercarriage assemblies Personal Safety I WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Before starting any disassembly or assembly procedures refer to Chapter 2 Product Safety Basic Precautions for personal safety information Machine Preparation WARNING Accidental machine starting can cause injury or death to personnel working on the machine To avoid accidental machine starting disconnect the battery cables from the battery and
74. tape the battery clamps and remove the key Place a Do Not Operate tag prominently on the machine to inform personnel that the machine is being worked on Before starting any disassembly or assembly procedures refer to Chapter 2 Product Safety Repair for machine preparation information 11 Undercarriage Disassembly and Assembly Preliminary Checkout If troubleshooting is required prior to disassembly or assembly refer to Chapter 15 Troubleshooting Undercarriage Disassembly and Assembly Procedures Disassembly and assembly procedures are provided for the following undercarriage components e Wheels e Sprockets e Sprocket rollers e Sprocket bearing e Tracks e Drive motors Note Procedures are provided for only those undercarriage components listed above However other helpful information can be obtained from the Rubber Track Loader Parts Manual Wheel Removal and Installation The tools required for wheel removal and installation are listed in Table 0 1 Use manufacturer recommended tools whenever possible Table 0 1 Required Tools Wheel Extractor Channel Lock Pliers Socket Wrench Screw Driver Rubber Track Loader 11 Undercarriage Disassembly and Assembly Wheel Removal 1 Locate the wheel cap snap ring Figure 0 1 12 005 2 Use a screw driver to remove the snap ring that secures the wheel cap Figure 0 2 12 006 3 Using a large channel lock pliers remove the w
75. th A pinhole leak can cause severe injury If fluid is injected into your skin get treatment im mediately Seek treatment from a doctor that is familiar with this type of injury 2 Relieve all pressure in air oil or water systems before disconnecting or removing any lines fit tings or related items Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure 3 Lower the bucket blade or other work tool to the ground before performing any work on the machine If this cannot be done make sure the bucket blade or other work tool is blocked cor rectly to prevent it from dropping unexpectedly 4 Loose or damaged fuel lubricant and 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 Do not use your bare hand to check for leaks 5 Pressurized air or water can cause personal in jury When pressurized air or water is used for cleaning wear a protective face shield protec tive clothing and protective shoes The maxi mum air pressure for cleaning purposes must be below 205 kPa 30 psi When using a pressure washer keep in mind that nozzle pressures are very high generally pressures are well above 13790 kPa 2000 psi Follow all recommended practices provided by the pressure washer manufacturer
76. tubes from the top of the loader valve Cap the tubes and fittings Rubber Track Loader 9 Loader Transmission Controls Disassembly and Assembly Figure 9 29 9 013 7 Remove the tubes from the side of the loader valve Cap the tubes and fittings Figure 9 30 9 014 8 Remove the tubes from the bottom of the loader valve Cap the tubes and fittings a Lh i Remover u Hoses Figure 9 31 9 015 9 Remove the hoses from the end and side of the loader valve Cap the hoses and fittings 9 8 Figure 9 32 9 016 10 Remove the nuts from the four bolts that secure the loader valve to the hydraulic reservoir Figure 9 33 9 017 11 Remove the loader valve from the engine compartment Rubber Track Loader 9 Loader Transmission Controls Disassembly and Assembly Loader Valve Installation Figure 9 34 9 017 1 Position the loader valve against the hydraulic reservoir Install Nuts Figure 9 35 9 016 2 Install the nuts on the four bolts that secure the loader valve to the hydraulic reservoir Install Hoses Figure 9 36 9 015 3 Install the hoses on the end and side of the loader valve 9 9 _ Install Tubes Figure 9 37 9 014 4 Install the tubes on the bottom of the loader valve Figure 9 38 9 013 5 Install the tubes on the side of the loader valve Install Tubes 9 012 Figure 9 39 6 Install the tubes on the top of the loader valve 7 A
77. ufacturer recommended tools whenever possible Table 0 4 Required Tools Socket Wrench Combination Wrench Snap Ring Pliers Two pry bars Figure 0 17 12 054 7 Install the wheel nut and torque to 125 ft lbs Sprocket Bearing Plate Removal 1 Remove the track 2 Remove the soft plug by hitting it with a hammer and chisel on the very edge Remove Snap Ring Figure 12 20 3 Remove the snap ring that secures the bearing pack unto the shaft Photo shows the bearing pack already removed Figure 0 19A 12 023 4 Remove the three bolts on the bottom that fastens the bearing plate to the drive table 5 Using two pry bars slowly and carefully pry the bearing plate off of the shaft Rubber Track Loader 11 Undercarriage Disassembly and Assembly Figure 0 20 12 024 6 Remove the 4 bolts that fasten the bearing pack to the bearing plate Sprocket Removal and Installation The tools required for sprocket removal and installation are listed in Table 0 5 Use manufacturer recommended tools whenever possible Table 0 5 Required Tools Socket Wrench Torque Wrench Sprocket Removal Rubber Track Loader 11 Undercarriage Disassembly and Assembly Figure 0 21 12 030 1 Remove the bearing plate as described above Remove the 10 lug nuts that mount the sprocket to the drive motor Remove the sprocket Reverse the procedure for sprocket installation and torque the lug nuts to 160 ft lbs
78. ve Model Husko Relief pressure 3000 psi 20 684 kPa Pilot pressure required to move spools 180 220 psi 1241 1517 kPa Cooler Burst pressure 400 psi 2757 kPa Operating pressure 250 psi 1724 kPa Bypass relief pressure 80 psi 689 kPa Hot oil sending unit 225 F 107 2 C Critical Torque Specs Transmission Mounting Bolts o 85 ft lb w Blue Loctite Drive Sprocket Drive Teeth Bolts o 105 ft lb Dry Bogie Wheel Retaining Nut o 125 ft lb Dry Drive Sprocket Lug Nut o 160 ft lb Dry Drive Motor Mounting Bolts o 160 ft lbs Dry Chapter Overview This chapter contains diagrams for the following RC 60 systems e Filtering and cooling system e Auxiliary circuit system e Drive loop system Figure 3 1 RC 60 Filtering and Cooling System 50 MICRUN SUCTION SCREE 3 System Diagrams Filtering and Cooling System The filtering and cooling system Figure 3 1 con tains the following major components e Hydraulic reservoir e Radiator oil cooler e Loader valve 3 001 3 1 UN ETURN FILTE IIL TE ENDING U Rubber Track L
79. with your hands Rubber Track Loader 12 Loader Disassembly and Assembly NOTICE Collect and contain liquids in a suitable container Dispose of all liquids according to local regulations and mandates Note During disassembly cap all hoses and fittings to prevent fluid loss and contamination of the system fluids 1 Lower the loader arms onto a jackstand with the arms resting about 6 inches off the ground 2 Turn the engine start switch to the OFF position Figure 0 1 13 001 3 Remove the bolt on the pin assembly on the loader tower 13 002 Figure 0 2 4 Remove the pin assembly 12 2 i Lift Cylinder Remove Hose Figure 0 3 13 003 5 Remove and cap the hose on the base end of the cylinder Figure 0 4 13 004 6 Remove and cap the hose on the loader end of the cylinder Figure 0 5 7 Remove the forward pin assembly bolt Remove Pin Figure 0 6 13 006 8 Remove the forward pin assembly Figure 0 7 13 007 9 Remove the lift cylinder from the machine Lift Cylinder Tilt Cylinder Installation Note Reverse the above steps to install the cylinder Note Begin the lift cylinder installation with the loader arms lowered and resting about 6 inches off the ground on a jack stand This is the position the loader arms were in following lift cylinder removal 12 3 Rubber Track Loader 12 Loader Disassembly and Assembly Quick Coupler Block Pressure Release Valv

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