SR-70/SR-80 Rubber Track Loaders P O S I - T R A C K SR-SERIES Operation and Maintenance Manual
INTRODUCTION Thank you for purchasing an ASV Rubber Track Loader. With this machine, you will be able to perform tasks faster and more efficiently than with any other machine its size. The SR-70/80 are rugged and agile machines capable of working on a variety of challenging terrains. They are designed to be very safe, but safe operation also requires caution and attentiveness on the part of the operator.
SAFETY OVERVIEW SAFETY SYMBOL ! This symbol means: Attention! Be alert! Your safety is involved! A safety message will follow this symbol describing the hazard and the precautions that need to be taken to ensure your safety. Read and understand all safety messages in order to protect yourself and others from personal injury or death. These safety messages are identified by the words: DANGER, WARNING, and CAUTION.
MACHINE IDENTIFICATION Serial Numbers Manual Storage Product ID Number The Machine PIN is located on the front of the cab near the lower right corner of the door opening. This number must be provided when contacting your dealer regarding parts, service, warranty or accessories. Warranty claims will not be processed unless the machine PIN is provided. The manual storage compartment is located in the lower left portion of the cab near the operator’s left leg.
TABLE OF CONTENTS Introduction ....................................... 1 Safety Overview ................................ 2 Machine Identification.................... 3 Safety ............................................................... 6 Controls .............................................................. 14 Operation........................................................... 22 Maintenance ..................................................... 32 Troubleshooting......................................
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SAFETY - CONTENTS Features .............................................................. 7 Tipping Load/Operating Cap./GVW ......... 9 Fire Prevention................................................. 10 Warning Decals................................................
SAFETY Features The SR 70/80 rubber track loaders are equipped with many safety features to reduce the possibility of injury to the operator during operation. C. Operator Presence Seat Switch This switch ensures that the operator is seated inside the machine before any motion is allowed to take place. This safety switch is activated when an operator is seated in the cab. These features include: A.
SAFETY Features F. Power Quick-Attach Safety Switch (if equipped) The purpose of this switch is to ensure attachments are properly fastened to the machine prior to operation. The engine will not start unless this switch is in the locked position. When installing an attachment, always perform a visual check to make sure it is correctly attached and locked in place prior to use. Note: Items D and F are equipped with small orange locking devices.
SAFETY Tipping Load/Operating Capacity/GVW Load C of G Tipping Load The tipping load is the amount of weight that, when applied to the bucket center of gravity, causes the machine to begin tipping forward. The tipping load is calculated with the machine still and on level ground, equipped with a standard dirt bucket that is raised to the point in the lift arm path where the load is positioned furthest from the machine.
SAFETY Fire Prevention Fire Prevention Precautionary Tasks: Rubber Track Loaders have components that operate at high temperatures. Steps must be taken to make sure that flammable items are kept clear of these components during operation. Failure to do so may result in a fire. • With the engine off and cool, remove any debris present in the engine compartment and chassis area (under cab). Remove the belly pans and pressure wash these areas to clean them properly.
SAFETY Warning Decals There are decals positioned throughout the machine to warn operators of potential hazards. They must be observed and obeyed to avoid risks of machine damage, personal injury or even death. They are displayed here along with supplementary graphics that help to illustrate their intent and significance.
SAFETY Warning Decals Operating Position 12
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CONTROLS - CONTENTS Instrument Display ......................................... 15 Switch Panels.................................................... 16 Drive & Lift Arm .............................................. 17 Throttle/Electric Attachment...................... 18 Auxiliary Hydraulic.......................................... 19 Two Speed/Power Quick Attach................
CONTROLS Instrument Display B C A D E G H I J F There are many instruments involved in the safe operation of your machine. Make sure to learn the location, and function of each of these items prior to operating your machine. Instrument Display The instrument display has been configured for visibility and ergonomic function. The display includes: A. Engine Temperature Gauge B. Oil Pressure Gauge C. Fuel Gauge D. Hydraulic Oil Temp. Gauge E. Voltmeter F. Tachometer G. High Range Indicator H.
CONTROLS Switch Panels Left Right O L P M Q N Switch Panels There are three main panels which house the switches used to control various functions throughout the machine. The switch panels include: L. Parking Brake Switch M.Headlight Switch N. Bucket Positioning Switch O. High Flow Aux. Switch P. Low Flow Aux. Switch Q. Hyd. Quick Attach Switch* R. Heater Fan Switch** S. Windshield Wiper Switch** T. Beacon Switch** U.
CONTROLS Drive & Lift Arm Drive Control Lift Arm Control The SR-70/80 are equipped with pilot operated joystick controls. The drive control (left joystick) is used to control track motion. The illustration above shows the relationship between joystick and machine movement. The lift arm control (right joystick) is used to control the lift arms and attachment (bucket) movement. The illustration above shows the relationship between joystick and lift arm/attachment movement.
CONTROLS Throttle/Electric Attachment Throttle Controls Electric Attachment Control The throttle controls engine RPM. When performing work that requires delicate, precise movements, use a lower RPM. When more speed, horsepower, or flow is required, use a higher RPM. Most attachments for ASV Rubber Track Loaders are controlled hydraulically, but some require electrical input as well.
CONTROLS Auxiliary Hydraulic The SR70/80 are equipped with high and low flow auxiliary hydraulic circuits that allow for the use of hydraulic attachments. The couplers for the auxiliary circuits are located on the left side of the lift arms near the front of the machine. They are positioned from top to bottom as such: (see photo) A. B. C. D. E. Note: Low and high flow circuits may not be used simultaneously.
CONTROLS Auxiliary Hydraulic Low Flow Continuous To activate the low flow auxiliary hydraulic circuit continuously, depress the rocker type switch located on the switch panel. (H) • To pressurize the upper low flow quick coupler, press the top of the switch. • To pressurize the lower low flow quick coupler, press the bottom of the switch. • To de-activate low flow continuous operation, move the switch into the middle (neu tral) position.
CONTROLS Two Speed/Power Quick Attach Two Speed Power Quick Attach The SR 80 is equipped with a two speed drive system with low and high range. The SR machines are available with a power quick attach feature that allows the operator to fasten and unfasten attachments without exiting the machine. (SR-80-standard/SR-70-optional) • Low range is best suited to performing strenuous tasks or running attachments. • High range is intended primarily for transporting.
OPERATION - CONTENTS Pre-Operation................................................... 23 Starting Procedure ......................................... 24 Operation Techniques ................................... 25 Attachments .....................................................
OPERATION Pre-Operation Pre-Operation Safety Check Before operating the machine, perform a pre-operation safety check. Inspect the machine for any items that may affect safe operation. Check to make sure: 1. Engine compartment, chassis and coolers are clean and free of debris. (see page 39) Note: The parking brake is automatically activated when the operator removes the seat belt or leaves the operator seat.
OPERATION Starting Procedure Starting Procedure Upon completion of the preoperation safety check, if all items are in compliance, you are ready to start your machine. To start the machine: 1. Enter the machine (lift arms in lowered position) from the front while maintaining at least 3-point contact with the machine at all times to ensure your safety. (2hands, one foot or viceversa) 2.
OPERATION Operation Techniques Operating Your Machine Dirt Work Operating an ASV Rubber Track Loader is intended to be as safe and simple as possible. The controls section of this manual covers the various controls used to operate the machine. Each operator should take the time necessary to familiarize him/herself with the controls section prior to attempting to operate the machine. ASV Rubber Track Loaders provide far superior traction and floatation than traditional wheeled loaders.
OPERATION Operation Techniques Filling The Bucket Steps: (see illustration) 1. Lower the lift arms until they rest on the frame. 2. Tilt the bucket slowly forward until the cutting edge engages the ground. 3. Drive the machine forward until the bucket is full of material. 4. Curl the bucket and raise the lift arms simultaneously to break the load free from the pile. 5.
OPERATION Operation Techniques Leveling Steps: (see illustration) 1. Moving forward, raise the lift arms as you tilt the bucket slowly forward to evenly spread the material out over the ground. 2. Once the load is released, tilt the bucket forward to an angle 45° or less to the ground. 3. Lower the lift arms until the cutting edge rests on the ground. 4. Engage the float function and back the machine over the material varying bucket angle slightly as necessary to maintain grade.
OPERATION Operation Techniques Hill Side Operation By design, Rubber Track Loaders are very stable on inclines. Machine weight is distributed evenly throughout the chassis and the suspended undercarriage track system provides excellent traction and floatation on nearly all surfaces. Even with these capabilities, caution should always be exercised while operating the machine on an incline. Never operate the SR-80 on an incline in excess of 18° or an SR-70 on an incline in excess of 15°.
OPERATION Attachments SR 70 Fastening To fasten an attachment: 1. Make sure the locking levers are in their respective unlocked positions. To unfasten an attachment: 1. Lower the lift arms so that the attachment is just barely off of the ground. 2. Drive the machine to the attachment and hook the top edge of the quick attach under the upper lip of the attachment. 2. Pull the locking levers upwards and toward the outside of the machine to unlock the attachment. 3.
OPERATION Attachments SR 80 (SR-70/optional) Unfastening To fasten an attachment: 1. Move the power quick-attach switch into the “unlock” posi tion. 2. Drive the machine to the attachment and hook the top edge of the quick attach under the upper lip of the attachment. 3. Curl the quick-attach slowly upward by moving the lift arm control joystick to the left until the attachment is properly mated with the quick attach mechanism. (Curl enough to lift the attachment off of the ground.) 4.
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MAINTENANCE - CONTENTS Precautions/Safety Warnings ....... 33 Lift Arm Brace Installation............. 34 Tilt-Up R.O.P.S./F.O.P.S. Cab ............ 35 Jacking Procedure............................ 36 Maintenance Schedule ................................. 37 Grease Points.................................................... 38 Radiator-Oil Cooler/Engine Cleaning ...... 39 Air Cleaner ......................................................... 40 Fuel Filter/Water Separator..........................
MAINTENANCE Precautions/Safety Warnings Precautions Rubber Track Loaders require periodic maintenance to ensure proper performance and prevent costly down time. When service is required, ASV recommends that all work be done by an authorized ASV Dealer. If you perform maintenance on your own machine, you should familiarize yourself with the information provided in this section on general maintenance. Incorrect or incomplete maintenance may cause improper or unsafe vehicle operation.
MAINTENANCE Lift Arm Brace Installation Lift Arm Brace Installation The lift arm brace (A) is intended to keep service personnel safe when it is necessary to work on a machine with the lift arms in the raised position. It is not safe to rely on the hydraulic system to hold the lift arms in the raised position just as it is not safe to crawl under a machine supported only by a jack.
MAINTENANCE Tilt Up R.O.P.S./F.O.P.S. Cab A B Tilt-Up Cab The ROPS/FOPS approved cab (A) tilts up to allow easy access to components while performing maintenance. It is equipped with a gas spring assist and a brace mechanism to hold it in place while tilted. To tilt the cab: 1. Remove any attachments that may be fastened to the machine. 2. (Optional) Raise the lift arms and secure them with the lift arm brace. (See page 34.) 3. Remove the two bolts (B) that fasten the cab to the footwell.
MAINTENANCE Jacking Procedure Jacking Procedure Occasionally, your machine may need to be suspended off of the ground to perform maintenance. Exercise caution when jacking the machine. Always use a jack that is capable of lifting the machine and support its weight with ASV approved jack stands while suspended. Never work on or under a machine supported only by a jack. To safely jack your machine: 1. Remove any attachments that may be fastened to the machine and raise the lift arms. 2.
MAINTENANCE Maintenance Schedule Maintenance Item Grease fittings Service required Lubricate Fluid levels Check Daily Fan-A/C belt tension Check Daily Adjust tension as necessary. Fan-A/C belt condition Inspect Daily Replace as a pair if worn or damaged. Water separator Drain Daily Track condition Inspect Daily Replace if severely damaged. Track tension Inspect Daily Adjust tension as necessary. Air cleaners Inspect Daily Replace if damaged or heavily soiled.
MAINTENANCE Grease Points Grease Fitting Locations A. B. C. D. E. F. G. H. Lower Bucket Cylinder Pivot Upper Bucket Cylinder Pivot Front Lift Cylinder Pivot Lift Arm Pivot Rear Lift Cylinder Pivot Rear Axle Pivot (2) B Front Axle Pivot (2) Lower Bucket Pivot D E C A H G F Grease Points The SR 70/80 are equipped with grease fittings at pivot points throughout the machine. The illustration above shows the locations of all fittings on the left side of the machine.
MAINTENANCE Radiator/Oil Cooler & Engine Cleaning Radiator/Oil Cooler The Radiator and Oil Cooler must be kept clean to ensure proper operation. Engine and hydraulic system overheating, damage and even failure can result if the radiator/oil cooler is not kept clean. A pressure washer or compressed air nozzle work well to blow debris clear of the fins in the oil cooler and radiator.
MAINTENANCE Air Cleaner Air Cleaner The SR 70/80 are equipped with two air filter elements to remove contaminants from the air used for combustion. Regular inspection and replacement is necessary to ensure proper performance and to prolong engine life. To remove and inspect your air cleaner elements: 1. Turn the engine off. A B 2. Open the hood at the rear of the machine to gain access to the engine compartment. 3.
MAINTENANCE Air Cleaner To clean your primary filter element: 1. Remove loose dirt from the filter element with compressed air or water hose. Compressed air: 100 P.S.I. max. 1/8" diameter nozzle at least 2" away from filter. 7. Once the inspection has been performed, install the new secondary filter element into the enclosure as found upon disassembly. 8. Install the primary element by sliding it into place in the enclosure as found upon disassembly. 9.
MAINTENANCE Fuel Filter/Water Separator A Fuel Filter The fuel filter removes contaminants from the fuel as it enters the engine for combustion. Over time the filter can become plugged and cause the engine to lose power, run roughly or fail to start. The fuel filter should be changed every 500 hours or more often if needed to prevent these conditions from occurring. To change the fuel filter: 1.
MAINTENANCE Accessory Belts 2 1 Accessory Belt Tension Drive belts typically stretch and wear during their service life. The fan and A/C belts should be checked for tension, condition and presence daily prior to operating your machine. To check fan or A/C belt tension: 1. With the engine cold and off, remove the key from the igni tion to avoid accidental start. 2. Lift the hood at the rear of the machine and check to make sure the fan and A/C belts are present and in good condition.
MAINTENANCE Accessory Belts Pry bar 1/2 cage Bolt 4 5 Bolts 6 Bolt Fan Belt Removal & Installation To remove the fan belt: 1. Follow steps 1 and 2 of the belt adjustment procedure. 2. Once loose, pivot the alternator towards the engine to increase slack. 3. Then, remove the three bolts securing the fan cage (half) to the fan shroud. Remove that portion of the cage. (fig. 5, 6) 4. Slip the belt off of the engine pulleys and work it around the fan until it is clear of the blades.
MAINTENANCE Engine Engine Oil/Filter Change Regular oil changes are necessary to maintain a strong running engine. The normal interval between oil changes is 500 hours or one year. Machines that are operated under harsh conditions should have their oil changed more frequently. ASV recommends oil change intervals of 250 hours or every six months for these machines. Harsh conditions may include: continuous high load applications, operation in high temperatures or abnormally dusty/dirty conditions.
MAINTENANCE Engine CAUTION Caution: If the old filter gasket (A) is not removed from the filter head and the new filter is installed on top of it, an oil leak will result when the engine is started. If unnoticed, the engine can run itself out of oil causing engine failure. 6 7. Prepare new filter for installation by rubbing fresh oil on the exposed surface of the filter gasket. 8. Thread the new filter onto the filter head.
MAINTENANCE Engine 5. Remove the dipstick once again and inspect the end for oil on the level indicator. Engine Oil Specifications ASV recommends using PosiLubeTM 10W-30 Heavy Duty Engine Oil for most conditions. In the event of an alternate working environment, the chart above may be used as a guide to oil viscosity grades. You may also use a quality engine oil substitute meeting the following minimum specification: • API CH-4 multigrade engine oil. 6.
MAINTENANCE Hydraulic System gasket material prior to installing the new filters. Hydraulic Fluid/Filter Change Hydrostatic components require extremely clean oil in order to have a long service life. Use extreme caution when changing the hydraulic oil. Introducing dirt or debris could be detrimental to the hydraulic system. ASV recommends service intervals of 500 hours for hydraulic fluid and 250 hours for hydraulic fluid filters. To change the hydraulic fluid: 1.
MAINTENANCE Hydraulic System 8. Install the hydraulic system drain plug and tighten. 10. Install and secure the hydraulic reservoir filler cap. 9. Remove the hydraulic reservoir filler cap (black) and fill the hydraulic system with ASV Posi-Lube Premium All Season MV Hydraulic Oil or equivalent until the full mark on the hydraulic fluid sight gauge has been reached (approx. 12.5 gal.). (fig. 3, 4) 11. Start the machine and operate all hydraulic circuits to work any trapped air out of the system.
MAINTENANCE Electrical/Undercarriages Fuse Panel Undercarriages The electrical systems in the SR machines are equipped with fuses that protect the electrical components from damage. They are located on the fuse panel behind the access cover on the lower right side of the cab interior. (fig. 6) The undercarriage assemblies in the SR machines typically operate in harsh working conditions. They work in mud, gravel, debris and various other abrasive materials during operation.
MAINTENANCE Undercarriages Track Tension (SR-70/80) Straight-Edge Proper track tension must be maintained for optimal performance and track/undercarriage life. Running a track that is too loose may cause the track to misfeed possibly causing damage to the track and or undercarriage components. Running a track that is too tight may cause track stretch, premature bearing failure, or other preventable damage to the machine.
MAINTENANCE Undercarriages Track Removal/Installation Tracks may need to be removed periodically to inspect undercarriage components or for replacement if worn or damaged. This section covers the procedure to remove and install a track on SR 70/80 machines.
MAINTENANCE Undercarriages 6. Remove the outer scraper plate from the suspension rail. (SR-80 only/fig. 9, 10) 7. Remove the bolts securing the inner wheel to the hub, then remove the wheel. (SR-80 only/fig. 11, 12) 8. Use a pry bar to peel the track over the inner wheel(s) toward the outside of the machine. (fig. 13) 11 9. Once the track is off of the front wheel(s), pull the rear of the track clear of the suspension. (fig.
MAINTENANCE Undercarriages Track Installation 1. Slide the track over the drive sprocket at the rear of the machine. (fig. 1) 2. Slide the front of the track into position for installation. 3. Lubricate the inner front wheel(s) and the inside of the front portion of the track with a spray lubricant.(fig. 2) 1 4. Attach a ratchet strap to the upper front portion of the track and the other end to one of the tow hooks on the front of the machine. (fig. 3) 5.
MAINTENANCE Undercarriages 9. Once the track is in position over the idler wheels, install the inner idler wheel onto the hub and secure it in place with the mounting bolts. Torque them to 90 +/- 10 Lb. Ft. (SR-80 only/fig. 6, 7, 8) 8 Note: You may need to use a bar to keep the wheel from spinning as you torque the mounting bolts to spec. (fig. 8) 10. Install the scraper onto the suspension rail and tighten the bolts to secure it in place. (SR-80 only/fig. 9) 9 11.
MAINTENANCE Drive Sprocket Rollers SR-70 E SR-80 F D F C J Steel Pin I (.088”) H E G D K A New Roller Normal Wear 35% life B Drive Sprocket Rollers ASV rubber track loaders utilize rollers on the drive sprockets to drive the track. These rollers help minimize friction between the track and the drive sprocket to prolong track life. The rollers rotate around hardened steel pins and usually wear on their inside surfaces.
MAINTENANCE Undercarriages 8. Repeat this process as required throughout the sprocket. 9. Reinstall the sprocket by reversing steps 2-6. Note: During removal of the bearing cap (step 3) the bulged area of the cap is beaten inward. When reinstalling, orient the cap so that the domed area is facing outward. Then tap the center of the cap with a ball peen hammer or similar device to reset the cap. Do this gently. Too much inward force can damage (mushroom) the bearing shaft. 10.
TROUBLESHOOTING - CONTENTS Overview/No-Start ......................................... 59 Hydraulics .......................................................... 60 Electrical ............................................................. 61 Overheat.............................................................
Troubleshooting Overview/No-Start Overview The most effective way to prevent a malfunction from occurring is to closely follow the recommended maintenance schedule and instructions throughout the life of the machine. However, if a malfunction does occur, finding the problem and fixing it quickly are important. This section covers a select set of symptoms that may occur and suggests possible causes. Problem Machine cranks, but will not start. Possible causes: 1.
Troubleshooting Hydraulics Problem Machine starts, but hydraulics will not operate. Possible causes: 1. Operator not in seat. 3. Drive control joystick (pilot control) malfunction. 4. Low charge pressure. 5. Parking brake switch in on position. 2. Seat belt not fastened. 3. Safety relay fuse and or safety solenoid fuse for seat belt and operator presence safety switches blown. 4. Faulty operator presence safety switch. a) Test for continuity through operator presence and seat belt switches.
Troubleshooting Hydraulics/Electrical Problem Lift arms are operational, but high/low flow auxiliary circuits are not. Possible causes: 1. Auxiliary hydraulic fuse blown. 2. Faulty ground at chassis crossmember. 3. Faulty auxiliary hydraulic switch. 4. Faulty auxiliary hydraulic solenoid at pilot generation block. 5. Loose, broken or disconnected wire at fuse, auxiliary hydraulic switch, or pin connector P10. 6. Auxiliary hydraulic pilot generation spool stuck in closed position. 7.
Troubleshooting Electrical/Overheat Problem Battery will not charge/maintain charge. Possible causes: 1. Loose alternator belt. Problem Engine coolant temperature elevated; engine overheating. Possible causes: 1. Low coolant level. 2. Alternator fuse blown. 2. Debris plugging radiator, limiting airflow. 3. Faulty alternator diode. 4. Loose, broken or disconnected wiring at battery, alternator, diode or fuse. 3. Damaged or missing cooling fan blades. 5.
MACHINE SPECIFICATIONS General Dimensions SR-80 Machine width: Ground clearance: Max. lift height, at hinge pin: Machine length, w/out bucket: Machine length, with bucket: 72 in. / 1,829 mm 15 in. / 381 mm 125 in. / 3,175 mm 112 in. / 2,845 mm 142 in. / 3,607 mm Height to top of ROPS: 86 in. / 2,184 mm SR-70 66 in. / 1,676 mm 15 in. / 381 mm 125 in. / 3,175 mm 112 in. / 2,845 mm 141 in. / 3,581 mm 86 in. / 2,184 mm Track Specifications Track width: 20 in. / 508 mm Length of track on ground: 71 in.
LIMITED WARRANTY The warranty herein set forth applies solely to the ASV Rubber Track Loaders manufactured by ASV, Inc. and is in lieu of all other warranties, expressed or implied. No person, agent, or dealer is authorized or empowered to give any other warranty or to assume other liability on behalf of ASV, Inc. Warranty of ASV Rubber Track Loaders is extended to the original purchaser, however, the balance of the unused warranty may be transferred to a second party. ASV Inc.
STANDARD TORQUE GUIDELINES Inch Fasteners Thread size Standard Torque 1/4" 9 +/- 2 lb ft 5/16" 18 +/- 4 lb ft 3/8" 35 +/- 7lb ft 7/16" 50 +/- 11 lb ft 1/2" 75 +/- 15 lb ft 9/16" 120 +/- 22 lb ft 5/8" 160 +/- 30 lb ft 3/4" 275 +/- 37 lb ft 7/8" 460 +/- 60 lb ft 1" 660 +/- 75 lb ft 1-1/8" 960 +/- 110 lb ft 1-1/4" 1320 +/- 150 lb ft 1-3/8" 1780 +/- 220 lb ft 1-1/2" 2280 +/- 260 lb ft Machine Specific Fasteners Drive Sprocket Roller Bolts/Nuts Torque to: 80 +/- 10 Ft./Lbs.
RECOMMENDED FLUIDS When replacing or replenishing the fluids and lubricants in your ASV Rubber Track Loader, you can specify ASV Posi-Lube products. This ensures that the new fluids and lubricants match those originally installed when your machine left the ASV factory. Posi-Lube products were developed for, tested and approved by ASV to assure optimum life and performance in all ASV Rubber Track Equipment, when used as recommended.
SERVICE LOG Hours Service Performed 67 Notes
SERVICE LOG Hours Service Performed 68 Notes
SERVICE LOG Hours Service Performed 69 Notes
SERVICE LOG Hours Service Performed 70 Notes
ASV Inc. 840 Lily Lane P.O. Box 5160 Grand Rapids, MN 55744 ASV Parts & Service Phone: 1-800-346-4367 Fax: 1-218-327-2297 Internet: www.asvi.com ASVSR1OM-02 (9/06) Copyright 2006 ASV Inc.
