ASV SC50 Scout Service & Repair Manual Download Page 72 | Manualshive

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Chapter Overview

This chapter provides procedures for the removal and
installation of the engine and associated components.
If there is an issue that requires troubleshooting, refer
to Chapter 15, Troubleshooting.

Personal Safety

Improper or incomplete maintenance/repair of a Rubber
Track Utility Vehicle can be dangerous and may result in
machine damage, injury or even death.

Do not attempt to perform repair or maintenance on a
Rubber Track Utility Vehicle until you have read and fully
understood the information in this manual.

Refer to the Operation and Maintenance manual for
instructions regarding proper machine operation tech-
niques before operating any Rubber Track Utility Vehicle.

Machine Preparation

Accidental machine starting can cause injury or even
death to personnel working on a Rubber Track Utility
Vehicle.

As a precaution, disconnect the battery cables from the
battery terminals, tape the battery clamps and remove
the key from the ignition switch prior to performing any
service work on a Rubber Track Utility Vehicle.

Place a “Do Not Operate” tag prominently on the ma-
chine to inform personnel that the machine is being
worked on.

Prior to performing any type of service work on a
Rubber Track Utility Vehicle, read and understand
Chapter 1 (Product Safety) for personal safety informa-
tion.

Removal and Installation

Removal and installation procedures are provided for
the following engine related components.

•

Battery

•

Exhaust

•

Air Cleaner Housing

•

Engine

Note:

Procedures are provided for only those engine associ-

ated components listed above. However, exploded parts dia-
grams exist in the SC-50 parts manuals to serve as visual
aids in the assembly and disassembly of other system com-
ponents.

Battery

Removal

1.

Open the access door to the rear console on the

driver’s side of the machine. (fig. 11-1)

2.

Disconnect the battery terminals from the battery

and lay them aside. (fig. 11-2)

11. Engine

11-1

11-1

!WARNING!

11-2

!WARNING!

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Summary of Contents for SC50 Scout

Page 1: ...ll English All Language Geographic Region Serial Number Range This manual is complements of TrackLoaderParts com The world s best source for ASV parts Track Loader Parts 6543 Chupp Road Atlanta Georgia 30058 USA 800 616 8156 https tractormanualz com ...

Page 2: ...lock 3 5 Brake 2 speed Control Block 3 6 Pilot Generation Block 3 7 Shuttle Block 3 8 Directional Control Valve 3 9 4 Maintenance Chapter Overview 4 1 Personal Safety 4 1 Dump Box Brace 4 1 Jacking Procedure 4 2 Radiator Oil Cooler cleaning 4 2 Engine Chassis cleaning 4 2 Maintenance Schedule 4 3 Air Cleaner 4 4 Fuel Filter 4 5 Water Separator 4 5 Fuse Panel 4 5 Accessory Belts 4 5 Engine Oil Filt...

Page 3: ...leaner Housing 11 4 Engine 11 5 12 Undercarriage Chapter Overview 12 1 Personal Safety 12 1 Machine Preparation 12 1 Removal Installation 12 1 Idler Wheels 10 12 1 Idler Wheels 14 12 3 Drive Sprocket 12 3 Drive Motor 12 5 Grease Tensioner 12 6 13 Hydraulic Component Service Chapter Overview 13 1 Personal Safety 13 1 Disassembly Assembly 13 1 Hydraulic Cylinders 13 1 Auxiliary Control Valve 13 4 Dr...

Page 4: ...Rubber Track Utility Vehicle may be unfamiliar with many of the sys tems on the machine This makes it especially impor tant to use caution when performing service tasks Familiarize yourself with the affected system s and components before attempting any type of mainte nance or service It is not possible to anticipate every potential haz ard The safety messages included in this docu ment and displa...

Page 5: ...ith large amounts of water for at least 15 minutes Call Physician Keep out of reach of children Batteries Do not smoke when inspecting the battery electrolyte level Never disconnect any charging unit circuit or bat tery circuit cable from the battery when the charging unit is operating A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the ...

Page 6: ... possibly overspeed and cause bodily injury death or property damage Be prepared to shut off the fuel and air supply to the engine in order to stop the engine 9 Be careful when removing cover plates Gradually back off the last two bolts or nuts located on oppo site sides of the cover Then pry the cover loose to relieve any spring or other pressure before removing the last two nuts or bolts complet...

Page 7: ...efficiency particulate air filter HEPA filter can also be used 2 Use exhaust ventilation on permanent machining 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 These OSHA requirements can be found in 29 CFR 1910 1001 5 Obey envi...

Page 8: ... death Pre Start Checklist 1 Operator and passen ger if present seated inside cab 2 Seat belts fastened 3 Auxiliary hydraulic switch in neutral position 4 Bystanders clear of all moving components Always Keep hands and feet inside the cab Watch for branches or other hazards that may enter the cab Keep clear of the tracks while the machine is in motion Never Operate the machine under the influence ...

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Page 10: ... introduced from the quick couplers Auxiliary Hydraulic Control Valve Model Husko Relief pressure 3000 psi 20 684 kPa Pilot pressure required to move spools 180 220 psi 1241 1517 kPa Oil Cooler Operating pressure 150 psi 1034 kPa Bypass relief pressure 80 psi 689 kPa Hot oil sending unit 225 F 107 2 C Avg oil operating temp 50 60 F above ambient High flow application 80 F above ambient Critical To...

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Page 12: ...uit hydraulic drive circuit steer ing control valve auxiliary control block brake 2 speed control block pilot generation solenoid block shuttle block and directional control valve Figure 3 1 SC 50 Hydraulic Charge Circuit Hydraulic Charge Circuit 3 Circuit Diagrams 3 1 CHARGE PUMP CHARGE PRESSURE RELIEF VALVE 420 30 PSI TANK https tractormanualz com ...

Page 13: ...c Auxiliary Circuit 3 2 Rubber Track Utility Vehicle 3 Circuit Diagrams OIL COOLER FLOW AUXILIARY CHARGE PUMP CHARGE AUX PUMP INLET FLOW TANK TANK AUXILIARY MANIFOLD TWO SPEED BRAKE MANIFOLD CHECK VALVE 80 PSI TO FILTER THEN TANK https tractormanualz com ...

Page 14: ... Figure 3 3 SC 50 Hydraulic Drive Circuit 3 3 Rubber Track Utility Vehicle 3 Circuit Diagrams DRIVE MOTOR DRIVE MOTOR DRIVE PUMP CASE DRAIN BRAKE 2 SPEED SHIFT DRIVE PRESSURE RELIEF VALVES 4 5500 PSI https tractormanualz com ...

Page 15: ...Steering Control Valve Figure 3 4 SC 50 Steering Control Valve 3 4 Rubber Track Utility Vehicle 3 Circuit Diagrams 1 2 https tractormanualz com ...

Page 16: ...Auxiliary Control Block Figure 3 5 SC 50 Auxiliary Control Block 3 5 Rubber Track Utility Vehicle 3 Circuit Diagrams https tractormanualz com ...

Page 17: ...Brake 2 Speed Control Block Figure 3 6 SC 50 Brake 2 Speed Control Block 3 6 Rubber Track Utility Vehicle 3 Circuit Diagrams TS PB https tractormanualz com ...

Page 18: ...Pilot Generation Block Figure 3 7 SC 50 Pilot Generation Block 3 7 Rubber Track Utility Vehicle 3 Circuit Diagrams 3 3 1 https tractormanualz com ...

Page 19: ...Shuttle Block Figure 3 8 SC 50 Shuttle Block 3 8 Rubber Track Utility Vehicle 3 Circuit Diagrams https tractormanualz com ...

Page 20: ...Directional Control Valve Figure 3 9 SC 50 Directional Control Valve 3 9 Rubber Track Utility Vehicle 3 Circuit Diagrams T P 1 2 https tractormanualz com ...

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Page 22: ...the hydraulic system to hold the dump box in the raised position just as it is not safe to crawl under a machine supported only by a jack The dump box brace is used to support the weight of the dump box much like jack stands are used to mechani cally support vehicle weight To install the dump box brace 1 Park the machine on level ground in a safe area for performing service work 2 Remove any load ...

Page 23: ...t the machine under the torsion axles only Jacking the machine at any other place may cause damage 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 i...

Page 24: ...Air cleaners Inspect Daily Replace if damaged or heavily soiled Radiator oil cooler fins Inspect Daily Clean often as necessary Undercarriages Inspect Daily Clean often as necessary Engine compartment Inspect Daily Clean often as necessary Drive sprocket rollers Inspect 50 hr Replace if damaged or worn 35 min Engine oil and filter Replace 12 Mo or 500 hr Harsh conditions 6 Mo 250 hr interval 11 2 ...

Page 25: ... Reverse steps 2 and 3 to reinstall the housing cover Note The secondary element is not serviceable It should be replaced after three cleanings of the primary filter Note The primary element may be cleaned and reused up to five times if properly maintained but should be replaced at least once a year Primary Element Cleaning Procedure 1 Remove loose dirt from the filter element with com pressed air...

Page 26: ... dam age They can be found in the fuse panel located beneath the passenger seat In the event of an electrical malfunction the most logi cal place to start is the fuse panel Check the fuse s related to the problem you are having and inspect it If the fuse filament appears broken black or burned it needs to be replaced Replace fuses with the correct amperage replacement fuse only Replacing a fuse wi...

Page 27: ...e oil 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 may run itself out of oil causing engine failure fig 4 16 7 Prepare the new filter for installation by rubbing fresh oil onto the exposed surface of the rubber filter gasket 8 Thread the new filter onto the filter head Tig...

Page 28: ...ube 4 Wipe the dipstick with a clean shop cloth and re insert it into the tube until it comes to rest in its seated position 5 Remove the dipstick once again and inspect the end for oil on the level indicator 6 Oil should be present on the dipstick up to but not over the upper full level indicator notch If the level is correct reinstall the dipstick and then reinstall the engine cover to complete ...

Page 29: ...hydraulic reservoir fig 4 21 6 Locate the hydraulic filter housing beneath the access cover 7 Thoroughly clean around the filter housing to pre vent dirt or debris from entering the system 8 Remove the bolts securing the filter housing cover to the housing then remove the cover fig 4 22 9 Remove the filter from the housing and replace it with a new one fig 4 23 10 Reverse steps 3 and 8 to close th...

Page 30: ...on and maximize component life Track Tension Proper track tension must be maintained for optimal performance and track undercarriage life Running a track that is too loose may cause the track to misfeed possibly causing damage to the track and or undercar riage components Running a track that is too tight may cause track stretch premature bearing failure or other preventable damage to the machine ...

Page 31: ...osen the bleeder bolt I on the grease tension unit J and allow grease to flow out until the front wheels are almost touching the 10 wheels behind them fig 4 26 Then tighten the bleeder bolt to hold them in place fig 4 30 This will put slack in the track and allow the two front 10 wheels to be removed fig 4 30 4 Remove the two front 10 diameter wheels second wheel back in the undercarriage from the...

Page 32: ...er in line with the axle as much as possible during wheel track removal to avoid damaging the inner wheel seal as it passes over the threads on the axle shaft Note The outer bearing on the 14 wheel will most likely fall out of the wheel as you remove it from the undercarriage Make sure to remove it or catch it if possible to keep it clean fig 4 37 7 Pull the track the rest of the way off of the un...

Page 33: ...the axle as you slide the track over the inner 14 wheel Once on the axle tap the wheel gently inward into position see note below fig 4 42 4 43 Note It is important to carefully align the wheel center with the axle prior to sliding it on to avoid damaging the inner seal during installation Note If for some reason your machine is higher off of the ground than recommended you may need to raise the l...

Page 34: ...t zerk Pump grease into the tensioner unit until the 14 wheel is just far enough forward to install the 10 wheel fig 4 47 7 Install the inner and outer 10 wheels and secure them in position with their nuts grease covers and snap rings fig 4 48 4 49 8 Attach a grease gun to the input zerk and pump grease into the tensioner unit until there is no visible sag in the track when viewed from the side fi...

Page 35: ...oller replacement see page 4 10 2 Remove one bolt A holding washer B steel pin C roller D and external roller E in place The pin and roller may then be removed from the sprocket fig 4 53 3 Install a new roller over the pin 4 Slide the bolt back through the sprocket washer pin and external roller fig 4 53 5 Install and tighten the retaining nut F 6 Repeat this procedure as required throughout the s...

Page 36: ...ntrol 4 controls intermittent auxil iary hydraulic function Instrumentation The Instruments Figure 5 2 5 3 are positioned in the dash panel for good visibility when seated inside the operator enclosure Instruments include the following components 1 Fuel Level Gauge fig 5 2 High Range Indicator Glow Plug Operation Indicator 2 Warning Light Display fig 5 3 Oil Pressure Warning Light Coolant Temp War...

Page 37: ...ght Activation Switch 2 Beacon Activation Switch 3 Heater Fan Activation Switch 4 Push To Operate Switch 5 2 Speed Activation Switch 6 Continuous Flow Auxiliary Hydraulic Switch 7 Ignition Switch Optional equipment is indicated by an Rubber Track Utility Vehicle 5 Machine Controls and Instrumentation 5 2 1 2 3 4 5 6 7 5 4 https tractormanualz com ...

Page 38: ...sonnel working on a Rubber Track Utility Vehicle As a precaution disconnect the battery cables from the battery terminals tape the battery clamps and remove the key from the ignition switch prior to performing any service work on a Rubber Track Utility vehicle Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Removal and Installation Rem...

Page 39: ...he switch then twist the switch assembly counter clockwise as shown to remove it from the under side of the seat fig 6 5 Note If the seat switch harness needs to be removed you must first remove the seat track that it passes under The harness may then be removed Installation 1 To reinstall the seat switch reverse the removal procedure Switches Removal 1 Remove the screws securing the driver s fron...

Page 40: ...procedure Front Fascia Removal 1 Remove the front fascia by first removing the retaining screws securing the perimeter Then lift and remove the fascia fig 6 8 Installation 1 To reinstall reverse the removal procedure Gauges Hour Meter Removal 1 Remove the front fascia from the machine to access the gauges Locate the retaining nuts and remove them fig 6 9 2 Disconnect the gauges from the wiring har...

Page 41: ... the engine cover from the machine fig 6 15 Installation 1 To reinstall the engine cover reverse the removal procedure Steering Wheel Mechanism Removal 1 Remove the front fascia as described on page 6 3 2 Pry the clip away from the ballstud then pull the gas spring away as shown Repeat on the other end of the gas spring to remove fig 6 16 6 4 Rubber Track Utility Vehicle 6 Operator Enclosure 6 12 ...

Page 42: ...ger radius on one end of the arc than on the other They need to be installed cor rectly in order to function properly 6 Once all of the components are off of the lower portion of the shaft slide it out through the top with the bushing as shown If necessary reinstall the lower bolt and tap it gently to get it to slide upward out of the lower bushing fig 6 22 Note The steering bushings are now acces...

Page 43: ...nstall the steering components reverse the removal procedure Dash Panel Removal 1 If your machine is equipped with a heater discon nect the duct hoses from the vent openings by loosening the clamps and pulling them off as shown fig 6 26 2 Remove the screws securing the dash panel to the chassis There are screws located in the top sides and underneath the dash panel fig 6 27 6 28 6 6 Rubber Track U...

Page 44: ... 5 Lift and remove the dash panel from the machine fig 6 31 NOTICE Make sure that all gauges switches meters etc are disconnected from the machine wiring harness before lifting the dash panel out of the machine Pulling these apart forcefully will most likely cause damage and require costly repairs Installation 1 To reinstall the dash panel reverse the removal procedure 6 7 Rubber Track Utility Veh...

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Page 46: ...a precaution disconnect the battery cables from the battery terminals tape the battery clamps and remove the key from the ignition switch prior to performing any service work on a Rubber Track Utility Vehicle Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Removal and Installation Removal and installation procedures are provided for th...

Page 47: ...bricant and a rubber mallot to ease it off of the pivot fig 7 4 6 Disconnect the battery cables from the battery 7 Once the battery has been disconnected remove the various leads attached to the starter solenoid Take note and label if necessary the leads and where they attach to the solenoid to aid during re assembly fig 7 5 8 Remove the bolts securing the starter to the engine as shown then remov...

Page 48: ...e to ensure correct assembly during throttle installation Cargo Bed Removal 1 Remove the retaining nuts securing the cargo bed sides to the cargo bed then remove both sides fig 7 10 2 Remove the bolts securing the cargo bed to the chassis as shown fig 7 11 3 Have an assistant help you to remove the cargo bed from the machine fig 7 12 Installation 1 To install the cargo bed reverse the removal pro ...

Page 49: ...a metal weight on the pickup tube that keeps the tube on the bottom of the tank Now is a good time to inspect the tubing and make sure the weight is still in place as intended Installation 1 To install the fuel sending unit reverse the removal procedure Fuel Tank Removal 1 Remove the cargo bed as described on page 7 3 to access the fuel tank Also remove the rear belly pan to access the fuel tank d...

Page 50: ...move the screws securing the driver s front intake screen then remove the screen fig 7 21 2 Disconnect the two front left R O P S wire harness connectors from the main harness These are located behind the front fascia and may be accessed through the left front intake grill removed in step 1 fig 7 22 3 Disconnect the two left rear R O P S connectors from the main harness as well They are located in...

Page 51: ... refer to the appropriate sections of this manual for direction in the removal of these prior to attempting to remove the rear console from the machine 2 Drain the hydraulic oil from the tank until the level is below the dipstick tube See page 4 8 of this manual for detailed instructions 3 Once the above components have been removed disconnect the fill and vent tubes including the hydraulic oil di...

Page 52: ...oval It may be wise to have a cou ple of helpers nearby to assist with this procedure Also take care not to damage the hydraulic oil dipstick tube as this may catch on other tubes or hoses as you remove the console Installation 1 To install the rear console reverse the removal procedure Torsion Axles undercarriages Removal 1 Raise and support the Scout on jack stands according to the jacking proce...

Page 53: ... Also If move ment is difficult it may be helpful to use a port a power to help push them off of the axles while supporting the weight with a forklift or rolling hydraulic jacks 7 Support the weight of each axle with a hydraulic jack then remove the bolts securing it to the chas sis fig 7 35 8 Once all bolts have been removed lower each axle to the ground and remove it from the machine Installatio...

Page 54: ... being worked on Prior to performing any type of service work on a Rubber Track Utility Vehicle read and understand Chapter 1 Product Safety for personal safety informa tion Removal and Installation Removal and installation procedures are provided for the following radiator oil cooler components Radiator Oil Cooler Fan Spacer and Shroud guard Note Procedures are provided for only those radiator oi...

Page 55: ...ful to use a crow s foot to loosen the nuts on these tubes fig 8 3 Note Cap and plug all hydraulic tubes ports to keep dirt debris out of the hydraulic system 6 Remove the bolts securing the cooler to the chas sis then remove the cooler from the machine fig 8 4 8 5 Installation 1 To install the radiator oil cooler reverse the removal procedure Fan Fan Spacer Shrouding Removal 1 Relieve the tension...

Page 56: ...ine fig 8 7 8 8 3 Once the fan has been removed the shroud and guard can simply be lifted out of the machine as shown fig 8 9 Installation 1 To install the fan spacer and shrouding reverse the removal procedure 8 3 Rubber Track Utility vehicle 8 Radiator and Oil Cooler 8 7 8 8 8 9 https tractormanualz com ...

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Page 58: ...e is being worked on Prior to performing any type of service work on a Rubber Track Utility Vehicle read and understand Chapter 1 Product Safety for personal safety informa tion Removal and Installation Removal and installation procedures are provided for the following hydraulic components Hydraulic Reservoir tank Suction Screen Note Procedures are provided for only those hydraulic com ponents lis...

Page 59: ...t hose from the reservoir fig 9 1 4 Disconnect the lead connected to the hydraulic oil temperature sending unit as shown fig 9 2 5 Remove the clamps securing the brake and two speed lines to the chassis fig 9 3 6 Disconnect the brake and two speed tubes from the valve block at the top and bottom fig 9 4 7 Pivot the tubes over the reservoir and out of the way fig 9 5 8 Remove the bolts securing the...

Page 60: ...al 2 Remove the cover from the hydraulic reservoir as shown fig 9 8 3 Thread the suction screen off of the system inlet tube and remove through the upper opening as shown fig 9 9 Installation 1 To reinstall the suction screen reverse the removal procedure 9 3 Rubber Track Utility Vehicle 9 Hydraulic Reservoir 9 8 9 9 Required Tools Combination Socket Wrench https tractormanualz com ...

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Page 62: ... Safety for personal safety informa tion NOTICE The hydraulic system fluid should be changed following any hydraulic component service according to the procedure described on page 4 8 Removal and Installation Removal and installation procedures are provided for the following hydraulic components Charge Auxiliary Pump Tandem Drive Pump 2 speed Brake Manifold Shuttle Block Pilot Generation Block Aux...

Page 63: ... Remove the bolts securing the charge auxiliary pump to the drive pump then remove it through the bottom of the machine as shown fig 10 4 Installation 1 To install the charge auxiliary pump reverse the removal procedure Tandem Drive Pump Removal 1 Remove the engine cover and unfasten and move the heater if equipped from its brackets to access the drive pump 2 Remove the charge auxiliary pump as de...

Page 64: ...likely need to remove the upper 90 fittings in order to access the lower hoses to disconnect them 6 Disconnect the hoses from the brass pump return outlet fitting fig 10 9 7 If possible use an eyelet style bolt similar to the one pictured here to attach the pump to an engine hoist If one is not available thread two or more lifting straps under the pump one at each end and attach them to the hoist ...

Page 65: ...aulic Components 10 12 10 13 10 14 10 15 To Tank return To Drive Motor LT To Drive Motor RT From Charge Pump Top Bottom Drive Pump Hoses View is from the right Bottom Top Front Rear 10 16 Bottom Top Front Rear Right and Left Drive Pump Hoses from shuttle bk btm rt from shuttle bk top rt from shuttle bk btm lt from shuttle bk top lt View is from the right The pump is to be perceived as transparent ...

Page 66: ...ctors running to the sole noids from the main wiring harness fig 10 20 7 Remove the bolts securing the manifold to the chassis from the outside as shown then lift and remove the manifold from the machine fig 10 21 10 22 Note It may make it easier to remove the manifold if you remove the tube clamps securing the upper tube to the chassis along the frame crossmember then pivot it up and out of the w...

Page 67: ...the hoses from the top and bottom of the shuttle block as shown fig 10 23 6 Disconnect the tubes from the front of the shuttle block fig 10 24 7 Remove the bolts securing the block to the chassis as shown Support the block when removing the bolts to avoid dropping it Remove it from the machine fig 10 25 10 26 Installation 1 To install the shuttle block reverse the removal procedure 10 6 Rubber Tra...

Page 68: ...o a ratchet may be helpful in disconnecting these tubes fig 10 27 6 Disconnect the hose from the lower 90 fitting as shown fig 10 28 7 Disconnect the tube from the forward fitting on the pilot generation block as shown fig 10 29 8 Remove the bolts securing the pilot generation block to the chassis fig 10 30 9 Once all hoses and tubes are disconnected dis connect the wire harness from the solenoid ...

Page 69: ... 6 Disconnect the tubes from the valve assembly as shown fig 10 33 7 Disconnect the solenoids from the wire harness as shown It may be wise to label the connectors to aid during installation fig 10 34 8 Remove the bolts securing the block valve assem bly to the chassis Support the weight of the block valve as you remove the bolts fig 10 35 9 Lift and remove the valve block assembly from the machin...

Page 70: ... best to first remove the valve as described in steps 1 4 of this procedure Then remove the two screws securing the plunger retaining plate fig 10 39 6 Gently remove the plate and the plungers should slide out with it Make sure to do this carefully to avoid dropping parts Note the order of part assembly upon removal to aid during reassembly fig 10 40 Installation 1 To install the steering valve as...

Page 71: ...10 43 5 Disconnect the tubes from the control valve as shown Cap and plug tubes and fittings to prevent fluid loss or contamination fig 10 44 6 Remove the bolts securing the valve to the floor of the cab as shown then lift the valve upward and remove fig 10 45 Installation 1 To install the directional control valve reverse the removal procedure 10 10 Rubber Track Utility Vehicle 10 Hydraulic Compo...

Page 72: ...he battery terminals tape the battery clamps and remove the key from the ignition switch prior to performing any service work on a Rubber Track Utility Vehicle Place a Do Not Operate tag prominently on the ma chine to inform personnel that the machine is being worked on Prior to performing any type of service work on a Rubber Track Utility Vehicle read and understand Chapter 1 Product Safety for p...

Page 73: ...efore attempting to service the exhaust system 1 Remove the forward belly pan to access the exhaust system Note Removal of the cargo bed page 7 3 may make muffler removal easier but it is not required 2 Remove the nuts on the exhaust clamp that secures the muffler to the exhaust pipe fig 11 6 3 Loosen the muffler clamp fasteners until they release then slide the muffler rearward and then away from...

Page 74: ...or to attempting to separate the pipe sections from each other This will make removal significantly easier 7 Slide the jointed section of pipe off of the header down tube and remove fig 11 11 Note Use caution not to damage the pipe or connec tion point during removal 8 Remove the pipe section from the machine as shown fig 11 12 Note If the individual sections of the jointed pipe need to be separat...

Page 75: ... forward away from the opening in the rear console and lay it aside fig 11 15 5 Loosen the hose clamp securing the intake hose to the air cleaner housing Then slide the hose off of the housing and lay it aside fig 11 16 6 Remove the air cleaner housing from the center of the machine through the opening in the rear con sole fig 11 17 Installation 1 To install the air cleaner reverse the removal pro...

Page 76: ...ecuring the drive pump from the engine adapter plate fig 11 18 3 Once the bolts have been removed slide the pump rearward and secure it away from the engine fig 11 19 4 Disconnect the various sending units from the wiring harness fig 11 20 Note Make note of the location and identity of each sending unit when you disconnect them to ensure proper connections when they are reconnected 5 Disconnect th...

Page 77: ... the chains prior to removing the engine mount bolts fig 11 25 10 Remove the bolts 4 securing the engine mounts to the chassis fig 11 26 11 Remove the bolts securing the rear engine mounts to the engine block then remove the rear engine mounts from the engine to allow for removal See note below fig 11 27 Note Prior to performing step 11 raise the engine slightly to remove any pressure on the mount...

Page 78: ...tems removed during engine removal to ensure proper operation Prior to starting make sure all fluids are at appropriate levels and that they have not been contaminated with dirt or debris during service Change fluids or adjust fluid levels as needed to ensure proper operation 11 7 Rubber Track Utility Vehicle 11 Engine WARNING https tractormanualz com ...

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Page 80: ...g worked on Prior to performing any type of service work on a Rubber Track Utility Vehicle read and understand Chapter 1 Product Safety for personal safety informa tion Removal and Installation Removal and installation procedures are provided for the following undercarriage components Idler Wheels Drive Sprocket Drive Motor Grease Tensioner Note Procedures are provided for only those components li...

Page 81: ...be removed from their axles see steps 4 6 of this procedure 4 Remove the bolts securing the undercarriage to the torsion axles as shown fig 12 6 5 Use a port a power or similar device to gently slide the undercarriage away from the chassis on the axles Slide the undercarriage outward only as far as needed to remove the inner wheels to prevent bending or damaging the drive hose tubes 6 Perform step...

Page 82: ... nut and washer from the axle then remove the wheel from the axle fig 12 9 Installation 1 To install the 14 idler wheels reverse the removal procedure Torque the wheel mounting bolts upon installation to 111 10 Lb Ft Drive Sprocket Removal 1 Perform the track removal procedure on pages 4 10 and 4 11 of this manual to remove the track from the undercarriage 2 Remove the bolts securing the outboard ...

Page 83: ...he bearing assembly loose from the sprocket shaft fig 12 13 6 Once loose remove the bearing assembly from the sprocket shaft as shown fig 12 14 7 Remove the bolts securing the sprocket to the drive motor fig 12 15 8 Remove the sprocket from the undercarriage fig 12 16 Note The sprocket is quite heavy it may be a good idea to use a hoist and suitable lifting straps to remove it from the machine Ins...

Page 84: ...s out of the hydraulic system fig 12 18 12 19 see note Note You must remove the lower tube guard from the rail in order to access and disconnect the lower large hydraulic tube from the motor fig 19 6 Remove the bolts securing the drive motor to the rail fig 12 20 7 Remove the motor from the rail fig 12 21 Note The drive motor is quite heavy use a hoist and suitable lifting straps to remove it from...

Page 85: ... shown fig 12 23 4 Once the tensioner assembly is free remove it from the machine out the front of the rail as shown fig 12 24 5 Remove the wheel and axle from the assembly as shown fig 12 25 6 Remove the grease tensioner from the assembly as shown fig 12 26 Installation 1 To install the grease tensioner reverse the removal procedure 12 6 Rubber Track Utility Vehicle 12 Undercarriage Required Tool...

Page 86: ...any hydraulic component service according to the procedure described on page 4 8 Disassembly Assembly Disassembly and assembly procedures are provided for the following components Hydraulic Cylinders Auxiliary Control Valve Drive motor Drive Pump Auxiliary Pump Note Procedures are provided for only those components listed above However exploded parts diagrams exist in the SC 50 parts manuals to se...

Page 87: ...aired func tion Defective components must be repaired or replaced 7 With the piston and rod removed from the cylinder inspect the cylinder bore for scratches or other damage If any are present that are deep enough to catch with your fingernail the cylinder tube weldment should be replaced figure 13 5 8 Remove the nut from the rod end figure 13 6 9 Support the piston loosely from the underside fig ...

Page 88: ...land outer seal from the end gland figure 13 10 16 Thoroughly clean all parts to prevent contamina tion of hydraulic oil when reinstalled Assembly 1 Install new seals and components in place of the originals paying close attention to orientation and location to ensure proper operation 2 Lubricate the piston ring and seals with fresh hydraulic oil prior to assembly to avoid damage 3 Reassemble comp...

Page 89: ...f damaged replace the auxiliary control valve fig 13 18 Note The spool must be oriented correctly in order for the valve to function There is a small dimple in the end of each spool Note the direction it is facing in relation to the valve section upon removal and reinstall it this same way The valve will not function properly if this spool is installed incorrectly fig 13 18 Assembly 1 Install new ...

Page 90: ... ensure correct reassembly fig 13 21 5 Insert an air nozzle into the port closest to the rear of the pump as shown fig 13 22 6 Cover the opening with a shop cloth and apply moderate force to the top of the brake piston to keep it in place when air is applied fig 13 22 7 Apply air to the port and the piston should slide upwards so that it can be removed Note There is a seal around the outer edge of...

Page 91: ...s thorough ly clean all parts then reassemble the motor by reversing the disassembly procedure Drive Motor motor portion Disassembly 1 Mark the casing across the parting lines as shown to ensure correct reassembly of the drive motor fig 13 27 2 Remove the allen bolts securing the output end of the drive motor to the main casting and remove it from the motor as shown fig 13 28 13 29 13 6 Rubber Tra...

Page 92: ...13 32 6 Once the snap rings and retainers are removed slide the piston assemblies out one at a time and inspect them for damage fig 13 33 13 34 Note While inspecting the piston assemblies pay close attention to the piston ring Look for any signs of damage or cracking fig 13 34 7 Inspect the rollers and sleeves as well to make sure there are no scratches or other damage that may affect operation fi...

Page 93: ...crew and reinstall by reversing the disassembly procedure Retest the pressure through the affected relief to check for proper adjustment If it is still not correct repeat the adjustment procedure until correct Drive Pump Posi Power Relief Valve Removal Note The posi power relief valve is usually a remove and replace item However If adjustment is required please see the posi power relief valve adju...

Page 94: ...scratches that can be felt with a fingernail fig 13 43 4 Inspect the end of the barrel face and the slipper faces for similar scratches fig 13 44 13 45 Note To inspect the slipper faces slide the barrel off of the assembly then slide the slippers and pistons off of the shaft as an assembly and inspect 13 9 Rubber Track Utility Vehicle 13 Hydraulic Component Service Required Tools Combination Socke...

Page 95: ...g then remove the seal fig 13 48 Note If you are repairing the existing pump you will need to replace the outer seal as it will be destroyed upon removal 7 Using a rubber mallot gently tap the shaft and bearing out of the case for inspection or replace ment fig 13 49 13 10 Rubber Track Utility Vehicle 13 Hydraulic Component Service 13 46 Swash Plate 13 47 Surfaces Bearings 13 48 13 49 https tracto...

Page 96: ...wo small pivot wires attached to the swash plate Remove these from their cavities while installing the swash plate 5 Assemble the bearing halves to the bottom of the swash plate orient the pins so that they are verti cal and then lower the assembly into place over the shaft fig 13 53 6 Once installed make sure each pin is centered in its opening then slide the pivot into the hole so that it mates ...

Page 97: ...57 Auxiliary Pump Disassembly 1 With machine off and cool and with hydraulic actu ators relaxed remove the drive pump from the machine by following the procedure on page 10 1 2 Remove the bolts that hold the pump end caps onto the housing fig 13 58 Note Draw a line across the cap and housing parting lines with a permanent marker to help ensure correct part orientation when you reassemble the pump ...

Page 98: ...spacer block faces both sides and pump gears for scratches or any other damage that can be felt with a fingernail If damaged replace the pump fig 13 64 Note If there are deep scratches grooves or signs of scoring on any of the surfaces that parts move slide or rotate upon the pump should be replaced Assembly 1 Install new seals and components in place of the worn originals paying close attention t...

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Page 100: ...er removes contaminants from the oil Small amounts of debris found on in the filter are to be expected but If there is significant metallic debris found in on the filter certain components of your hydraulic system may be contaminated To inspect for contamination remove the hydraulic filter and inspect it for debris If contamination is suspected contact the ASV service department at 1 800 346 4367 ...

Page 101: ...ecessary adjust the charge relief pressure To adjust a Remove the engine cover to access the drive pump b Locate the charge relief valve on the driver s side of the drive pump fig 14 2 c Remove the relief valve from the side of the pump as shown in figure 14 3 d Add shims to increase the pressure setting or remove shims to decrease the setting until within specification figure 14 4 5 Retest once a...

Page 102: ...nd you will read the actual pressures required to activate the relief valve for the circuit Record the pressure reading Check your reading against the reading stated below If your reading differs an adjustment and or repair may be required Pressure should read 3000 100 PSI with continuous flow activated 3 If necessary adjust the setting on the auxiliary valve inlet relief figure 14 7 To adjust a L...

Page 103: ...so you or an assistant can read the gauge during testing 4 If tapped into an upper port depress the direction al control pedal in an attempt to drive the machine forward This will force oil over relief and give you a reading for the circuit you are tapped into 5 If tapped into a lower port depress the directional control pedal in an attempt to drive the machine in reverse This will force oil over ...

Page 104: ... clear of moving parts and start the engine 5 At low rpm posi power pressure should read 80 40 psi 300 40 at high rpm 6 If your reading is low remove the cap and loosen the jam nut on the posi power adjustment screw and turn it counter clockwise until it stops then retighten the jam nut figure 14 11 a If the screw was already turned completely out and pressure reads lower than specified the posi p...

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Page 106: ...ticular attention to the following items Track tension Fluid levels Fan belt tension and condition Hoses no visible sign of wear Fittings no apparent leaks Battery cables Fuse panel fuses in place and operational Controls for neutral A simple visual inspection and operational check can identify many problems without the need for extensive troubleshooting However if these checks indicate a problem ...

Page 107: ...d connections 7 Faulty safety relay 8 Faulty safety solenoid or safety solenoid spool 9 Loose broken or disconnected wiring at fuse relay or safety solenoid 10 Low charge pressure Problem Battery will not accept or maintain charge Possible causes 1 Loose alternator belt 2 Alternator fuse blown 3 Faulty alternator diode 4 Loose broken or disconnected wiring at battery alternator diode or fuse 5 Exc...

Page 108: ...0402 840 6 gallons Engine Anti freeze Coolant ASV Posi Lube Long Life 50 50 Antifreeze Coolant Capacity 1 75 U S gallons P N 0300 766 1 gallon P N 0402 841 6 gallons Hydraulic Oil ASV Posi Lube Premium All Season MV Hydraulic Oil Capacity 5 125 U S gallons service refill only P N 0400 253 5 gallons P N 0402 833 55 gallons Grease general use ASV Posi Lube Multi Purpose EP Lithium Grease P N 0300 76...

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Page 110: ...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 Thread Size Standard Torque M6 12 3 Nm M8 28 7 Nm M10 55 10 Nm M12 100 20 Nm M14 160 30 Nm M16 240 40 Nm M20 460 60 Nm M24 800 100 Nm M30 1600 200 Nm M36 2700 300 Nm https tractormanualz com ...

Page 111: ...Terex Construction Americas 8800 Rostin Road Southaven MS 38671 888 201 6008 662 393 1800 www terex com https tractormanualz com ...

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