Struck Magnatrac RS1000 Operator / Technical Manual

MAGNATRAC

®

RS1000

Operator / Technical Manual

Version 1.01.19

Struck Corp. - Cedarburg, WI 53012

Copyright 2019 C. F. Struck Corp. All rights reserved.

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Very Important Facts

& Tips for

Top Performance

The following are random facts that will be ex­panded on within this Manual. They are brought
to you “first” to impress upon you their primary im­portance in preventing damage to your RS1000
and also to protect your safety and prevent costly
and unnecessary maintenance expenses.

SAFE BLOCKING AREA

When “blocking” your Crawler off the ground for
service, be aware that you should only apply a

hydraulic jack, in the black shaded area
marked below.

ENGINE TORQUE

The greatest amount of power (drawbar torque)
your RS1000 can deliver is near the Engine’s mid­speed range. This is marked on your dash area.
To go faster, your Engine’s “drawbar torque” will
be diminished by having to go faster.

Doing all your heavy work at mid-speed does
three things:

1. It keeps the Engine cooler working at a
slower speed.

2

. It gives you maximum drawbar torque.

3. It provides time to make “attachment ad­justments” on the go!

You’re encouraged to completely read this Man­u

al to get a firm over-view of: how your RS100 op­erates, significant safety points, and also
maintenance tips on how to increase your MAG­NATRAC’S life.

PARKING BRAKE

NEVER FORGET to take off your Parking Brake...
BEFORE you drive away. If you fail to disengage

the Parking Brake, it will wear very rapidly and be
of no value in an emergency!

LUBRICATION OF POWER SHAFT
ENDS

Read and understand the “Special Note” in the
“Belt Installation” section of this manual. By fol­lowing it ‘s simple lubrication instructions your can
save yourself a lot of work, and potential expense
in the future and make Belt changing much easier.

CLUTCH BELTS

The use of rugged, though uncomplicated Belt
Clutches, gives the RS1000 amazing performance
while at the same time keeps its initial purchase
price and later maintenance costs within the
homeowner’s budget.

The life expectancy of these Clutch Belts is the di­rect result of the type of work being done and the
operator’s driving technique. It is strongly recom­mended at this time that you thoroughly read the
Track Clutch Belt Removal & Installation chapter
in the Service Section of this Manual to give you
an over-view of the mechanics of your drive sys­tem.

In factory tests of different driving techniques, it
has been found that Belt life will range from 25 to
200 hours. This testing proved that the operator
is the greatest variable in determining Belt life.
From these tests, the following driving rules have
evolved. If followed, they will give you the best
Belt life consistent with the severity of work you
are doing.

2

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1

. Do not “ride” your Clutch Controls ...rather op-

erate them smoothly and engage your belts fully.
If your Crawler can not push a particular load you
have two options: immediately reduce the load
(raise the Bucket or Blade) or backup and take a
n

ew angle at the load...never hold your track

controls in a fixed position (forward or rearward)
against an immovable object, you will unneces-

sarily wear the Belts.

2. Your RS1000 has outstanding pushing ability,
but its up to you, the operator, to use its ability in
the most efficient and economical manner.

3. When you want to go slowly for a sustained pe­riod, reduce your engine speed...do not “slip” your
Belt Clutches for long periods of time! Your Belt
Clutches are no different than the disk clutch
found in a large truck...if you constantly slip the
Clutch under heavy loads you will burn the clutch
faces and decrease clutch life. It’s no different
with your Belt Clutches.

4. Reserve horsepower has been designed into
your Crawler. This means you can reach the max­imum torque necessary to fully drive your RS1000
with your engine operating at only about half­speed.

TRACKS

The track system of your Magnatrac is the result of
over 50 years of experience.

It is not uncommon in the inital operating hours for
the steel track system to make popping noises

as the intial “wear in” occurs.

The steel track system is of an “unguided” design,
but is extremely stable due to its double track
chain design. A few rules are listed below that if
followed will give you maximum Track perform­ance.

1. Avoid overloading your track system with the
material you are working in. Always work in loose
materials by clearing a “driving path” with the at­tachment (Blade, Bucket, etc.) you are using. This
technique will allow a minimum amount of material
to enter the track system.

2. Avoid climbing on a pile of loose material and
counter-rotating your tracks. This action will “cork­screw” the Tracks into the pile and force unnec-

e

ssarily large amounts of material into the Tracks.
The steel or rubber track system is designed to
absorb a great deal of material, but the less you
force it to “digest”, the greater will be the Track’s
stability and overall life.

3. Periodically, following the Steel or Rubber Track
Tensioning instructions in your Operator’s/Techni­cal Manual, check your Track tension by checking
the length of the #1806 Spring.

4. Though this Spring adjustment is not a precise
type of adjustment, it must be realized that to over­tension the Spring will cause a higher level of wear
in your track bearings, while under-tensioning will
cause potential derailing of your Track.

As always, the Struck Corporation through the
customer service department, stands ready to
help you with any technical or work related ques­tions you may have either now or in the future!
Call [phone] or Fax [phone].

3

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LIMITED WARRANTY

NEW STRUCK CRAWLERS and/or ATTACHMENTS

(Effective with shipments made after August 1st, 2017)

A. GENERAL PROVISIONS

C.F. Struck Corp. will repair or replace, at its option, for the original purchaser of a new Struck Crawler and/or Attach­ment, any covered part or parts found upon examination at our factory in Cedarburg, Wisconsin, to be defective in mate­rial or workmanship or both; this is the exclusive remedy. Warranty service must be performed by the C. F. Struck Corp. at
their factory in Cedarburg, Wisconsin 53012. Warranty service will be performed without charge for parts or labor. The
purchaser will be responsible, however, for transportation charges to and from the factory.

B

. WHAT IS WARRANTED

A

ll parts of any new Struck Crawler and/or Attachment are warranted for two (2) years, with the following exceptions: Belts,
which are warranted for 90 days (excludes normal wear and tear); Engines, which are warranted by their manufacturer;
and Batteries, which are provided on a complimentary basis and carry no warranty whatsoever. C. F. Struck Corp. re­serves the right to make product design and specification changes without notice and without obligation on their part to
present product owners. The Warranty term begins on the date the product is shipped to the purchaser.

C. WHAT IS NOT WARRANTED

(1) Used Products; (2) Any product that has been altered or modified in ways not approved by C. F. Struck Corp.; (3) De­preciation or damage caused by normal wear, lack of reasonable and proper maintenance, failure to follow the product’s
Operator’s/Technical Manual instructions, failure to upgrade crawler with parts furnished at no charge, misuse, lack of
proper protection during storage, or accident (4) Normal maintenance parts and service; (5) Use of Struck Crawler and/or
Attachments in certain industrial-type applications may affect Warranty coverage.

D. RETURNS AND REFUNDS

In the event of defective materials or workmanship the purchaser agrees to allow C.F. Struck Corp the opportunity to cor­rect the defect in a timely manner at the expense of C.F. Struck Corp. It is at the discretion of C.F. Struck Corp to either
correct the defect or refund the purchaser.

To return a Struck Crawler and/or attachment for reasons other than defect the purchaser will be financially responsible
for an 8% restocking fee, and for shipping the Struck Crawler and/or Attachment to the C.F Struck Corp. factory in Cedar­burg, Wisconsin 53012. No Returns after 90 days.

E. SECURING WARRANTY SERVICE

To secure Warranty service, the purchaser must:
(1) Report the product defect to the factory in Cedarburg, Wisconsin 1-262-377-3300 or 1-877-828-8323.
(2) Make the part available to the factory in a reasonable period of time.

F. LIMITATION OF IMPLIED WARRANTIES AND OTHER REMEDIES

To the extent permitted by law, neither C. F. Struck Corp. nor any company affiliated with it makes any Warranties, rep­resentations or promises as to the quality, performance or freedom from defect of the products covered by this Warranty.
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, TO THE EXTENT APPLI­CABLE, SHALL BE LIMITED IN DURATION TO THE APPLICABLE PERIOD OF WARRANTY SET FORTH ON THIS PAGE. THE
PURCHASER’S ONLY REMEDIES IN CONNECTION WITH BREACH OR PERFORMANCE OF ANY WARRANTY ON C. F.
STRUCK CORP. PRODUCTS ARE THOSE SET FORTH ON THIS PAGE. IN NO EVENT WILL C. F. STRUCK CORP. OR ANY
COMPANY AFFILIATED WITH IT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

(Note: Some states do not allow limitations on how long an implied Warranty lasts or the exclusion or limitation of incidental
or consequential damages so the above limitations and exclusions may not apply to you.) This Warranty gives you specific
legal rights, and you may also have other rights which vary from state to state.

G. ASSEMBLY RESPONSIBILITY

Though the MAGNATRAC RS1000, MH4900 and MH8500 are offered completely assembled, it’s still the customer’s re-

sponsibility to provide competent service ability! The servicing can be provided either by the mechanically customer, or by a
local mechanic. All Attachments and accessories are shipped in easy-to-assemble “semi-kit” form for lowest cost shipping. We
provide Manuals and Illustrations for complete service and repair so that anyone with reasonable mechanical skill can preform
all required service work. Check the MAGNATRAC Specifications & Ratings (in Spec Book or Buyer’s Guide) for a list of all
standard features.

I hereby accept the terms and conditions of Warranty described above:

RS1000
MH4900
MH8500
Warranty 9.18

signature

print name

date

4

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TABLE OF CONTENTS

VERY IMPORTANT FACTS & TIPS FOR PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1- TO THE OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Recognize Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Understand Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Follow Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Service Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2- SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Safety Before Starting or Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Service Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Fire Prevention Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Protection From Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Start Engine From Operator Seat Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3- CONTROLS AND INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Left & Right Clutch Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Dashboard Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

4- OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Pre-Starting Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Prepare For Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Warm-up Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Parking & Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

5- FUELS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

6- LUBRICATION AND PERIODIC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Lubrication and Service Intervals & Periodic Servce Chart . . . . . . . . . . . . . . . . . . . . . . . . . . .19

7- SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Engine & Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Safety Interlock Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Seat & Rear Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Rear Drive Chain Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Parking/Emergency Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Track Clutch Belts (Removal & Install) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Engine Drive Chain (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Eninge Drive Micro V-Belt (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Steel Track Removal (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Steel Track Tensioning (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Rubber Track Removal (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Rubber Track Tensioning (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

8- TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

9- SAFETY & WORK PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Loader Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Bulldozing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Backhoe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Misc. (Snowplowing, logging, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

10- PARTS LISTING & DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Index of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

IMPORTANT: Though the MAGNATRAC is offered completely assembled, it’s still the customer’s responsibility
to provide competent service ability! The servicing can be provided either by the mechanically-inclined cus­tomer, or by a local mechanic. We provide manuals & drawings for complete service and repair so that anyone
with reasonable mechanical skill can perform all required service work.

5

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Congratulations…

on your purchase of a quality-built, American
made compact Crawler. We are confident that the
d

ependability and economical performance of
your Magnatrac will prove that you made a wise
choice.

The purpose of this Manual is to acquaint you with
the RS1000 Magnatrac Crawler. This Manual ex­plains how to operate and service your Crawler,
and how to maintain its high operating efficiency.
Instructions are given clearly, with the intention of
making these operations as easy as possible.

Keep this Manual in a convenient place for quick
and easy reference. Use it as a guide whenever
questions arise. You have purchased a depend­able, sturdy Crawler, but only by operating and
caring for it properly can you expect to receive the
service and long life for which it was designed.

If in the future you need new parts to replace
those that may be worn, insist on genuine Struck
parts. They are exact duplicates of the originals,
made from the same patterns and of the same
high-quality materials.

When ordering parts, always be sure to give the
following information for your Crawler:

MAGNATRAC Records

MAGNATRAC Model: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

MAGNATRAC Serial # _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Engine Model: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Engine Serial # _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Ship Date: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Mail: STRUCK CORPORATION

W51N545 STRUCK LANE
CEDARBURG, WI 53012

Phone*: [phone] local

[phone] toll-free

Fax: [phone]

email: [e-mail]

Web: www.struckcorp.com

*

For immediate service always call the factory

and ask for a technician.

1- TO THE OPERATOR

RECOGNIZE

SAFETY

INFORMATION

This is the safety-alert symbol. When
you see this symbol on your Crawler or
in this Manual, be alert to the potential
for personal injury.

UNDERSTAND SIGNAL WORDS

A signal word — DANGER, WARNING, or CAU­TION — is used with the safety-alert symbol.
DANGER identifies the most serious hazards.

Safety labels with the signal word DANGER or
WARNING are typically near specific hazards.

General precautions are listed on CAUTION
safety labels. CAUTION also calls attention to
safety messages in this Manual.

FOLLOW SAFETY INSTRUCTIONS

Carefully read all safety messages in this Manual
and on your Crawler and Attachment safety labels.
Follow recommended precautions and safe oper­ating practices.

Keep safety labels in good condition. Replace
missing or damaged safety labels.

To keep your Crawler running efficiently, read the
instructions in this Manual.

Left side, right side, front, and rear are viewed by
facing in the direction of the Crawler’s forward
travel.

Record your Crawler serial numbers in the space
provided. You need this information when you
order parts.

6

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Date Service Work
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Date Service Work

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

SERVICE & MAINTENANCE RECORDS

Proper service and maintenance work is critical to trouble free operation of your equipment. It is
also critical to diagnosing problems should they arise. Use the space provided on the following ­p

age to record maintenance and service work performed.

7

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 7

2- SAFETY RULES

Reports on accidents show that care­less use of machinery causes a high
p

ercentage of accidents. You can avoid

many accidents by following the safety
rules on these pages. Study these rules carefully
and enforce them on the job
.

SAFETY BEFORE STARTING OR
OPERATION

The Crawler should be operated only by persons
approved to do so.

Clothing worn by the operator should be fairly tight
and belted.

Fasten a first aid kit to the Crawler.

Fasten a fire extinguisher to the Crawler. Keep
the extinguisher fully charged. Learn to use it cor­rectly.

If the Crawler has an unsafe condition, do not op­erate. Put a tag on the Track Drive Controls.

Do not start or operate the Crawler unless you are
in the operator’s seat.

Before you start the Engine, be sure there is
plenty of ventilation.

Keep hands, feet, and clothing away from power­driven parts.

Fasten a slow-moving vehicle sign to the rear of
the Crawler.

Guards, shields, and other protective devices
must be in place and in good condition.

Before you start or operate the Crawler, clear the
area of all persons and obstacles.

OPERATION SAFETY

When you operate the Crawler, do not allow any­one to ride on the Crawler or its equipment.

Drive at safe speeds at all times, especially on
rough ground and hillsides.

Carry the Bucket or Blade as low as possible at
all times, especially when you work on a hillside
or back up a steep hill.

D

o not drive too close to the edge of a ditch or ex-

cavation.

Watch for overhead wires. Do not touch wires
with any part of the Crawler or its Attachments.

Do not leave your Crawler unattended with the En­gine running.

Keep work areas as level as possible.

When loading logs with the Log Forks, make sure
the logs are balanced.

When you drive out of a ditch or excavation, or up
a steep hillside, or when Crawler is hitched to a
heavy load, engage Track Drive Controls slowly. If
the front of the Crawler comes off the ground, re­lease Track Controls immediately.

Do not use the Crawler as a battering ram.

Do not guide cable onto Winch Drum with your
hands.

When you drive the Crawler on a road, use the
correct lights to warn operators of other vehicles.

Before you move any equipment, be sure all per­sons are away from the Crawler.

When the Crawler is operating, only the operator
should be on it.

If it is necessary to make checks with the Engine
running, always use two people...the operator at
the controls should be able to see the person
doing the checking

KEEP HANDS AWAY FROM MOVING PARTS!

BEFORE YOU GET OFF THE UNIT:

Move Track Drive Controls to neutral.
Engage Parking Brake Lever.
Lower all equipment to the ground.
Move throttle to idle for 1 minute.
Stop Engine and remove the key.

8

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 8

SERVICE SAFETY

Be sure you understand a service procedure be­fore you work on the Crawler.

U

nauthorized modifications to the Crawler may
impair the function and/or safety and affect
Crawler life.

Do not work under Crawler or raised equipment
unless it is correctly supported...contact factory for
recommended procedures.

Before you work on the Engine or electrical sys­tem, disconnect the battery’s “ground” ( - ) termi­nal first! When work is finished, connect battery’s
“ground” terminal ( - ) last.

When driving connecting pins (Spring Pins), wear
goggles or safety glasses.

Do not run Engine while working on the Crawler.

Be careful when handling any type of fuel. Do not
smoke while filling the fuel tank or working on the
fuel system.

Check for faulty wiring or loose connections.

Do not lubricate or work on the Crawler while it is
moving.

When you work near the Track Springs, use ex­treme care. Do not disassemble parts unless you
know the correct procedure and have correct
tools.

FIRE PREVENTION MAINTENANCE

Be prepared if an accident or fire should occur.

Know where the first aid kit and the fire extin­guisher are located...know how to use them.

Check fire extinguisher for correct charge.

Do not smoke while refueling or handling highly
flammable material.

Shut off the Engine when refueling.

Use care in refueling if the Engine is hot.
Do not use open pans of gasoline or diesel fuel for

c

leaning parts. Use good commercial, nonflam-

mable solvents.

Provide adequate ventilation when charging bat­tery.

Do not check battery charge by placing metal ob­jects across the posts.

Do not allow sparks or an open flame near battery.

Do not smoke near battery.

Never check fuel, battery electrolyte, or coolant
levels with an open flame.

Never use an open flame to look for leaks any­where on the equipment.

Never use an open flame as light anywhere on or
around the equipment.

When preparing Engine for storage, remember
that inhibitor is volatile and therefore dangerous.

Seal and tape openings after adding the inhibitor.

Keep container tightly closed when not in use.
Inspect electrical wiring for worn or frayed insula­tion. Install new wiring if wires are damaged.

Temperature in Engine compartment may go up
immediately after you stop the Engine. Be on
guard for fires.

Before you clean trash from the Engine compart­ment, wait until the Engine has cooled. Open
Hood to cool the Engine faster. While the Engine
cools, clean trash from other areas.

Check for leaking fuel lines or fittings with a piece
of cardboard or wood. Do not use your hands.

Tighten loose fittings. If hoses are kinked, install
new parts.

9

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 9

NOISE PROTECTION

Prolonged exposure to loud noise can cause im­pairment or loss of hearing. Wear a suitable hear­ing protective device such as earmuffs or earplugs
to protect against objectionable or uncomfortably
l

oud noise.

START ENGINE ONLY FROM THE
OPERATOR’S SEAT!

Avoid possible injury or death from Crawler run­away.

Do not start Engine by shorting across starter so­lenoid terminals. Crawler may start and move if
normal circuitry is bypassed.

CAUTION: Never start Engine while
standing on ground. Start Engine only
from operator’s seat, with Brake en­gaged.

Inspect your Crawler carefully each day before
you start it. See “Pre-Start Inspection”.

Clean your Crawler regularly.

10

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 10

3- CONTROLS

& INSTRUMENTS

Learn the location and purpose of all Controls,
Instruments and Warning labels. Thoroughly
study the Operator’s Manual furnished by the en­gine manufacture and included with your Crawler
instructions.

A - LEFT TRACK

CLUTCH CONTROL

B - RIGHT TRACK

CLUTCH CONTROL

C - THROTTLE CONTROL

D - CHOKE CONTROL

E - HEADLIGHT SWITCH

F - KEY IGNITION SWITCH

G - CIRCUIT PROTECTOR

H - FUEL VALVE

I - PARKING BRAKE (not shown)

J - HOUR METER/TACH (if equipped)

11

A

B

C

D

E

F

G

J

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 11

A & B - LEFT & RIGHT

TRACK CLUTCH CONTROLS

INTRODUCTION: The turn

demonstrated (above) is the key to
your Crawler’s superior maneuver­ability. It is accomplished with only
two controls, the A & B Left & Right
Track Controls. The illustrations
(below) show how to maneuver
your crawler in other turns.

MOVING FORWARD:

To move straight ahead, simulta­neously push forward on both Left
and Right Track Controls.

MOVING REARWARD:

To move straight rearward, simultaneously pull
rearward on both Left and Right Track Controls.

T

URNING RIGHT:

To turn sharply right, push forward on Left Track
Control while holding Right Track Control in neu­tral.

TURNING LEFT:

To turn sharply left, push forward on Right Track
Control while holding Left Track Control in neutral.

COUNTER-ROTATING TRACKS

To counter-rotate Tracks (tightest turn possible),
push one Track Control forward while simultane­ously pulling rearward on the other Track Control.

NOTE: When either Track Control is “slowly” re-

leased, it will automatically return to neutral.
NEVER allow Track Controls to “snap-back” to
neutral. See OPERATION section of this manual
for further instructions.

12

A - Left

B - Right

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 12

DASHBOARD CONTROLS

C - THROTTLE CONTROL

The Throttle is lever operated, rotating in a wide
arc. This arc is divided into two speed ranges; the
slower Work Speeds and the faster Travel
Speeds. Your Crawler has maximum “pushing
force” (maximum torque, according to the engine
manufacturer) at the mid-range speed but with a
declining level of torque as you increase your
travel speed. We advise using only as much throt­tle as needed for a particular application. If the
engine bogs down, please feel free to use more
throttle when you feel it is needed.

Though all crawlers by their design are somewhat
“rough riding”, you can minimize the “roughness”
by traveling at the lowest speeds when going over
hard surfaces.

D - CHOKE

The Choke Control is lever operated. Rotate the
lever counter-clockwise to increase engine chok­ing; rotate clockwise to decrease engine choking.
(Consult engine manual for more information).

E - HEADLIGHT SWITCH

The Headlight Switch is a basic “Pull ON”, “Push
OFF” switch. Behind the Switch is a replaceable
Safety Fuse. When replacing, use a new fuse of
the same amps as the one being replaced.

F - KEY IGNITION SWITCH

Switch is activated by rotating key clockwise.
Turning it fully clockwise will engage engine starter
...release key and it will re­turn automatically to the
RUN “ON” position. Turn
fully counter-clockwise to
OFF position to stop en­gine. Remove key.

G - CIRCUIT

PROTECTOR

The Circuit Protector pro­tects the battery charging
circuit. (Consult engine
manual for more informa­tion).

H - FUEL SHUT OFF VALVE

The Fuel Shut Off
Valve Lever con­trols the fuel to the
carburetor. Turn it

OFF for transport

or when cleaning
carburetor. (Con­sult Engine Manual
for more informa­tion).

13

H

a

r

d

Su

r

fa

c

e

T

r

a

v

e

l

Ma

x

imu

m To

rq

u

e

D

C

E

H

F

G

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 13

I - PARKING BRAKE

The Parking Brake acts both as a parking brake

and as an emergency brake.

To “engage” Parking Brake, pull Brake Handle up
firmly and loop it “up and over” the Carriage Bolt
provided...make sure handle edge is on top of Bolt

and behind “inside face” of Carriage Bolt.

To “disengage” Parking Brake, reverse the above
procedure and allow Brake Handle to rest on
Fender.

As the Parking Brake is also your emergency
brake, it’s extremely important to maintain its per­formance with daily inspection. See Service sec­tion of this manual for proper procedures.

EXTREMELY IMPORTANT:

As it’s mandatory to engage the Parking Brake be-
fore starting your crawler, always remember to
disengage it before driving away.

If you fail to disengage the Parking
Brake it will wear very rapidly and be
of no value in an emergency!!

J - HOUR METER /TACH (If equipped)

The Hour Meter/Tach dis­plays the hours run and the
RPM of the engine. Keeping
up with your maintenance of
your MAGNATRAC keeps it
running in top condition!

HOUR METER / TACH FLASH ALERT:

Flashes “CHG OIL” at 100 hour service

intervals and “LUBE” at 25 hour service inter­vals, the service interval is based on actual run
h

ours.

OPERATION:

Alerts begin flashing a warning 4 hours be­fore service is due, and clear automatically 1 hour
afterward. Meter displays RPM while enigne is
running, hours while eningeis off.

FLASH SERVICE RESET:

Service alarms will automatically reset 1
hour after service interval.

14

DISENGAGED

I - Brake Handle

I - Brake Handle

ENGAGED

Carriage Bolt

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 14

4- OPERATION

PRE-STARTING INSPECTION

Before you start your Crawler for the first time
each day, perform the following checks:

ENGINE COMPARTMENT

Check oil level.
Check air intake system.
Remove trash and oil/dirt deposits.

TRACKS, ATTACHMENTS, SHEET METAL

Check for bent, broken, or missing parts.
Check Track Springs.

HARDWARE

Check for loose or missing parts.

ELECTRICAL SYSTEM

Check for worn or frayed wires or loose
connections.

LUBRICATION

Check lubrication points shown in Periodic
Service section of this Manual.

GUARDS AND SHIELDS

Check for tightness and condition.

BATTERY COMPARTMENT

Remove trash.
Check cables for tightness and corrosion.

FUEL TANK

Check fuel level.

OPERATOR’S STATION

Check control levers for free movement.
Clean fenders and instrument panel.
Adjust Seat location to fit operator.

CAUTION - Before you start the engine:

Clear the work area of people and obstacles

C

heck the condition of the Crawler. (Prestart

inspection).

Be sure there is enough ventilation.

Be sure to know the correct starting and stop

ping procedure.

Sit in the Operator’s Seat.

PREPARE FOR ENGINE STARTING

1. Allow Left (A) and Right (B) Track Controls to
assume their natural “spring-loaded” center neu­tral positions.

2. Engage Parking Brake (I). (Make sure Brake
lever is pulled “up and over” round head of Car­riage Bolt provided...make sure handle “edge” is
on top of this Bolt and behind its inside face).

3. Check that all Attachments are in the fully low­ered position.

4. Make sure you are properly seated so Seat
Safety Switch will engage

STARTING THE ENGINE

1a. Cold Engine - Place the Throttle Control (C)
midway between the Slow and Fast positions.
Place the Choke Control (D) into the On (fully
choked) position.

1b. Warm Engine (normal operating tempera­tures) - Place the Throttle Control midway be­tween the Slow and Fast positions. Place the
Choke Control into the Off (no choke) position.

2. Activate the Key Ignition Switch (F) by rotating
the key clockwise until starter engages. Release
the key as soon as the Engine starts ...Switch will
return to the Run “On” position.

NOTE: After starting a “cold” Engine, it may be
necessary to leave the Choke partially On for a
few minutes before moving it to the Off position

15

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 15

C

AUTION: Do not crank the Engine

continuously for more than 10 seconds
at a time. If the Engine does not start,

allow a 60-second cool-down period be­tween starting attempts. Failure to follow these
g

uidelines can burn out the starter motor.

CAUTION: If the Engine develops suffi-

cient speed to disengage the starter but

does not keep running (a “false start”),

the Engine rotation must be allowed to
come to a complete stop before attempting to
restart the Engine.

If the starter is engaged while the flywheel is ro­tating, the starter pinion and flywheel ring gear
may clash, resulting in damage to the starter.

If the starter does not turn the Engine over, shut off
starter immediately. Do not make further attempts
to start the Engine until the condition is corrected.

If the battery charge is not sufficient to turn over
the Engine, recharge the battery.

CAUTION: Do not attempt to jump start

the Engine with another battery. Start-

ing with batteries larger than those rec-

ommended can burn out starter motor.

WARM-UP PERIOD

Run Engine at half speed for 5 minutes.

Do not run Engine at fast, or slow idle.

Operate Crawler at less-than-normal loads and
speeds for the first 15 minutes.

WARNING: Lethal Exhaust Gases!

Engine exhaust gases contain poison-

ous carbon monoxide. Avoid inhaling

fumes, and never run the Engine in a

closed building or confined area.

NOTE: Assembled Crawlers are “run in”
under no load at the factory to properly
break-in their drive train.

TRAVELING

Disengage Parking Brake (I); Fully raise all At­tachments to recommended traveling heights.

To move straight ahead, simultaneously push
both Left Track Control (A) and Right Track Con­trol (B) forward.

To move straight to the rear, simultaneously pull
both Right and Left Track Controls rearward.

To turn sharply to the right, push Left Track
Control fully forward...leave Right Track Control in
neutral.

To turn slowly to the right, push Left Track Con­trol fully forward while simultaneously pushing
“partially” forward on Right Track Control...the far­ther you push the Right Track Control forward, the
slower you will turn right.

16

DISENGAGED

I - Brake Handle

Reverse

Reverse

Forward

Forward

Neutral

Neutral

Control A

Control B

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 16

To turn sharply to the left, push Right Track
Control fully forward...leave Left Track Control in
neutral.

To turn slowly to the left, push Right Track Con­trol fully forward while simultaneously pushing
“partially” forward on the Left Track Control...the
farther you push the Left Track Control forward,
the slower you will turn to the left.

To counter-rotate Tracks, (shortest turn possi­ble), push one Track Control forward while simul­taneously pulling rearward on the other Track
Control. You may counter-rotate “clockwise” or
“counter-clockwise”; move in which ever direction
satisfies the job at hand.

Stopping the Crawler: The Right and Left Track
Controls are of the self-centering (neutral) type.
This allows you to simply release pressure on both
Track Controls to disconnect (declutch) active
power to the Tracks and come to a complete stop.

Never “snap” Track Controls back into neutral!

P

ARKING THE CRAWLER

1. Lower all Attachments to the ground.

2. Allow Right and Left Track Controls
t

o go “slowly” to neutral.

3. Engage Parking Brake.

4. Run Engine at half speed 2 minutes
without load.

5. Move Throttle Control to slow idle.

6. Turn Ignition Switch to Off.

IMPORTANT: If Engine stops under load, remove
load. Start Engine immediately. Run 30 seconds
at half speed before adding load.

CAUTION: When you park your
Crawler on a slope, put blocks against
tracks. Do not park Crawler with
tracks pointed downhill, always park

“cross-ways” to the hill!

STORAGE

Always store your MAGNATRAC in a garage,
shed or barn. If the only option is to park outside,
make sure to securely tarp the unit and park on a
flat surface with the parking brake engaged.

During freezing weather, park on a hard surface
to avoid freezing the Steel Tracks (if equipped) to
the ground. We recomend parking on rubber track
mats or using some inexpensive plywood. This will
keep moisture away from the steel tracks and ex­tend the life of them. If Tracks are frozen to the
ground, be careful to avoid damage to the Tracks
and drive train when you try to move the Crawler.

We advise to turn off the fuel shut off valve and
run until the unit stops if going to store for a long
period of time. This is to ensure easy starting dur­ing the next season. Remember to turn ON the
fuel when ready for work the next time!

17

Reverse

Reverse

Forward

Forward

Neutral

Neutral

Control A

Control B

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 17

5- FUELS

&

LUBRICANTS

FUELS

FUEL SPECIFICATIONS

Add fuel to fuel tank per engine manual specs.

Unleaded 86 octane or higher is recc­ommended per HONDA. Verify fuel shut­off valve is in the open position.

FILLING FUEL TANK

The Fuel Tank is located underneath the hood, on
the eninge.

Fill Fuel Tank at end of each day’s operation.

Fuel Tank capacity is 6.4 U.S. qts. or 1.6 gallons.

Use unleaded gasoline per Engine Owner’s Man-

ual.

CAUTION: Handle fuel carefully. Do

not fill fuel tank when the Engine is running. Do
not smoke while you fill fuel tank or work on fuel
system.

STORING FUELS

Keep fuel in a container in a protected area.
Water and sediment must be removed before fuel
gets to the Engine. Do not depend on fuel filters
to remove water.

If possible, install a water separator at the storage
tank outlet.

Store fuel drums on their sides with plugs up.

IMPORTANT: Keep all dirt, scale, water, or other
foreign matter out of fuel.

LUBRICANTS

ENGINE OIL

Check enclosed Engine Owner’s Manual and
closely follow their recommendations.

HYDRAULIC OIL (If equipped)

Use a premium quality hydraulic oil with max­imum anti-wear properties, rust and oxidation
treatment. A high quality antiwear hydraulic fluid
designed for use in high pressure, high speed hy­draulic pumps in industrial hydraulic systems. We
use an AW46 Hydraulic Oil. (ISO 46). An ISO of

46 is good in standard temperatures. If oper­ated at exteme hot or cold temperatures,
please consult a local oil shop for an oil vis­cosity best suited for your conditions.

If the above specifications can not be found
consult with a local tractor/equipment dealer­ship or oil supplier for other brands of hy­draulic oil suitable for loaders, backhoe, and
hydraulic drive systems.

Fill Hydraulic Oil Tank through #616 breather,
on the top of the hydraulic tank, behind the oper­ator seat. Check level by “eye check”, it should be
a few inches from the top...remove breather with
a crescent wrench at the black nut and hand
tighten once full!

Approximately 2 gallons of hydraulic fluid
fills the hydraulic reservoir to the proper
level (when empty & no hydraulic cylinders
are attached).

GREASE

Use premium quality SAE Multi-Purpose Grease
in a grease gun with a flexible “nose” to lubricate
grease zerks throughout the MAGNATRACS pivot
points.

STORING LUBRICANTS

Store lubricants in clean containers in an area pro­tected from dust, moisture, and other contamina-

tion.

18

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 18

6- LUBRICATION

&

PERIODIC SERVICE

LUBRICATION AND SERVICE
INTERVALS

Recommended service intervals are for normal
conditions. Service more often if Crawler is oper­ated under more difficult conditions such as high
temperature, dust, etc. Use only quality lubricants
at intervals specified in this manual.

PERIODIC SERVICE CHART

Air Cleaner(s) - Service per instructions in En-

gine Owner’s Manual.

Engine Oil - Service per instructions in Engine

Owner’s Manual

Battery - Change as needed. Approximately every

3 years.

1ST USAGE

1ST USAGE

Hydraulic Oil - Attach any additional attach-

ments first (Grapple, backhoe, rear hitch,
etc.) Check level on a flat & level surface;
with equipment on the ground (retract all
possible cylinders), level should be ap­prox. 5” away from the top of the tank.
Add additional fluid if needed.

Engine Oil - Check enigne oil level before use to

make sure oil level is at acceptable level
on the dipstick. Add additonal if needed.
NOTE: First oil change for a new Engine
is at 5 hours

Fuel - Add fuel to fuel tank per engine manual

specs. Unleaded 86 octane or higher is
reccommended per HONDA. Verify fuel
shut-off valve is in the open position.

EVERY TEN HOURS

EVERY TEN HOURS

Grease Fittings - Lubricate all grease fittings

per location instructions in manual of
each attachment you have mounted on
your MAGNATRAC. Recommended
grease: Multipurpose NLGI 2 Grade
Lithium Complex, ISO VG 220.[Clean
grase fittings and area around them be­fore servicing].

Clean area around each grease fitting on Front
Idler and Rear Drive Assemblies. Grease each
grease fitting until you feel back pressure building.
A small breakdown of how many grease fittings
are on the RS1000 and various Attachments is as
follows:

RS1000 with Steel Tracks: 6

RS1000 with Rubber Tracks: 10

Note: 4 are located on the front idlers &
rear drives and 2 are on the #1791 Rear
Bearings. (shown on the next page)

For all others, please see each individual
attachment for the quantity of grease fit­tings.

As a standard guide, there will be a grease
fitting for each Axle/Pin that you see on a
particular attachment. (See below).

HFH15 Front Hitch: 2

D1060 Backhoe: 14

D1060UG Backhoe: 18

HRH35 Rear Hitch: 2

Rubber Track Idlers: 4

#1791 Bearing Assemblies: 2

Lubricate the “grease fitting” in each #1791
Bearing Assembly. NOTE: The #1791
Bearings are the hardest working Bearings
in your RS1000, never spare proper lubri
cation and maintenance! See picture on
the next page.

19

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 19

EVERY FIFTY HOURS

EVERY FIFTY HOURS

Engine Oil

Drain and refill per recommendations in
Engine Owner‘s Manual.

NOTE: Change Engine oil every 25 hours
if you’re working under constant heavy
loads or extremely dirty conditions.

Filters

Replace Engine Air Filter with filter recom­mended in Engine Owner’s Manual.

Tracks and Track Sprockets

Pressure wash track system, including:
Front Idler and Rear Drive Sprockets.

Track Tension

Maintain 1-3/8” overall length of #1806
Spring on each Track.
Check Service section of this Manual for
complete explanation and Track Tension­ing procedures.

Rear Drive Chain Tension

Maintain proper chain tension in Crawler’s
Rear Drive. Check Service section of this
Manual for complete Rear Drive Chain
Tensioning procedures.

Rear Drive Chain Lubrication

Use SAE 30 motor oil in pressure oil can.
Thoroughly lubricate each Drive Chain.
[TIP: Drive Crawler forward approximately
six feet stopping to oil the Chain every
foot]. Don’t forget to do both Drive Chains!

T

ip: wipe the chain down after oiling to keep oil

spatter to a minimum.

Engine Drive Chain Tension (If equipped)

M

aintain proper chain tension in Crawler’s
Engine Drive Chain. Check Service sec­tion of this Manual for complete Engine
Drive Chain tensioning procedures.

General Once-Over

Check for loose nuts and bolts and any
signs of premature wear. Correct any
problems immediately. Contact factory
with any questions or requests for help.

EVERY 200 HOURS

EVERY 200 HOURS

Fuel Tank

Remove and drain tank of any water or
sediment. Clean or replace the in-tank
fuel filter.

Fuel Filter - Replace with new Fuel Filter at this

time: Filters can be purchased through the
Struck Corporation or through local engine
dealers.

Hydraulic Oil (If equipped) - Run the RS1000 for

approx. 5 minutes at idle, shut off. Drain
system by angling the 90 degree fitting on
the bottom right of the hydraulic oil tank.
NOTE: Drain when fluid is warm. Block up
the right front corner of Crawler a few
inches to get oil to flow completely to drain
opening. Refill with approx. 2 gallons of hy­draulic fluid. Fill the hydraulic reservoir to
the proper level. (See PP35 Power Pack

section of the attachment manual)

Enigne Spark Plugs - Replace Engine Spark

Plugs with spark plugs recommended in
Engine Owner’s Manual.

20

Zerk

#1791 Bearing Assembly

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 20

7- SERVICE

In the following Service section of this Manual, you
w

ill be required to do various assembly and dis-

a

ssembly procedures. Each section will try to re­mind you of safe procedures, but the best safety
device is still the mechanic himself.

CAUTION: Try to do your work in a
level, open area away from people and
obstacles.

1. Pay attention to what you are doing..the parts
you will be handling can be heavy, sharp or could
pinch. Always wear heavy gloves when handling
the Tracks and similar sharp, pinching parts.

2. When you are required to block your crawler to
raise it off the ground, make sure you use strong
blocking materials and think out how the Crawler
will safely balance on blocking. To protect your-

self and your Crawler from damage, check
“Safe Blocking Diagram” on front page of this
Manual!

Never be too proud to ask a friend or neighbor for
help...especially when blocking up your Crawler
or working with the Tracks.

As always, the factory is your best source for com­petent service advice and explanations of any
service procedures that are unclear...always feel
comfortable calling for whatever advice you may
need!

ENGINE

Your Crawler comes with a complete Engine
Owner’s ManuaI. It provides complete operation
and maintenance instructions for your engine. If
further help is needed, contact your local engine
dealer...he’s listed in the telephone “Yellow Pages”
under “Engines, gasoline”.

STARTER

IMPORTANT: Don’t operate starter switch longer

than 10 seconds at a time. If engine does not start
within 10 seconds, wait 60 seconds before trying
to start again. After a false start, do not turn starter
button until Engine has stopped turning.

If the starter will not operate or operates slug-

g

ishly, check for the following:

Run down battery.
Dirty, loose, or corroded cables and wires.
Engine oil viscosity too heavy.

BATTERY

Your Crawler has a 12 volt, negative-grounded
system with one battery (battery not included on
basic recoil start models).

BATTERY PRECAUTIONS

CAUTION: Sulfuric acid in batteries is

a poison and could cause severe burns.
Avoid contact with skin, eyes, and

clothes. When you work around batter­ies, protect eyes and face from battery fluid and
explosion.

Antidotes for Sulfuric Acid:

EXTERNAL

1. Flush skin well with water.

2. Flush eyes for 15 minutes.

3. Get medical attention immediately.

INTERNAL

1. Drink a large amount of water or

milk.

2. Then drink milk of magnesia, beaten
eggs, or vegetable oil.

3. Get medical attention immediately.

CAUTION: Keep flames and sparks
away from battery.

Do not use booster cables or adjust battery termi­nal connections unless you know the correct pro­cedure.

When you charge a battery or use a battery in a
closed space, be sure there is enough ventilation.

Keep batteries where children cannot reach them
with vent caps tight and level.

21

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 21

COLD WEATHER BATTERY SERVICE

During cold weather, keep electrolyte in battery at
correct level (if applicable). Keep battery fully
c

harged.

BATTERY STORAGE

If Crawler will be stored for more than 30 days, re­move battery. Keep it fully charged.

BATTERY MAINTENANCE

1. Remove corrosion from terminals with

a stiff, non-metallic brush.

CAUTION: Use care when cleaning
terminals so that you do not “short them
out” with metallic brushes, scrapers,
screwdrivers etc.

2. Clean battery with a baking soda solu­tion (1/4 pound in a quart of water)...best done
with battery removed from crawler.

3. Flush battery and compartment with
clear water.

4. Check electrolyte level (if applicable).
Fill each cell to bottom of filler neck with distilled
water or clean, soft water (not hard water).

5. Put petroleum jelly on terminals. Main­tain protective cover on “positive” (+) terminal of
battery.

SAFETY INTERLOCK SWITCHES

Two Switches, one on underside of the #933A
Seat and the other one on the Brake Lever Rod
inside Crawler.

These switches are used in the Crawler’s electri­cal system as safety devices. They detect if the

operator is properly seated, and that the Parking
Brake is engaged before the Crawler can start.

To check either the #1162 Seat Switch or the
#1148 Parking Brake Switch, you must remove
the electrical connectors attached to each switch’s
terminals and connect a continuity tester to its ter­minals (a simple flashlight type continuity tester
would be fine).

SEAT SWITCH TEST

Remove #933A Seat from its #1674 Seat Mount­ing Bracket. Then remove the electrical connec­tors attached to each of the #1162 Seat Switch’s
two terminals.

1. By pushing down on the center of the
seat the Seat Switch should “open”. A continuity
tester, attached to the two terminals of the Switch,
should have its light Off at his time!

2. With pressure removed from the seat,
the Switch should “close”...the light should be On!

If both of the above conditions are not met, the
Switch is defective and must be replaced. When
test is completed, remove continuity tester and re­place original electrical connectors on both termi­nals of Seat Switch. Remount seat to its Mounting
Bracket.

Reassemble the Seat Assembly to your Crawler
and reconnect it’s Plug.

At this time following recommended safe starting
procedures, start the Engine and check Seat
Switch response...readjust if necessary.

22

#1162

#1829

#933A

Brake Lever Rod

#440

#1148

#1674

Terminals

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 22

SEAT & REAR COVER
ASSEMBLY

Your Seat & Rear Cover Assembly is made up of
three main components: The #1674 Mounting
Bracket (with attached #933A Seat) and #1625
Arm Rests mounted to #1608 Rear Cover. They
are held together with four “keyhole slots” over
four “posts”. The “posts” can be located in three
different positions to satisfy the operator’s “seating
comfort”.

When all components are nested together they
will share a common “seat pin hole” that will lock
the assembly together with a #1688 Seat Pin.

T

here are two methods to remove the Seat As-

sembly. One is by removing the Assembly as a
complete unit (It weighs about 45 lbs.). The sec­ond method takes longer but allows you to disas­semble the unit into three components that weigh
a

bout 15 lbs. each. Both methods are explained

below...the choice is yours.

METHOD 1 - Seat Removal

Fully open the Hood by loosening a few turns of
the two #1866 “threaded” Knobs (located at lower
rear of Hood) and then rotating fully forward. Dis­connect the #1824 & 1825 Wires at their mating
Plug. Remove the two #1866 “threaded” Knobs at
lower front edge of #1608 Rear Cover. Slide the
complete Seat Assembly rearward and remove.

Seat Assembly:

To replace your Seat Assembly “reverse” the steps
above.

1) Upon completion of reassembly, make sure
that #1824 Wire & Plug pass through #1854 &
#278 Grommets and connects to mating #1825
Wire & Plug.

2) Make sure “front top edge” of #1608 Cover
rests on top of “lip” that protrudes rearward out of
lower section of #1618 Dash.

3) Close Hood and secure it and Cover Assembly
with #1866 Knobs.

METHOD 2 - Seat Removal

Fully open the Hood by loosening a few turns the
two #1866 “threaded” Knobs (located at lower rear
of Hood). Rotate Hood fully forward until Chain
holds it. Disconnect the #1824 & 1825 Wires at
mating Plug. Draw #1824 Wire & Plug out of #278
Grommet. Remove #1688 Seat Pin and slide “for­ward” the #1674 Mounting Bracket with #933A
Seat and lift up to remove. Take #1625 Arm Rests,
slide forward and lift up to remove. Remove the
two #1866 “threaded” Knobs on front lower edges
of #1608 Cover. Slide the Cover rearward and re­move.

Seat Assembly:

To replace your Seat Assembly “reverse” the steps
above.

1) Upon completion of reassembly, make sure
that #1824 Wire & Plug pass through #1854 &
#278 Grommets and connect to mating #1825
Wire & Plug.

2) Make sure “front top edge” of #1608 Cover
rests on top of “lip” that protrudes rearward out of
lower section of #1618 Dash.

3) Close Hood and secure it and Cover Assembly
with #1866 Knobs.

23

#933A

#1824

#1674

#1625

#1608

3 Seat

Positions

Seat Post

Keyhole Slot

#278

Seat Pin Holes

Body Post

#1625

#933A

#1608

#1688

#1674

On

Off

#1829

#1825

Plugs

#1854

#278

Body Post

#1866

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 23

PARKING BRAKE SWITCH TEST

Begin your procedure by parking your Crawler on
an open, firm, level surface. Shut off engine and
engage Parking Brake. Open Hood and swing
fully forward. Remove #1688 Seat Pin. Remove
#933A Seat & #1674 Mounting Bracket, #1625
Arm Rests, and #1608 Rear Cover. NOTE: Be
sure to disconnect the “mating” #1829 and #1825
Seat Wires at their common Plug.

Disengage Parking Brake. Remove the two elec­trical wire plugs from their #1148 Parking Brake
Switch and connect a continuity tester to its two
terminals.

(1) With “plunger” of #1148 Parking Brake Switch
not depressed, the light of the continuity tester
should be On. With “plunger” of Parking Brake
Switch fully depressed, the light of the continuity
tester should be Off.

(2) When the Parking Brake Lever is pulled “up­ward” and looped “up and over” the Carriage Bolt

p

rovided into an “engaged” position, Parking
Brake Switch should be “open” (the result of con­tact with the rotated #440 Leaf Spring). The light of
the continuity tester should be Off!

(3) When the Parking Brake Lever is released
and put into it’s “disengaged” mode (Lever should
be free to touch Left Fender) the Parking Switch
should be “closed” (the Leaf Spring would have
rotated back and away). Continuity light should
now be On!

If both conditions of procedure (1) (above) are not
met, replace Parking Brake Switch. If both condi­tions of procedure (1) are met, but the conditions
of procedure (2) & (3) are not met, you must adjust
the “horizontal location” of the #1148 Switch in its
#1620 Bracket.

The #1148 Parking Brake Switch is secured “front
to rear” in it’s #1620 Bracket with hex nuts.

Adjust Switch’s location “front to rear” to meet re­quirements (1), (2) and (3) (above) by relocating
its two hex nuts.

When adjustment is completed, tighten Switch’s
hex nuts...terminals on Switch should point
straight up. Remove continuity tester and replace
electrical plug on terminals of Switch. Replace
Seat & Mounting Bracket, Arm Rest and Rear
Cover Assembly...check that it is positively latched
with #1688 Seat Pin! Close Hood and secure it
and Rear Cover with #1866 threaded Knobs.

NOTE: Be sure to reconnect “mating” #1829 &
1825 Seat Wires at their common Plug.

At this time, following recommended safe starting
procedures, start the Engine and check Parking
Brake’s Switch setting...readjust if necessary.

24

Brake Lever Rod

#440

#1148

#1620

Terminals

ENGAGED

Carriage Bolt

DISENGAGED

#1625

#933A

#1608

#1688

#1674

On

Off

#1829

#1825

Plug

Brake Lever

Brake Lever

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 24

REAR DRIVE CHAIN TENSIONING

The #1805 Rear Drive Chains (#50 Roller Chain)
are tightened by increasing the center distance
between the movable #2065 Rear Axle and the

f

ixed #2048 Sprocket & Shafts.

NOTE: If you have the Rubber Track System
design, the sprockets will look differrent from
the ones shown in the next few pages, but the
rear drive tensioning procedure will still be the
same.

Begin your Drive Chain Tensioning procedure by
driving Crawler onto a firm, level surface. Shut off
Engine and dismount...do not “engage” Parking
Brake Lever.

[Though not absolutely necessary, it’s extremely
helpful in the following procedure to block your
Crawler up and remove its Tracks...see Track Re­moval section of this Manual for instructions].

Open Hood and swing fully forward; remove
#1688 Seat Pin. Remove Seat & Bracket, Arm
Rests and Rear Cover. Remove the #1636 Right
& Left Chain Guards from left and right sides of
Crawler.

Do a thorough washing and cleaning of the #1805
Chains and mating Sprockets with a powerwasher
or a stiff brush. The Sprockets and their mating
Drive Chains must be clean to give proper chain
adjustment. [Remove the Drive Chains and soak
in penetrating oil overnight if stiff].

From “outside” the Crawler’s body, loosen (but do
not remove) the five nuts on each (Left & Right)
#1611 Front Axle Plate. Similarly loosen, but do

not remove the four nuts on each (Left & Right)
#1656 Rear Axle Plate. NOTE: loosen the Car­riage Bolt “nuts” from inside of body, all others
from outside.

On each side, from inside body, rotate each #2043
Pulley Assembly. Check that each #1850 Drive
Chain is moving smoothly and that it is free of de­bris.

[TIP: It will ease rotating the Pulley Assemblies
(above) if you follow the procedure for “Removal ­Steering Clutch Belts” in Service section of this
Manual. Replace Belts per “Installation - Steering
Clutch Belts” in Service section of this Manual
after you have completed your chain tensioning].

To tighten the Drive Chains, start rotating clock-
wise the Locknut located on left and right lower
rear of Body. To draw Rear Axle back evenly, turn

one Locknut 1/4 turn, then go to the other side and
tighten the other Locknut 1/4 turn...use this back
and forth procedure until both #1805 Drive Chains
are reasonably tight...not “bow-string” tight, but
about a 1/4” of “sag” in the slack strand when the
balance of the chain is taught.

NOTE: While doing the above procedure, make
sure you rotate each #1650 Rear Track Sprocket

25

#2048

#2065

#1656

#1611

Carriage Bolts

Locknuts

#1637

#1636

#1650

#1805

“Sag”

Locknuts

#1805

#1650

#1805

#2043

#1805

#1650A

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 25

A

ssembly (left side & right of body) a full revolution
after each 1/4 turn of its respective Locknut. This
will determine if there is a slight “high spot” in one
of the (#1805 Chain) mating sprockets...if so, use
the “high spot” location for your point of tighten­i

ng. When satisfied that both Drive Chains are
tightened evenly, retighten the four Bolts holding
the #1656 Rear Plates on left & right side of Body.
Thoroughly lubricate your Drive Chains at this
time.

Replace the #1636 Right & Left Chain Guards
using original Cap Screws, #1637 Spacers, and
Nuts . Replace Seat Assembly, Arm Rests and
Rear Cover and close Hood...secure all with
#1866 “threaded” Knobs.

Using a “flat-nosed” punch and hammer, push the
#1611 Front Axle Plate (located on both sides of
Body) rearward till it hits a solid stop. NOTE: in the
work done in steps above, this Plate may have al-

ready worked its way rearward. To
check, push Plate forward from the rear,
then push it back the required 3/16” dis­tance.

NOTE: Though this is a simple adjustment, it’s
proper execution now will result in extremely
stable Track performance in the future!

If you have removed your Tracks, reassemble
them on your crawler at this time using the “Track
Replacement” instructions in Service section of
this manual...make sure to properly tension them.

PARKING BRAKE ADJUSTMENT

B

egin your procedure by parking your Crawler on
an open, firm, level surface. Shut off Engine, en­gage your Parking Brake Lever and dismount.
Raise Hood and rotate it fully forward, then re­move the #1688 Seat Pin. Remove the #933A
S

eat & #1674 Mounting Bracket, #1625 Arm
Rests, and #1608 Rear Cover. NOTE: Disconnect
the “mating” #1829 and #1825 Seat Wires at their
common Plug.

Put the Parking Brake Lever in the disengaged po­sition...end of Lever should be free to touch top of
Left Fender.

Loosen Jam Nut on the #225L Left & #225R
Right Disc Brake Calipers a few turns to free their
Adjuster Pins for rotation (see two Photos below).

With Brake Lever firmly touching underside of
Carriage Bolt, set each Brake’s tension by rotating
it’s Adjuster Pin clockwise until the the Pulleys on
each side are not able to be easily rotated by
hand.

26

#1802 Disk

Jam Nut

Wrench Slot

DISENGAGED

Push #1611 fully to rear,
approximately 3/16”!

#1611

#1625

#933A

#1608

#1688

#1674

On

Off

#1829

#1825

Plug

Brake Lever

Adjuster

Pin

#225L Disc

Brake Caliper

#225R Disc

Brake Caliper

#225L Disc

Brake Caliper

#1792 Yoke

#1791 Bearing Assembly

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 26

Tighten each of these Brake Assemblies by hold­ing their Adjuster Pin “motionless” with one wrench
while tightening their respective Jam Nut se­curely... a Wrench Slot is provided in each #1792
Yoke (see Photo previous page, lower right).

Engage Parking Brake by pulling up on Brake
Lever and draw it up, over, and behind the head of
the Carriage Bolt stop.

NOTE: In the process of making Brake adjust­ments, try to keep both Brakes synchronized with
each other for even braking! CHECK WITH FAC­TORY IF YOU HAVE  ANY QUESTIONS RE­GARDING YOUR BRAKE ADJUSTMENTS!

Close Hood, then Replace Seat Assembly, Arm
Rests and Rear Cover...secure all with #1866
“threaded” Knobs. Reconnect mating #1829 &

1825 Plugs.

TRACK CLUTCH BELTS

The following segment is divided into three sec­t

ions:

1) Belt Removal.

2) Belt Installation.

3) Belt Adjustment.

It’s suggested that you read all three sections that
follow to gain an overview before you begin any
work. You can then return to the sections that
apply to the job you’re doing.

NOTE: In the following photos many are “cut­aways” of an actual crawler which were created to
best illustrate the points covered in the following
instructions. Though the components are actual
crawler parts, many associated parts are missing.

SPECIAL NOTE: Though all six Track Clutch
Belts are identical and carry the same part number
(#2078), for simplicity they are designated in the
following drawings and descriptions as Belts #1
through #6. In a similar manner, the Pulleys have
their own part numbers (#2043 - 14” dia. and
#2041B - 3” dia.), but in the following instructions
they will be designated as Pulleys AA through LL

Begin your procedure by parking your Crawler on
an open, firm, level surface. Shut off Engine, en­gage your Parking Brake Lever and dismount.

Raise Hood and rotate it fully forward; remove the
#1688 Seat Pin. Remove the #933A Seat & #1674
Mounting Bracket, #1625 Arm Rests, and #1608
Rear Cover. NOTE: Be sure to disconnect the
“mating” #1824 and #1825 Seat Wires at their
common Plug. (see Photo at left)

Pull the #910 Hitch Pins and remove both #1638
Spring Rod assemblies...leave Springs, and Col­lars in place on each Rod.

27

#1638

#910

#1625

#933A

#1608

#1688

#1674

On

Off

#1829

#1825

Plug

Carriage Bolt

Brake Lever firmly touching

underside of Carriage Bolt

Carriage Bolt

ENGAGED

Brake Lever

RS1000 Operator Manual 1.01.19.qxp_Layout 1 4/24/19 12:41 PM Page 27