ASV 4810 Posi-Track Loader Operation and Maintenance...

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8/17/2016 Operation and Maintenance Manual 4810 SN All 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

Transcript of ASV 4810 Posi-Track Loader Operation and Maintenance...

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8/17/2016

Operation and Maintenance

Manual

4810

SN All

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

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POSI-TRACK 4810

PAGE 2 ASV, INC.

1 YEAR, UNLIMITED HOUR WARRANTY

T he WARRANTY herein set forth applies solely to the POSI-TRACK 4810 manu-factured by ASV, INC. and is in lieu of all other warranties, expressed or implied. No person, agent, or dealer is authorized or empowered to give any other warranty or to assume any other liability on behalf of ASV, INC. The WARRANTY is

limited to the original purchaser only. No warranty is transferable to any subsequent owner. ASV, INC. warrants the POSI-TRACK 4810 against defects in material and workmanship under normal use and service for a period of ONE YEAR with unlimited hours, from the date of delivery, and will repair or replace any part that our examination reveals to be defec-tive in material or workmanship. The WARRANTY does not include transportation costs, clean up, or consequential damages. (A) Only Original Equipment Manufacture parts are covered by this WARRANTY. (B) Wear Items are not warranted against normal use. (C) The Caterpillar Engine is separate from ASV, INC.’s WARRANTY. ASV, INC. reserves the right to inspect the equipment prior to any decision involving a war-ranty claim. In no case shall ASV, INC. grant a remedy that exceeds the purchase price of the component or part. ASV, INC. reserves the right to make design changes without incurring any obligation to make such changes to previously manufactured equipment. This WARRANTY does not ap-ply to damage caused by misuse, abuse, neglect, or improper adjustment, accident, or im-proper application. Any repairs or alterations made to the equipment without authorization from ASV, INC. will void this WARRANTY. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY ASV, INC. EXPRESSED OR IMPLIED, STATUTORY, BY OPERATION OR LAW, OR OTHER-WISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PUR-POSE. ASV, INC. DISCLAIMS LIABILITY FOR INDIRECT, INCIDENTAL, OR CON-SEQUENTIAL DAMAGES OF ANY KIND.

WARRANTY

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POSI-TRACK 4810

PAGE 3 ASV, INC.

GROSS VEHICLE WEIGHT The GVW (Gross Vehicle Weight) of the POSI-TRACK 4810 should not exceed 12,500 lbs. This weight includes any accessories, attachments, or material being carried. Exceeding the 12,500 lb. GVW will void the WARRANTY. MODIFICATIONS Any modifications made to the vehicle can affect the WARRANTY. Before any modifications are made, have your dealer contact ASV, INC. for written approval. Modifications include, but are not limited to: additional hydraulic plumbing, alternative attachment mounting, welding to the frame or roll cage, welding to the undercarriage, track modification, etc. ATTACHMENTS Attachment use can also affect the WARRANTY. The attachment should be sized correctly for the vehicle’s operating capacity and hydraulic system. An attachment that cannot accept the machines hydraulic flow and pressure can create extreme heat and cause failures to the ve-hicle’s hydraulic system. An attachment which is oversized for the vehicle’s carrying capac-ity, can cause premature failure to the vehicle’s mounting system, frame, undercarriage, axles, bearings, etc. When determining the weight of the attachment the following items must be considered: the distance the mounted attachment is extended from the vehicle and the weight of the attachment’s load. Refer to page 19 for operating capacity limits.

WARRANTY LIMITATIONS

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POSI-TRACK 4810

PAGE 4 ASV, INC.

TABLE OF CONTENTS

WARRANTY ......................................................................................................................................................................................2 WARRANTY LIMITATIONS ............................................................................................................................................................3 FOREWORD .......................................................................................................................................................................................5

SECTION 1 - SPECIFICATIONS GENERAL ..........................................................................................................................................................................................6 ENGINE ..............................................................................................................................................................................................6 TRACKS .............................................................................................................................................................................................6 FINAL DRIVE ....................................................................................................................................................................................7 CAPACITIES ......................................................................................................................................................................................7 LOADER ASSEMBLY .......................................................................................................................................................................8 ELECTRICAL .....................................................................................................................................................................................8

SECTION 2 – GENERAL SAFETY .................................................................................................................................9,10

SECTION 3 – GENERAL OPERATION MAIN CONTROL CONSOLE DEFINITIONS ..................................................................................................................................11 ELECTRICAL CONSOLE DEFINITIONS ........................................................................................................................................12,13 OPERATING INSTRUCTIONS .........................................................................................................................................................14,15 HYDROSTATIC DRIVE ....................................................................................................................................................................16 LOADER VALVE CONTROL ...........................................................................................................................................................17 LOADER LOCK OUTS ......................................................................................................................................................................17,18 OPERATING CAPACITY ..................................................................................................................................................................19 MOVING DIRT ..................................................................................................................................................................................20 SIDE HILLING ...................................................................................................................................................................................21 PRE START CHECK LIST ................................................................................................................................................................22 STARTING INSTRUCTIONS ............................................................................................................................................................22 SHUTTING ENGINE OFF ................................................................................................................................................................22

SECTION 4 – GENERAL MAINTENANCE BREAK IN PROCEDURES ................................................................................................................................................................23,24 MAINTENANCE SCHEDULE ..........................................................................................................................................................25 GREASE POINTS ...............................................................................................................................................................................26 ENGINE OIL AND FILTER CHANGE .............................................................................................................................................27 HYDRAULIC OIL AND FILTER CHANGE .....................................................................................................................................28 PRIMING THE FUEL SYSTEM ........................................................................................................................................................29 TRACK TENSION ..............................................................................................................................................................................30 PLANETARY OIL CHANGE ............................................................................................................................................................31,32 RADIATOR AND OIL COOLER .......................................................................................................................................................33 AIR CLEANER ...................................................................................................................................................................................34 CHANGING FUEL FILTER ...............................................................................................................................................................35

SECTION 5 – SERVICE TRACK REMOVAL ...........................................................................................................................................................................36,37 TRACK INSTALLATION ..................................................................................................................................................................38,39 BOGIE CARRIAGE REMOVAL .......................................................................................................................................................40 WHEEL TUBE REMOVAL ...............................................................................................................................................................40 WHEEL REPLACEMENT .................................................................................................................................................................41 END TUBE REMOVAL .....................................................................................................................................................................41 SPROCKET REMOVAL ....................................................................................................................................................................42 CHECKING PRESSURES ..................................................................................................................................................................43

SECTION 6 - TROUBLE SHOOTING GENERAL ..........................................................................................................................................................................................54-47

SERVICE LOG ...........................................................................................................................................................................48,49

NOTES ............................................................................................................................................................................................50-52

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POSI-TRACK 4810

PAGE 5 ASV, INC.

This manual contains operation, maintenance, service and trouble shooting information for the POSI-TRACK 4810. It is designed to aid and instruct operators and service personnel in the safe operation and normal maintenance of the vehicle. This manual is divided into six sections. The sections cover specifications, general safety, general operation, general maintenance, service and trouble shooting. By studying this manual, operators and service personnel will become more familiar with the construction, operation and normal maintenance of the vehicle. As operators and service personnel become more efficient in operation and maintenance, they will save time and be-come more productive. Throughout this manual the words WARNING, CAUTION, and NOTE are used to empha-size certain information. The word WARNING is used to identify personal safety informa-tion. The information should be read carefully and understood. Failure to heed warnings could result in bodily injury. The word CAUTION is used to identify possible damage to the vehicle or components. Failure to follow the suggested procedures will probably result in damage to the vehicle. The word NOTE identifies supplementary information worthy of particular attention. At the time of publication of this manual, all information, photographs, and illustrations are technically correct. Since ASV, INC. is constantly improving and refining its products, no retroactive obligation is incurred. PRODUCT IDENTIFICATION NUMBERS (PIN) The POSI-TRACK PIN is located on the side of the control console. Always provide the PIN when contacting the dealer about parts, service, warranty, or accessories. No warranty claims will be processed if the PIN number is not given.

FOREWORD

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POSI-TRACK 4810

PAGE 6 ASV, INC.

GENERAL Height Width Length Ground Clearance Weight (Without Loader) Weight (With Loader) Top Speed Ground Pressure w/Zero Track Penetration Square Inches of Track on the Ground ENGINE Model Type Displacement Gross Horsepower Peak Torque TRACK SPECIFICATIONS Width Length Weight P

82.5" 69" 114.75" 16" 7,500 lbs. 8,640 lbs. 6 mph 3 psi (With Loader) 2826 sq. in. P Caterpillar 3054T Diesel, Liquid Cooled, In-Line 4 Cylinder 4 liter 105 hp at 2,400 rpm 284 ft.-lb. P 18" 220" 265 lbs.

SPECIFICATIONS

SECTION

1

TRACK CONSTRUCTION Molded Rubber with Kevlar™ reinforcement, no steel in track, 2 rows of internal drive lugs.

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POSI-TRACK 4810

PAGE 7 ASV, INC.

POSITIVE DRIVE Self-Cleaning Internal Drive Sprocket drives the track via two rows of molded rubber drive lugs on interior of track. 24 roller pins per sprocket, 110 molded drive lugs per track.

UNDERCARRIAGE Type Number of contact points Lubrication TRANSMISSION & FINAL DRIVE Drive Pumps Drive Motors Final Drive AUXILIARY PUMPS Low Flow at full engine rpm High Flow at full engine rpm Pressure (Low Flow) Pressure (High Flow) CAPACITIES Fuel Tank Hydraulic Reservoir Engine Oil w/filter P

MTSS 48 Sealed, oil bath bearings P Sundstrand, tandem variable displacement Eaton Model , 2.48 cu. In. Planetary gear box P 19 gallons per minute max. 30 gallons per minute max. 2,950 psi 3,200 psi P 25 gal. 28 gal. 8 qt.

SPECIFICATIONS

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POSI-TRACK 4810

PAGE 8 ASV, INC.

LOADER ASSEMBLY Operating Capacity (SAE J818, Skid-Steer) Operating Capacity (SAE J818, Track Loader) Lift height to hinge pin Quick-Attach OPERATOR’S COMPARTMENT Protection system Seat Controls INSTRUMENTATION Standard instruments include: ELECTRICAL SYSTEM Lights Battery Alternator ADDITIONAL FEATURES Cooling package Environmental Attachment receptacle Hydraulic filter compartment Battery compartment P

2,950 lbs. 2,065 lbs. 114" 2 pin, universal skid steer type P ROPS/FOPS approved Reversible, operator presence switch Hand controls for drive and loader/bucket P Fuel, engine RPM, water temp., hour meter, engine oil pressure, amp meter, hot hydraulic, oil light, replace filter lights P 2 front, 2 rear 12 volt, 950 CCA 65 amp P Swing-out radiator and oil cooler Pumps mounted inside reservoir to minimize potential oil leaks from reaching the ground Dozer blade, 3-point hitch, and backhoe can be mounted to the frame of the POSI-TRACK. Hydraulic filters housed on a manifold Easy access to battery

ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTIFICATION.

SPECIFICATIONS

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POSI-TRACK 4810

PAGE 9 ASV, INC.

SECTION

2 GENERAL SAFETY

NEVER attempt to start the machine without sitting in the seat with the seat belt fastened. ALWAYS wear your seat belt when operating the POSI-TRACK. ALWAYS drive with the loader in the lowest possible position. Traveling with the loader raised causes the center of gravity (CG) to be raised, which increases the possibility of roll over in any direction. USE EXTREME CAUTION and common sense when traveling on inclines. Avoid sudden stops, excessive speed, and avoid obstacles. Sudden shifts in CG could cause roll over. NEVER use the POSI-TRACK to transport per-sonnel. Never let anyone ride on the vehicle or in the bucket. ALWAYS shut the engine off when adding fuel, oil, or water to the engine. Always shut the engine off when cleaning the radiator and oil cooler or when doing any maintenance or adjustments. NEVER get out of the vehicle when an attach-ment is running.

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POSI-TRACK 4810

PAGE 10 ASV, INC.

NEVER get in or out of the operator’s seat with the loader in the raised position, unless the loader lock out pins are engaged. Lower the loader all the way down before getting out of the vehicle. Always step over the attachment when getting in or out of the vehicle – NEVER UNDER IT. THE SIDE SCREENS MUST be installed when the loader is attached to the vehicle. Fail-ure to install side screens could result in serious injury or death to the operator. ALWAYS use caution when carrying a load. Sudden stops can cause roll over. ALWAYS make sure all levers are in neutral before starting the engine. BECOME FAMILIAR with all controls and WARNING decals before operating the vehi-cle. NEVER allow an unqualified person to operate the POSI-TRACK. Anyone operating the vehi-cle must read and understand the operator’s manual. NEVER operate the POSI-TRACK on any fro-zen body of water. Ice can be very dangerous and unpredictable.

THINK SAFETY FIRST

GENERAL SAFETY

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POSI-TRACK 4810

PAGE 11 ASV, INC.

SECTION

3 CONSOLE DEFINITIONS MAIN CONTROL CONSOLES (Fig. 1 and Fig. 2) A) Coolant Temperature Gauge This gauge indicates the temperature of the en-gine coolant. Normal coolant temperature should be less than 210°F. B) Engine Oil Pressure Gauge This gauge is used to monitor the engines oil pressure. If the gauge shows low oil pressure, turn off the engine and determine the cause. C) Tachometer The tachometer displays the RPM of the engine. Normal operating RPM should be between 2,000 and 2,400 RPM. Maximum RPM is 2,400. D) Hour Meter The hour meter should be used to schedule maintenance intervals. (See maintenance chart) E) Throttle Controls engine RPM. F) Drive Levers Each lever controls one track. G) Main Valve Joystick Controls the loader, dozer or 3-point hitch. H) Auxiliary Low Flow Lever Controls the direction of the low flow hydraulic circuit.

GENERAL OPERATION

A

B

C

D

E F

G

Fig. 1

Fig. 2

H

I

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POSI-TRACK 4810

PAGE 12 ASV, INC.

I) Amp Gauge Used to monitor the battery charging system while the engine is running. It is normal for the gauge needle to be centered or slightly to the right of center. J) Fuel Gauge K) Auxiliary High Flow Lever Controls the direction of the high flow hydrau-lic circuit.

GENERAL OPERATION

I

J

K

Fig. 3

Fig. 4

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POSI-TRACK 4810

PAGE 13 ASV, INC.

ELECTRICAL CONSOLES L) Parking Brake Switch Used to activate the parking brake while the en-gine is running. This switch locks in position to prevent accidental engagement. There is a small switch within the main switch, that must be pressed before the main switch will unlock.

M) Beacon switch Activates the optional beacon. N) Light Switch This switch turns on/off both the front and rear work lights. O) Ignition Key operated switch starts engine and powers electrical accessories P) Change Low Flow Filter This light will come on if the low flow filter needs to be changed. Q) Change High Flow Filter This light will come on if the high flow filter needs to be changed. R) Hot Hydraulic Oil Indicator This light will come on if the hydraulic oil rises above normal operating temperature.

GENERAL OPERATION

NOTE The parking brake is automatically engaged when the engine is turned off. If the brake will not disengage upon start-up, check to see if brake switch is in the “ON” position.

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POSI-TRACK 4810

PAGE 14 ASV, INC.

OPERATING INSTRUCTIONS Enter the vehicle when the loader is all the way down. Never enter the vehicle by going under a raised loader. (Fig. 7)

Adjust the seat forward or back so both feet reach the footrest and both hands reach the con-trols. Check to make sure all auxiliary levers are in

the neutral position and that the throttle is in the idle position. Fasten seat belt, and adjust so it fits snugly around your waist.

GENERAL OPERATION

!WARNING! Entering or exiting the vehicle under a raised loader could cause serious injury or death. Never put yourself underneath a raised, unse-cured, loader. (Fig. 8)

NOTE It is recommended that your elbows reach the arm rests on the seat. This will allow for steadier control over rough terrain and will also lessen fatigue.

!WARNING! Failure to wear the seat belt could lead to seri-ous injury or death.

Fig. 7

Fig. 8

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POSI-TRACK 4810

PAGE 15 ASV, INC.

Start the vehicle and allow engine to warm up for two minutes before increasing throttle to de-sired RPM. First time operators will want to learn at a lower RPM (2,000 or less) until they feel comfortable with the controls. It is also rec-ommended that the first time operator concen-trate on learning the drive controls before mov-ing on to the loader or other attachment controls. Place one hand over both drive control levers. Push both levers forward in unison to move for-

ward, and pull both levers back in unison to move in reverse. The further the levers are moved, the faster the vehicle travels in either di-rection. To turn to the right, push the left lever farther than the right lever (this makes the left track turn faster than the right track). To turn to the left, push the right lever further than the left lever. To turn the vehicle in its own axis (counter-rotate) push one lever forward and pull the other in reverse.

NOTE The engine will not start if the drive controls or the aux. hydraulic levers are not in neutral. Loader valve will not function unless the op-erator is seated.

NOTE For best performance, always put power to both tracks when making a turn. When both tracks are turning, the vehicle will turn easier, which also results in less damage to the ground.

GENERAL OPERATION

Fig. 9

Fig. 10

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POSI-TRACK 4810

PAGE 16 ASV, INC.

HYDROSTATIC DRIVE POWER & SPEED CONTROL The POSI-TRACK transmits the power from the engine to the tracks using a hydrostatic transmission. The hydrostatic transmission sends oil under pressure to two individual hy-draulic motors, one for each track. The hydro-static transmission consists of two individual hydrostatic pumps. One pump for each motor. Track speed is increased by sending more oil to the hydraulic motors, and power is increased by sending less oil to the hydraulic motors. With a mechanical transmission the operator must shift down to increase power. With hydrostatic drive the operator can simply pull back on the drive controls, reducing speed and increasing power at the same time. HYDRAULIC RELIEF PRESSURE There are three main forces involved in trans-mitting power from the engine to the ground: ENGINE POWER, HYDRAULIC RELIEF PRESSURE, & TRACTION. Engine power and traction can be easily understood, however relief pressure must be explained in greater de-tail. All hydrostatic pumps have a “relief valve”. A relief valve makes the oil by-pass the hydraulic motor to prevent the pump from pro-ducing too much pressure. Every pump has it’s pressure limitations. The lower the pressure, the longer the pump, as well as other drive com-ponents, will last. The relief valves protect the vehicle from a damaging situation. For exam-ple: The relief valves minimize track damage and track derailment.

The hydrostatic pumps of the POSI-TRACK 4810 have relief valve settings of 4,000 lbs. psi. This means each drive pump can produce a maximum of 4,000 pounds per square inch of pressure. The harder the pumps are worked, the more pressure they will produced until they reach their relief valve setting. For example: It takes a certain amount of force to push a large rock across hard ground. If it takes 6,000 psi of oil pressure to push this rock straight forward, each drive pump produces 3,000 psi for a total of 6,000 psi. Under good traction the vehicle will push this rock straight forward since the pumps have not reached their individual 4,000 psi relief valve setting. If the opera-tor tries to turn the vehicle while pushing the same rock, the load on the inside track will be less, and it’s pressure will decrease. The load on the outside track will be in-creased, thus increasing it’s pressure. If the outside track is getting good traction, the 4,000 psi relief valve setting can be reached, making the track stop until the load is reduced. The oil for both tracks could be made to go over the relief valves if the same rock was pushed up hill since it would take much greater force.

GENERAL OPERATION

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POSI-TRACK 4810

PAGE 17 ASV, INC.

LOADER VALVE CONTROL (Fig. 11 and Fig. 12) To raise the loader, pull back on the joystick at a controlled rate. To lower the loader, push forward on the joy-stick at a controlled rate. To put the loader in “float” position, push the lever all the way forward with a quick motion. To curl the attachment, such as a bucket, move the joystick to the left at a controlled rate. To tilt the attachment forward, move the joy-stick to the right at a controlled rate.

Fig. 11

Fig. 12

GENERAL OPERATION

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POSI-TRACK 4810

PAGE 18 ASV, INC.

LOADER LOCK OUT PINS The roll cage comes equipped with two retract-able pins that slide outward to secure the loader in the “up” position. It is critical to use these pins when there is service to be done on the ve-hicle, when the loader is up, hooking up a frame mount attachment, or when someone has to get in or out of the vehicle when the loader is up.

ENGAGING THE LOCK OUT PINS (Fig. 13) 1. Raise the loader past the top of the roll cage and turn off the engine. 2. Loosen the two knobs and pull down on the spring loaded rings. 3. Slide the pins outward until they stop, make sure the spring loaded rings snap back into place. 4. Turn the key to the “on” position, to unlock the loader valve (DO NOT START ENGINE). Lower the loader onto the pins.

GENERAL OPERATION

Fig. 13

!WARNING! The loader lock out pins must be used to prevent serious injury or death. Never leave the loader in the “up” position without using the lock out pins.

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POSI-TRACK 4810

PAGE 19 ASV, INC.

OPERATING CAPACITIES

The operating capacity refers to how much addi-tional weight can be put into the 4810’s bucket while attached to the loader arms. This operating capacity is measured at the mid point of the low profile bucket. The operating capacity is 2,950 lbs. when the low profile bucket is quick attached to the loader assembly, and is at the farthest point from the vehicle (half way up). The heavier the attachment, such as a 4-in-1 bucket, the less the operating capacity will be. Moving the load farther from the vehicle, such as a tree spade, will significantly reduce the operating capacity.

THE MOST SIGNIFICANT FACTOR IN OPERATING CAPACITY IS THE DISTANCE BETWEEN THE FRONT PIVOT POINT OF THE VEHICLE AND THE CENTER OF GRAVITY OF THE MATERIAL BEING CARRIED.

GENERAL OPERATION

FRONT PIVOT POINT

2950 LB. OPERATING CA-PACITY RATED AT BUCKET’S CENTER OF GRAVITY

INCREASING THE DISTANCE FROM THE FRONT PIVOT POINT TO THE PAYLOAD WILL DECREASE THE OPERATING CAPACITY

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POSI-TRACK 4810

PAGE 20 ASV, INC.

MOVING DIRT WITH THE BUCKET Certain techniques can be used to become more efficient in moving dirt with the bucket. The following are simple guidelines for those who do not have much experience moving dirt. The POSI-TRACK’S loader is designed to push against the frame while leveling or digging dirt. Lower the loader all the way down until it stops against the loader-stop. Tilt the bucket forward until the bucket engages the ground. This is the proper position for dig-ging with the POSI-TRACK. (Fig. 14) In uneven terrain, it may be necessary to dig with the loader raised off the loader-stop, how-ever, digging in this manner should be kept to a minimum to reduce damage to the loader arms. Always move dirt with the bucket level with the ground. Never tilt the bucket all the way for-ward and use as a dozer blade. (Fig. 15) This puts tremendous stress on the bucket, the quick-attach, and the bucket cylinders. Damage to any of the previously mentioned can occur if the bucket is used in this manner. Never back drag with the bucket in this manner (Fig. 16). The bucket cylinders are fully ex-tended and can be exposed to great forces if the bucket catches on something solid. Using the bucket in this manner can cause the cylinders to bend.

Fig. 14

Fig. 15

GENERAL OPERATION

Fig. 16

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POSI-TRACK 4810

PAGE 21 ASV, INC.

SIDE HILLING Although the POSI-TRACK works well on side hills, extreme caution must always be used. Never exceed a 3 to 1 slope. This means 3 feet of run to every 1 foot of rise. (Fig. 17) When turning to go up hill while side hilling, the following technique should always be used: 1. Stop the vehicle and back the vehicle down the hill until the front of the vehicle is pointed in the direction you want to go. Then drive for-ward. (Fig. 18,19,20) 2. This turning technique will reduce the chance of track derailment and will also put less stress on the track system.

1

1

1

1

2

3

1:1 = 100% = 45°

2:1 = 50% = 26.6°

3:1 = 33.3% = 18.4°

Fig. 18

CAUTION While operating on a side hill, the more weight there is on the vehicle, the greater the chance of track derailment. Gravity is trying to pull the vehicle downhill, while the tracks are keep-ing the vehicle on the hill. The less weight that is on the vehicle, the less chance there will be for track derailment

Fig. 19

Fig. 20

Fig. 17

GENERAL OPERATION

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POSI-TRACK 4810

PAGE 22 ASV, INC.

PRESTART CHECKLIST Prior to operating the POSI-TRACK, several items need to be checked to ensure safe, trou-ble-free operation. It is also important that pe-riodic maintenance be done correctly and safely. Follow a regular maintenance schedule that includes replacement and / or adjustment of any component found to be excessively worn, out of adjustment, or damaged. Before starting the engine and operating the POSI-TRACK, check the items on figure 21. STARTING INSTRUCTIONS 1. Perform all Pre-Start checks outlined (Fig. 21) before starting engine. 2. Adjust seat, fasten seat belt, make sure all levers are in neutral. 3. From the slow idle position, push the throt-tle 1/3 of the way open. 4. Turn the key switch clockwise to the “run” position. SHUTTING THE ENGINE OFF 1. Pull the throttle to slow idle. 2. Idle engine for at least two minutes to allow hot engine parts to cool. 3. Turn key counter clockwise to the “off” po-sition.

ITEM REMARKS Tracks Check tension Engine coolant Check level Hydraulic fluid Check level Engine oil Check level Fan belt Check tension Hoses Check for wear Fittings Check for leaks Radiator Clean thoroughly Nuts & bolts Tighten if needed Battery Check cables Aux. levers Check for neutral Drive controls Check for neutral

Fig. 21

CAUTION Do not operate the starter for more than 30 seconds at a time. If the engine does not start, wait at least 2 minutes before trying again. If engine still does not start, refer to the trouble shooting section in this manual.

GENERAL OPERATION

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POSI-TRACK 4810

PAGE 23 ASV, INC.

GENERAL MAINTENANCE

BREAK-IN PROCEDURES Although all systems on the POSI-TRACK are tested at the factory to ensure proper op-eration, there are a few items that require a break-in period. Certain components need re-adjustment and others require special care within the first 100 hours of operation. PROPER BREAK-IN PROCEDURES ARE CRITICAL TO THE LONG TERM RELI-ABILITY OF THE POSI-TRACK. Extra care during this period will pay-off down the road. TRACKS Proper track tension plays an important part in the over-all performance of the Posi-Track. A track run too loose can cause premature track failure and cause the track to derail. Although track tension is set properly at the factory, the tracks will need an adjustment after break-in. Once the KevlarTM and other special materials in the track are pulled straight, minimal ad-justment will be required. The break-in pe-riod of a track can range from just a few hours to over 10 hours, depending on the track and how the vehicle is operated. The tracks on the POSI-TRACK 4810 are easy to tighten. It takes only a few minutes and will be well worth the time (See page 30 for track tensioning procedure.) After the ini-tial track break-in, the tracks may not need to be tightened for several hundred hours, how-ever, the tracks should be inspected daily and tightened as necessary.

CAUTION Failure to perform the proper break-in procedures will cause premature compo-nent failure.

SECTION

4

Track will loosen during break-in

Track needs to be tightened after break-in

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POSI-TRACK 4810

PAGE 24 ASV, INC.

PLANETARY DRIVES Each track’s final drive consists of a hydraulic drive motor, a planetary gearbox and an inter-nal drive sprocket. The planetary gearbox re-quires a break-in period for the lug nuts and for the planetary oil. The 9 lug nuts, which attach the sprocket to the planetary gearbox, are torqued to 115 ft.-lbs. at the factory, and should be re-torqued to 115 ft.-lbs. after 10 hours of operation. (Fig. 22) The planetary gearbox requires an oil change at 50 hours. The break-in time allows the gears in the planetary to properly mesh. This is a crucial oil change since the oil will have a high metal content. After this initial oil change, the planetary oil should be changed every 1,000 hours or annually. (Refer to page 31 for proper planetary oil changing proce-dure.)

Fig. 22

CAUTION Failure to change the planetary oil at the 50 hour break-in interval, will drastically shorten the life of the planetary gear box. Failure to follow this procedure will also void the warranty of the plane-tary gear box.

Lug nuts

GENERAL MAINTENANCE

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POSI-TRACK 4810

PAGE 25 ASV, INC.

MAINTENANCE SCHEDULE ITEM FREQUENCY LUBRICANT Hydraulic fluid 500 hours Amoco Rykon MV Hydraulic filters 250 hours or as needed Engine oil and filter 500 hours Caterpillar approved Engine fuel filter 500 hours or as needed Primary air filter Clean and replace as needed Secondary air filter Every 3 cleanings of primary Planetary oil 1,000 hours or annually (After 50 hr. break-in) SAE 80w-90 gear lube Loader grease fittings Daily Low temp grease Wheel tubes Check level at 1,000 hours SAE 80w-90 gear lube Track tension As needed

SERVICE ITEMS FLUID CAPACITY TYPE Fuel 25 gallons Diesel Hydraulic oil 28 gallons Amoco Rykon MV Planetary oil 1 quart SAE 80w-90 gear lube Wheel tube oil 12 ounces SAE 80w-90 gear lube Engine oil 8 quarts See chart below

GENERAL MAINTENANCE

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POSI-TRACK 4810

PAGE 26 ASV, INC.

GREASE POINTS LOADER ASSEMBLY There are 12 grease fittings on the POSI-TRACK’S loader assembly, which should be greased daily. The grease fittings are located in the following spots on both sides of the loader: 1. The main loader hinge points. (Fig. 23) 2. Both ends of the lift cylinders. (Fig. 24, 25) 3. Both ends of the quick-attach cylinders. (Fig. 26, 27) 4. Hinge points for the quick-attach. (Fig. 28)

GENERAL MAINTENANCE

Fig. 23

Fig. 24

Fig. 25

Fig. 26

Fig. 27

Fig. 28

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POSI-TRACK 4810

PAGE 27 ASV, INC.

ENGINE OIL & FILTER CHANGE The normal oil change interval is every 500 ser-vice hours or six months. Engines, which are operated under severe conditions, may need the oil changed to be changed every 250 service hours or three months. Severe conditions in-clude the following: high temperatures, continu-ous high loads, and dusty conditions. 1. Run engine approximately 5 minutes to warm up oil. Shut off engine. 2. Remove oil drain plug beneath the engine compartment and allow to drain. After the oil has been allowed to drain, clean the oil drain plug and reinstall. 3. Remove oil filter element and dispose of properly or consult your dealer for analysis. 4. Clean the sealing surface of the filter mount-ing base. Ensure that all of the old oil filter gas-ket is removed. Apply clean engine oil to the new oil filter gasket. 5. Install the new oil filter. Tighten the oil filter until the oil filter gasket contacts the base. Tighten the oil filter by hand according to the instructions that are shown on the filter. DO NOT over tighten the oil filter. 6. Fill engine crankcase to specified level. (Approximately 8 quarts) (Fig. 30) 7. Start the engine and run the engine at LOW IDLE for two minutes. Check for leaks. Wait ten minutes and check oil level.

GENERAL MAINTENANCE

Fig. 29

Fig. 30

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POSI-TRACK 4810

PAGE 28 ASV, INC.

HYDRAULIC OIL & FILTER CHANGE One of the most critical systems on the POSI-TRACK is the hydrostatic system. The hydraulic oil should be changed every 500 hours and the hydraulic filters should be changed every 250 hours. These precision components require ex-tremely clean oil in order to have a long service life. Changing the hydraulic oil and filters at the proper intervals can prevent expensive repairs later down the road. Before beginning the procedure extreme care should be taken to ensure the vehicle is in a clean working environment. Precautions should be taken to prevent any debris from entering the hy-drostatic system. 1. Remove hydraulic oil drain plug (A) from bot-tom of reservoir. Drain into suitable container. 2. The three hydraulic filters are housed inside the loader tower service compartment on the side of the vehicle. (Fig. 32) 3. The filters are disposable spin on type filters. These filters can be removed by hand or by using a filter wrench. Always dispose of filters prop-erly. 4. Fill with new approved hydraulic fluid. The fill cap is located in the loader tower (Fig. 33). The level gauge is located on the floor of the cab.

Fig. 31

Fig. 32

A

GENERAL MAINTENANCE

Fig. 33

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POSI-TRACK 4810

PAGE 29 ASV, INC.

PRIMING THE FUEL SYSTEM If the engine has run out of fuel, or the fuel sys-tem has been opened for service, it will be nec-essary to bleed the fuel system. 1. Loosen the bolt at the top of the fuel filter in order to vent (A). 2. Pump primer lever (B) until fuel flowing out the vent is continuous and free of air bubbles. Tighten the bolt at the top of the fuel filter.

3. Loosen the nut for the fuel inlet line at the fuel injection pump (C) in order to vent. 4. Turn the start switch to the RUN position (do not actually attempt to start the engine). Operate the priming lever for the fuel lift pump until the flow of fuel from the vent is continuous and free of air bubbles. Tighten the nut for the fuel inlet

line.

GENERAL MAINTENANCE

NOTE It is not possible to operate the priming lever if the cam of the fuel lift pump is at the maxi-mum lift position of the cam. If this occurs, rotate the crankshaft one revolution.

NOTE If engine still won’t start, it may be necessary to bleed air from fuel system at the injection nozzles. Refer to the Caterpillar Operation and Maintenance manual for this procedure.

Fig. 34

Fig. 35

A

B

C

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POSI-TRACK 4810

PAGE 30 ASV, INC.

COLLAPSING AND TENSIONING THE TRACK The tracks should be adjusted so there is no sag between the drive sprocket and the top carrier wheels. DO NOT OVER TIGHTEN. Only tighten the amount it takes to eliminate the sag. Over tightening the tracks can lead to power loss, bearing failure, and track damage. Located under the seat is a screw jack and a wrench that will allow the tracks to be tightened in the field 1. Use the jack housing and hook as shown to relieve tension on bolts. (Fig. 36) 2. Loosen the two drive table bolts “A”, and re-move the two track tension bolts, “B”. (Fig. 37) 3. Use the long hook as shown, to begin col-lapsing the suspension. (Fig. 38) 4. Use the short hook as shown, to finish col-lapsing the suspension. (Fig. 39)

GENERAL MAINTENANCE

Hook

Jack Housing

Fig. 36

Bolt "B"

Bolt "A" Fig. 37

Long Hook

Fig. 38

Short Hook

Fig. 39

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POSI-TRACK 4810

PAGE 31 ASV, INC.

COLLAPSING AND TENSIONING THE TRACK Continued 5. Unscrew the jack housing from the hook and screw in the push plate. Then position to begin expanding the suspension. (Fig. 40) 6. To continue expanding the suspension, posi-tion the push plate, jack housing, and pin as shown. (Fig. 41) 7. Reposition the jack housing, push plate, and pin as shown to continue expanding the suspen-sion. (Fig. 42) 8. To finish tightening the track, position the jack housing and push plate as shown. (Fig. 43)

Push Plate

Jack Housing

Hook Fig. 40

Push Plate Jack Housing

Pin

Fig. 41

Fig. 42

Fig.

Push Plate Jack Housing

Pin

Push Plate

Jack Housing

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POSI-TRACK 4810

PAGE 32 ASV, INC.

PLANETARY OIL CHANGE After the initial 50-hour break-in change, the planetary oil should be changed every 1,000 hours or annually, which ever comes first. Before starting the procedure, the planetary case must be cleaned thoroughly. It is crucial that no dirt falls into the case when removing the plugs. In the drawer under the seat of the POSI-TRACK 4810, there is a kit which will make changing the planetary oil easier. This kit in-cludes a fitting and a hose. The kit is located in the drawer under the seat. There are two plugs, which are 180° from each other. One is for draining the oil, the other is for filling the oil. It doesn’t matter which plug is used for which part of the job.

1. Rotate the sprocket until one of the plugs is lined up with the u-shaped notch at the top of the bearing plate. This will also line up the other plug with the hole in the bottom of the bearing plate. (Fig. 44) 2. Attach the hose to the fitting and be prepared to insert the fitting into the drain hole. Remove the drain plug through the bottom hole and quickly insert the fitting with the hose. (Fig. 45)

NOTE Drive the POSI-TRACK for 10 to 15 minutes Before changing the planetary oil. This will warm up the oil and allow it to drain more thor-oughly.

Fig. 44

Fig. 45

GENERAL MAINTENANCE

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POSI-TRACK 4810

PAGE 33 ASV, INC.

3. Remove the top plug to vent the case and al-low the oil to drain. (Fig. 46) 4. Remove the fitting with the hose from the bottom plug and reinsert the plug. 5. Insert the fitting and hose into the top hole. Use a 32 oz. Bottle of 80W-90 gear lube or simi-lar container, which can be filled with gear lube. Attach the other end of the hose to the bottle. Squeezing the bottle slightly will help push the oil into the case. (Fig. 47)

Fig. 46

Fig. 47

GENERAL MAINTENANCE

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POSI-TRACK 4810

PAGE 34 ASV, INC.

RADIATOR AND OIL COOLER The radiator and oil cooler should be inspected and cleaned before operating the vehicle, or if the engine or hydraulic oil overheats while op-erating. 1. Undo the latch that secures the hood to the frame (Fig. 48) 2. Undo the latch that secures the radiator as-sembly to the frame (Fig. 49) 4. Undo the two clasps that secure the grill to the radiator and oil cooler. Swing the grill away from radiator and oil cooler. (Fig. 50)

5. The coolers are now totally accessible for cleaning. A pressure washer or an air compressor works the best for cleaning the coolers completely.

!WARNING! NEVER OPEN THE RADIATOR / OIL COOLER DOOR WHILE THE ENGINE IS RUNNING. THE FAN COULD CAUSE SERI-OUS INJURY. ALWAYS SHUT THE VEHI-CLE OFF BEFORE CLEANING THE RADIA-TOR AND OIL COOLER.

Fig. 48

Fig. 49

Fig. 50

GENERAL MAINTENANCE

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POSI-TRACK 4810

PAGE 35 ASV, INC.

SERVICING THE AIR CLEANER The air cleaner is one of the most important maintenance items on the vehicle. A poorly maintained air cleaner can seriously shorten the life of the engine. 1. Open the hood and , undue the latches on ei-ther side of the air cleaner, then remove the cover. (Fig. 51) 2. Remove the primary element. The primary element can be washed and reused up to six times but should be changed at least once a year. (Fig. 52) 3. Remove the secondary element. The secon-dary element is not serviceable or washable. The secondary element should be removed and discarded for every three cleanings of the pri-mary element. (Fig. 53)

4. Install new elements or replace cleaned pri-mary element, make sure both element are prop-erly seated be for installing cover.

NOTE When working in dusty conditions the air cleaner elements should be checked and changed more frequently.

Fig. 51

Fig. 52

Fig. 53

GENERAL MAINTENANCE

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POSI-TRACK 4810

PAGE 36 ASV, INC.

CHANGING THE FUEL FILTER 1. Close the fuel supply valve. 2. Clean the outside of the fuel filter thor-oughly. Open the drain (A) and drain fuel into suitable container. 3. Hold the element and rotate the locking ring counterclockwise (B). Remove the locking ring, and dispose of the used element. 4. Make sure the filter head is clean, push a new element fully into the filter head. 5. Hold element in place and fit locking ring into position. Rotate the locking ring clockwise to fasten the element in place. 6. Prime the fuel system.

A

GENERAL MAINTENANCE

Fig. 54 A

B

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POSI-TRACK 4810

PAGE 37 ASV, INC.

SERVICE

TRACK REMOVAL In some cases removing the track is necessary to work on some undercarriage components. Using a floor jack or a forklift, jack the POSI-TRACK off the ground (Fig. 55) until there is approximately 4 inches between the bottom of the track and the floor. Jack stands specially de-signed for the POSI-TRACK can be purchased through your POSI-TRACK dealer (PN # 454-876) For occasional track tensioning, the screw jack that comes with the machine is fine, however, a remote hydraulic jack is best for track removal and installation. A remote hydraulic jack with all the necessary extensions can be purchased from your POSI-TRACK dealer. 1. On the inside and the outside of the under-carriage, there are two long slots. Loosen the bolts (A) that are in these slots (DO NOT RE-MOVE). (Fig. 56) 2. Place the jack between the sliding planetary mount and the undercarriage frame (Fig. 57). Jack the planetary mount back just enough so the track adjustment bolts can be removed. Af-ter the bolts have been removed, release the jack and remove it from the undercarriage. 3. On the inside of the undercarriage there is a steel tab (B) welded to the sliding planetary mount. This tab will allow the planetary mount to be jacked forward. (Fig. 58)

Fig. 55

Fig. 56

Fig. 57

A

SECTION

5

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POSI-TRACK 4810

PAGE 38 ASV, INC.

4. Insert the jack between the rear axle mount and the steel tab (Fig. 58). Jack the planetary mount forward until the jack is full stroke. Re-move the jack and add an extension to the ram of the jack. Continue jacking the planetary mount forward until it comes in contact with the undercarriage frame. 5. There are 4 bolts, which mount the carrier wheels to the undercarriage frame. The 2 bolts closest to the drive sprocket (C) need to be loos-ened enough so the assembly can hinge on them. (DO NOT REMOVE ). 6. Remove the other 2 bolts and hinge the as-sembly back until it hits the undercarriage frame. (Fig. 59) 7. Position yourself behind the drive sprocket and grab the bottom inside portion of the track. Pull the track down, getting the drive lugs to clear the 10" idler wheels and then pull the track to the outside. Do not attempt to get the whole track off yet, just get one row of drive lugs past the outside 10" idler wheel. 8. Pull the track up and off the drive sprocket. The track can now be pulled off the 10" idler wheels. Continue pulling the track off the top of the undercarriage and slide it out from be-neath the undercarriage. Pull the track forward and out to remove the track from the 14" idler wheels. The track is now off. (Fig. 61)

B

Fig. 58

C Fig. 59

Fig. 60

Fig. 61

SERVICE

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POSI-TRACK 4810

PAGE 39 ASV, INC.

TRACK INSTALLATION 1. Place the track parallel to the undercarriage so the end of the track is even with the end of the undercarriage. 2. Pull the track up and onto the 14" idler wheels. Slide as much track as possible under the undercarriage. Pull the track up and on to the hinged carrier wheels. (Fig. 62) 3. Pull the track up and onto the drive sprocket. Get one row of drive lugs into the drive sprocket. Move one row of drive lugs past the 10" idler wheels. (Fig. 63) 4. Pull the rest of the track up and onto the drive sprocket, and then under the 10" idler wheels. 5. Hinge the carrier wheels back in place, and retighten all bolts. The track is now on. It only needs to be tightened. 6. To tighten the track, the jack can either be placed on the inside of the undercarriage be-tween the two steel tabs or on the outside be-tween the carrier wheel assembly and the sliding planetary mount (Shown Fig. 64). If the plane-tary mount starts to bind, place the jack on the other side. 7. Once the planetary mount is back far enough, place the jack between the sliding planetary mount and the rear axle mount. (Fig. 65)

Fig. 62

Fig. 63

Fig. 64

Fig. 65

SERVICE

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POSI-TRACK 4810

PAGE 40 ASV, INC.

8. Jack the planetary mount back until the track is straight (Fig. 66) between the drive sprocket and the carrier wheels. (DO NOT OVER TIGHTEN). 9. Line up the set of holes in the sliding motor mount and the undercarriage frame. Insert track adjustment bolts and tighten. (bolts should be in same hole location.) (Fig. 67) 10. Tighten bolts in slots on both sides of the undercarriage.

Fig. 66

Fig. 67

CAUTION It is critical that the drive sprocket is aligned with the undercarriage frame. The tension ad-justment bolts must be in the same hole location or track derailment will occur.

SERVICE

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POSI-TRACK 4810

PAGE 41 ASV, INC.

BOGIE CARRIAGE REMOVAL 1. Once the track is removed, slide a floor jack under the bogie carriage that is being removed and raise until there is some pressure on the bo-gie carriage. (Fig. 68) 2. Remove the 4 bolts that secure the bogie car-riage to the undercarriage frame. 3. Lower the floor jack and slide the jack out from the bogie carriage. 4. Using the floor jack, raise the suspension frame (A) just enough so the bogie carriage can be slid out from under the suspension frame. (Fig. 69) WHEEL TUBE REMOVAL 1. Place the bogie carriage on the floor so all wheels are facing up. (Fig. 70 2. Remove the 4 bolts (B), which secure the wheel tube to the bogie carriage. 3. Lift wheel tube straight up out of the slots in the bogie carriage. 4. Once the wheel tube is removed, the two brackets that secure the tube to the carriage will be visible. These two brackets keep the shaft from turning and allow the tube and the wheels to rotate.

Fig. 68

Fig. 69

A

Fig. 70

B

SERVICE

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POSI-TRACK 4810

PAGE 42 ASV, INC.

WHEEL REPLACEMENT 1. The center wheel is split (A) for easy removal and the two outside wheels are whole wheels. 2. Remove wheels by unbolting the wheel hub that secures the wheels to the tube. The outside wheel hubs are slid off the shaft and the wheel can then be removed easily (Fig. 71). END TUBE REMOVAL The end wheel tubes are extremely easy to re-move. There are 4 bolts that fasten the shaft to the undercarriage frame. Remove 4 bolts and the tube will slide off the end of the frame. (Fig. 72)

A

Fig. 71

Fig. 72

SERVICE

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POSI-TRACK 4810

PAGE 43 ASV, INC.

SPROCKET REMOVAL There are 3 bolts that fasten the planetary bear-ing plate to the undercarriage frame, and 4 bolts that fasten it to the bearing flange. The track needs to be removed before beginning this pro-cedure. 1. Remove the 4 bolts that fasten the bearing plate to the flange. (Fig. 73) 2. Remove the 3 bolts that fasten the bearing plate to the undercarriage frame. (Fig. 74) 3. Tapping the bearing plate with a rubber ham-mer will help dislodge it from the flange. Pull the bearing plate straight out. (Fig. 75) 4. Remove the 9 lug nuts that fasten the drive sprocket to the planetary gearbox. Pull the sprocket straight out from the planetary gearbox. (Fig. 76)

Fig. 73

Fig. 74

Fig. 75

Fig. 76

SERVICE

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POSI-TRACK 4810

PAGE 44 ASV, INC.

CHECKING CHARGE PRESSURE The charge pressure refers to the oil that is sup-plied to the main drive pumps, this oil allows the pumps to shift. If the charge pressure is low, the drive pumps may not shift at all when the levers are stroked or they may shift sluggishly, resulting in erratic track behavior. 1. Open the filter access panel on the side of the vehicle. Locate the test port in the upper right hand corner (A). 2. Remove the cap and screw on a pressure gauge. 3. Start the engine and let idle. At an idle, the charge pressure should be between 280 to 320 psi when the oil is warm.

Fig. 77

A

SERVICE

A

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POSI-TRACK 4810

PAGE 45 ASV, INC.

PROBLEM CAUSE REMEDY Vehicle won’t 1. Battery cables loose 1. Tighten or clean cables turn over or corroded. 2. Drive levers or auxiliary 2. Put levers in neutral levers are not in neutral 3. Operator not in seat with 3. Sit down and put seat seat belt on belt on Vehicle turns over 1. Out of fuel or 1. Add more fuel but will not start fuel pick-up may not and bleed fuel system be in fuel if parked on a hill 2. Pinched fuel line 2. Find and correct 3. Load on engine from 3. Put lever in neutral High or Low flow auxiliary lever being engaged 4. Fuel solenoid is not opening 4. Check wiring 5. Plugged fuel filter 5. Change filter Vehicle starts but 1. Low-flow auxiliary 1. Put lever in neutral engine runs rough hydraulic lever is engaged 2. High-flow auxiliary 2. Put lever in neutral hydraulic lever is engaged Vehicle starts but 1. Operator not seated in seat 1. Sit down & fasten tracks won’t go seat belt. 2. Defective seat switch 2. Refer to electrical trouble shooting guide 3. Defective solenoid 3. Refer to electrical trouble shooting guide 4. Low charge pressure 4. Refer to page 44 Under heavy load 1. Tracks have lost traction 1. Reduce load or put more or in loose material power to the inside track vehicle won’t turn 2. Oil going to drive motor 2. Reduce load. Increase is going over the relief valve power to inside track

TROUBLE SHOOTING (GENERAL)

SECTION

6

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POSI-TRACK 4810

PAGE 46 ASV, INC.

PROBLEM CAUSE REMEDY Attachment won’t 1. Quick-coupler not plugged 1. Find and plug in operate in all the way quick coupler 2. Faulty quick-coupler 2. Replace 3. The other auxiliary lever 3. Put lever in neutral is engaged 4. Hoses hooked up wrong 4. Correct 5. Faulty attachment 5. Contact dealer or refer to an attachment owners manual Hot oil light comes on 1. Hydraulic oil cooler is 1. Clean with compressed plugged with debris air or pressure washer 2. Hydraulic attachment is 2. Get the right sized undersized for the flow attachment or reduce the and/ or pressure engine rpm until the flow is in the correct range (Refer to decal on vehicle) 3. One of the auxiliary hydraulic 3. Put lever in neutral levers is engaged without an attachment being hooked up. 4. Defective sender or light 4. Replace as needed 5. Wires to light are grounding out 5. Repair Attachment doesn’t 1. Attachment is incorrect size 1. Get the appropriate work properly for the flow and pressure. attachment 2. Auxiliary hydraulic pressure 2. Set to proper pressure is set too low. Loader doesn’t 1. Auxiliary hydraulic pressure 1. Set to proper pressure lift proper weight is set too low 2. Weight is too far out from 2. Bring load in closer vehicle or reduce load 3. Auxiliary lever is engaged 3. Put lever in neutral

TROUBLE SHOOTING (GENERAL)

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PROBLEM CAUSE REMEDY Attachments, tracks 1. One or both auxiliary hydraulic 1. Put lever in neutral weak on power levers are engaged 2. Hydraulic oil is still cold 2. Let oil warm up for a few minutes Tracks respond 1. Hydraulic oil is still cold 1. Let oil warm up for sluggishly a few minutes 2. Low charge pressure 2. Refer to page 43 3. Low hydraulic oil 3. Add hydraulic oil 4. Hydraulic filters plugged 4. Change filters One track won’t go 1. Brake is engaged 1. Turn brake switch off, or rotate track in both directions to take bind off brake ram 2. Cable is disconnected on 2. Reconnect cable lever 3. Cable is disconnected on 3. Contact dealer pump Track will only 1. Loosen or disconnected drive go in one direction tube or fitting 1. Contact dealer 2. Broken drive tube inside 2. Contact dealer hydraulic reservoir 3. Cable linkage in tank 3. Contact dealer is broken Track derails 1. Track is too loose 1. Adjust 2. Bearing failure in one of 2. Replace bearing the end tubes or out board bearing on drive sprocket 3. Drive Sprocket miss aligned 3. Make sure tension undercarriage frame. Adjustment bolts are in the same adjustment holes 4. Bent idler wheel 4. Replace wheel 5. Terrain too steep or improper driving techniques

TROUBLE SHOOTING (GENERAL)

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PROBLEM CAUSE REMEDY Engine coolant 1. Radiator is plugged with 1. Clean with compressed overheats debris air or pressure washer 2. Low engine coolant 2. Add approved coolant 3. Fan belt is slipping 3. Check tension pulley 4. Fan is on backward 4. Replace correctly 5. Faulty sender, light or 5. Replace wiring After running out of 1. Fuel system has not been primed 1. Refer to page 29 fuel and refueling, engine will not start

TROUBLE SHOOTING (GENERAL)

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DATE DATE DATE DATE DATE ITEM HOURS HOURS HOURS HOURS HOURS

MAINTENANCE & SERVICE

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DATE DATE DATE DATE DATE ITEM HOURS HOURS HOURS HOURS HOURS

MAINTENANCE & SERVICE

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NOTES

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NOTES

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NOTES

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