ASV HD4500 Posi-Track Loader Operation and Maintenance...

8/17/2016

Operation and Maintenance

Manual

HD4500

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POSI-TRACK HD 4500

PAGE 1 ASV, INC.

CONGRATULATIONS! You have chosen the world’s most versatile crawler/tractor. You will soon discover that no other machine can match the POSI-TRACK’s per-formance, versatility, and productivity. As an owner or operator, it is your responsibility to learn the capabilities of the POSI-TRACK to maximize both performance and safety. Before operating the POSI-TRACK make sure you read and understand this owners manual. If you have any questions, don’t hesitate to contact your dealer for an-swers.

WELCOME

POSI-TRACK HD 4500

PAGE 2 ASV, INC.

1 YEAR, UNLIMITED HOUR WARRANTY

T he WARRANTY herein set forth applies solely to the POSI-TRACK HD 4500 & POSI-TRACK HD 4520 manufactured by ASV, INC. and is in lieu of all other warranties, expressed or implied. No person, agent, or dealer is authorized or em-powered 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 HD 4500 and the POSI-TRACK HD 4520 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 at ASV, INC.’s option, free of charge to the original purchaser, any part that our examination reveals to be defective in material or workmanship. The WARRANTY includes labor based on a flat rate, but 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 John Deere Engine is separate from ASV, INC.’s WARRANTY. The JohnDeere Engine Warranty is described in the John Deere Engine Operator Manual.

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, and the time to remove and replace the component.

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

POSI-TRACK HD 4500

PAGE 3 ASV, INC.

GROSS VEHICLE WEIGHT

The GVW (Gross Vehicle Weight) of the POSI-TRACK HD should not exceed 12,000 lbs. This weight includes any accessories, attachments, or material being carried. Exceeding the 12,000 lb. GVW will void the WARRANTY.

MODIFICATIONS

The limited WARRANTY covers the POSI-TRACK and its accessories as built by ASV, INC. 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 23 for operating capacity limits.

WARRANTY LIMITATIONS

POSI-TRACK HD 4500

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 DRIVE CONTROL CONSOLE DEFINITIONS ....................................................................................................................................11 HYDRAULIC CONTROL CONSOLE DEFINITIONS ........................................................................................................................12,13 OPERATING INSTRUCTIONS .............................................................................................................................................................14,15 HYDROSTATIC DRIVE ........................................................................................................................................................................16 LOADER VALVE CONTROL ...............................................................................................................................................................17 LOADER LOCK OUTS ..........................................................................................................................................................................17,18 OPTIONAL FOOT VALVE ................................................................................................................................................................... 18,19 QUICK ATTACH MOUNT ....................................................................................................................................................................20 FRAME UP .............................................................................................................................................................................................21,22 OPERATING CAPACITY ......................................................................................................................................................................23 MOVING DIRT ......................................................................................................................................................................................24 BI-DIRECTIONAL OPERATION .........................................................................................................................................................25 SIDE HILLING .......................................................................................................................................................................................26 PRE START CHECK LIST ....................................................................................................................................................................27 STARTING INSTRUCTIONS ................................................................................................................................................................27 SHUTTING ENGINE OFF ....................................................................................................................................................................27 SECTION 4 – GENERAL MAINTENANCE BREAK IN PROCEDURES ...................................................................................................................................................................28,29 MAINTENANCE SCHEDULE ..............................................................................................................................................................30 GREASE POINTS ...................................................................................................................................................................................31,32 ENGINE OIL AND FILTER CHANGE .................................................................................................................................................33 HYDRAULIC OIL AND FILTER CHANGE ........................................................................................................................................34 BLEEDING THE FUEL SYSTEM .........................................................................................................................................................35 TRACK TENSION ..................................................................................................................................................................................36 PLANETARY OIL CHANGE ................................................................................................................................................................37,38 RADIATOR AND OIL COOLER ..........................................................................................................................................................39 AIR CLEANER .......................................................................................................................................................................................40 CHANGING FUEL FILTER ..................................................................................................................................................................41 SECTION 5 – SERVICE TRACK REMOVAL ...............................................................................................................................................................................42,43 TRACK INSTALLATION ......................................................................................................................................................................44,45 BOGIE CARRIAGE REMOVAL ...........................................................................................................................................................46 WHEEL TUBE REMOVAL ...................................................................................................................................................................46 WHEEL REPLACEMENT .....................................................................................................................................................................47 END TUBE REMOVAL .........................................................................................................................................................................47 SPROCKET REMOVAL ........................................................................................................................................................................48 CHECKING PRESSURES ......................................................................................................................................................................49,50 SECTION 6 - TROUBLE SHOOTING GENERAL ...............................................................................................................................................................................................51-54 ELECTRICAL .........................................................................................................................................................................................55-60 SERVICE LOG ...............................................................................................................................................................................61,62 NOTES ................................................................................................................................................................................................63-65

POSI-TRACK HD 4500

PAGE 5 ASV, INC.

This manual contains operation, maintenance, service and trouble shooting information for the POSI-TRACK HD 4500 and the HD 4520. 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.

VEHICLE IDENTIFICATION NUMBERS (VIN)

The POSI-TRACK VIN is located on the side of the control console.

Always provide the VIN when contacting the dealer about parts, service, warranty, or accessories. No warranty claims will be processed if the VIN number is not given.

FOREWORD

POSI-TRACK HD 4500

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 Horsepower , 4500 Horsepower , 4520 Peak Torque, 4500 Peak Torque, 4520

TRACK SPECIFICATIONS

Width Length Weight P

82.5" 69" 113" 16" 7,500 lbs. 8,500 lbs. 6 mph 2.65 psi (Without Loader) 2826 sq. in.

P

John Deere Power Tech 4045 & 4045T Diesel, liquid Cooled, In-Line 4 Cylinder 4.5 liter (276 cid) 80 hp at 2,500 rpm 115 hp at 2,500 rpm 215 ft.-lb. 291 ft.-lb.

P

18" 220" 265 lbs. 2

SPECIFICATIONS

SECTION

1

TRACK CONSTRUCTION

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

POSI-TRACK HD 4500 & HD 4520

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 wheels supporting the track 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 at full flow CAPACITIES Fuel Tank Hydraulic Reservoir Coolant Engine Oil w/filter P

Articulating roller carriages with rubber tor-sion axles 27 per side 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. 2,750 psi P 25 gal. 28 gal. 5.5 gal. 14 qt.

SPECIFICATIONS


PAGE 8 ASV, INC.

LOADER ASSEMBLY Operating Capacity (SAE, Skid-Steer loader) Operating Capacity (SAE, Tracked loader) Breakout force 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 Loader towers Hydraulic filter compartment Battery compartment P

2,800 lbs. 1,900 lbs. 5,500 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. Allows loader to be installed on PTO end. Hydraulic filters housed on a manifold Easy access to battery and fuse panel.

ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTIFICATION.

SPECIFICATIONS


PAGE 9 ASV, INC.

SECTION

2 GENERAL SAFETY

NEVER start vehicle 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 ad-justments. NEVER get out of the vehicle when the PTO shaft is engaged or when an attachment is run-ning. NEVER operate the PTO shaft with the safety shields removed. Always use extreme caution when working near a PTO shaft.


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


PAGE 11 ASV, INC.

SECTION

3 CONSOLE DEFINITIONS MAIN DRIVE CONTROL (Fig. 1 and Fig. 2) A) Coolant Temperature Gauge This gauge indicates the temperature of the en-gine coolant. Normal coolant temperature should be between 180° and 205°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. (Refer to troubleshooting section) C) Tachometer The tachometer displays the RPM of the engine. Normal operating RPM should be between 2,000 and 2,500 RPM. Maximum RPM is 2,500. 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) High Flow Lever Controls the direction of the high flow hydraulic oil. H) Seat Switch Receptacle Allows seat switch to be plugged in when seat is reversed.

GENERAL OPERATION

A

B

C

D

E F

G

Fig. 1

Fig. 2 H

I


PAGE 12 ASV, INC.

I) VIN Vehicle identification number. HYDRAULIC CONTROL CONSOLE (Fig. 3 and Fig. 4) J) Main Valve Joystick Controls the loader, dozer or 3-point hitch. K) Auxiliary Low Flow Lever Controls the direction of the low flow hydraulic oil.

L) Parking Brake Switch Used to activate the optional brake activating solenoid. This switch locks in position to pre-vent accidental engagement. There is a small switch within the main switch, that must be pressed before the main switch will unlock. M) Auxiliary Switch Can be used for added electrical accessories.

NOTE It is important that the low flow Aux. lever is in neutral if nothing is hooked up to the low-flow circuit. If it is not in neutral, sluggish operation of the machine, loader and engine will occur. The machine will also start hard if this lever is not in the center (neutral) posi-tion.

NOTE The parking brake is automatically engaged when the engine is turned off. The optional brake solenoid will allow you to engage the brake while the engine is running.

J

K

L M

Fig. 3

GENERAL OPERATION


PAGE 13 ASV, INC.

N) Light Switch This switch turns on/off both the front and rear work lights. O) Front Windshield Wiper Switch Controls the optional front windshield wipers. P) Fan Switch Controls the optional heater fan. Q) Rear Windshield Wiper Switch Controls the optional rear windshield wiper. R) Ignition Key operated switch starts engine and powers electrical accessories. S) Change 5" Filter This light will come on if the 5" filter needs to be changed. T) Change 3" Filter This light will come on if the 3" filter needs to be changed. U) Hot Hydraulic Oil Indicator This light will come on if the hydraulic oil rises above 200°F. V) 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. W) Fuel Gauge

N O P Q

V W

R S T U Fig. 4

GENERAL OPERATION


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. 5)

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. (Fig. 7)

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. 6)

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. 5

Fig. 6

Fig. 7


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 high flow aux. lever 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. 8

Fig. 9


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 HD models have relief valve set-tings 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. Of course it takes a lot of horsepower to send the oil over the relief valves on both tracks at the same time. Therefore, the 80 hp HD 4500 will rarely send the oil over both relief valves at the same time with out bogging the engine down. The 115 hp HD 4520, however, has more than enough horse-power to send the oil over both relief valves with out bogging down the engine.

GENERAL OPERATION


PAGE 17 ASV, INC.

LOADER VALVE CONTROL (Fig. 10 and Fig. 11) 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. 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 vehicle, 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.

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

Fig. 10

Fig. 11

GENERAL OPERATION


PAGE 18 ASV, INC.

ENGAGING THE LOCK OUT PINS (Fig. 12) 1. Raise the loader past the top of the roll cage and turn off the engine. 2. Loosen the two knobs and undo the red latch. 3. Slide the knobs outward until they stop and tighten. 4. Turn the key to the “on” position, to unlock the loader valve (DO NOT START ENGINE). Lower the loader onto the pins. INSTALLING THE OPTIONAL FOOT VALVE (Fig. 13) The foot valve can be used to replace the func-tion of the low-flow auxiliary lever on the con-sole. This makes operating auxiliary attach-ments, such as the dozer blade easier, because you can keep operating the main joystick while running the low flow circuit. The foot valve is easy to hook up and can be installed and ready to use within 10 minutes. 1. Remove the existing footrest and replace with the footrest that has the foot valve built in. (If the vehicle has a front door, the doorsill will have to be removed to put the foot valve in place. 2. Disconnect the top hose on both quick-coupler banks on either side of the fuel tank.

GENERAL OPERATION

Fig. 12

Fig. 13

Left Right


PAGE 19 ASV, INC.

3. There are FOUR hoses that come off the bot-tom of the foot valve. The bottom two hoses should be routed so the left hose runs along the left side of the vehicle, and the right hose runs along the right side of the vehicle. (The hoses should not cross). The hoses should be routed between the side screens and the loader towers. 4. The left hose should be plugged into the top quick-coupler on the left side quick-coupler bank (A). The right hose should be plugged into the top quick-coupler on the right side quick-coupler bank (B). 5. The top two hoses coming out of the foot valve should then be routed between the loader towers and the roll cage, again, making sure the hoses do not cross. Plug the left hose into the quick coupler of the hose that was removed ear-lier on the muffler side of the vehicle (C). Plug the right hose into the quick coupler of the hose that was removed earlier on the battery side of the vehicle (D). These hoses bring the oil down to the quick-couplers on the loader. If the foot valve was being hooked to a six-way dozer blade, the top two hoses from the foot valve would be hooked to the dozer’s swing cylinder hoses. 6. Pull the low flow auxiliary lever downward to engage. This will activate the foot valve.

Fig. 14

Fig. 15

A

Muffler side of vehicle

B

C

D

Battery side of vehicle

GENERAL OPERATION


PAGE 20 ASV, INC.

QUICK-ATTACH MOUNT Quick-attach attachments are designed to be quick and easy to install or remove. The follow-ing instructions use the backhoe as an example. The backhoe uses additional stabilizers that other quick-attach attachments do not. 1. With the quick-attach levers up, drive into the backhoe’s quick-attach plate and curl the backhoe towards the vehicle with the quick-attach tilt cylinders. (Fig. 16) 2. Lock the levers in place by pulling the levers inward and down. (Fig. 17) 3. Replace the loaders lift cylinder pins, with the pins that are supplied with the backhoe. These pins will allow a place for the stabilizers to attach to the loader for extra stability. (A) 4. Secure the stabilizers to the loaders lift cylin-der pins using the supplied lynch pins. (Fig. 18) 5. Hook up the hydraulic quick-couplers. 6. Move the low flow auxiliary lever to the “down” position. This will send hydraulic oil to the backhoe valve and it is ready to use. (Fig. 19)

Fig. 16

Fig. 17

Fig. 18

Fig. 19

GENERAL OPERATION

A


PAGE 21 ASV, INC.

FRAME MOUNT Frame mount attachments include the six-way dozer blade, three-point hitch, and the frame mount backhoe. The frame mount receptacle allows the attachment to be rigidly mounted to the frame for added strength and stability. The following instructions are for the six-way dozer blade. 1. If the vehicle has a loader assembly installed, use the loader lockout pins to secure the loader in the “up” position. (See page 18) 2. Turn the engine off and then turn the key to the “on” position to unlock the loader valve. (DO NOT RESTART THE ENGINE) Move the loader control and the auxiliary valve in all directions to relieve any pressure in the lines. 3. Disconnect all loader hoses at the quick-couplers. 4. Using a floor jack, raise the dozer mount so it is high enough to line up with the vehicle frame mount receptacle. (Fig. 20) 5. Remove the loader stop (A) by removing the two pins (B). 6. Drive the vehicle so the dozer mount (C) and the axle arms (D) slide into the receptacle (E) and around the front axle.

Fig. 20

A B

C D

E

GENERAL OPERATION


PAGE 22 ASV, INC.

7. Route the hoses between the roll cage and the loader towers and hook up the hoses to the quick-couplers. The hoses and the quick-couplers are all color coded for easy hook up; however, if the color codes have been removed, refer to figures, 21, 22, 23, for proper hose configuration. (Match the letters on the dozer blade with the let-ters on the quick-couplers for proper hose con-figuration). 8. Line up the holes in the receptacle and in the dozer blade and insert the pins through the recep-tacle. Secure the pins with the small lynch pins. If the pins do not line up, use the blade hydrau-lics to fine tune the hole alignment.

Fig. 21 F A

B E

C

D

F

A

B

Fig. 22

Fig. 23

E

C

D

GENERAL OPERATION


PAGE 23 ASV, INC.

OPERATING CAPACITIES

The operating capacity refers to how much addi-tional weight can be put into the POSI-TRACK’s loader bucket. This operating capacity is meas-ured at the mid point of the low profile bucket. The operating capacity is 2,800 lbs. when the low profile bucket is quick attached to the HD’s 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

2800 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


PAGE 24 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. 24) 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. 25) 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. When filling the bucket with dirt, the slower you travel the more power the vehicle will have. The POSI-TRACK has incredible traction and the bucket can easily be filled by slowly driving into the pile of dirt.

Fig. 24

Fig. 25

GENERAL OPERATION


PAGE 25 ASV, INC.

BI-DIRECTIONAL OPERATION A unique feature of the POSI-TRACK is the ability to reverse the seat and the footrest in or-der to face the engine. 1. Remove the footrest by pulling up from both ends with even pressure. (Fig. 26) 2. To remove the seat, remove the two lynch pins, which secure the seat to the pegs, and un-plug the seat cord from the console. Pull up on the seat from both sides. (Fig. 27) 3. Once removed, take the seat out of the cab. Place the footrest over the pegs where the seat used to be. Place the seat on the pegs where the footrest used to be. (Fig. 28) 4. The seat cord must be plugged into the recep-tacle on the console in order for the vehicle to operate. There is a receptacle on both consoles so the seat can be plugged in no matter which di-rection it is facing. (Fig. 29)

NOTE When operating the POSI-TRACK as a tractor, with the loader removed and with the seat fac-ing the engine, the side screens should be re-moved to allow better access to the operator's seat.

NOTE When the seat is facing the engine, the en-closed cab is not functional. The door will not close and there is poor access to the operator’s compartment.

Fig. 26

Fig. 27

Fig. 28

Fig. 29

GENERAL OPERATION


PAGE 26 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. 30) 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. 31, 32, 33) 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. 31

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. 32

Fig. 33

Fig. 30

GENERAL OPERATION


PAGE 27 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 safety. 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 34. STARTING INSTRUCTIONS 1. Perform all Pre-Start checks outlined (Fig. 34) 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. 34

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


PAGE 28 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 HD. A track run too loose can cause premature track fail-ure 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 HD are easy to tighten. It takes only a few minutes and will be well worth the time (See page 36 for track tensioning procedure.) After the initial track break-in, the tracks may not need to be tightened for several hundred hours, however, 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


PAGE 29 ASV, INC.

ENGINE The engine is ready for normal use; however, extra care during the first 100 hours will result in longer engine performance and life. The John Deere engine is factory filled with John Deere Break-In Oil. Change the break-in oil at 100 hours. DO NOT exceed 100 hours of operation with break-in oil. After the initial break-in, the oil should be changed every 250 hours or sooner if working in a dusty environ-ment. (See page 34 for proper oil changing procedure). 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. 35) 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 38 for proper planetary oil changing proce-dure.)

Fig. 35

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


PAGE 30 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 250 hours (after 100 hr. break-in) Refer to page 31 Engine fuel filter 600 hours or as needed Engine air filter As needed Planetary oil 1,000 hours or annually (After 50 hr. break-in) SAE 80w-90 gear lube Drive shaft 250 hours Low temp grease Loader grease fittings 25 hours, or as needed 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 coolant 5.5 gallons John Deere approved Engine oil 14 quarts See chart below Engine oil viscosity chart.

GENERAL MAINTENANCE


PAGE 31 ASV, INC.

GREASE POINTS LOADER ASSEMBLY There are 12 grease fittings on the POSI-TRACK’S loader assembly, which should be greased every 25 hours, or as needed. The grease fittings are located in the following spots on both sides of the loader: 1. The main loader hinge points. (Fig. 36) 2. Both ends of the lift cylinders. (Fig. 37, 38) 3. Both ends of the quick-attach cylinders. (Fig. 39, 40) 4. Hinge points for the quick-attach. (Fig. 41)

GENERAL MAINTENANCE

Fig. 36

Fig. 37

Fig. 38

Fig. 39

Fig. 40

Fig. 41


PAGE 32 ASV, INC.

DRIVE SHAFT The drive shaft must be greased every 250 hours. Lack of grease will cause a failure of the drive shaft, which could cause damage to other components. The time it takes to grease the drive shaft can be kept to a minimum if the following instruc-tions are used. 1. Remove seat. 2. Remove drive shaft / hose guard panel. This panel can be removed without any tools. (A) 3. Using a grease gun with a hose extension, grease both u-joints of the drive shaft. There is also a grease fitting in the middle of the drive shaft that needs to be greased. (Fig. 43) 4. If the u-joint on the engine end of the drive shaft is difficult to reach, there is an access panel underneath the vehicle (B). Once the four bolts which secure the access panel are removed, the u-joint on the engine end can be easily greased.

GENERAL MAINTENANCE

Fig. 42

Fig. 43

A

B

Fig. 44


PAGE 33 ASV, INC.

ENGINE OIL & FILTER CHANGE Engine oil and filter should be changed every 250 hours after the initial 100 hour break-in. This service interval should be shortened if the vehicle is used in extremely dusty conditions. 1. Run engine approximately 5 minutes to warm up oil. Shut off engine. 2. Remove oil drain plug (A) beneath the en-gine compartment and allow to drain. 3. Using a filter wrench, remove oil filter ele-ment (B) and dispose of properly. 4. Replace with new filter element, and tighten ¾ to 1¼ turn after the filter contacts the housing. DO NOT over tighten. 5. Install oil pan drain plug, ensure plug seal is still in good condition. 6. Fill engine crankcase to specified level. (Approximately 14 quarts) 7. Run engine to check for possible leaks. 8. Stop engine and check oil level after 10 min-utes. Oil level should be within the crosshatch of the dipstick.

Fig. 45

Fig. 46

A

B

GENERAL MAINTENANCE


PAGE 34 ASV, INC.

HYDRAULIC OIL & FILTER CHANGE One of the most critical systems on the POSI-TRACK is the hydrostatic drive. 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 muf-fler side of the vehicle. (Fig. 48) 3. The three inch and the five inch filters are both disposable spin on type filters. These filters can be removed by hand or by using a filter wrench. Always dispose of filters properly. 4. The third filter is a canister type. The canister has an interior filter element (B) which must be replaced. DO NOT REPLACE THE CANISTER ITSELF.

Fig. 47

Fig. 48

A

Fig. 49

B

GENERAL MAINTENANCE


PAGE 35 ASV, INC.

BLEEDING 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 air bleed vent screw two full turns. (Fig. 50) 2. Pump primer lever until fuel flowing out the vent is free of air bubbles. (Fig. 51) 3. Tighten bleed screw securely, continuing to pump primer lever until resistance is minimal. Push lever inward, toward engine, as far as it will go. 4. Start engine and check for leaks. If engine still won’t start, it may be necessary to bleed air from fuel system at fuel injection pump or injection nozzles. Refer to the John Deere Operation and Maintenance manual for this pro-cedure.

Fig. 50

Fig. 51

GENERAL MAINTENANCE


PAGE 36 ASV, INC.

TRACK TENSION 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 in the side filter box is a screw jack and a wrench that will allow the tracks to be tight-ened in the field. 1. Insert the screw jack between the undercar-riage frame and the sliding mount, which houses the drive sprocket. (Fig. 52) 2. Loosen (DO NOT REMOVE) the bolts in the slots which allow the sprocket mount to slide. (Fig. 53) 3. Rotate the screw jack with the wrench to take some pressure off the tension adjustment bolts. 4. Remove the tension adjustment bolts (one on each side). (Fig. 54) 5. Rotate the screw jack with the wrench until the track has zero sag between the drive sprocket and the top carrier wheels. (Fig. 55) 6. Line up the next available holes in the sliding mount with a hole in the undercarriage frame and reinsert the tension adjustment bolts and tighten. (both sides). Tighten bolts in slots. Tension adjustment bolts must be placed in the same adjustment hole, or the sprocket will be out of alignment causing track derailment.

Fig. 52

Fig. 53

Fig. 54

Fig. 55

GENERAL MAINTENANCE


PAGE 37 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 filter service compartment of the POSI-TRACK HD, there is a kit which will make changing the planetary oil easier. This kit in-cludes a fitting and a hose. 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. 56) 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. 57)

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. 56

Fig. 57

GENERAL MAINTENANCE


PAGE 38 ASV, INC.

3. Remove the top plug to vent the case and al-low the oil to drain. (Fig. 58) 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. 59)

Fig. 58

Fig. 59

GENERAL MAINTENANCE


PAGE 39 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. Remove the pre-cleaner. (Fig. 60) 2. Remove the hood by undoing the 4 rubber bungie cords, which secure the hood. (Fig. 61) 3. Remove the lynch pin from the clasp. Then undo the clasp that holds the radiator and oil cooler door shut. Swing the door away from the engine. (Fig. 62) 4. Undo the two clasps that secure the radiator

and oil cooler grill from the door. Swing the grill away from radiator and oil cooler. (Fig. 63) 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. 60

Fig. 61

Fig. 62

Fig. 63

GENERAL MAINTENANCE


PAGE 40 ASV, INC.

CHANGING 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. After the hood is removed, loosen the first wing nut on the end of the air cleaner until the cover can be removed. (Fig. 64) 2. Loosen the second wing nut, holding the main filter in and remove the element. (Fig. 65) 3. Loosen the third wing nut, holding in the secondary filter element, and then remove the element. (Fig. 66)

NOTE When working in dusty conditions the air cleaner should be checked frequently.

Fig. 64

Fig. 65

Fig. 66

GENERAL MAINTENANCE


PAGE 41 ASV, INC.

CHANGING THE FUEL FILTER The fuel filter should be changed every 600 hours, or as needed. 1. Clean filter area thoroughly before removing the filter. 2. Loosen drain plug (A) and drain fuel into a suitable container. 3. Rotate retaining ring (B) counterclockwise ¼ turn. Remove ring with filter element. 4. Install new filter element onto base. 5. Align keys on filter element with slots in fil-ter base. 6. Install retaining ring onto base and hand tighten ring until it “snaps” into the detent. (DO NOT OVER TIGHTEN). 7. Bleed the fuel system. (See page 35)

Fig. 67

A

B

GENERAL MAINTENANCE


PAGE 42 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. 68) 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. 69) 2. Place the jack between the sliding planetary mount and the undercarriage frame (Fig. 70). 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. 71)

Fig. 68

Fig. 69

Fig. 70

A

SECTION

5


PAGE 43 ASV, INC.

4. Insert the jack between the rear axle mount and the steel tab (Fig. 71). 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. 72) 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. 74)

B

Fig. 71

C Fig. 72

Fig. 73

Fig. 74

SERVICE


PAGE 44 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. 75) 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. 76) 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). If the planetary mount starts to bind, place the jack on the other side. (Fig. 77) 7. Once the planetary mount is back far enough, place the jack between the sliding planetary mount and the rear axle mount. (Fig. 78)

Fig. 75

Fig. 76

Fig. 77

Fig. 78

SERVICE


PAGE 45 ASV, INC.

8. Jack the planetary mount back until the track is straight (Fig. 79) 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. 80) 10. Tighten bolts in slots on both sides of the undercarriage.

Fig. 79

Fig. 80

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


PAGE 46 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. 81) 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. 82) WHEEL TUBE REMOVAL 1. Place the bogie carriage on the floor so all wheels are facing up. (Fig. 83) 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. 81

Fig. 82

A

Fig. 83

B

SERVICE


PAGE 47 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. 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. 85)

A

Fig. 84

Fig. 85

SERVICE


PAGE 48 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. 86) 2. Remove the 3 bolts that fasten the bearing plate to the undercarriage frame. (Fig. 87) 3. Tapping the bearing plate with a rubber ham-mer will help dislodge it from the flange. Pull the bearing plate straight out. (Fig. 88) 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. 89)

Fig. 86

Fig. 87

Fig. 88

Fig. 89

SERVICE


PAGE 49 ASV, INC.

CHECKING PRESSURES 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 muffler side of the vehicle. Locate the cap on the elbow fitting in the lower right hand corner (A). 2. Remove this cap and quickly screw on a pres-sure gauge. (Fig. 90) 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. 90

A

SERVICE


PAGE 50 ASV, INC.

LOW FLOW PRESSURE If the loader or another attachment is weak on power and all other causes have been ruled out, it may be necessary to check the low or high flow pressure. 1. Using a quick coupler on a pressure gauge, couple into the left female quick coupler on the loader's cross tube. (Fig. 91) 2. Start the vehicle and pull the low flow auxil-iary lever down into the detent position. In-crease the engine rpm to full throttle. The pres-sure at full throttle should read between 3,200 and 3,500 psi when the oil is warm. HIGH FLOW PRESSURE The high flow pressure should be checked in the same manner as the low flow pressure. 1. Using a male quick coupler on the pressure gauge, as you are facing the front of the loader, plug the gauge into the left quick coupler on the top of the loader arm. (Fig. 92) 2. Start the engine and pull the high flow lever to the "AUX" position when the engine is at an idle (Fig. 93). Increase the engine to full throt-tle. 3. The pressure at wide open should be between 3,000 and 3,300 psi when the oil is warm.

Fig. 91

Fig. 92

Fig. 93

SERVICE


PAGE 51 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 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. Refer to electrical trouble shooting guide 5. Plugged fuel filter 5. Change filter 6. Cold weather – need 6. Refer to John Deere starting aid. Engine manual 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 49 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


PAGE 52 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. Refer to hydraulic flow diagram on page 22 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. Refer to page 50 is set too low. Loader doesn’t 1. Auxiliary hydraulic pressure 1. Refer to page 50 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



PAGE 53 ASV, INC.

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 49 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. 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. Tighten to proper adjustment. 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



PAGE 54 ASV, INC.

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 bled 1. Refer to page 35 fuel and refueling, engine will not start



PAGE 55 ASV, INC.

TROUBLE SHOOTING (ELECTRICAL)


PAGE 56 ASV, INC.



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PAGE 61 ASV, INC.

DATE DATE DATE DATE DATE ITEM HOURS HOURS HOURS HOURS HOURS

MAINTENANCE & SERVICE


PAGE 62 ASV, INC.

DATE DATE DATE DATE DATE ITEM HOURS HOURS HOURS HOURS HOURS

MAINTENANCE & SERVICE


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ASV HD4500 Posi-Track Loader Operation and Maintenance...

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