Asv 8305 4810 Operation and Maintenance Manual 6051 SN All English All PDF
Asv 8305 4810 Operation and Maintenance Manual 6051 SN All English All PDF
Asv 8305 4810 Operation and Maintenance Manual 6051 SN All English All PDF
Language:
English
Geographic Region:
All
SN All
4810
Operation and Maintenance
Manual
USA
(800)616-8156
POSI-TRACK 4810
WARRANTY
he WARRANTY herein set forth applies solely to the POSI-TRACK 4810 manufactured by ASV, INC. and is in lieu of all other warranties, expressed or implied.
No person, agent, or dealer is authorized or empowered to give any other warranty
or to assume 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 defective in material or workmanship. The WARRANTY does not include transportation costs,
clean up, or consequential damages.
(A)
(B)
(C)
ASV, INC. reserves the right to inspect the equipment prior to any decision involving a warranty 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 apply to damage caused by misuse, abuse, neglect, or improper adjustment, accident, or improper 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 OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. ASV, INC. DISCLAIMS LIABILITY FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND.
ASV, INC.
PAGE 2
POSI-TRACK 4810
WARRANTY LIMITATIONS
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 vehicles 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 vehicles hydraulic system. An attachment which is oversized for the vehicles carrying capacity, can cause premature failure to the vehicles 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 attachments load. Refer to page 19 for operating capacity limits.
ASV, INC.
PAGE 3
POSI-TRACK 4810
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 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
ASV, INC.
PAGE 4
POSI-TRACK 4810
FOREWORD
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 become more productive.
Throughout this manual the words WARNING, CAUTION, and NOTE are used to emphasize certain information. The word WARNING is used to identify personal safety information. 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.
ASV, INC.
PAGE 5
SECTION
POSI-TRACK 4810
SPECIFICATIONS
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
82.5"
69"
114.75"
16"
7,500 lbs.
8,640 lbs.
6 mph
3 psi (With Loader)
2826 sq. in.
P
ENGINE
Model
Type
Displacement
Gross Horsepower
Peak Torque
Caterpillar 3054T
Diesel, Liquid Cooled, In-Line 4 Cylinder
4 liter
105 hp at 2,400 rpm
284 ft.-lb.
P
TRACK SPECIFICATIONS
Width
Length
Weight
18"
220"
265 lbs.
TRACK CONSTRUCTION
Molded Rubber with Kevlar reinforcement, no steel in track, 2 rows of internal drive lugs.
ASV, INC.
PAGE 6
POSI-TRACK 4810
SPECIFICATIONS
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
MTSS
48
Sealed, oil bath bearings
Type
Number of contact points
Lubrication
P
TRANSMISSION & FINAL DRIVE
Drive Pumps
Drive Motors
Final Drive
P
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
25 gal.
28 gal.
8 qt.
P
ASV, INC.
PAGE 7
POSI-TRACK 4810
SPECIFICATIONS
LOADER ASSEMBLY
2,950 lbs.
2,065 lbs.
Operating Capacity (SAE J818, Skid-Steer)
Operating Capacity (SAE J818, Track Loader) 114"
2 pin, universal skid steer type
Lift height to hinge pin
Quick-Attach
P
OPERATORS COMPARTMENT
Protection system
Seat
Controls
ROPS/FOPS approved
Reversible, operator presence switch
Hand controls for drive and loader/bucket
P
INSTRUMENTATION
Standard instruments include:
P
ELECTRICAL SYSTEM
Lights
Battery
Alternator
2 front, 2 rear
12 volt, 950 CCA
65 amp
P
ADDITIONAL FEATURES
Cooling package
Environmental
Attachment receptacle
Hydraulic filter compartment
Battery compartment
ASV, INC.
PAGE 8
POSI-TRACK 4810
SECTION
GENERAL SAFETY
ASV, INC.
PAGE 9
POSI-TRACK 4810
GENERAL SAFETY
NEVER get in or out of the operators 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. Failure 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 vehicle.
NEVER allow an unqualified person to operate
the POSI-TRACK. Anyone operating the vehicle must read and understand the operators
manual.
NEVER operate the POSI-TRACK on any frozen body of water. Ice can be very dangerous
and unpredictable.
ASV, INC.
PAGE 10
SECTION
POSI-TRACK 4810
GENERAL OPERATION
CONSOLE DEFINITIONS
Fig. 1
I
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)
Fig. 2
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.
ASV, INC.
PAGE 11
POSI-TRACK 4810
GENERAL OPERATION
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 hydraulic circuit.
Fig. 3
Fig. 4
ASV, INC.
PAGE 12
POSI-TRACK 4810
GENERAL OPERATION
ELECTRICAL CONSOLES
L) Parking Brake Switch
Used to activate the parking brake while the engine 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.
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.
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.
ASV, INC.
PAGE 13
POSI-TRACK 4810
GENERAL OPERATION
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)
!WARNING!
Entering or exiting the vehicle under a raised
loader could cause serious injury or death.
Never put yourself underneath a raised, unsecured, loader. (Fig. 8)
Fig. 7
Fig. 8
!WARNING!
Failure to wear the seat belt could lead to serious injury or death.
ASV, INC.
PAGE 14
POSI-TRACK 4810
GENERAL OPERATION
Start the vehicle and allow engine to warm up
for two minutes before increasing throttle to desired 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 recommended that the first time operator concentrate on learning the drive controls before moving 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-
Fig. 9
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 operator is seated.
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 direction.
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 (counterrotate) push one lever forward and pull the other
in reverse.
Fig. 10
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.
ASV, INC.
PAGE 15
POSI-TRACK 4810
GENERAL OPERATION
The hydrostatic pumps of the POSITRACK 4810 have relief valve settings of
4,000 lbs. psi. This means each drive pump
POWER & SPEED CONTROL
can produce a maximum of 4,000 pounds
per square inch of pressure. The harder the
The POSI-TRACK transmits the power from
pumps are worked, the more pressure they
the engine to the tracks using a hydrostatic
will produced until they reach their relief
transmission. The hydrostatic transmission
valve setting.
sends oil under pressure to two individual hyFor example: It takes a certain amount of
draulic motors, one for each track. The hydroforce to push a large rock across hard
static transmission consists of two individual
ground. If it takes 6,000 psi of oil pressure
hydrostatic pumps. One pump for each motor.
Track speed is increased by sending more oil to to push this rock straight forward, each
the hydraulic motors, and power is increased by drive pump produces 3,000 psi for a total of
sending less oil to the hydraulic motors. With a 6,000 psi. Under good traction the vehicle
mechanical transmission the operator must shift will push this rock straight forward since
down to increase power. With hydrostatic drive the pumps have not reached their individual
4,000 psi relief valve setting. If the operathe operator can simply pull back on the drive
tor tries to turn the vehicle while pushing
controls, reducing speed and increasing power
the same rock, the load on the inside track
at the same time.
will be less, and its pressure will decrease.
The load on the outside track will be inHYDRAULIC RELIEF PRESSURE
creased, thus increasing its pressure. If the
outside track is getting good traction, the
There are three main forces involved in trans4,000 psi relief valve setting can be
mitting power from the engine to the ground:
reached, making the track stop until the
ENGINE POWER, HYDRAULIC RELIEF
load is reduced. The oil for both tracks
PRESSURE, & TRACTION. Engine power
and traction can be easily understood, however could be made to go over the relief valves
relief pressure must be explained in greater de- if the same rock was pushed up hill since it
would take much greater force.
tail. All hydrostatic pumps have a relief
valve. A relief valve makes the oil by-pass the
hydraulic motor to prevent the pump from producing too much pressure. Every pump has its
pressure limitations. The lower the pressure,
the longer the pump, as well as other drive components, will last. The relief valves protect the
vehicle from a damaging situation. For example: The relief valves minimize track damage
and track derailment.
HYDROSTATIC DRIVE
ASV, INC.
PAGE 16
POSI-TRACK 4810
GENERAL OPERATION
LOADER VALVE CONTROL (Fig. 11 and
Fig. 12)
Fig. 11
Fig. 12
ASV, INC.
PAGE 17
POSI-TRACK 4810
GENERAL OPERATION
LOADER LOCK OUT PINS
The roll cage comes equipped with two retractable 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.
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.
ASV, INC.
PAGE 18
POSI-TRACK 4810
GENERAL OPERATION
OPERATING CAPACITIES
The operating capacity refers to how much additional weight can be put into the 4810s 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.
ASV, INC.
PAGE 19
POSI-TRACK 4810
GENERAL OPERATION
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-TRACKS loader is designed to push
against the frame while leveling or digging dirt.
Fig. 14
Fig. 15
Fig. 16
ASV, INC.
PAGE 20
POSI-TRACK 4810
GENERAL OPERATION
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 forward. (Fig. 18,19,20)
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 keeping the vehicle on the hill. The less weight that
is on the vehicle, the less chance there will be
for track derailment
Fig. 19
1:1 = 100% = 45
1
Fig. 20
2
1
3:1 = 33.3% = 18.4
Fig. 17
ASV, INC.
PAGE 21
POSI-TRACK 4810
GENERAL OPERATION
PRESTART CHECKLIST
Prior to operating the POSI-TRACK, several
items need to be checked to ensure safe, trouble-free operation. It is also important that periodic 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 POSITRACK, check the items on figure 21.
ITEM
Tracks
Engine coolant
Hydraulic fluid
Engine oil
Fan belt
Hoses
Fittings
Radiator
Nuts & bolts
Battery
Aux. levers
Drive controls
REMARKS
Check tension
Check level
Check level
Check level
Check tension
Check for wear
Check for leaks
Clean thoroughly
Tighten if needed
Check cables
Check for neutral
Check for neutral
STARTING INSTRUCTIONS
1. Perform all Pre-Start checks outlined
(Fig. 21) before starting engine.
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.
ASV, INC.
PAGE 22
SECTION
POSI-TRACK 4810
GENERAL MAINTENANCE
BREAK-IN PROCEDURES
Although all systems on the POSI-TRACK
are tested at the factory to ensure proper operation, there are a few items that require a
break-in period. Certain components need readjustment and others require special care
within the first 100 hours of operation.
PROPER BREAK-IN PROCEDURES ARE
CRITICAL TO THE LONG TERM RELIABILITY OF THE POSI-TRACK. Extra care
during this period will pay-off down the road.
TRACKS
CAUTION
Failure to perform the proper break-in
procedures will cause premature component failure.
ASV, INC.
PAGE 23
POSI-TRACK 4810
GENERAL MAINTENANCE
PLANETARY DRIVES
Each tracks final drive consists of a hydraulic
drive motor, a planetary gearbox and an internal drive sprocket. The planetary gearbox requires 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 procedure.)
ASV, INC.
Fig. 22
Lug nuts
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 planetary gear box.
PAGE 24
POSI-TRACK 4810
GENERAL MAINTENANCE
MAINTENANCE SCHEDULE
ITEM
FREQUENCY
LUBRICANT
Hydraulic fluid
Hydraulic filters
Engine oil and filter
Engine fuel filter
Primary air filter
Secondary air filter
Planetary oil
500 hours
250 hours or as needed
500 hours
500 hours or as needed
Clean and replace as needed
Every 3 cleanings of primary
1,000 hours or annually
(After 50 hr. break-in)
Daily
Check level at 1,000 hours
As needed
Amoco Rykon MV
Caterpillar approved
SERVICE ITEMS
FLUID
CAPACITY
TYPE
Fuel
Hydraulic oil
Planetary oil
Wheel tube oil
Engine oil
25 gallons
28 gallons
1 quart
12 ounces
8 quarts
Diesel
Amoco Rykon MV
SAE 80w-90 gear lube
SAE 80w-90 gear lube
See chart below
ASV, INC.
PAGE 25
POSI-TRACK 4810
GENERAL MAINTENANCE
GREASE POINTS
LOADER ASSEMBLY
There are 12 grease fittings on the POSITRACKS loader assembly, which should be
greased daily. The grease fittings are located
in the following spots on both sides of the
loader:
Fig. 25
Fig. 23
Fig. 27
Fig. 28
Fig. 24
ASV, INC.
PAGE 26
POSI-TRACK 4810
GENERAL MAINTENANCE
ENGINE OIL & FILTER CHANGE
The normal oil change interval is every 500 service 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 include the following: high temperatures, continuous high loads, and dusty conditions.
Fig. 29
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.
Fig. 30
4. Clean the sealing surface of the filter mounting base. Ensure that all of the old oil filter gasket 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.
ASV, INC.
PAGE 27
POSI-TRACK 4810
GENERAL MAINTENANCE
HYDRAULIC OIL & FILTER CHANGE
One of the most critical systems on the POSITRACK 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 extremely 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.
Fig. 31
Fig. 32
ASV, INC.
Fig. 33
PAGE 28
POSI-TRACK 4810
GENERAL MAINTENANCE
PRIMING THE FUEL SYSTEM
If the engine has run out of fuel, or the fuel system has been opened for service, it will be necessary to bleed the fuel system.
A
Fig. 34
NOTE
It is not possible to operate the priming lever if
the cam of the fuel lift pump is at the maximum lift position of the cam. If this
occurs, rotate the crankshaft one revolution.
B
3. Loosen the nut for the fuel inlet line at the
fuel injection pump (C) in order to vent.
Fig. 35
ASV, INC.
PAGE 29
POSI-TRACK 4810
GENERAL MAINTENANCE
COLLAPSING AND TENSIONING THE
TRACK
Fig. 36
Jack Housing
Hook
Bolt
"B"
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 remove the two track tension bolts, B. (Fig. 37)
Fig. 37
3. Use the long hook as shown, to begin collapsing the suspension. (Fig. 38)
Fig. 38
Bolt "A"
4. Use the short hook as shown, to finish collapsing the suspension. (Fig. 39)
Long Hook
Fig. 39
ASV, INC.
Short
Hook
PAGE 30
POSI-TRACK 4810
Fig. 40
Hook
Jack Housing
Push Plate
Fig. 41
Pin
Push Plate
Jack Housing
Fig. 42
Pin
Push Plate
Jack Housing
Fig.
Push Plate
Jack Housing
ASV, INC.
PAGE 31
POSI-TRACK 4810
GENERAL MAINTENANCE
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.
Fig. 44
In the drawer under the seat of the POSITRACK 4810, there is a kit which will make
changing the planetary oil easier. This kit includes 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 doesnt matter which plug is
used for which part of the job.
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 thoroughly.
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)
ASV, INC.
PAGE 32
POSI-TRACK 4810
GENERAL MAINTENANCE
3. Remove the top plug to vent the case and allow 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 similar 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
ASV, INC.
PAGE 33
POSI-TRACK 4810
GENERAL MAINTENANCE
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 operating.
1. Undo the latch that secures the hood to the
frame (Fig. 48)
Fig. 48
2. Undo the latch that secures the radiator assembly 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)
!WARNING!
NEVER OPEN THE RADIATOR / OIL
COOLER DOOR WHILE THE ENGINE IS
RUNNING. THE FAN COULD CAUSE SERIOUS INJURY. ALWAYS SHUT THE VEHICLE OFF BEFORE CLEANING THE RADIATOR AND OIL COOLER.
Fig. 49
ASV, INC.
PAGE 34
POSI-TRACK 4810
GENERAL MAINTENANCE
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 either side of the air cleaner, then remove the
cover. (Fig. 51)
Fig. 51
Fig. 52
NOTE
When working in dusty conditions the air
cleaner elements should be checked and
changed more frequently.
4. Install new elements or replace cleaned primary element, make sure both element are properly seated be for installing cover.
ASV, INC.
Fig. 53
PAGE 35
POSI-TRACK 4810
GENERAL MAINTENANCE
CHANGING THE FUEL FILTER
1. Close the fuel supply valve.
2. Clean the outside of the fuel filter thoroughly. Open the drain (A) and drain fuel into
suitable container.
B
A
Fig. 54
A
ASV, INC.
PAGE 36
SECTION
POSI-TRACK 4810
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 POSITRACK off the ground (Fig. 55) until there is
approximately 4 inches between the bottom of
the track and the floor. Jack stands specially designed for the POSI-TRACK can be purchased
through your POSI-TRACK dealer (PN # 454876)
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 undercarriage, there are two long slots. Loosen the
bolts (A) that are in these slots (DO NOT REMOVE). (Fig. 56)
Fig. 55
Fig. 56
ASV, INC.
Fig. 57
PAGE 37
POSI-TRACK 4810
SERVICE
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. Remove 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 loosened enough so the assembly can hinge on
them. (DO NOT REMOVE ).
Fig. 58
6. Remove the other 2 bolts and hinge the assembly 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 beneath the undercarriage. Pull the track forward
and out to remove the track from the 14" idler
wheels. The track is now off. (Fig. 61)
Fig. 59
Fig. 60
Fig. 61
ASV, INC.
PAGE 38
POSI-TRACK 4810
SERVICE
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)
Fig. 62
Fig. 63
Fig. 64
Fig. 65
ASV, INC.
PAGE 39
POSI-TRACK 4810
SERVICE
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)
Fig. 66
CAUTION
It is critical that the drive sprocket is aligned
with the undercarriage frame. The tension adjustment bolts must be in the same hole location
or track derailment will occur.
ASV, INC.
Fig. 67
PAGE 40
POSI-TRACK 4810
SERVICE
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 bogie carriage. (Fig. 68)
2. Remove the 4 bolts that secure the bogie carriage to the undercarriage frame.
Fig. 68
B
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.
Fig. 70
ASV, INC.
PAGE 41
POSI-TRACK 4810
SERVICE
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).
Fig. 71
ASV, INC.
PAGE 42
POSI-TRACK 4810
SERVICE
SPROCKET REMOVAL
There are 3 bolts that fasten the planetary bearing plate to the undercarriage frame, and 4 bolts
that fasten it to the bearing flange. The track
needs to be removed before beginning this procedure.
1. Remove the 4 bolts that fasten the bearing
plate to the flange. (Fig. 73)
Fig. 73
Fig. 74
Fig. 75
Fig. 76
ASV, INC.
PAGE 43
POSI-TRACK 4810
SERVICE
CHECKING CHARGE PRESSURE
A
The charge pressure refers to the oil that is supplied 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).
Fig. 77
ASV, INC.
PAGE 44
SECTION
POSI-TRACK 4810
PROBLEM
CAUSE
REMEDY
Vehicle wont
turn over
1. Out of fuel or
fuel pick-up may not
be in fuel if parked on a hill
2. Pinched fuel line
3. Load on engine from
High or Low flow auxiliary lever
being engaged
4. Fuel solenoid is not opening
5. Plugged fuel filter
1. Low-flow auxiliary
hydraulic lever is engaged
2. High-flow auxiliary
hydraulic lever is engaged
1. Operator not seated in seat
2. Defective seat switch
3. Defective solenoid
4. Low charge pressure
ASV, INC.
4. Check wiring
5. Change filter
1. Put lever in neutral
2. Put lever in neutral
PAGE 45
POSI-TRACK 4810
TROUBLE SHOOTING (GENERAL)
PROBLEM
CAUSE
REMEDY
Attachment wont
operate
4. Correct
5. Contact dealer or refer to
an attachment owners
manual
Loader doesnt
lift proper weight
ASV, INC.
PAGE 46
POSI-TRACK 4810
TROUBLE SHOOTING (GENERAL)
PROBLEM
CAUSE
REMEDY
Attachments, tracks
weak on power
Tracks respond
sluggishly
1. Brake is engaged
2. Cable is disconnected on
lever
3. Cable is disconnected on
pump
Track will only
go in one direction
Track derails
ASV, INC.
1. Contact dealer
2. Contact dealer
3. Contact dealer
1. Adjust
2. Replace bearing
PAGE 47
POSI-TRACK 4810
TROUBLE SHOOTING (GENERAL)
PROBLEM
CAUSE
REMEDY
Engine coolant
overheats
ASV, INC.
PAGE 48
POSI-TRACK 4810
MAINTENANCE & SERVICE
DATE
DATE
DATE
DATE
DATE
HOURS
HOURS
HOURS
HOURS
HOURS
ITEM
ASV, INC.
PAGE 49
POSI-TRACK 4810
MAINTENANCE & SERVICE
DATE
DATE
DATE
DATE
DATE
HOURS
HOURS
HOURS
HOURS
HOURS
ITEM
ASV, INC.
PAGE 50
POSI-TRACK 4810
NOTES
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ASV, INC.
PAGE 51
POSI-TRACK 4810
NOTES
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ASV, INC.
PAGE 52
POSI-TRACK 4810
NOTES
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ASV, INC.
PAGE 53