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8/17/2016 Operation and Maintenance Manual 2800 SN All English All Language: Geographic Region: Serial Number Range: This manual is complements of TrackLoaderParts.com The world's best source for ASV parts. Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-8156

ASV 2800 Posi-Track Loader Operation and Maintenance …

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8/17/2016

Operation and Maintenance

Manual

2800

SN All

English

All

Language:

Geographic Region:

Serial Number Range:

This manual is complements of

TrackLoaderParts.com

The world's best source for ASV parts.

Track Loader Parts 6543 Chupp Road Atlanta, Georgia 30058 USA (800)616-8156

POSI-TRACK 2800 & 2810

PAGE 3 ASV, INC.

GROSS VEHICLE WEIGHT The GVW (Gross Vehicle Weight) of the POSI-TRACK 2800 or 2810 should not exceed 10,500 lbs. This weight includes any accessories, attachments, or material being carried. Ex-ceeding the 10,500 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 22 for operating capacity limits)

WARRANTY LIMITATIONS

POSI-TRACK 2800 & 2810

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 ......................................................................................................................................................................18 QUICK ATTACH MOUNT ................................................................................................................................................................19 FRAME MOUNT ................................................................................................................................................................................20,21 OPERATING CAPACITY ..................................................................................................................................................................22 MOVING DIRT ..................................................................................................................................................................................23 BI-DIRECTIONAL OPERATION ......................................................................................................................................................24 SIDE HILLING ...................................................................................................................................................................................25 PRE START CHECK LIST ................................................................................................................................................................26 STARTING INSTRUCTIONS ............................................................................................................................................................26

SECTION 4 – GENERAL MAINTENANCE BREAK IN PROCEDURES ................................................................................................................................................................27,28 MAINTENANCE SCHEDULE ..........................................................................................................................................................29 GREASE POINTS ...............................................................................................................................................................................30,31 ENGINE OIL AND FILTER CHANGE .............................................................................................................................................32 HYDRAULIC OIL AND FILTER CHANGE .....................................................................................................................................33 BLEEDING THE FUEL SYSTEM .....................................................................................................................................................34 TRACK TENSION ..............................................................................................................................................................................35 PLANETARY OIL CHANGE ............................................................................................................................................................36,37 RADIATOR AND OIL COOLER .......................................................................................................................................................38 AIR CLEANER & BATTERY ............................................................................................................................................................39 CHANGING FUEL FILTER ...............................................................................................................................................................40

SECTION 5 – SERVICE TRACK REMOVAL ...........................................................................................................................................................................41,42 TRACK INSTALLATION ..................................................................................................................................................................43,44 BOGIE CARRIAGE REMOVAL .......................................................................................................................................................45 WHEEL TUBE REMOVAL ...............................................................................................................................................................45 WHEEL REPLACEMENT .................................................................................................................................................................46 END TUBE REMOVAL .....................................................................................................................................................................46 SPROCKET REMOVAL ....................................................................................................................................................................47 HYDRAULIC FLOWS .......................................................................................................................................................................48

SECTION 6 - TROUBLE SHOOTING GENERAL ..........................................................................................................................................................................................49-52 ELECTRICAL .....................................................................................................................................................................................53-58

SERVICE LOG ...........................................................................................................................................................................59-60

NOTES ............................................................................................................................................................................................61-63

POSI-TRACK 2800 & 2810

PAGE 5 ASV, INC.

This manual contains operation, maintenance, service and trouble shooting information for the POSI-TRACK 2800 and the 2810. It is designed to aid and instruct operators and ser-vice 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 2800 & 2810

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 , 2800 Horsepower , 2810 Peak Torque, 2800 Peak Torque, 2810 TRACK SPECIFICATIONS Width Length Weight P

82.5" 69" 113" 16" 6,800 lbs. 7,450 lbs. 7 mph 2.4 psi (Without Loader) 2826 sq. in. P Isuzu 4JB1 Diesel, liquid Cooled, In-Line 4 Cylinder 2.8 liter ( cid) 70 hp at 3,000 rpm 75 hp at 3,000 rpm 128 ft.-lb. 152 ft.-lb. (Continuous) 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 2800 & 2810

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 48 Sealed, oil bath bearings P Sundstrand, tandem variable displacement Eaton Model , 2.48 cu. In. Planetary gear box P 19 gallons per minute max. 25 gallons per minute max. 2,750 psi P 13 gal. 28 gal. 2.3 gal. 6.8 qt.

SPECIFICATIONS

POSI-TRACK 2800 & 2810

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 P

2,350 lbs. 1,645 lbs. 5,000 lbs. 109" 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 35 amp P Side by side 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.

ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTIFICATION.

SPECIFICATIONS

POSI-TRACK 2800 & 2810

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 adjustments. NEVER get out of the vehicle when an attach-ment is in motion.

POSI-TRACK 2800 & 2810

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

POSI-TRACK 2800 & 2810

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 3,000 RPM. Maximum RPM is 3,000. 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

Fig. 1

Fig. 2

G G

H

POSI-TRACK 2800 & 2810

PAGE 12 ASV, INC.

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 brake activating solenoid. This switch locks in position to prevent acci-dental engagement. There is a small switch within the main switch, that must be pressed before the main switch will unlock.

M) Glow Plug Switch When pressed, activates the engine glow plugs.

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 brake so-lenoid will allow you to engage the brake while the engine is running.

J

L M

Fig. 3

GENERAL OPERATION

Fig. 3

J

K

L M

POSI-TRACK 2800 & 2810

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) Glow Plug Indicator Element T) Change 5" Filter This light will come on if the 5" filter needs to be changed. U) Change 3" Filter This light will come on if the 3" filter needs to be changed. V) Hot Hydraulic Oil Indicator This light will come on if the hydraulic oil rises above 200°F. W) Amp Gauge Used to monitor the battery charging system while the engine is running. X) Fuel Gauge

N O P Q

W

R S T U Fig. 4

GENERAL OPERATION

Fig. 4

N O P Q R

S

T

U

V

W X

POSI-TRACK 2800 & 2810

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

POSI-TRACK 2800 & 2810

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 are not in neutral. Loader valve will not func-tion unless the operator 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

POSI-TRACK 2800 & 2810

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.

ARE THERE GEARS? No, not in the traditional sense. Hydro-static drive offers an infinite amount of gears from 0 to full speed. The closer the levers are to the neutral position the lower the gear the vehicle is in. ADVANTAGES With hydrostatic drive there aren't any clutches, brakes, or shift sticks to mess with. Hydrostatic drive enables the opera-tor to always find the right speed, and also turn, counter-rotate and stop with ease and precision.

GENERAL OPERATION

1 = MOST POWER and least speed 2 = LESS POWER and more speed 3 = MORE SPEED and less power 4 = MOST SPEED and least power

DRIVE CONTROLS

POSI-TRACK 2800 & 2810

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

POSI-TRACK 2800 & 2810

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. FUSE PANEL The fuse panel is located to the left of the opera-tors seat when the operators seat is facing the loader end of the vehicle. 1. Loosen the fiberglass cover (A) by removing the three thumb screws (B). 2. Remove the cover by lifting straight up on the fiberglass cover. This will expose the fuse panel (C) 3. For extensive work on the fuse panel, remov-ing the seat will allow better access to the fuse panel and wiring.

GENERAL OPERATION

Fig. 12

!WARNING! Before working on the fuse panel or any wir-ing, always disconnect the battery before be-ginning.

Fig. 13

Fig. 14

A

B

C

POSI-TRACK 2800 & 2810

PAGE 19 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. 15) 2. Lock the levers in place by pulling the levers inward and down. (Fig. 16) 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. 17) 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. 18)

Fig. 15

Fig. 16

Fig. 17

Fig. 18

GENERAL OPERATION

A

POSI-TRACK 2800 & 2810

PAGE 20 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. 19) 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. 19

A

B C

D

E

GENERAL OPERATION

POSI-TRACK 2800 & 2810

PAGE 21 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, 20, 21, 22 for proper hose configuration. (Match the letters on the dozer blade with the letters on the quick-couplers for proper hose configura-tion). 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.

F A

B

C

D

GENERAL OPERATION

F E A B

C D

F

E

A

B

C

D

Fig. 20

Fig. 21

Fig. 22

POSI-TRACK 2800 & 2810

PAGE 22 ASV, INC.

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 2,350 lbs. when the low profile bucket is quick attached to the machines 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

2,350 LB. OPERATING CAPACITY RATED AT BUCKET’S CENTER OF GRAVITY

FRONT PIVOT POINT

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

POSI-TRACK 2800 & 2810

PAGE 23 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. 23) 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. 24) 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. 23

GENERAL OPERATION

POSI-TRACK 2800 & 2810

PAGE 24 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. 25) 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. 26) 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. 27) 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. 28)

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. 25

Fig. 26

Fig. 27

Fig. 28

GENERAL OPERATION

POSI-TRACK 2800 & 2810

PAGE 25 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. 29) 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. 30, 31, 32) 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°

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. 29

GENERAL OPERATION

Fig. 30

Fig. 31

Fig. 32

POSI-TRACK 2800 & 2810

PAGE 26 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 33. STARTING INSTRUCTIONS 1. Perform all Pre-Start checks outlined (Fig. 33) 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. Pre-heating: In temperatures below 32° F it may be necessary to use the glow plugs. The glow plug indicator will glow red while the glow plugs are activated. 5. Activate the glow plugs for at least 30 sec-onds or for as long as 3 minutes depending on the outside temperature. 6. After the glow plugs have been activated immediately turn the key to the "start" posi-tion. Any delay will allow the glow plugs to cool making them much less affective.

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. 33

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

GENERAL OPERATION

CAUTION The engine should be brought back to an idle and run for at least 2 minutes be-fore shutting off. This will allow hot engine parts to cool.

POSI-TRACK 2800 & 2810

PAGE 27 ASV, INC.

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 Proper track tension plays an important part in the over-all performance of the POSI-TRACK. A track run too loose can cause premature track failure and cause the track to derail. Al-though track tension is set properly at the fac-tory, the tracks will need an adjustment after break-in. Once the KevlarTM and other special materials in the track are pulled straight, mini-mal adjustment will be required. The break-in period 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 are easy to tighten. It takes only a few minutes and will be well worth the time (See page 35 for track tensioning procedure.) After the initial track break-in, the tracks may not need to be tight-ened for several hundred hours, however, the tracks should be inspected daily and tight-ened 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

POSI-TRACK 2800 & 2810

PAGE 28 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. During the break-in period set the engine at 2400 rpm. Brief periods of full throttle operation and variations in engine load also contribute to good engine break-in. 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. 34) 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 36 for proper planetary oil changing proce-dure.)

Fig. 34

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

POSI-TRACK 2800 & 2810

PAGE 29 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 100 hours Refer to page 31 Engine fuel filter 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 13 gallons Diesel Hydraulic oil 28 gallons Amoco Rykon MV Planetary oil 1 quart SAE 80w-90 gear lube Wheel tube oil 1 pint SAE 80w-90 gear lube Engine coolant 2.3 gallons Isuzu approved Engine oil 6.8 quarts See chart below Engine oil viscosity chart.

GENERAL MAINTENANCE

POSI-TRACK 2800 & 2810

PAGE 30 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. 35) 2. Both ends of the lift cylinders. (Fig. 36, 37) 3. Both ends of the quick-attach cylinders. (Fig. 38, 39) 4. Hinge points for the quick-attach. (Fig. 40)

GENERAL MAINTENANCE

Fig. 36

Fig. 37

Fig. 38

Fig. 39

Fig. 40

Fig. 35

POSI-TRACK 2800 & 2810

PAGE 31 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. 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. 41)

GENERAL MAINTENANCE

Fig. 41

POSI-TRACK 2800 & 2810

PAGE 32 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. (6.8 quarts) 7. Run engine to check for possible leaks. 8. Stop engine for 10 minutes and recheck oil level. Oil level should be within the crosshatch of the dipstick.

GENERAL MAINTENANCE

Fig. 42

Fig. 43

A

B

POSI-TRACK 2800 & 2810

PAGE 33 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 on a manifold under the engine hood. (Fig. 45) 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 which must be re-placed. DO NOT REPLACE THE CANISTER ITSELF.

Fig. 44

A

GENERAL MAINTENANCE

Fig. 45

POSI-TRACK 2800 & 2810

PAGE 34 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. (A) (2810, Fig. 46) (2800, Fig. 47) 2. Unscrew primer on the 2800 until the primer pops up. It is not necessary to unscrew the primer on the 2810. Pump the primer until fuel flowing out the vent is free of air bubbles. (B) (2810, Fig. 46) (2800, Fig. 48) 3. Tighten bleed screw securely, screw the primer on the 2800 back in until it is secure. 4. Start engine and check for leaks.

GENERAL MAINTENANCE

A

B

B

A Fig. 46

Fig. 47

Fig. 48

POSI-TRACK 2800 & 2810

PAGE 35 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. 49) 2. Loosen (DO NOT REMOVE) the bolts in the slots which allow the sprocket mount to slide. (Fig. 50) 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. 51) 5. Rotate the screw jack with the wrench until the track has zero sag between the drive sprocket and the top carrier wheels. (Fig. 52) 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. 49

Fig. 50

Fig. 51

Fig. 52

GENERAL MAINTENANCE

POSI-TRACK 2800 & 2810

PAGE 36 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, there is a kit which will make chang-ing the planetary oil easier. This kit includes 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. 53) 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. 54)

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. 53

Fig. 54

GENERAL MAINTENANCE

POSI-TRACK 2800 & 2810

PAGE 37 ASV, INC.

3. Remove the top plug to vent the case and al-low the oil to drain. (Fig. 55) 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. 56)

Fig. 55

Fig. 56

GENERAL MAINTENANCE

POSI-TRACK 2800 & 2810

PAGE 38 ASV, INC.

RADIATOR AND OIL COOLER The 2800 and 2810 use a "pusher" fan which pull air in through the sides of the engine hood and pushes it through the coolers and the lou-vered grill (Fig. 57). This system allows the air to be "filtered" through the hood's screening be-fore it reaches the coolers. This also keeps hot air and dust off the operator. Depending on the conditions the coolers will most likely need to be cleaned at some point. Since any debris will collect on the engine side of the coolers the de-bris must be cleaned by forcing the debris off from the other side of the coolers. Air or water under pressure works best for thorough clean-ing. 1. Open the hood by undoing the 2 rubber

bungie cords, which secure the hood to the frame. 2. Undo the two clasps (A) that holds the lou-vered grill shut. (Fig. 58) 3. Swing the grill away from the engine. (Fig. 59) 4. The coolers are now totally accessible for cleaning.

!WARNING! Always shut the vehicle off before cleaning the radiator and oil cooler.

GENERAL MAINTENANCE

Fig. 57

Fig. 58

Fig. 59

A

POSI-TRACK 2800 & 2810

PAGE 39 ASV, INC.

CHANGING THE AIR FILTER 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 opened, loosen the clamp (A) on the end of the air cleaner until the cover can be removed. (Fig. 60) 2. Loosen the wing nut (B), holding the filter in and remove the element. (Fig. 61 & 62)

BATTERY The Battery is located behind a removable fiber-glass fire wall between the engine and the op-erators compartment. (Fig. 63) The battery re-quires minimal maintenance to operate at its peak performance. 1. Ensure the cables and posts are free from corrosion at all times. 2. Make sure the cables are tight on the posts and that the battery is secured properly. 3. Always maintain the battery at full charge.

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

GENERAL MAINTENANCE

A

Fig. 60

B

Fig. 61

Fig. 62

Fig. 63

POSI-TRACK 2800 & 2810

PAGE 40 ASV, INC.

CHANGING THE FUEL FILTER The fuel filter should be changed every 500 hours or as needed. Both the 2800 (A) and the 2810 (B) have spin on fuel filters, however they do not have the same filter. 1. Clean filter area thoroughly before removing the filter. 2.. Using a filter wrench remove the filter slowly and catch any spilled fuel with a rag. 3. Install new filter element onto base, and bleed the fuel system.

FILTER PRE-SCREEN (2800 only) Another main cause of poor engine perform-ance is a plugged pre-screen. This small item is often overlooked and is often the culprit. 1. Remove the banjo nut underneath the fuel primer with 17mm wrench (C). There are two rubber washers on the banjo nut, one on top and one below the banjo nut. Be extra careful not to lose these rubber washers, the engine will not run without them. 2. Remove the white plastic screen (D) and clean thoroughly. Reinstall making sure both rubber washers are in place.

A

B

GENERAL MAINTENANCE

Fig. 64

Fig. 65 NOTE A plugged or partially plugged fuel filter can cause loss of engine power, erratic engine rpm, and poor starting.

A

B

C

D

Fig. 66

Fig. 67

POSI-TRACK 2800 & 2810

PAGE 41 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 ( PN # 455-3445) 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

POSI-TRACK 2800 & 2810

PAGE 42 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

POSI-TRACK 2800 & 2810

PAGE 43 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

POSI-TRACK 2800 & 2810

PAGE 44 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

POSI-TRACK 2800 & 2810

PAGE 45 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

POSI-TRACK 2800 & 2810

PAGE 46 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

POSI-TRACK 2800 & 2810

PAGE 47 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

POSI-TRACK 2800 & 2810

PAGE 48 ASV, INC.

HIGH & LOW FLOW AUXILIARY HYDRAULIC CIRCUIT

APPENDIX 1

POSI-TRACK 2800 & 2810

PAGE 49 ASV, INC.

PROBLEM CAUSE REMEDY Vehicle won’t 1. Battery cables loose 1. Tighten or clean cables turn over or corroded. 2. Drive levers 2. Put levers in neutral 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 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. Contact dealer Under heavy load 1. Tracks have broken 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

POSI-TRACK 2800 & 2810

PAGE 50 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 48 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. Contact dealer is set too low. Loader doesn’t 1. Auxiliary hydraulic pressure 1. Contact dealer lift proper weight is set too low 2. Weight is too far out from 2. Bring load in closer vehicle or reduce load 3. Auxiliary lever is engaged 3. Put lever in neutral

TROUBLE SHOOTING (GENERAL)

POSI-TRACK 2800 & 2810

PAGE 51 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. Contact Dealer 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

TROUBLE SHOOTING (GENERAL)

POSI-TRACK 2800 & 2810

PAGE 52 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, gauge or 5. Replace wiring After running out of 1. Fuel system has not been bled 1. Refer to page 34 fuel and refueling, engine will not start

TROUBLE SHOOTING (GENERAL)

POSI-TRACK 2800 & 2810

PAGE 53 ASV, INC.

TROUBLE SHOOTING (ELECTRICAL)

POSI-TRACK 2800 & 2810

PAGE 54 ASV, INC.

TROUBLE SHOOTING (ELECTRICAL)

POSI-TRACK 2800 & 2810

PAGE 55 ASV, INC.

TROUBLE SHOOTING (ELECTRICAL)

POSI-TRACK 2800 & 2810

PAGE 56 ASV, INC.

TROUBLE SHOOTING (ELECTRICAL)

POSI-TRACK 2800 & 2810

PAGE 57 ASV, INC.

TROUBLE SHOOTING (ELECTRICAL)

POSI-TRACK 2800 & 2810

PAGE 58 ASV, INC.

TROUBLE SHOOTING (ELECTRICAL)

POSI-TRACK 2800 & 2810

PAGE 59 ASV, INC.

DATE DATE DATE DATE DATE ITEM HOURS HOURS HOURS HOURS HOURS

MAINTENANCE & SERVICE

POSI-TRACK 2800 & 2810

PAGE 60 ASV, INC.

DATE DATE DATE DATE DATE ITEM HOURS HOURS HOURS HOURS HOURS

MAINTENANCE & SERVICE

POSI-TRACK 2800 & 2810

PAGE 61 ASV, INC.

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NOTES

POSI-TRACK 2800 & 2810

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NOTES

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POSI-TRACK 2800 & 2810

PAGE 63 ASV, INC.

NOTES

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