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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

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Summary of Contents for 2810

Page 1: ...anual 2810 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 ...

Page 2: ...not warranted against normal use C The CATERPILLAR Engine is separate from ASV INC S WARRANTY and is described in the CATERPILLAR Warranty Information D The ISUZU engine warranty is separate from ASV INC s WARRANTY The ISUZU engine warranty is described in the ISUZU Warranty Information ASV INC reserves the right to inspect the equipment prior to any decision involving a war ranty claim In no case...

Page 3: ...ing 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 ...

Page 4: ... 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...

Page 5: ...UTION 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 ve...

Page 6: ...0 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 reinf...

Page 7: ...SMISSION 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 ga...

Page 8: ...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...

Page 9: ... 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...

Page 10: ...cle 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 ...

Page 11: ... 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 Con...

Page 12: ...hat 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 ti...

Page 13: ...ition 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 chargin...

Page 14: ...nd 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 contr...

Page 15: ...o 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 rev...

Page 16: ...rator 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 hy...

Page 17: ... 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 ...

Page 18: ... 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 pane...

Page 19: ...ck 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...

Page 20: ...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 ...

Page 21: ...r 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...

Page 22: ...e 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...

Page 23: ...K 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 cyl...

Page 24: ...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 ...

Page 25: ... 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...

Page 26: ...ed 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 Ch...

Page 27: ...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 tight...

Page 28: ...ich 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 pl...

Page 29: ...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 Engi...

Page 30: ...sed 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 ...

Page 31: ...ther 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 ...

Page 32: ...h 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 to 1 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 le...

Page 33: ...are 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 disposab...

Page 34: ...crew 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...

Page 35: ...9 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...

Page 36: ...re 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 prepar...

Page 37: ...se 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 ...

Page 38: ... 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...

Page 39: ...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 Al...

Page 40: ... 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...

Page 41: ...k 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 b...

Page 42: ...r 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 ...

Page 43: ...ler 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 an...

Page 44: ... 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 SER...

Page 45: ...oor 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 ...

Page 46: ...lting the wheel hub that secures the wheels to the tube The outside wheel hubs are slid off the shaft and the wheel can then be removed easily END TUBE REMOVAL The end wheel tubes are extremely easy to re move There are 4 bolts that fasten the shaft to the undercarriage frame Remove 4 bolts and the tube will slide off the end of the frame Fig 85 A Fig 84 Fig 85 SERVICE ...

Page 47: ...e 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...

Page 48: ...POSI TRACK 2800 2810 PAGE 48 ASV INC HIGH LOW FLOW AUXILIARY HYDRAULIC CIRCUIT APPENDIX 1 ...

Page 49: ...ilter 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 ...

Page 50: ...zed 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 ap...

Page 51: ... 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...

Page 52: ...bris 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 ...

Page 53: ...POSI TRACK 2800 2810 PAGE 53 ASV INC TROUBLE SHOOTING ELECTRICAL ...

Page 54: ...POSI TRACK 2800 2810 PAGE 54 ASV INC TROUBLE SHOOTING ELECTRICAL ...

Page 55: ...POSI TRACK 2800 2810 PAGE 55 ASV INC TROUBLE SHOOTING ELECTRICAL ...

Page 56: ...POSI TRACK 2800 2810 PAGE 56 ASV INC TROUBLE SHOOTING ELECTRICAL ...

Page 57: ...POSI TRACK 2800 2810 PAGE 57 ASV INC TROUBLE SHOOTING ELECTRICAL ...

Page 58: ...POSI TRACK 2800 2810 PAGE 58 ASV INC TROUBLE SHOOTING ELECTRICAL ...

Page 59: ...POSI TRACK 2800 2810 PAGE 59 ASV INC DATE DATE DATE DATE DATE ITEM HOURS HOURS HOURS HOURS HOURS MAINTENANCE SERVICE ...

Page 60: ...POSI TRACK 2800 2810 PAGE 60 ASV INC DATE DATE DATE DATE DATE ITEM HOURS HOURS HOURS HOURS HOURS MAINTENANCE SERVICE ...

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