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Camoplast Tatou UTV T4S, User Manual, Page: 3 / 88

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Camoplast Tatou UTV T4S User Manual Download Page 3

TABLE OF CONTENTS

INTRODUCTION   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1

SAFETY   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3

HINTS AND TIPS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3

USER NOTICE AND DISCLAIMER  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4

USING THE ATV WITH TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6

INSTALLATION, REMOVAL AND RE-INSTALLATION . . . . . . . . . . . . . . . . . . .  16

ADJUSTMENTS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20

INSTALLATION OF A RUBBER TRACK   . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  37

BREAK-IN PERIOD   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  39

REPLACEMENT OF A WHEEL WITH EXTRACTOR   . . . . . . . . . . . . . . . . . . .  40

TENSIONER ALIGNMENT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  42

MAINTENANCE SCHEDULE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  46

LUBRICATION   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  49

STORAGE   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  64

WEAR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  65

2-YEAR LIMITED WARRANTY   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70

TROUBLESHOOTING  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  73

SERIAL NUMBER LOCATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  74

TECHNICAL SUPPORT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  75

’’CE’’ DECLARATION OF CONFORMITY   . . . . . . . . . . . . . . . . . . . . . . . . . . . .  76

PARTS LIST  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  783

Summary of Contents for Tatou UTV T4S

Page 1: ......

Page 2: ...vered under normal warranty It is the user s responsibility to abide by these terms of use IMPORTANT Please read carefully each part of this document as well as model specific Installation Guidelines...

Page 3: ...AL AND RE INSTALLATION 16 ADJUSTMENTS 20 INSTALLATION OF A RUBBER TRACK 37 BREAK IN PERIOD 39 REPLACEMENT OF A WHEEL WITH EXTRACTOR 40 TENSIONER ALIGNMENT 42 MAINTENANCE SCHEDULE 46 LUBRICATION 49 STO...

Page 4: ...referred to as the UTV provides exceptional floatation with very low ground pressure Its strong lightweight steel frame its internal sprockets adapted to the vehicle s capacity and its track specific...

Page 5: ...y tranferred to a new user the User Manual must also be transferred to the new user MOVING PARTS Hands or fingers caught between moving parts of the equipment present a danger to life or limb Turn mot...

Page 6: ...s UTV track systems are designed to reduce ground pressure and increase vehicle traction However during normal operating conditions vehicle speed will be reduced compared to a wheeled vehicle HINTS AN...

Page 7: ...ng an UTV with the particularities of this type of System The UTV driver must at all times respect all applicable laws and regulations the indications of the System manufacturer and the indications fr...

Page 8: ...e crosses obstacles circulates through narrow paths meets vehicles coming in the opposing direction etc As it was designed the System will considerably reduce the UTV top speed and can falsify the spe...

Page 9: ...and serious malfunctions that could affect the occupants the vehicle or the track systems from occurring NOTE Non compliance with usage recommendations can lead to a warranty claim refusal Pre use ver...

Page 10: ...This can lead to a serious malfunction of the UTV s steering system and track systems During a steep descent it is advisable to keep the handlebar in a forward direction and to begin turning when the...

Page 11: ...verse to ease it from its position as this could lead to a malfunction of the systems If possible move it in the forward direction to free it from the snow It is advisable to remove the snow from the...

Page 12: ...ITH TRACKS Towing a vehicle out of the snow WARNING If your vehicle must be towed out of the snow never tow it in the direction in which it sank Tow the vehicle in the direction of the trail it left a...

Page 13: ...ep ridge WARNING It is not advisable to attempt to drive over an obstacle such a tree trunk a big rock or a steep ridge that could lodge itself between the front and the rear track systems and immobil...

Page 14: ...nti rotation stroke on rough terrain WARNING Never exceed anti rotation stroke of the front and rear track systems system or vehicle faillure may occur It is recommended to drive on a surface on which...

Page 15: ...nches WARNING It is not advisable to attempt to drive over an obstacle of more than 12 inches such a tree trunk a stump or a big rock If the situation appears inserted a log or a pebble to decrease th...

Page 16: ...ead Location of the towing cable WARNING Never do sharp turns in locked diffential 4x4 mode on a sticky terrain without lubrication The track system is designed to slip into the drive system keeping t...

Page 17: ...following activities races rallies jumps stunts acrobatics or any other extreme applications WARNING Never exceed vehicle cargo and tow capacity specified by your vehicle manufacturer on any type of...

Page 18: ...elling in groups people driving behind vehicles equipped with a track system should by warned as the tracks can propel dangerous objects Be especially cautious on rocky trails WARNING Adapt your drivi...

Page 19: ...ded with the System for installation instructions dedicated to your UTV model When the system is removed and when the wheels are reinstalled on vehicle make sure that you reinstall all the components...

Page 20: ...ed to suspension arms or anti rotation bars attached to the skid plate when the UTV rides on wheels he can result from it grave damages in the vehicle Never leave components other than the skid plate...

Page 21: ...ack system NOTE Leave anchor bracket attached to the stabilizing rod Figure 1 Remove track systems Re install wheels At the rear on an independent suspension Same procedure as the front At the rear on...

Page 22: ...l hubs Re install track systems at the rear and secure stabilizing rod to anchor bracket for rigid axle Re install track systems at the front Tighten the fasteners in an alternate crosswise pattern to...

Page 23: ...k on front tracks systems perform the following Loosen the nut 1 compressing the spring of the stabilizing rod refer to Figure 3 Figure 3 IMPORTANT Verifying your adjustments on the system is mandator...

Page 24: ...nd Install a flat bar on rear wheels of the track systems and measure the height as shown on Figure 4 Figure 4 Set the nut 2 shown on Figure 5 until the flat bar reaches 315 5 mm above the ground For...

Page 25: ...22 ADJUSTMENTS Figure 5 Turn the nut 1 until it comes in contact with the spring then compress the spring by turning this nut 1 5 turns refer to Figure 6 Figure 6...

Page 26: ...7 Basic Tuning front track systems An adjustment of more than 315 mm measured with the flat bar gives easier steering with wobbling effect at high speed An adjustment of less than 315 mm measured wit...

Page 27: ...ion Loosen the nut 1 compressing the spring of the stabilizing rod see Figure 8 Set the nut 2 to obtain a distance of 15 20 mm as shown Turn the nut 1 until it comes in contact with the spring then co...

Page 28: ...at the anti rotation retainer 4 to rotate in the axe See Figure 9 Figure 9 Attach the stabilizing rod 1 to anti rotation bracket installed on the suspension a arm See Figure 10 Loosen the nut 2 compr...

Page 29: ...d The nut does not apply pressure on the rubber cone refer to Figure 11 Figure 11 Position the anti rotation retainer at 90o perpendicular with the stabilizing rod Tightened the two fixation bolts 1 a...

Page 30: ...not apply pressure on rubber cone See Figure 13 Figure 13 Turn the nut 2 until it comes in contact with the spring Then compress the spring by turning the nut completely twice See Figure 14 Figure 14...

Page 31: ...Basic tuning rear track systems More gap at the rubber bushing gives better obstacle climb and flotation capacity on powder snow while moving forward Compressing the rubber bushing gives better obstac...

Page 32: ...e then drive forward again on about 3 meters 10 ft NOTE Verify the condition of the components of the steering system before adjusting the parallelism Components damaged can prevent a proper ajustment...

Page 33: ...qual number of revolutions on the both sides of the vehicle See Figure 17 CAUTION During the unscrewing of the nut 1 of each coupling rod of the vehicle s direction system 2 remember that certain nuts...

Page 34: ...the distance which separates the external plastic wheels of the front axle on the front track systems See Figure 18 and Figure 19 Figure 18 Distance between the front plastic wheels Figure 19 Distance...

Page 35: ...the distance which separates the external plastic wheels of the rear axle on the front track systems See Figure 20 and Figure 21 Figure 20 Distance between the rear plastic wheels Figure 21 Distance...

Page 36: ...RNING The tensioner mounting bolt must never be loosened while adjusting the track tension This bolt is designed for assembly and alignment of the tensioner with the frame The tensioner must always be...

Page 37: ...ension by turning the adjusting nuts item 1 on Figure 22 of the track tensioner Figure 22 NOTE The two nuts are tightened together to set the tension adjustment Loosen the jam nut and then raise or lo...

Page 38: ...he conditions of use NOTE Tool 1 used in Figure 24 and shown below in Figure 23 can be bought through an authorized Camoplast Hi Performance Tracks dealer The brand is Gates Corporation and the Camopl...

Page 39: ...racking and reduces drive ratcheting for severe use only A lower rubber track tension provides better performance better rolling and better fuel economy recreational use Final check Ride at slow speed...

Page 40: ...ice Turn off the engine Proceed as follows Set rubber track tension to the minimum refer to Figure 25 Figure 25 WARNING The tensioner mounting bolt must never be loosened while adjusting the track ten...

Page 41: ...heels opposite to the track tensioner side refer to Figure 26 Figure 26 Install the rubber track NOTE Compare with the other rubber tracks to find the correct orientation Re install 255 mm wheels Adju...

Page 42: ...arp turns at very low speed 10 km h maximum real speed A GOOD break in period must be done in a lubricated environment such as water mud snow soft soil sand dust etc A BAD break in period can generate...

Page 43: ...or 2000 00 1050 and the following procedure to make the replacement Figure 27 Remove the rubber cap of the wheel If the wheel is retaining by a bolt unscrew it and remove the wheel If there is no bolt...

Page 44: ...heel as shown on Figure 28 Then screw the threaded rod to remove the wheel Figure 28 Hit the end of the threaded rod to shake the wheel loose Check to see if the rod needs tightening Repeat until whee...

Page 45: ...ng procedure Attach the alignment tool to system frame using the provided tie wraps Refer to Figure 29 Figure 29 WARNING Incorrect alignment of the tensioner will recreate the conditions that lead to...

Page 46: ...shaft ends in the corners of the tool notches Attach alignment tool to the track system frame using the provided tie wraps Refer to Figure 30 Figure 30 WARNING Make sure that the wheel shaft ends are...

Page 47: ...eated on the alignment tool surfaces pivot the tensioner to adjust the position Refer to Figure 31 Figure 31 WARNING Make sure the wheel shaft ends are well seated on all 4 surfaces of the alignment t...

Page 48: ...45 TENSIONER ALIGNMENT Torque tensioner nut to 33 N m Refer to Figure 32 Figure 32 Remove the alignment tool from the track system frame...

Page 49: ...optimum performance and maximum durability please refer to the maintenance grid on the following page WARNING Do not insert hands nor feet into or near the system unless the engine is off and the veh...

Page 50: ...ON 4 A I A I A TRACK WEAR I WHEEL LATERAL WEAR 4 I I I I R WHEEL BEARING 5 1 I L I L I L R FRAME TRACK GUIDE WEAR 1 I I R FRAME HUB BEARINGS 1 I R FRAME STABILIZERS 1 I L I L I L R FRAME CRACKS I ANTI...

Page 51: ...hafts and wheel bearing seals CAUTION Hub bearings should be checked every 50 hours of use and if necessary replaced Bearings that make noise and restrict rotation of hub are indications that they mus...

Page 52: ...49 LUBRICATION LUBRICATION I H G B A L K C E F D...

Page 53: ...50 LUBRICATION LUBRICATION J M...

Page 54: ...Refer to the following recommendations for optimal lubrication NOTE Use a water resistant anti friction synthetic grease Aerochem MF grease is recommended REFERENCE A 132MM WHEEL BEARING SEAL LUBRICAT...

Page 55: ...52 LUBRICATION REFERENCE B 255MM TIRE BEARING SEAL LUBRICATION Apply evenly 1 to 1 5 CC cubic centimeter of grease on and between the tire bearing seal lips Apply over the entire circumference 360...

Page 56: ...TION REFERENCE C WHEEL SHAFT AND SEAL BEARING DIAMETER LUBRICATION Apply evenly 1 to 1 5 CC cubic centimeter of grease on the wheel shaft and seal bearing diameter over their entire circumference 360...

Page 57: ...LS LUBRICATION Apply evenly 1 5 to 2 CC cubic centimeter of grease between the hub seal s lips and over its the entire circumference 360 IMPORTANT the hub seal must not extend beyond the hub face It s...

Page 58: ...55 LUBRICATION REFERENCE E LUBRICATION OF THE HUB SPEED SLEEVE Apply 1 to 1 5 CC cubic centimeter of grease over the entire width and circumference 360 of the hub speed sleeve...

Page 59: ...360 and to a depth of about 12 to 15 cm 5 to 6 in IMPORTANT Application of lubricant inside the frame tubing is performed to prevent corrosion inside the tube which can cause the tensioner tail to mo...

Page 60: ...57 LUBRICATION REFERENCE G STABILIZER SHAFT LUBRICATION Apply evenly 1 to 1 5 cc cubic centimeter of grease all around 360 the stabilizer shaft and over its entire length...

Page 61: ...58 LUBRICATION REFERENCE H STABILIZER SHAFT BORE LUBRICATION Apply evenly 1 to 1 5 cc cubic centimeter of grease inside the stabilizer shaft bore over its entire length and circumference 360...

Page 62: ...9 LUBRICATION REFERENCE I STABILIZER MOUNTING BOLT HEAD LUBRICATION Apply evenly 0 75 to 1 5 cc cubic centimeter of grease on the stabillizer mounting bolt head Apply over the entire circumference 360...

Page 63: ...BUSHING LUBRICATION RIGID SUSPENSION ARM On vehicles with rigid rear suspension apply evenly 0 5 to 1 CC cubic centimeter of grease on the inner o ring of the rigid suspension arm bushing Apply over t...

Page 64: ...61 LUBRICATION REFERENCE K FRONT TRACK SYSTEM STABILIZING ARM LUBRICATION Apply spray lubricant e g motorcycle chain grease all around the stabilizing arm compression spring and over its entire length...

Page 65: ...ION REFERENCE L REAR TRACK SYSTEM STABILIZING ARM LUBRICATION INDEPENDENT SUSPENSION Apply spray lubricant e g motorcycle chain grease all around the stabilizing arm compression spring and over its en...

Page 66: ...ION REFERENCE M REAR TRACK SYSTEM STABILIZING ARM LUBRICATION RIGID AXLE SUSPENSION Apply spray lubricant e g motorcycle chain grease all around the stabilizing arm compression spring and over its ent...

Page 67: ...ts on the track system NOTE Use a threadlocker Loctite 263 type or its equivalent at the indicated places in the explode view of the system in this manual STORAGE The best way to store the System is t...

Page 68: ...erior guidance strip Figure 34 The wheel must be replaced if the inner surface 1 is perforated or when the thickness of the wheel rolling band reaches a thickness of 45 mm A wheel that is excessively...

Page 69: ...rofiles A wheel that is excessively worn will not offer enough support for the track s guidance Refer to Figure 35 Figure 35 Track Verify the wear of the track by inspecting the rolling path the drivi...

Page 70: ...ensions of the guide illustrated in Figure 36 are lower than 5 mm at any place replace the part If the guidance strip is worn so that the concave shape is no longer visible replace the part An overly...

Page 71: ...sprocket by measuring the part as illustrated on Figure 37 Replace the part when the dimension shown is less than 19 mm An excessive wear could lower the efficiency of the drive of the track and redu...

Page 72: ...rotation Verify the wear of anti rotation system mainly at the ball joint Figure 38 to make sure that it is not seized or extremely loose Ball joint damage could harm the performance of the track syst...

Page 73: ...m is not installed by an authorized Camoplast Hi Performance Tracks network dealer or distributor This warranty specifically excludes any damage or breakage to the UTV and related defects on the UTV w...

Page 74: ...comply with those described by the manufacturer will render the warranty null and void Any repaired or replaced components or parts are guaranteed only to the extent of the original warranty in other...

Page 75: ...he System to the dealer location are the responsibility of the System owner Camoplast Hi Performance Tracks reserves its sole and exclusive right to update or modify this warranty without impact on en...

Page 76: ...system Correct the system alignment Refer to the Adjustments section of the manual Wheel blocked Try to free the wheel and replace if necessary Constant turn Vary your turning radius and seek areas w...

Page 77: ...74 SERIAL NUMBER LOCATION SERIAL NUMBER LOCATION The following pictures show the location of the serial numbers on the track system frame Figure 39 and rubber track Figure 40 Figure 39 Figure 40...

Page 78: ...olve a problem related with the System you may contact the Camoplast Hi Performance Tracks support team from Monday to Friday Camoplast Solideal Inc 4162 Burrill Local A Shawinigan Qu bec G9N 0C3 CANA...

Page 79: ...879 7UDFN 6 VWHPV 86720 5 IS IN CONFORMITY WITH THE FOLLOWING STANDARDS 180 5 7 7 7 1 3UHSDUDWLRQ RI QVWUXFWLRQ 1 6DIHW RI 0DFKLQHU 1 RQIRUPLW VVHVVPHQW AND IN CONFORMITY WITH THE FOLLOWING EC DIRECT...

Page 80: ...This page is left intentionally blank...

Page 81: ...18 15 G 8 45 E 13 22 21 23 14 49 38 TORQUE 125 N m THREAD LOCKER 43 TORQUE 70 N m THREAD LOCKER 30 12 40 41 5 3 6 4 2 35 27 7 28 34 9 46 44 47 TORQUE 30 N m THREAD LOCKER TORQUE 125 N m THREAD LOCKER...

Page 82: ...EX SCR BOUL HEX DENTEL HFSCS M10 1 5X30 10 9 ZP TL DIN 6921 4 29 1036 12 4030 HEX FLG SCR BOUL HEX EMBASE HFSCS M12 1 75X30 10 9 ZP TL DIN 6921 1 30 1042 00 0001 COTTER PIN GOUPILLE 1 8 1 3 4 ZP 1 31...

Page 83: ...m THREAD LOCKER TORQUE 125 N m THREAD LOCKER 28 TORQUE 125 N m THREAD LOCKER 29 38 18 5 2 7 21 6 4 22 3 25 20 19 11 1 13 30 31 27 8 36 43 44 41 46 42 40 12 10 23 37 TORQUE 30 N m THREAD LOCKER 39 45...

Page 84: ...1019 77 0031 MULTI HUB MODEL ASS Y METRIC ESSIEU MULTI MOD LE ASS M TRIQUE 1 23 1024 00 1255 WHEEL 4 10 3 50 6 ASSY ROUE 4 10 3 50 6 ASSEMBL 4 24 1033 10 2026 HEX SCR W WASH VIS HEX A ROND HCSW M10 1...

Page 85: ...82 9 14 3 15 4 11 7 TORQUE 70 N m THREAD LOCKER TORQUE 50 N m THREAD LOCKER 16 12 1 2 13 6 11 8 10 5...

Page 86: ...BOULON LONG BRAS STABILISATEUR 1 7 1036 10 4030 HEX BOLT BOULON HEX HFSCS M10 1 5X30 10 9 ZP TL DIN 6921 2 8 1047 00 7010 ROD END M12 1 25 TIGE IL M12 1 25 1 9 1050 00 0013 ROD END SPACER ESPACEUR PO...

Page 87: ...84 3 TORQUE 50 N m THREAD LOCKER 1 6 7 4 5 2 TORQUE 125 N m THREAD LOCKER 8...

Page 88: ...ION UTV DROIT ER 1 3 1035 12 A050 HEX SCR FLANGE VIS HEX REBORD HFCS M10 1 5X30 8 8 ZP DIN6921 1 4 1036 10 4030 HEX BOLT BOULON HEX HFSCS M10 1 5X30 10 9 ZP TL DIN 6921 2 5 1050 00 8000 BUSHING ANTI R...

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