8/17/2016

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4810
Operation and Maintenance
Manual

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POSI-TRACK 4810
WARRANTY

1 YEAR, UNLIMITED HOUR WARRANTY

he WARRANTY herein set forth applies solely to the POSI-TRACK 4810 manufactured by ASV, INC. and is in lieu of all other warranties, expressed or implied.
No person, agent, or dealer is authorized or empowered to give any other warranty
or to assume any other liability on behalf of ASV, INC. The WARRANTY is
limited to the original purchaser only. No warranty is transferable to any subsequent owner.
ASV, INC. warrants the POSI-TRACK 4810 against defects in material and workmanship
under normal use and service for a period of ONE YEAR with unlimited hours, from the
date of delivery, and will repair or replace any part that our examination reveals to be defective in material or workmanship. The WARRANTY does not include transportation costs,
clean up, or consequential damages.
(A)

Only Original Equipment Manufacture parts are covered by this WARRANTY.

(B)

Wear Items are not warranted against normal use.

(C)

The Caterpillar Engine is separate from ASV, INC.s WARRANTY.

ASV, INC. reserves the right to inspect the equipment prior to any decision involving a warranty claim. In no case shall ASV, INC. grant a remedy that exceeds the purchase price of
the component or part.
ASV, INC. reserves the right to make design changes without incurring any obligation to
make such changes to previously manufactured equipment. This WARRANTY does not apply to damage caused by misuse, abuse, neglect, or improper adjustment, accident, or improper application. Any repairs or alterations made to the equipment without authorization
from ASV, INC. will void this WARRANTY.
NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY ASV, INC.
EXPRESSED OR IMPLIED, STATUTORY, BY OPERATION OR LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. ASV, INC. DISCLAIMS LIABILITY FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND.

ASV, INC.

PAGE 2

POSI-TRACK 4810
WARRANTY LIMITATIONS
GROSS VEHICLE WEIGHT
The GVW (Gross Vehicle Weight) of the POSI-TRACK 4810 should not exceed 12,500 lbs.
This weight includes any accessories, attachments, or material being carried. Exceeding the
12,500 lb. GVW will void the WARRANTY.
MODIFICATIONS
Any modifications made to the vehicle can affect the WARRANTY. Before any modifications
are made, have your dealer contact ASV, INC. for written approval. Modifications include, but
are not limited to: additional hydraulic plumbing, alternative attachment mounting, welding to
the frame or roll cage, welding to the undercarriage, track modification, etc.
ATTACHMENTS
Attachment use can also affect the WARRANTY. The attachment should be sized correctly
for the vehicles operating capacity and hydraulic system. An attachment that cannot accept
the machines hydraulic flow and pressure can create extreme heat and cause failures to the vehicles hydraulic system. An attachment which is oversized for the vehicles carrying capacity, can cause premature failure to the vehicles mounting system, frame, undercarriage, axles,
bearings, etc. When determining the weight of the attachment the following items must be
considered: the distance the mounted attachment is extended from the vehicle and the weight
of the attachments load. Refer to page 19 for operating capacity limits.

ASV, INC.

PAGE 3

POSI-TRACK 4810
TABLE OF CONTENTS
WARRANTY ......................................................................................................................................................................................2
WARRANTY LIMITATIONS ............................................................................................................................................................3
FOREWORD.......................................................................................................................................................................................5

SECTION 1 - SPECIFICATIONS
GENERAL ..........................................................................................................................................................................................6
ENGINE ..............................................................................................................................................................................................6
TRACKS .............................................................................................................................................................................................6
FINAL DRIVE ....................................................................................................................................................................................7
CAPACITIES ......................................................................................................................................................................................7
LOADER ASSEMBLY .......................................................................................................................................................................8
ELECTRICAL .....................................................................................................................................................................................8
SECTION 2 GENERAL SAFETY .................................................................................................................................9,10

SECTION 3 GENERAL OPERATION

MAIN CONTROL CONSOLE DEFINITIONS ..................................................................................................................................11
ELECTRICAL CONSOLE DEFINITIONS ........................................................................................................................................12,13
OPERATING INSTRUCTIONS .........................................................................................................................................................14,15
HYDROSTATIC DRIVE ....................................................................................................................................................................16
LOADER VALVE CONTROL ...........................................................................................................................................................17
LOADER LOCK OUTS ......................................................................................................................................................................17,18
OPERATING CAPACITY ..................................................................................................................................................................19
MOVING DIRT ..................................................................................................................................................................................20
SIDE HILLING ...................................................................................................................................................................................21
PRE START CHECK LIST ................................................................................................................................................................22
STARTING INSTRUCTIONS ............................................................................................................................................................22
SHUTTING ENGINE OFF ................................................................................................................................................................22

SECTION 4 GENERAL MAINTENANCE

BREAK IN PROCEDURES................................................................................................................................................................23,24
MAINTENANCE SCHEDULE ..........................................................................................................................................................25
GREASE POINTS ...............................................................................................................................................................................26
ENGINE OIL AND FILTER CHANGE .............................................................................................................................................27
HYDRAULIC OIL AND FILTER CHANGE .....................................................................................................................................28
PRIMING THE FUEL SYSTEM ........................................................................................................................................................29
TRACK TENSION..............................................................................................................................................................................30
PLANETARY OIL CHANGE ............................................................................................................................................................31,32
RADIATOR AND OIL COOLER .......................................................................................................................................................33
AIR CLEANER ...................................................................................................................................................................................34
CHANGING FUEL FILTER ...............................................................................................................................................................35

SECTION 5 SERVICE
TRACK REMOVAL ...........................................................................................................................................................................36,37
TRACK INSTALLATION ..................................................................................................................................................................38,39
BOGIE CARRIAGE REMOVAL .......................................................................................................................................................40
WHEEL TUBE REMOVAL ...............................................................................................................................................................40
WHEEL REPLACEMENT .................................................................................................................................................................41
END TUBE REMOVAL .....................................................................................................................................................................41
SPROCKET REMOVAL ....................................................................................................................................................................42
CHECKING PRESSURES ..................................................................................................................................................................43

SECTION 6 - TROUBLE SHOOTING

GENERAL ..........................................................................................................................................................................................54-47
SERVICE LOG...........................................................................................................................................................................48,49
NOTES ............................................................................................................................................................................................50-52

ASV, INC.

PAGE 4

POSI-TRACK 4810
FOREWORD
This manual contains operation, maintenance, service and trouble shooting information for
the POSI-TRACK 4810. It is designed to aid and instruct operators and service personnel in
the safe operation and normal maintenance of the vehicle.
This manual is divided into six sections. The sections cover specifications, general safety,
general operation, general maintenance, service and trouble shooting.
By studying this manual, operators and service personnel will become more familiar with
the construction, operation and normal maintenance of the vehicle. As operators and service
personnel become more efficient in operation and maintenance, they will save time and become more productive.
Throughout this manual the words WARNING, CAUTION, and NOTE are used to emphasize certain information. The word WARNING is used to identify personal safety information. The information should be read carefully and understood. Failure to heed warnings
could result in bodily injury. The word CAUTION is used to identify possible damage to
the vehicle or components. Failure to follow the suggested procedures will probably result
in damage to the vehicle. The word NOTE identifies supplementary information worthy of
particular attention.
At the time of publication of this manual, all information, photographs, and illustrations are
technically correct. Since ASV, INC. is constantly improving and refining its products, no
retroactive obligation is incurred.
PRODUCT IDENTIFICATION NUMBERS (PIN)
The POSI-TRACK PIN is located on the side of the control console.

Always provide the PIN

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

ASV, INC.

PAGE 5

SECTION

POSI-TRACK 4810

SPECIFICATIONS
GENERAL
Height
Width
Length
Ground Clearance
Weight (Without Loader)
Weight (With Loader)
Top Speed
Ground Pressure w/Zero Track Penetration
Square Inches of Track on the Ground

82.5"
69"
114.75"
16"
7,500 lbs.
8,640 lbs.
6 mph
3 psi (With Loader)
2826 sq. in.

P
ENGINE
Model
Type
Displacement
Gross Horsepower
Peak Torque

Caterpillar 3054T
Diesel, Liquid Cooled, In-Line 4 Cylinder
4 liter
105 hp at 2,400 rpm
284 ft.-lb.

P
TRACK SPECIFICATIONS
Width
Length
Weight

18"
220"
265 lbs.

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

ASV, INC.

PAGE 6

POSI-TRACK 4810
SPECIFICATIONS
POSITIVE DRIVE
Self-Cleaning Internal Drive Sprocket drives the track via two rows of molded rubber drive lugs
on interior of track. 24 roller pins per sprocket, 110 molded drive lugs per track.

UNDERCARRIAGE
MTSS
48
Sealed, oil bath bearings

Type
Number of contact points
Lubrication

P
TRANSMISSION & FINAL DRIVE
Drive Pumps
Drive Motors
Final Drive

Sundstrand, tandem variable displacement

Eaton Model , 2.48 cu. In.
Planetary gear box

P
AUXILIARY PUMPS
Low Flow at full engine rpm
High Flow at full engine rpm
Pressure (Low Flow)
Pressure (High Flow)

19 gallons per minute max.

30 gallons per minute max.
2,950 psi
3,200 psi

CAPACITIES
Fuel Tank
Hydraulic Reservoir
Engine Oil w/filter

25 gal.
28 gal.
8 qt.

P
ASV, INC.

PAGE 7

POSI-TRACK 4810
SPECIFICATIONS
LOADER ASSEMBLY
2,950 lbs.
2,065 lbs.
Operating Capacity (SAE J818, Skid-Steer)
Operating Capacity (SAE J818, Track Loader) 114"
2 pin, universal skid steer type
Lift height to hinge pin
Quick-Attach

P
OPERATORS COMPARTMENT
Protection system
Seat
Controls

ROPS/FOPS approved
Reversible, operator presence switch
Hand controls for drive and loader/bucket

P
INSTRUMENTATION
Standard instruments include:

Fuel, engine RPM, water temp., hour meter,

engine oil pressure, amp meter, hot hydraulic,
oil light, replace filter lights

P
ELECTRICAL SYSTEM
Lights
Battery
Alternator

2 front, 2 rear
12 volt, 950 CCA
65 amp

P
ADDITIONAL FEATURES
Cooling package
Environmental
Attachment receptacle
Hydraulic filter compartment
Battery compartment

Swing-out radiator and oil cooler

Pumps mounted inside reservoir to minimize
potential oil leaks from reaching the ground
Dozer blade, 3-point hitch, and backhoe can be
mounted to the frame of the POSI-TRACK.
Hydraulic filters housed on a manifold
Easy access to battery

ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTIFICATION.

ASV, INC.

PAGE 8

POSI-TRACK 4810

SECTION

GENERAL SAFETY

NEVER attempt to start the machine 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 personnel. 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 attachment is running.

ASV, INC.

PAGE 9

POSI-TRACK 4810
GENERAL SAFETY
NEVER get in or out of the operators seat with
the loader in the raised position, unless the
loader lock out pins are engaged. Lower the
loader all the way down before getting out of
the vehicle. Always step over the attachment
when getting in or out of the vehicle NEVER
UNDER IT.
THE SIDE SCREENS MUST be installed
when the loader is attached to the vehicle. Failure to install side screens could result in serious
injury or death to the operator.
ALWAYS use caution when carrying a load.
Sudden stops can cause roll over.
ALWAYS make sure all levers are in neutral
before starting the engine.
BECOME FAMILIAR with all controls and
WARNING decals before operating the vehicle.
NEVER allow an unqualified person to operate
the POSI-TRACK. Anyone operating the vehicle must read and understand the operators
manual.
NEVER operate the POSI-TRACK on any frozen body of water. Ice can be very dangerous
and unpredictable.

THINK SAFETY FIRST

ASV, INC.

PAGE 10

SECTION

POSI-TRACK 4810

GENERAL OPERATION
CONSOLE DEFINITIONS

MAIN CONTROL CONSOLES (Fig. 1 and Fig. 2)

A
A) Coolant Temperature Gauge
This gauge indicates the temperature of the engine coolant. Normal coolant temperature
should be less than 210F.
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.

Fig. 1
I

C) Tachometer
The tachometer displays the RPM of the engine.
Normal operating RPM should be between
2,000 and 2,400 RPM. Maximum RPM is
2,400.

D) Hour Meter
The hour meter should be used to schedule
maintenance intervals. (See maintenance chart)

Fig. 2

E) Throttle
Controls engine RPM.
F) Drive Levers
Each lever controls one track.
G) Main Valve Joystick
Controls the loader, dozer or 3-point hitch.
H) Auxiliary Low Flow Lever
Controls the direction of the low flow hydraulic
circuit.

ASV, INC.

PAGE 11

POSI-TRACK 4810
GENERAL OPERATION
I) Amp Gauge
Used to monitor the battery charging system
while the engine is running. It is normal for the
gauge needle to be centered or slightly to the
right of center.

J) Fuel Gauge
K) Auxiliary High Flow Lever
Controls the direction of the high flow hydraulic circuit.

Fig. 3

Fig. 4

ASV, INC.

PAGE 12

POSI-TRACK 4810
GENERAL OPERATION
ELECTRICAL CONSOLES
L) Parking Brake Switch
Used to activate the parking brake while the engine is running. This switch locks in position to
prevent accidental engagement. There is a small
switch within the main switch, that must be
pressed before the main switch will unlock.
NOTE
The parking brake is automatically engaged
when the engine is turned off. If the brake
will not disengage upon start-up, check to see
if brake switch is in the ON position.
M) Beacon switch
Activates the optional beacon.
N) Light Switch
This switch turns on/off both the front and rear
work lights.
O) Ignition
Key operated switch starts engine and powers
electrical accessories
P) Change Low Flow Filter
This light will come on if the low flow filter
needs to be changed.
Q) Change High Flow Filter
This light will come on if the high flow filter
needs to be changed.
R) Hot Hydraulic Oil Indicator
This light will come on if the hydraulic oil rises
above normal operating temperature.

ASV, INC.

PAGE 13

POSI-TRACK 4810
GENERAL OPERATION
OPERATING INSTRUCTIONS
Enter the vehicle when the loader is all the way
down. Never enter the vehicle by going under a
raised loader. (Fig. 7)
!WARNING!
Entering or exiting the vehicle under a raised
loader could cause serious injury or death.
Never put yourself underneath a raised, unsecured, loader. (Fig. 8)

Fig. 7

Adjust the seat forward or back so both feet

reach the footrest and both hands reach the controls.
Check to make sure all auxiliary levers are in
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.

Fig. 8

the neutral position and that the throttle is in the

idle position.
Fasten seat belt, and adjust so it fits snugly
around your waist.

!WARNING!
Failure to wear the seat belt could lead to serious injury or death.

ASV, INC.

PAGE 14

POSI-TRACK 4810
GENERAL OPERATION
Start the vehicle and allow engine to warm up
for two minutes before increasing throttle to desired RPM. First time operators will want to
learn at a lower RPM (2,000 or less) until they
feel comfortable with the controls. It is also recommended that the first time operator concentrate on learning the drive controls before moving on to the loader or other attachment controls.
Place one hand over both drive control levers.
Push both levers forward in unison to move for-

Fig. 9

NOTE
The engine will not start if the drive controls
or the aux. hydraulic levers are not in neutral.
Loader valve will not function unless the operator is seated.
ward, and pull both levers back in unison to
move in reverse. The further the levers are
moved, the faster the vehicle travels in either direction.
To turn to the right, push the left lever farther
than the right lever (this makes the left track turn
faster than the right track). To turn to the left,
push the right lever further than the left lever.
To turn the vehicle in its own axis (counterrotate) push one lever forward and pull the other
in reverse.

Fig. 10

NOTE
For best performance, always put power to
both tracks when making a turn. When both
tracks are turning, the vehicle will turn easier,
which also results in less damage to the
ground.

ASV, INC.

PAGE 15

POSI-TRACK 4810
GENERAL OPERATION
The hydrostatic pumps of the POSITRACK 4810 have relief valve settings of
4,000 lbs. psi. This means each drive pump
POWER & SPEED CONTROL
can produce a maximum of 4,000 pounds
per square inch of pressure. The harder the
The POSI-TRACK transmits the power from
pumps are worked, the more pressure they
the engine to the tracks using a hydrostatic
will produced until they reach their relief
transmission. The hydrostatic transmission
valve setting.
sends oil under pressure to two individual hyFor example: It takes a certain amount of
draulic motors, one for each track. The hydroforce to push a large rock across hard
static transmission consists of two individual
ground. If it takes 6,000 psi of oil pressure
hydrostatic pumps. One pump for each motor.
Track speed is increased by sending more oil to to push this rock straight forward, each
the hydraulic motors, and power is increased by drive pump produces 3,000 psi for a total of
sending less oil to the hydraulic motors. With a 6,000 psi. Under good traction the vehicle
mechanical transmission the operator must shift will push this rock straight forward since
down to increase power. With hydrostatic drive the pumps have not reached their individual
4,000 psi relief valve setting. If the operathe operator can simply pull back on the drive
tor tries to turn the vehicle while pushing
controls, reducing speed and increasing power
the same rock, the load on the inside track
at the same time.
will be less, and its pressure will decrease.
The load on the outside track will be inHYDRAULIC RELIEF PRESSURE
creased, thus increasing its pressure. If the
outside track is getting good traction, the
There are three main forces involved in trans4,000 psi relief valve setting can be
mitting power from the engine to the ground:
reached, making the track stop until the
ENGINE POWER, HYDRAULIC RELIEF
load is reduced. The oil for both tracks
PRESSURE, & TRACTION. Engine power
and traction can be easily understood, however could be made to go over the relief valves
relief pressure must be explained in greater de- if the same rock was pushed up hill since it
would take much greater force.
tail. All hydrostatic pumps have a relief
valve. A relief valve makes the oil by-pass the
hydraulic motor to prevent the pump from producing too much pressure. Every pump has its
pressure limitations. The lower the pressure,
the longer the pump, as well as other drive components, will last. The relief valves protect the
vehicle from a damaging situation. For example: The relief valves minimize track damage
and track derailment.
HYDROSTATIC DRIVE

ASV, INC.

PAGE 16

POSI-TRACK 4810
GENERAL OPERATION
LOADER VALVE CONTROL (Fig. 11 and
Fig. 12)

To raise the loader, pull back on the joystick at

a controlled rate.
To lower the loader, push forward on the joystick at a controlled rate.
To put the loader in float position, push the
lever all the way forward with a quick motion.

Fig. 11

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 joystick to the right at a controlled rate.

Fig. 12

ASV, INC.

PAGE 17

POSI-TRACK 4810
GENERAL OPERATION
LOADER LOCK OUT PINS
The roll cage comes equipped with two retractable pins that slide outward to secure the loader
in the up position. It is critical to use these
pins when there is service to be done on the vehicle, when the loader is up, hooking up a frame
mount attachment, or when someone has to get
in or out of the vehicle when the loader is up.
Fig. 13
!WARNING!
The loader lock out pins must be used to
prevent serious injury or death. Never leave
the loader in the up position without using
the lock out pins.

ENGAGING THE LOCK OUT PINS

(Fig. 13)

1. Raise the loader past the top of the roll cage

and turn off the engine.
2. Loosen the two knobs and pull down on the
spring loaded rings.
3. Slide the pins outward until they stop, make
sure the spring loaded rings snap back into
place.
4. Turn the key to the on position, to unlock
the loader valve (DO NOT START ENGINE).
Lower the loader onto the pins.

ASV, INC.

PAGE 18

POSI-TRACK 4810
GENERAL OPERATION
OPERATING CAPACITIES
The operating capacity refers to how much additional weight can be put into the 4810s bucket
while attached to the loader arms. This operating
capacity is measured at the mid point of the low
profile bucket. The operating capacity is 2,950
lbs. when the low profile bucket is quick attached
to the loader assembly, and is at the farthest point
from the vehicle (half way up). The heavier the
attachment, such as a 4-in-1 bucket, the less the
operating capacity will be. Moving the load
farther from the vehicle, such as a tree spade, will
significantly reduce the operating capacity.

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.

2950 LB. OPERATING CAPACITY RATED AT

BUCKETS CENTER OF
GRAVITY

FRONT PIVOT POINT

ASV, INC.

INCREASING THE DISTANCE FROM

THE FRONT PIVOT POINT TO THE
PAYLOAD WILL DECREASE THE
OPERATING CAPACITY

PAGE 19

POSI-TRACK 4810
GENERAL OPERATION
MOVING DIRT WITH THE BUCKET
Certain techniques can be used to become more
efficient in moving dirt with the bucket. The
following are simple guidelines for those who
do not have much experience moving dirt.
The POSI-TRACKS loader is designed to push
against the frame while leveling or digging dirt.

Fig. 14

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 digging with the POSI-TRACK. (Fig. 14)
In uneven terrain, it may be necessary to dig
with the loader raised off the loader-stop, however, digging in this manner should be kept to a
minimum to reduce damage to the loader arms.

Fig. 15

Always move dirt with the bucket level with the

ground. Never tilt the bucket all the way forward and use as a dozer blade. (Fig. 15) This
puts tremendous stress on the bucket, the quickattach, and the bucket cylinders. Damage to
any of the previously mentioned can occur if
the bucket is used in this manner.
Never back drag with the bucket in this manner
(Fig. 16). The bucket cylinders are fully extended and can be exposed to great forces if the
bucket catches on something solid. Using the
bucket in this manner can cause the cylinders to
bend.

Fig. 16

ASV, INC.

PAGE 20

POSI-TRACK 4810
GENERAL OPERATION
SIDE HILLING
Although the POSI-TRACK works well on side
hills, extreme caution must always be used.
Never exceed a 3 to 1 slope. This means 3 feet
of run to every 1 foot of rise. (Fig. 17)
When turning to go up hill while side hilling,
the following technique should always be used:
1. Stop the vehicle and back the vehicle down
the hill until the front of the vehicle is pointed
in the direction you want to go. Then drive forward. (Fig. 18,19,20)

Fig. 18

2. This turning technique will reduce the

chance of track derailment and will also put
less stress on the track system.

CAUTION
While operating on a side hill, the more weight
there is on the vehicle, the greater the chance
of track derailment. Gravity is trying to pull
the vehicle downhill, while the tracks are keeping the vehicle on the hill. The less weight that
is on the vehicle, the less chance there will be
for track derailment

Fig. 19

1:1 = 100% = 45
1

2:1 = 50% = 26.6

Fig. 20

2
1
3:1 = 33.3% = 18.4

Fig. 17

ASV, INC.

PAGE 21

POSI-TRACK 4810
GENERAL OPERATION
PRESTART CHECKLIST
Prior to operating the POSI-TRACK, several
items need to be checked to ensure safe, trouble-free operation. It is also important that periodic maintenance be done correctly and
safely. Follow a regular maintenance schedule
that includes replacement and / or adjustment
of any component found to be excessively
worn, out of adjustment, or damaged. Before
starting the engine and operating the POSITRACK, check the items on figure 21.

ITEM
Tracks
Engine coolant
Hydraulic fluid
Engine oil
Fan belt
Hoses
Fittings
Radiator
Nuts & bolts
Battery
Aux. levers
Drive controls

REMARKS
Check tension
Check level
Check level
Check level
Check tension
Check for wear
Check for leaks
Clean thoroughly
Tighten if needed
Check cables
Check for neutral
Check for neutral

STARTING INSTRUCTIONS
1. Perform all Pre-Start checks outlined
(Fig. 21) before starting engine.

Fig. 21

2. Adjust seat, fasten seat belt, make sure all

levers are in neutral.
3. From the slow idle position, push the throttle 1/3 of the way open.
4. Turn the key switch clockwise to the run
position.

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

SHUTTING THE ENGINE OFF

1. Pull the throttle to slow idle.
2. Idle engine for at least two minutes to allow
hot engine parts to cool.
3. Turn key counter clockwise to the off position.

ASV, INC.

PAGE 22

SECTION

POSI-TRACK 4810

GENERAL MAINTENANCE
BREAK-IN PROCEDURES
Although all systems on the POSI-TRACK
are tested at the factory to ensure proper operation, there are a few items that require a
break-in period. Certain components need readjustment and others require special care
within the first 100 hours of operation.
PROPER BREAK-IN PROCEDURES ARE
CRITICAL TO THE LONG TERM RELIABILITY OF THE POSI-TRACK. Extra care
during this period will pay-off down the road.
TRACKS

CAUTION
Failure to perform the proper break-in
procedures will cause premature component failure.

Track will loosen during break-in

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. Although
track tension is set properly at the factory, the
tracks will need an adjustment after break-in.
Once the KevlarTM and other special materials
in the track are pulled straight, minimal 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.

Track needs to be tightened after break-in

The tracks on the POSI-TRACK 4810 are

easy to tighten. It takes only a few minutes
and will be well worth the time (See page 30
for track tensioning procedure.) After the initial track break-in, the tracks may not need to
be tightened for several hundred hours, however, the tracks should be inspected daily
and tightened as necessary.

ASV, INC.

PAGE 23

POSI-TRACK 4810
GENERAL MAINTENANCE
PLANETARY DRIVES
Each tracks final drive consists of a hydraulic
drive motor, a planetary gearbox and an internal drive sprocket. The planetary gearbox requires a break-in period for the lug nuts and
for the planetary oil. The 9 lug nuts, which
attach the sprocket to the planetary gearbox,
are torqued to 115 ft.-lbs. at the factory, and
should be re-torqued to 115 ft.-lbs. after 10
hours of operation. (Fig. 22)
The planetary gearbox requires an oil change
at 50 hours. The break-in time allows the
gears in the planetary to properly mesh. This
is a crucial oil change since the oil will have a
high metal content. After this initial oil
change, the planetary oil should be changed
every 1,000 hours or annually. (Refer to page
31 for proper planetary oil changing procedure.)

ASV, INC.

Fig. 22

Lug nuts

CAUTION
Failure to change the planetary oil at the
50 hour break-in interval, will drastically
shorten the life of the planetary gear
box. Failure to follow this procedure
will also void the warranty of the planetary gear box.

PAGE 24

POSI-TRACK 4810
GENERAL MAINTENANCE

MAINTENANCE SCHEDULE
ITEM

FREQUENCY

LUBRICANT

Hydraulic fluid
Hydraulic filters
Engine oil and filter
Engine fuel filter
Primary air filter
Secondary air filter
Planetary oil

500 hours
250 hours or as needed
500 hours
500 hours or as needed
Clean and replace as needed
Every 3 cleanings of primary
1,000 hours or annually
(After 50 hr. break-in)
Daily
Check level at 1,000 hours
As needed

Amoco Rykon MV

Loader grease fittings

Wheel tubes
Track tension

Caterpillar approved

SAE 80w-90 gear lube

Low temp grease
SAE 80w-90 gear lube

SERVICE ITEMS
FLUID

CAPACITY

TYPE

Fuel
Hydraulic oil
Planetary oil
Wheel tube oil
Engine oil

25 gallons
28 gallons
1 quart
12 ounces
8 quarts

Diesel
Amoco Rykon MV
SAE 80w-90 gear lube
SAE 80w-90 gear lube
See chart below

ASV, INC.

PAGE 25

POSI-TRACK 4810
GENERAL MAINTENANCE
GREASE POINTS
LOADER ASSEMBLY
There are 12 grease fittings on the POSITRACKS loader assembly, which should be
greased daily. The grease fittings are located
in the following spots on both sides of the
loader:

Fig. 25

1. The main loader hinge points. (Fig. 23)

2. Both ends of the lift cylinders. (Fig. 24, 25)
3. Both ends of the quick-attach cylinders.
(Fig. 26, 27)
4. Hinge points for the quick-attach. (Fig. 28)
Fig. 26

Fig. 23
Fig. 27

Fig. 28

Fig. 24

ASV, INC.

PAGE 26

POSI-TRACK 4810
GENERAL MAINTENANCE
ENGINE OIL & FILTER CHANGE
The normal oil change interval is every 500 service hours or six months. Engines, which are
operated under severe conditions, may need the
oil changed to be changed every 250 service
hours or three months. Severe conditions include the following: high temperatures, continuous high loads, and dusty conditions.
Fig. 29
1. Run engine approximately 5 minutes to warm
up oil. Shut off engine.
2. Remove oil drain plug beneath the engine
compartment and allow to drain. After the oil
has been allowed to drain, clean the oil drain
plug and reinstall.
3. Remove oil filter element and dispose of
properly or consult your dealer for analysis.

Fig. 30

4. Clean the sealing surface of the filter mounting base. Ensure that all of the old oil filter gasket is removed. Apply clean engine oil to the
new oil filter gasket.
5. Install the new oil filter. Tighten the oil filter
until the oil filter gasket contacts the base.
Tighten the oil filter by hand according to the
instructions that are shown on the filter. DO
NOT over tighten the oil filter.
6. Fill engine crankcase to specified level.
(Approximately 8 quarts) (Fig. 30)
7. Start the engine and run the engine at LOW
IDLE for two minutes. Check for leaks. Wait
ten minutes and check oil level.

ASV, INC.

PAGE 27

POSI-TRACK 4810
GENERAL MAINTENANCE
HYDRAULIC OIL & FILTER CHANGE
One of the most critical systems on the POSITRACK is the hydrostatic system. The hydraulic
oil should be changed every 500 hours and the
hydraulic filters should be changed every 250
hours. These precision components require extremely clean oil in order to have a long service
life. Changing the hydraulic oil and filters at the
proper intervals can prevent expensive repairs
later down the road.

Fig. 31

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 hydrostatic system.
1. Remove hydraulic oil drain plug (A) from bottom of reservoir. Drain into suitable container.

Fig. 32

2. The three hydraulic filters are housed inside

the loader tower service compartment on the side
of the vehicle. (Fig. 32)
3. The filters are disposable spin on type filters.
These filters can be removed by hand or by using
a filter wrench. Always dispose of filters properly.
4. Fill with new approved hydraulic fluid. The
fill cap is located in the loader tower (Fig. 33).
The level gauge is located on the floor of the cab.

ASV, INC.

Fig. 33

PAGE 28

POSI-TRACK 4810
GENERAL MAINTENANCE
PRIMING THE FUEL SYSTEM
If the engine has run out of fuel, or the fuel system has been opened for service, it will be necessary to bleed the fuel system.

1. Loosen the bolt at the top of the fuel filter in

order to vent (A).
2. Pump primer lever (B) until fuel flowing out
the vent is continuous and free of air bubbles.
Tighten the bolt at the top of the fuel filter.

A
Fig. 34

NOTE
It is not possible to operate the priming lever if
the cam of the fuel lift pump is at the maximum lift position of the cam. If this
occurs, rotate the crankshaft one revolution.
B
3. Loosen the nut for the fuel inlet line at the
fuel injection pump (C) in order to vent.

Fig. 35

4. Turn the start switch to the RUN position (do

not actually attempt to start the engine). Operate
the priming lever for the fuel lift pump until the
flow of fuel from the vent is continuous and free
of air bubbles. Tighten the nut for the fuel inlet
NOTE
If engine still wont start, it may be necessary
to bleed air from fuel system at the injection
nozzles. Refer to the Caterpillar Operation and
Maintenance manual for this procedure.
line.

ASV, INC.

PAGE 29

POSI-TRACK 4810
GENERAL MAINTENANCE
COLLAPSING AND TENSIONING THE
TRACK

Fig. 36
Jack Housing

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.

Hook

Located under the seat is a screw jack and a

wrench that will allow the tracks to be tightened
in the field

Bolt

"B"
1. Use the jack housing and hook as shown to
relieve tension on bolts. (Fig. 36)
2. Loosen the two drive table bolts A, and remove the two track tension bolts, B. (Fig. 37)

Fig. 37

3. Use the long hook as shown, to begin collapsing the suspension. (Fig. 38)

Fig. 38

Bolt "A"

4. Use the short hook as shown, to finish collapsing the suspension. (Fig. 39)
Long Hook

Fig. 39

ASV, INC.

Short
Hook

PAGE 30

POSI-TRACK 4810

COLLAPSING AND TENSIONING THE

TRACK Continued

Fig. 40

Hook

5. Unscrew the jack housing from the hook and

screw in the push plate. Then position to begin
expanding the suspension. (Fig. 40)
6. To continue expanding the suspension, position the push plate, jack housing, and pin as
shown.
(Fig. 41)

Jack Housing

Push Plate
Fig. 41
Pin

7. Reposition the jack housing, push plate, and

pin as shown to continue expanding the suspension. (Fig. 42)
8. To finish tightening the track, position the
jack housing and push plate as shown. (Fig. 43)

Push Plate

Jack Housing

Fig. 42
Pin

Push Plate

Jack Housing

Fig.
Push Plate

Jack Housing

ASV, INC.

PAGE 31

POSI-TRACK 4810
GENERAL MAINTENANCE
PLANETARY OIL CHANGE
After the initial 50-hour break-in change, the
planetary oil should be changed every 1,000
hours or annually, which ever comes first.
Before starting the procedure, the planetary case
must be cleaned thoroughly. It is crucial that no
dirt falls into the case when removing the plugs.

Fig. 44

In the drawer under the seat of the POSITRACK 4810, there is a kit which will make
changing the planetary oil easier. This kit includes a fitting and a hose. The kit is located in
the drawer under the seat.
There are two plugs, which are 180 from each
other. One is for draining the oil, the other is for
filling the oil. It doesnt matter which plug is
used for which part of the job.

Fig. 45

NOTE
Drive the POSI-TRACK for 10 to 15 minutes
Before changing the planetary oil. This will
warm up the oil and allow it to drain more thoroughly.
1. Rotate the sprocket until one of the plugs is
lined up with the u-shaped notch at the top of
the bearing plate. This will also line up the
other plug with the hole in the bottom of the
bearing plate. (Fig. 44)
2. Attach the hose to the fitting and be prepared
to insert the fitting into the drain hole. Remove
the drain plug through the bottom hole and
quickly insert the fitting with the hose. (Fig. 45)

ASV, INC.

PAGE 32

POSI-TRACK 4810
GENERAL MAINTENANCE
3. Remove the top plug to vent the case and allow the oil to drain. (Fig. 46)
4. Remove the fitting with the hose from the
bottom plug and reinsert the plug.
5. Insert the fitting and hose into the top hole.
Use a 32 oz. Bottle of 80W-90 gear lube or similar container, which can be filled with gear lube.
Attach the other end of the hose to the bottle.
Squeezing the bottle slightly will help push the
oil into the case. (Fig. 47)

Fig. 46

Fig. 47

ASV, INC.

PAGE 33

POSI-TRACK 4810
GENERAL MAINTENANCE
RADIATOR AND OIL COOLER
The radiator and oil cooler should be inspected
and cleaned before operating the vehicle, or if
the engine or hydraulic oil overheats while operating.
1. Undo the latch that secures the hood to the
frame (Fig. 48)
Fig. 48
2. Undo the latch that secures the radiator assembly to the frame (Fig. 49)
4. Undo the two clasps that secure the grill to
the radiator and oil cooler. Swing the grill away
from radiator and oil cooler. (Fig. 50)
!WARNING!
NEVER OPEN THE RADIATOR / OIL
COOLER DOOR WHILE THE ENGINE IS
RUNNING. THE FAN COULD CAUSE SERIOUS INJURY. ALWAYS SHUT THE VEHICLE OFF BEFORE CLEANING THE RADIATOR AND OIL COOLER.

Fig. 49

5. The coolers are now totally accessible for

cleaning.
A pressure washer or an air compressor works
the best for cleaning the coolers completely.
Fig. 50

ASV, INC.

PAGE 34

POSI-TRACK 4810
GENERAL MAINTENANCE
SERVICING THE AIR CLEANER
The air cleaner is one of the most important
maintenance items on the vehicle. A poorly
maintained air cleaner can seriously shorten the
life of the engine.
1. Open the hood and , undue the latches on either side of the air cleaner, then remove the
cover. (Fig. 51)

Fig. 51

2. Remove the primary element. The primary

element can be washed and reused up to six
times but should be changed at least once a
year. (Fig. 52)
3. Remove the secondary element. The secondary element is not serviceable or washable.
The secondary element should be removed and
discarded for every three cleanings of the primary element. (Fig. 53)

Fig. 52

NOTE
When working in dusty conditions the air
cleaner elements should be checked and
changed more frequently.

4. Install new elements or replace cleaned primary element, make sure both element are properly seated be for installing cover.

ASV, INC.

Fig. 53

PAGE 35

POSI-TRACK 4810
GENERAL MAINTENANCE
CHANGING THE FUEL FILTER
1. Close the fuel supply valve.
2. Clean the outside of the fuel filter thoroughly. Open the drain (A) and drain fuel into
suitable container.
B

3. Hold the element and rotate the locking ring

counterclockwise (B). Remove the locking
ring, and dispose of the used element.
4. Make sure the filter head is clean, push a
new element fully into the filter head.

A
Fig. 54
A

5. Hold element in place and fit locking ring

into position. Rotate the locking ring clockwise
to fasten the element in place.
6. Prime the fuel system.

ASV, INC.

PAGE 36

SECTION

POSI-TRACK 4810

SERVICE
TRACK REMOVAL
In some cases removing the track is necessary to
work on some undercarriage components.
Using a floor jack or a forklift, jack the POSITRACK off the ground (Fig. 55) until there is
approximately 4 inches between the bottom of
the track and the floor. Jack stands specially designed for the POSI-TRACK can be purchased
through your POSI-TRACK dealer (PN # 454876)
For occasional track tensioning, the screw jack
that comes with the machine is fine, however, a
remote hydraulic jack is best for track removal
and installation. A remote hydraulic jack with
all the necessary extensions can be purchased
from your POSI-TRACK dealer.
1. On the inside and the outside of the undercarriage, there are two long slots. Loosen the
bolts (A) that are in these slots (DO NOT REMOVE). (Fig. 56)

Fig. 55

Fig. 56

2. Place the jack between the sliding planetary

mount and the undercarriage frame (Fig. 57).
Jack the planetary mount back just enough so
the track adjustment bolts can be removed. After 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. 58)

ASV, INC.

Fig. 57

PAGE 37

POSI-TRACK 4810
SERVICE
4. Insert the jack between the rear axle mount
and the steel tab (Fig. 58). Jack the planetary
mount forward until the jack is full stroke. Remove the jack and add an extension to the ram
of the jack. Continue jacking the planetary
mount forward until it comes in contact with the
undercarriage frame.
5. There are 4 bolts, which mount the carrier
wheels to the undercarriage frame. The 2 bolts
closest to the drive sprocket (C) need to be loosened enough so the assembly can hinge on
them. (DO NOT REMOVE ).

Fig. 58

6. Remove the other 2 bolts and hinge the assembly back until it hits the undercarriage
frame. (Fig. 59)
7. Position yourself behind the drive sprocket
and grab the bottom inside portion of the track.
Pull the track down, getting the drive lugs to
clear the 10" idler wheels and then pull the track
to the outside. Do not attempt to get the whole
track off yet, just get one row of drive lugs past
the outside 10" idler wheel.
8. Pull the track up and off the drive sprocket.
The track can now be pulled off the 10" idler
wheels. Continue pulling the track off the top
of the undercarriage and slide it out from beneath the undercarriage. Pull the track forward
and out to remove the track from the 14" idler
wheels. The track is now off. (Fig. 61)

Fig. 59

Fig. 60

Fig. 61

ASV, INC.

PAGE 38

POSI-TRACK 4810
SERVICE
TRACK INSTALLATION
1. Place the track parallel to the undercarriage
so the end of the track is even with the end of
the undercarriage.
2. Pull the track up and onto the 14" idler
wheels. Slide as much track as possible under
the undercarriage. Pull the track up and on to
the hinged carrier wheels. (Fig. 62)

Fig. 62

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. 63)
4. Pull the rest of the track up and onto the
drive sprocket, and then under the 10" idler
wheels.

Fig. 63

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 between the two steel tabs or on the outside between the carrier wheel assembly and the sliding
planetary mount (Shown Fig. 64). If the planetary mount starts to bind, place the jack on the
other side.

Fig. 64

7. Once the planetary mount is back far enough,

place the jack between the sliding planetary
mount and the rear axle mount. (Fig. 65)

Fig. 65

ASV, INC.

PAGE 39

POSI-TRACK 4810
SERVICE
8. Jack the planetary mount back until the track
is straight (Fig. 66) between the drive sprocket
and the carrier wheels. (DO NOT OVER
TIGHTEN).
9. Line up the set of holes in the sliding motor
mount and the undercarriage frame. Insert track
adjustment bolts and tighten. (bolts should be in
same hole location.) (Fig. 67)

Fig. 66

10. Tighten bolts in slots on both sides of the

undercarriage.

CAUTION
It is critical that the drive sprocket is aligned
with the undercarriage frame. The tension adjustment bolts must be in the same hole location
or track derailment will occur.

ASV, INC.

Fig. 67

PAGE 40

POSI-TRACK 4810
SERVICE
BOGIE CARRIAGE REMOVAL
1. Once the track is removed, slide a floor jack
under the bogie carriage that is being removed
and raise until there is some pressure on the bogie carriage. (Fig. 68)
2. Remove the 4 bolts that secure the bogie carriage to the undercarriage frame.

Fig. 68

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. 69)
Fig. 69

WHEEL TUBE REMOVAL

1. Place the bogie carriage on the floor so all
wheels are facing up. (Fig. 70

B
2. Remove the 4 bolts (B), which secure the
wheel tube to the bogie carriage.
3. Lift wheel tube straight up out of the slots in
the bogie carriage.

Fig. 70

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.

ASV, INC.

PAGE 41

POSI-TRACK 4810
SERVICE
WHEEL REPLACEMENT
1. The center wheel is split (A) for easy removal
and the two outside wheels are whole wheels.
2. Remove wheels by unbolting the wheel hub
that secures the wheels to the tube. The outside
wheel hubs are slid off the shaft and the wheel
can then be removed easily (Fig. 71).

Fig. 71

END TUBE REMOVAL

The end wheel tubes are extremely easy to remove. 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. 72)
Fig. 72

ASV, INC.

PAGE 42

POSI-TRACK 4810
SERVICE
SPROCKET REMOVAL
There are 3 bolts that fasten the planetary bearing plate to the undercarriage frame, and 4 bolts
that fasten it to the bearing flange. The track
needs to be removed before beginning this procedure.
1. Remove the 4 bolts that fasten the bearing
plate to the flange. (Fig. 73)

Fig. 73

2. Remove the 3 bolts that fasten the bearing

plate to the undercarriage frame. (Fig. 74)
3. Tapping the bearing plate with a rubber hammer will help dislodge it from the flange. Pull
the bearing plate straight out. (Fig. 75)
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. 76)

Fig. 74

Fig. 75

Fig. 76

ASV, INC.

PAGE 43

POSI-TRACK 4810
SERVICE
CHECKING CHARGE PRESSURE
A
The charge pressure refers to the oil that is supplied to the main drive pumps, this oil allows the
pumps to shift. If the charge pressure is low, the
drive pumps may not shift at all when the levers
are stroked or they may shift sluggishly, resulting
in erratic track behavior.
1. Open the filter access panel on the side of the
vehicle. Locate the test port in the upper right
hand corner (A).

Fig. 77

2. Remove the cap and screw on a pressure

gauge.
3. Start the engine and let idle. At an idle, the
charge pressure should be between 280 to 320 psi
when the oil is warm.

ASV, INC.

PAGE 44

SECTION

POSI-TRACK 4810

TROUBLE SHOOTING (GENERAL)

PROBLEM

CAUSE

REMEDY

Vehicle wont
turn over

1. Battery cables loose

or corroded.
2. Drive levers or auxiliary
levers are not in neutral
3. Operator not in seat with
seat belt on

1. Tighten or clean cables

Vehicle turns over

but will not start

Vehicle starts but

engine runs rough

Vehicle starts but

tracks wont go

1. Out of fuel or
fuel pick-up may not
be in fuel if parked on a hill
2. Pinched fuel line
3. Load on engine from
High or Low flow auxiliary lever
being engaged
4. Fuel solenoid is not opening
5. Plugged fuel filter
1. Low-flow auxiliary
hydraulic lever is engaged
2. High-flow auxiliary
hydraulic lever is engaged
1. Operator not seated in seat
2. Defective seat switch
3. Defective solenoid
4. Low charge pressure

Under heavy load

or in loose material
vehicle wont turn

1. Tracks have lost traction

2. Oil going to drive motor
is going over the relief valve

ASV, INC.

2. Put levers in neutral

3. Sit down and put seat
belt on
1. Add more fuel
and bleed fuel system
2. Find and correct
3. Put lever in neutral

4. Check wiring
5. Change filter
1. Put lever in neutral
2. Put lever in neutral

1. Sit down & fasten

seat belt.
2. Refer to electrical
trouble shooting guide
3. Refer to electrical
trouble shooting guide
4. Refer to page 44
1. Reduce load or put more
power to the inside track
2. Reduce load. Increase
power to inside track

PAGE 45

POSI-TRACK 4810
TROUBLE SHOOTING (GENERAL)
PROBLEM

CAUSE

REMEDY

Attachment wont
operate

1. Quick-coupler not plugged

in all the way
2. Faulty quick-coupler
3. The other auxiliary lever
is engaged
4. Hoses hooked up wrong
5. Faulty attachment

1. Find and plug in

quick coupler
2. Replace
3. Put lever in neutral

1. Hydraulic oil cooler is

plugged with debris
2. Hydraulic attachment is
undersized for the flow
and/ or pressure

1. Clean with compressed

air or pressure washer
2. Get the right sized
attachment or reduce the
engine rpm until the flow
is in the correct range
(Refer to decal on vehicle)
3. Put lever in neutral

Hot oil light comes on

4. Correct
5. Contact dealer or refer to
an attachment owners
manual

3. One of the auxiliary hydraulic

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 doesnt
work properly

1. Attachment is incorrect size

for the flow and pressure.
2. Auxiliary hydraulic pressure
is set too low.

1. Get the appropriate

attachment
2. Set to proper pressure

Loader doesnt
lift proper weight

1. Auxiliary hydraulic pressure

is set too low
2. Weight is too far out from
vehicle
3. Auxiliary lever is engaged

1. Set to proper pressure

ASV, INC.

2. Bring load in closer

or reduce load
3. Put lever in neutral

PAGE 46

POSI-TRACK 4810
TROUBLE SHOOTING (GENERAL)
PROBLEM

CAUSE

REMEDY

Attachments, tracks
weak on power

1. One or both auxiliary hydraulic

levers are engaged
2. Hydraulic oil is still cold

1. Put lever in neutral

Tracks respond
sluggishly

1. Hydraulic oil is still cold

2. Low charge pressure
3. Low hydraulic oil
4. Hydraulic filters plugged

One track wont go

1. Brake is engaged

2. Cable is disconnected on
lever
3. Cable is disconnected on
pump
Track will only
go in one direction

Track derails

1. Loosen or disconnected drive

tube or fitting
2. Broken drive tube inside
hydraulic reservoir
3. Cable linkage in tank
is broken
1. Track is too loose
2. Bearing failure in one of
the end tubes or out board
bearing on drive sprocket
3. Drive Sprocket miss aligned
undercarriage frame.
4. Bent idler wheel
5. Terrain too steep or improper
driving techniques

ASV, INC.

2. Let oil warm up for a

few minutes
1. Let oil warm up for
a few minutes
2. Refer to page 43
3. Add hydraulic oil
4. Change filters
1. Turn brake switch off,
or rotate track in both
directions to take bind
off brake ram
2. Reconnect cable
3. Contact dealer

1. Contact dealer
2. Contact dealer
3. Contact dealer

1. Adjust
2. Replace bearing

3. Make sure tension

Adjustment bolts are in
the same adjustment holes
4. Replace wheel

PAGE 47

POSI-TRACK 4810
TROUBLE SHOOTING (GENERAL)
PROBLEM

CAUSE

REMEDY

Engine coolant
overheats

1. Radiator is plugged with

debris
2. Low engine coolant
3. Fan belt is slipping
4. Fan is on backward
5. Faulty sender, light or
wiring

1. Clean with compressed

air or pressure washer
2. Add approved coolant
3. Check tension pulley
4. Replace correctly
5. Replace

After running out of

fuel and refueling,
engine will not start

1. Fuel system has not been primed 1. Refer to page 29

ASV, INC.

PAGE 48

POSI-TRACK 4810
MAINTENANCE & SERVICE
DATE

DATE

DATE

DATE

DATE

HOURS

HOURS

HOURS

HOURS

HOURS

ITEM

ASV, INC.

PAGE 49

POSI-TRACK 4810
MAINTENANCE & SERVICE
DATE

DATE

DATE

DATE

DATE

HOURS

HOURS

HOURS

HOURS

HOURS

ITEM

ASV, INC.

PAGE 50

POSI-TRACK 4810
NOTES
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ASV, INC.

PAGE 51

POSI-TRACK 4810
NOTES
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ASV, INC.

PAGE 52

POSI-TRACK 4810
NOTES
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ASV, INC.

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