Camoplast 1099-01-1105 User manual

User Manual
1099-01-1105 - VERSION B
TATOU®UTV 4S Track System
Original notice
Other languages translation available at www.camoplast.com
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Camoplast Inc.
1701, 3rd Avenue
Grand-Mère, (Québec) J1X 0E6 CANADA
E-mail : [e-mail]
Website : www.camoplast.com
© 20
®and TM are trademarks of Camoplast Inc. All rights reserved. ©2010 Camoplast Inc.
Printed in Canada.
IMPORTANT
Please read carefully each part of this
document as well as model specific Installation
Guidelines prior to assembling, installing and
using the track system.
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TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
USING THE UTV WITH TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HINTS AND TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
USER NOTICE AND DISCLAIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DANGEROUS SITUATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION, REMOVAL AND RE-INSTALLATION . . . . . . . . . . . . . . . . . . . 14
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION OF A RUBBER TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REPLACEMENT OF A WHEEL WITH EXTRACTOR . . . . . . . . . . . . . . . . . . . 33
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
TECHNICAL SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
“CE” DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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1
INTRODUCTION
INTRODUCTION
Thank you for choosing Tatou®UTV 4S, a Camoplast UTV
Track System, (hereinafter referred to as the "System"). You
have made the right choice. This system will provide you with
all the traction, performance and durability you require for
recreational or work purposes and allows for year-round
operation. This track system for utility vehicle,side-by-side
(hereinafter 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, specifically designed for UTV, make it
the best system on the market.
USING THE UTV WITH TRACKS
The driver must remain vigilant and cautious at all times.
Powder snow and mud can hide dangerous obstacles.
The driving characteristics of your UTV will change with
the installation of the System. It is important to take the
time to become familliar with the Systems.
Before each ride make sure that all the wheels and moving
parts of the system are free and that they are not frozen or
stuck on to the frame.
It is the driver’s responsibility to verify that the air intake of
the vehicle is well adapted to weather conditions and is not
blocked by snow accumulation.
When travelling 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.
Adapt your driving style to surrounding conditions
(weather, traffic, etc.) and to your driving abilities.
An UTV equipped with the System must never be used for
the following activities: races, rallies, jumps, stunts,
acrobatics or any other extreme applications.
Allow for a greater braking distance and periodically apply
the brakes while driving to prevent ice buildup on brake
components.
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USING THE UTV WITH TRACKS
Always follow the UTV manufacturer's safety rules and
regulations regarding, for exemple passengers
transportation, maximum loads, ect.
It is the driver’s responsibility to follow the recommended
schedules maintenance further described in this manual.
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3
HINTS AND TIPS
HINTS AND TIPS
Before leaving for an excursion, make sure you have the
following within arms reach : 12 mm, 14mm, 16 mm, 17 mm,
19mm and 30 mm wrenches, one axe, one shovel, one tow
cable, a lifting jack and one adjustable wrench.
Generally, the slower you go, the better the traction will be.
For riding or excursions in unknown, or remote terrain, make
sure you have a cellular phone or satellite phone, a first aid kit
and spare parts in your possession.
When driving off trails, always be cautious to the presence of
hidden obstacles.
When driving in deep snow, do not intentionally spin the track
(tracks keep on turning while the vehicule does not).This could
cause the vehicle to get stuck.
GENERAL INFORMATION
All figures, information or photos presented in this document
are up to date at the time of publication. However, they may
change without notice.
Read and follow indications of the UTV user manual and
installation guidelines carefully. Their contents remains
applicable after installating of the System.
This document should be read by every person who drives the
UTV equipped with the System.
This document is an integral part of the System. Pass it along to
any new System owner.
Consult legal authorities where you drive your UTV equipped
with the System before usage to ensure that you respect all
applicable laws and regulations.
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.
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4
SAFETY
SAFETY
This guide uses the following symbols to emphasize particular
information :
CAUTION: Indicates a potentially hazardous situation which, if
not avoided, may result in damage to vehicle components.
NOTE: Indicates supplementary information.
USER NOTICE AND DISCLAIMER
The Tatou®UTV 4S System was initially designed to be used
in winter conditions and was then adapted to be used in fall and
spring conditions.
This document holds important information regarding driving an
UTV equipped with the Tatou®UTV 4S System by Camoplast.
It is mandatory that every user takes the time to carefully read,
understand and then consult this reference manual and user
guide as well as the UTV owner's manual as needed. When
purchasing either a new or used track System, the user must
obtain all documentation related to the System, including
manuals and guides related to the UTV on which the System is
installed. If need be, contact the Camoplast products dealer
nearest to you to obtain any additional information. You may
also consult the Camoplast Web site at www.camoplast.com
and call our technical support line at 1 866-533-0008 or by
email at [e-mail].
Camoplast believes that there are certain risks related to the
installation and use of the System. Our experience shows that
the System is safe. However, the user must be aware of the
risks related with driving 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 from the vehicle manufacturer
fixed by law, namely when age restrictions exist and UTV base
equipment is required (headlights, flashers and brake lights,
rearview mirror, etc.). The user must always wear adequate
safety equipment, such as a helmet, safety glasses (or visor),
protective clothing, boots and gloves. It is understood that
driving while impaired or intoxicated presents a danger for the
UTV user and others and is against the law.
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
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5
USER NOTICE AND DISCLAIMER
The System consists of many moving parts, including
transmission wheels. If an object lodges itself or becomes
jammed into the System and blocks the track, it is mandatory to
stop the engine and the vehicle and apply the security brake
before removing object said. By avoiding to do so, the user
exposes himself to sudden movement of the UTV or to
breakage of a part or component coming from the System,
which could cause severe injuries. It is also very important to
wear full length clothing and always avoid hanging or stringy
accessories.
Driving an UTV equipped with such a System requires
particular precautions and a knowledge of proper driving
techniques of such vehicles. An evaluation by the user of the
conditions and terrain (state of the ground, grade of hill, density
of snow, etc.) is equally essential. An UTV equipped with a
System cannot compete and/or be used to perform stunts,
acrobatics or other exploits, as these could result in loss of
control or severe injuries.
Insufficient knowledge of an UTV during down hill riding, climbs
and crossing of obstacles and turns can result in tipping or roll
over, and can cause severe injuries.
Carrying a passenger, a load or attaching a tow can cause the
UTV to be less stable, and affect driveability. Unless otherwise
prescribed by law and by the UTV manufacturer, you must not
carry a passenger, loads or tow any objects.
The installation of a System:
• Increases ground clearance.
• Changes the center of gravity.
• Increases the UTV width and weight.
• Reduces ground pressure.
These parameters will effectively change driving characteristics
of an UTV equipped with the System.
Consequentially, it is highly recommended that the user adapts
his driving style in function of the new characteristics mentioned
above. The driver must always use caution when he 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 speedometer. Generally, the
System transmission wheel diameter is less than that of the tire.
Therefore, the vehicle speed will be less than that actually dis-
played. Whether the UTV is equipped or not with the System,
users must always adapt the speed to actual driving conditions.
Users must never exceed speed limits or drive faster than their
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6
USER NOTICE AND DISCLAIMER
capacities allow. Excessive speed remains one of the main
causes of severe accidents on UTV.
Camoplast is proud to offer UTV conversion kits within its wide
range of products. UTV Track Systems are not only reliable, but
safe. However, there are risks inherent to driving an UTV
equipped with the System. It is therefore very important that
any driver familiarizes himself with proper driving techniques of
an UTV equipped with a System, and that he adapts his driving
to his level of experience and continually evaluates operating
conditions and terrain to safely and efficiently make the best of
these Camoplast UTV track systems.
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DANGEROUS SITUATIONS
DANGEROUS SITUATIONS
When using a vehicle equipped with track systems, it is
important to respect the following safety recommendations. It is
strongly recommended that the safety guidelines provided
below are followed to prevent any accidents and serious
malfunctions that could affect the occupants, the vehicle or the
track systems from occurring.
Special recommandations:
• Never exceed vehicle cargo and tow capacity specified
by your vehicle manufacturer on any type of terrain.
• In loaded / working mode (100 kg and over) reduce
significantly your speed and be extra careful on rough
terrain.
• Reduce your speed at all times, a track system
installed on your vehicle does'nt have the same
absorbtion capacity as manufacturer's tires.
• Always operate in 4x4 mode, this significantly reduces
possibility of derailling in any conditions.
Jumping
WARNING
It is strictly forbidden to jump with vehicles equipped with
track systems. These systems were not designed to carry
out this type of operation.
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DANGEROUS SITUATIONS
Steep descents
WARNING
It is not advisable to change direction during steep
descents. 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 UTV is on flat
ground, thus to avoid subjecting the components of the
vehicle and the system to any high stress.
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9
DANGEROUS SITUATIONS
Descending and being stuck in reverse
WARNING
If the rear track systems get stuck in the snow, avoid
moving or towing the vehicle in reverse 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 top of the rear track systems and to compact it using
your feet, behind the systems to dislodge the track.
Shovelling remains the best alternative in this situation.
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DANGEROUS SITUATIONS
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 as it became stuck.
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DANGEROUS SITUATIONS
Driving over an obstacle
Driving over a steep 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
immobilize the vehicle. The best option remains to bypass
this type of obstacle.
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DANGEROUS SITUATIONS
Exceeding the anti-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 the track
system is always fully supported.
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13
DANGEROUS SITUATIONS
Sharp turns in locked 4x4 mode
NOTE: Somes vehicles don’t have unlocked 4x4 mode on the rear
differential, for those vehicles avoid the current situation, take
wider turns instead.
NOTE: Non-compliance with usage recommendations can lead to a
warranty claim refusal.
WARNING
Never do sharp turns in locked diffential 4x4 mode on a
sticky terrain without lubrification. The track system is
designed to slip into the drive system, keeping the vehicle
from being overloaded.
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14
INSTALLATION, REMOVAL AND RE-INSTALLATION
INSTALLATION, REMOVAL
AND RE-INSTALLATION
Always follow good shop practices. The place where you will be
working must be security, clean, bright and well ventilated. If
you are to use a floor jack, never use it as a stand. Always use
appropriate stands. To avoid vehicle movement during
operations, place blocks behind wheels that remain in contact
with the ground. These recommendations also apply when
removing parts.
Read this manual before proceeding with the installation
work. Read Installation Guidelines included 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 of origin (wheels, guards, etc.) such as they
were in the initial condition on the vehicle.
WARNING
Never place body parts under the vehicle unless it is
securely placed on appropriate stands. Severe injuries
could occur if the vehicle collapses or moves. Do not use a
lifting device as a secure stand.
WARNING
Before beginning the installation, ensure you that the
vehicle is immobilized and that the engine is stopped.
WARNING
To avoid any possibilities of burn, leave time at the engine
and the exhaust to cool before beginning the installation of
the system.
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15
INSTALLATION, REMOVAL AND RE-INSTALLATION
Installation
Execute all tasks described in Installation Guidelines of the
vehicle model. Then, proceed to adjust the angle of attack,
alignment and track tension as described in this manual. Test
drive and re-adjust as required.
Removal
CAUTION: Leaving anchor brackets attached 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
and foot rest reinforcement parts.
Using a lifting device, raise the UTV and install appropriate
stands. Ensure that the vehicle is immobilized and safe to work
on.
WARNING
To avoid any injury to your hands during the manipulation
of the systems, we recommend you to manipulate the
systems at places indicated in following figure (near to hub
and near to the anchoring of the anti-pivot).
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16
INSTALLATION, REMOVAL AND RE-INSTALLATION
At the front:
• Remove the anti-rotation bracket cover but keep the
anchor bracket attached to the anti-rotation device on
the track system.
Figure 1
Leave anchor bracket attached to the stabilizing rod.
• Remove track systems.
• Re-install wheels.
At the rear on an independent suspension:
• Same procedure as the front.
At the rear on a rigid axle suspension:
• Disconnect the anti-rotation bar from the skid plate
under the vehicle.
NOTE: Leave the skid plate in place.
• Remove track systems.
• Re-install wheels.
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17
INSTALLATION, REMOVAL AND RE-INSTALLATION
Re-installation
Always clean wheel hubs on the UTV before installing wheels
or track systems.
Figure 2
Clean wheel 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 the torque recommended by the manufacturer.
• Verify track tension. Adjust if required.
• Verify angle of attack. Adjust if required.
• Verify alignment. Adjust if required.
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