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Camoplast 1099-01-1105 User Manual

Manual is about: Tatou UTV 4S Track System

Summary of 1099-01-1105

  • Page 1

    User manual 1099-01-1105 - version b tatou ® utv 4s track system original notice other languages translation available at www.Camoplast.Com 2010-07-09 tatou utv 4s 2011 en.Fm page -2 mercredi, 4. Août 2010 1:20 13.

  • Page 2: Important

    Camoplast inc. 1701, 3 rd avenue grand-mère, (québec) j1x 0e6 canada e-mail : atvtracksystems@camoplast.Com 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 docume...

  • Page 3: Table Of Contents

    Table of contents introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 using the utv with tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 hints and tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 4: Introduction

    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...

  • Page 5

    2 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. 2010-07-09 tatou utv...

  • Page 6: Hints and Tips

    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 tractio...

  • Page 7: Safety

    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...

  • Page 8

    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 avo...

  • Page 9

    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...

  • Page 10: Dangerous Situations

    7 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 coul...

  • Page 11: Steep Descents

    8 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 turnin...

  • Page 12: Warning

    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...

  • Page 13: Warning

    10 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. 2010-07-09 tatou utv 4s 2011 en.Fm page 10 mercredi, 4. Août 2010 ...

  • Page 14: Driving Over An Obstacle

    11 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 optio...

  • Page 15: Terrain

    12 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. 2010-07-09 tat...

  • Page 16: Warning

    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 n...

  • Page 17: Installation, Removal

    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. T...

  • Page 18: Installation

    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 ...

  • Page 19

    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...

  • Page 20: Re-Installation

    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 ...

  • Page 21: Adjustments

    18 adjustments adjustments angle of attack for front tracks systems note: before adjusting your kit, make sure the vehicle is on a hard and flat surface like concrete. No lifting device should be installed. To obtain the correct angle of attack on front tracks systems, perform the following : • loos...

  • Page 22

    19 adjustments figure 4 • set the nut (2) shown on figure 5 until the flat bar reaches 315 ± 5 mm above the ground. For right hand side, rotating the wrench towards a makes the system rotate towards c while rotating the wrench towards b makes the system rotate towards d (reverse for left hand side)....

  • Page 23

    20 adjustments • 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 note: in certain rare cases, where the adjustment of the nut (article 1 on figure 6) compressing the spring, is close to the end of the th...

  • Page 24

    21 adjustments figure 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 with the flat bar, gives harder steering and more stability at high speed...

  • Page 25

    22 adjustments angle of attack for rear track systems to obtain the correct angle of attack on rear tracks systems, perform the following : vehicles with rigid axle or trailing arm suspension • loosen the nut (1) compressing the spring of the stabilizing rod (see figure 8). • set the nut (2) to obta...

  • Page 26

    23 adjustments vehicles with independent suspension • loosen the nut (1) compressing the spring of the stabilizing rod (refer to figure 9). • turn the nut (2) until it comes in contact with both rubber damper and bracket (3). Then, compress the rubber damper by turning the nut (2) one turn. • turn t...

  • Page 27

    24 adjustments note: in some rare cases where the adjustment of the nut (1) compressing the spring is near the end of the threaded rod, extend the rod by unlocking the jam nut (item 3 on figure 10) and unscrew the rod to obtain 19 mm max. Of visible threads. Re-tighten the jam nut. Figure 10 basic t...

  • Page 28: Alignment

    25 adjustments alignment it is required to align the tracks when the vehicle is placed on the ground. Before the measurements, move the vehicle for- wards on a distance of approximately 3 meters. Use a tape for the following measurements. Measure a: measure the distance which separates the external ...

  • Page 29: A -

    26 adjustments measure b: measure the distance which separates the exter- nal plastic wheels of the rear axle on the front track systems. See figures 13 and 14. Figure 13 ( distance between the rear plastic wheels) figure 14 ( distance between the rear plastic wheels) the distance between the outsid...

  • Page 30

    27 adjustments figure 15 (steering mechanism) note: everytime you verify the measurements, move the vehicle back and forth on a distance of approximately 3 meters. Method of ajustment to adjust the utv, first unscrew the nut (1) of the coupling rod of the vehicle's direction system (2), screw or uns...

  • Page 31: Rubber Track Tension

    28 adjustments rubber track tension adjust the tension the rubber track by turning the adjusting nuts of the track tensioner. Adjust track tension. Figure 16 note: the two nuts are screwed on against the other to clamp the tension adjustment. Free the two nuts on against the other and then loosen th...

  • Page 32

    29 adjustments the following table indicates the force (1) applied and the deflection (2) which must occur according to the conditions of use. Figure 17 basic tuning • a higher rubber track tension reduces the risk of “detracking” and reduces drive “ratcheting” (for severe use only). • a lower rubbe...

  • Page 33

    30 installation of a rubber track installation of a rubber track if possible, position the vehicle on a flat and level surface (or on a suitable lift device). Turn off the engine. Proceed as follows : • set rubber track tension to the minimum (refer to figure 18). Figure 18 • remove the two 255 mm w...

  • Page 34

    31 installation of a rubber track figure 19 • install the rubber track note: compare with the other rubber tracks to find the correct orientation. • re-install 255 mm wheels. • adjust track tension. Refer to ‘’rubber track tension’’ on page 28. 2010-07-09 tatou utv 4s 2011 en.Fm page 31 mercredi, 4....

  • Page 35: Break-In Period

    32 break-in period break-in period a break-in period is necessary in order to allow the components of the system to match themselves to each others. During the break-in period (4 hours or 80 kilometers), follow these recommendations : • avoid running under dry and clean conditions. (for example: asp...

  • Page 36: Warning

    33 replacement of a wheel with extractor replacement of a wheel with extractor use tatou extractor # 2000-00-1050 (article 1, figure 20), and the following procedure to make the replacement: figure 20 • remove the rubber cap of the wheel. If the wheel is retaining by a bolt, unscrew it and remove th...

  • Page 37

    34 replacement of a wheel with extractor • place the extractor under the wheel as shown on figure 21 • then screw the threaded rod to remove the wheel. . Figure 21 • insert the new wheel on the shaft until it reaches the shoulder. 2010-07-09 tatou utv 4s 2011 en.Fm page 34 mercredi, 4. Août 2010 1:2...

  • Page 38: Maintenance Schedule

    35 maintenance schedule maintenance schedule for optimum performance and maximum durability, please refer to the following maintenance grid : note: phillips screwdriver. Do not use a brake cleaning solvent to clean the track system. This may damage sealing components and stickers. Warning do not ins...

  • Page 39: Torque Table

    36 torque table torque table storage the best way to store the system is to lay down each frame on its side, away from direct sunlight. Bolt n-m m8 - 8.8 25 m10 - 8.8 50 m10 - 10.9 70 m12 - 10.9 125 2010-07-09 tatou utv 4s 2011 en.Fm page 36 mercredi, 4. Août 2010 1:20 13.

  • Page 40: Wear

    37 wear wear wheel verify the wear of the wheels especially on the interior guidance strip (figure 22). The wheel must be replaced if the inner sur- face (article 1, figure 22) is perforated or when the thickness of the wheel rolling band reaches a thickness of 45 mm. A wheel that is excessively wor...

  • Page 41: Track

    38 wear figure 23 track verify the wear of the track by inspecting the rolling path, the driving lug, the profile and the internal and external condition of the track's carcass. Make sure that the track’s internal structure are not visible at cuts or worn area. Too much wear could cause damage to th...

  • Page 42: Anti-Rotation

    39 wear figure 24 anti-rotation verify the wear of anti-rotation system, mainly at the ball joint (figure 25) to make sure that it is not seized or extremely loose. Ball joint damage could harm the performance of the track sys- tem. Figure 25 2010-07-09 tatou utv 4s 2011 en.Fm page 39 mercredi, 4. A...

  • Page 43: Warranty

    40 warranty warranty camoplast guarantees that the new, unused tatou ® utv 4s system (system) installed by an authorized dealer or distributor is free from any defects in materials and workmanship during the period and in conditions described below. When operating a new tatou ® utv 4s system, the us...

  • Page 44

    41 warranty 4) damage resulting in non-compliance with the user manual and with maintenance instructions recommended in the user’s manual and other technical documents. 5) damage resulting in abusive use, abnormal use, negligence or even a use which does not comply with recommendations of the manual...

  • Page 45: Troubleshooting

    42 troubleshooting troubleshooting problem potential cause correction to do presence of debris in the system. Remove any debris which could prevent the proper operation of the system severe and localized wear of a wheel ( flat spot) replace the part sprocket or wheel frozen remove the ice/snow build...

  • Page 46: Serial Number Location

    43 serial number location serial number location the following pictures show the location of the serial numbers on the track system frame and rubber track. Figure 26 figure 27 2010-07-09 tatou utv 4s 2011 en.Fm page 43 mercredi, 4. Août 2010 1:20 13.

  • Page 47: Technical Support

    44 technical support technical support if your dealer or distributor is unable to solve a problem related with the system, you may contact the camoplast support team from monday to friday. Camoplast inc. 1701, 3 rd avenue grand-mère, (québec) j1x 0e6 canada e-maill : atvtracksystems@camoplast.Com we...

  • Page 48

    45 “ce” declaration of conformity “ce” declaration of conformity ce declaration of conformity we: manufacturer : camoplast inc. Adress : 1701, 3 iÈme avenue grand-mère (québec) canada g9t 2w6 phone : (819) 533-0008 fax : (819) 533-5532 web site : www.Camoplast.Com hereby sole responsability the conf...

  • Page 49

    This page is left intentionally blank. 2010-07-09 tatou utv 4s 2011 en.Fm page 46 mercredi, 4. Août 2010 1:20 13.

  • Page 50

    47 2010-07-09 tatou utv 4s 2011 en.Fm page 47 mercredi, 4. Août 2010 1:20 13.

  • Page 51

    48 item # part # description qty tatou utv4s - my2011 front left & right 1 1001-00-7005 stabilizing rod ass'y, 370 lbs/in 1 2 1008-77-0010 multi hub spacer 1-1/8" ass'y (metric) 1 3 1008-77-0020 multi hub spacer 2" ass'y (metric) 1 4 1009-00-7115 inj sprocket, 15 teeth 1 5 1009-00-7116 inj sprocket,...

  • Page 52

    49 2010-07-09 tatou utv 4s 2011 en.Fm page 49 mercredi, 4. Août 2010 1:20 13.

  • Page 53

    50 item # part # description qty tatou utv4s - my2011 rear left & right 1 1008-77-0010 multi hub spacer 1-1/8" ass'y (metric) 1 2 1008-77-0020 multi hub spacer 2" ass'y (metric) 1 3 1008-77-0040 multi hub spacer 4" ass'y (metric) 1 4 1009-00-7115 inj sprocket, 15 teeth 1 5 1009-00-7116 inj sprocket,...

  • Page 54

    51 2010-07-09 tatou utv 4s 2011 en.Fm page 51 mercredi, 4. Août 2010 1:20 13.

  • Page 55

    52 item # part # description qty tatou utv4s - my2011 independent suspension (is) option 1 1000-00-8002 threaded rod, long 1 2 1001-00-8005 stabilizing rod ass'y, 480 lbs/in 1 3 1015-00-7026 back plate 1 4 1015-00-8005 bracket anti-rot, utv (is) 1 5 1015-05-7005 spacer 5/8", anti-rotation bracket va...