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Camoplast UTV T4S User Manual

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  • Page 2 IMPORTANT The way to use the Camoplast Hi-Performance Tracks Camoplast UTV T4S track system has a direct link with the longevity of the system components. Sportive driving, rapid direction changes and repeated fast turns (more specifically on power steering vehicles) are not advised.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ..........1 SAFETY .

  • Page 4: Introduction

    INTRODUCTION INTRODUCTION Thank you for choosing Camoplast UTV T4S, a Camoplast Hi–Performance Tracks 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.
  • Page 5 SAFETY On the track system frames, the following warning sticker is affixed: USER MANUAL - Every user must read User Manual before attempting to operate vehicle equipped with track systems. If track systems are sold or in any way tranferred to a new user, the User Manual must also be transferred to the new user.

  • Page 6: General Information

    GENERAL INFORMATION 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.

  • Page 7: User Notice And Disclaimer

    USER NOTICE AND DISCLAIMER USER NOTICE AND DISCLAIMER The Camoplast UTV T4S 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 Camoplast UTV T4S System by Camoplast Hi-Performance Tracks.
  • Page 8 Excessive speed remains one of the main causes of severe accidents on UTV. Camoplast Hi-Performance Tracks 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.

  • Page 9: Using The Atv With Tracks

    USING THE ATV WITH TRACKS USING THE ATV WITH TRACKS 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.
  • Page 10 USING THE ATV WITH TRACKS 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.
  • Page 11 USING THE ATV WITH TRACKS 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.
  • Page 12 USING THE ATV WITH TRACKS Towing a vehicle out of the snow WARNING If your vehicle must be towed out of the snow, never tow it in the direction in which it sank. Tow the vehicle in the direction of the trail it left as it became stuck.
  • Page 13 USING THE ATV WITH TRACKS 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.
  • Page 14 USING THE ATV WITH TRACKS 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.
  • Page 15 USING THE ATV WITH TRACKS Driving over an obstacle of more than 12 inches WARNING It is not advisable to attempt to drive over an obstacle of more than 12 inches, such a tree trunk, a stump or a big rock.
  • Page 16 USING THE ATV WITH TRACKS Sharp turns in locked 4x4 mode WARNING Never do sharp turns in locked diffential 4x4 mode on a sticky terrain without lubrication. The track system is designed to slip into the drive system, keeping the vehicle from being overloaded.
  • Page 17 USING THE ATV WITH TRACKS 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. An UTV equipped with the System must never be used for the following activities: races, rallies, jumps, stunts, acrobatics or any other extreme applications.
  • Page 18 USING THE ATV WITH TRACKS WARNING Always operate in 4x4 mode, this significantly reduces possibility of derailling in any conditions. WARNING 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.

  • Page 19: Installation, Removal And Re-Installation

    INSTALLATION, REMOVAL AND RE-INSTALLATION INSTALLATION, REMOVAL AND RE-INSTALLATION 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. Always follow good shop practices.
  • Page 20 INSTALLATION, REMOVAL AND RE-INSTALLATION 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). Installation Execute all tasks described in Installation Guidelines of the vehicle model.
  • Page 21 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. NOTE: Leave anchor bracket attached to the stabilizing rod. Figure 1 • Remove track systems. •...
  • Page 22 INSTALLATION, REMOVAL AND RE-INSTALLATION Re-installation Always clean wheel hubs on the UTV before installing wheels or track systems. Figure 2 NOTE: Clean wheel hubs. • Re-install track systems at the rear and secure stabilizing rod to anchor bracket for rigid axle. •...

  • Page 23: Adjustments

    ADJUSTMENTS ADJUSTMENTS IMPORTANT Verifying your adjustments on the system is mandatory after the first use of the vehicle, the track tension, alignment and angle of attack of the each track systems must be re-verified. Bad adjustments can decrease the performance of the system and create premature wear of certains components Angle of attack for front tracks systems NOTE: Before adjusting your kit, make sure the vehicle is on a hard...
  • Page 24 ADJUSTMENTS • Orient the steering wheel and the track systems straight forward. • Temporarily apply pressure to the front of the track to make sure that it stays flat on the ground. • Install a flat bar on rear wheels of the track systems and measure the height as shown on Figure 4.
  • Page 25 ADJUSTMENTS Figure 5 • Turn the nut (1) until it comes in contact with the spring, then compress the spring by turning this nut 1.5 turns (refer to Figure 6). Figure 6...
  • Page 26 ADJUSTMENTS 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 threaded rod, lengthen the assembly by loosening the locknut (article 3 on Figure 7) and unscrewing the rod end so that a maximum 19 mm of its threads are visible.
  • Page 27 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).
  • Page 28 ADJUSTMENTS Vehicles with independent suspension • Loose the bolts (1) and (2) of the bracket anti-rotation (3) to allow at the anti-rotation retainer (4) to rotate in the axe. (See Figure 9). Figure 9 • Attach the stabilizing rod (1) to anti-rotation bracket installed on the suspension a-arm.
  • Page 29 ADJUSTMENTS • Loosen the nut (3) compressing the rubber cone of the stabilizing rod. The nut does not apply pressure on the rubber cone (refer to Figure 11). Figure 11 • Position the anti-rotation retainer at 90 (perpendicular) with the stabilizing rod. Tightened the two fixation bolts (1 and 2) of the bracket anti-rotation with a torque of 50 N-m.
  • Page 30 ADJUSTMENTS • Turn the nut (3) until the rubber cone are in contact with the housing of the anti-rotation retainer. The nut does not apply pressure on rubber cone (See Figure 13). Figure 13 • Turn the nut (2) until it comes in contact with the spring. Then compress the spring by turning the nut completely twice (See Figure 14).
  • Page 31 ADJUSTMENTS NOTE: In some rare cases where the adjustment of the nut (item 2 on Figure 14) compressing the spring is near the end of the threaded rod, extend the rod by unlocking the jam nut (item 3 on Figure 15) and unscrew the rod to obtain 19 mm max. of visible threads.
  • Page 32 ADJUSTMENTS Alignment It is required to align the tracks when the vehicle is placed on the ground. Before the measurements, move the vehicle forwards on a distance of approximately 3 meters (10 ft). Use a tape for the following measurements. NOTE: Every time the measurement has to be verified, drive in reverse, then, drive forward again on about 3 meters (10 ft).
  • Page 33 ADJUSTMENTS NOTA: It is easier to begin the parallelism adjustment when the adjustment is open (Measure A - Measure B = positive) than when it is closed (Measure A - Measure B = negative). Starting with an open adjustment of the parallelism allow a better precision in the adjustment.
  • Page 34 ADJUSTMENTS Measure A: Measure the distance which separates the external plastic wheels of the front axle on the front track systems. See Figure 18 and Figure 19. Figure 18 (Distance between the front plastic wheels) Figure 19 ( Distance between the front plastic wheels)
  • Page 35 ADJUSTMENTS Measure B: Measure the distance which separates the external plastic wheels of the rear axle on the front track systems. See Figure 20 and Figure 21. Figure 20 ( Distance between the rear plastic wheels) Figure 21 ( Distance between the rear plastic wheels)
  • Page 36 ADJUSTMENTS Rubber track tension WARNING The tensioner mounting bolt must never be loosened while adjusting the track tension. This bolt is designed for assembly and alignment of the tensioner with the frame. The tensioner must always be realigned when this bolt is loosened.
  • Page 37 ADJUSTMENTS Adjust the rubber track tension by turning the adjusting nuts (item 1 on Figure 22) of the track tensioner. Figure 22 NOTE: The two nuts are tightened together to set the tension adjustment. Loosen the jam nut and then raise or lower track tension with the adjusting nut.
  • Page 38 11 kg [24 lb] 19 mm [¾ in] NOTE: Tool 1, used in Figure 24 and shown below in Figure 23, can be bought through an authorized Camoplast Hi-Performance Tracks dealer. The brand is Gates Corporation and the Camoplast part number is 2000-00-3125...
  • Page 39 ADJUSTMENTS Figure 24 Basic tuning • A higher rubber track tension reduces the risk of “detracking” and reduces drive “ratcheting” (for severe use only). • A lower rubber track tension provides better performance, better rolling and better fuel economy (recreational use). Final check Ride at slow speed on a distance of about 1.5 km.

  • Page 40: Installation Of A Rubber Track

    INSTALLATION OF A RUBBER TRACK INSTALLATION OF A RUBBER TRACK WARNING The tensioner mounting bolt must never be loosened while adjusting the track tension. This bolt is designed for assembly and alignment of the tensioner with the frame. The tensioner must always be realigned when this bolt is loosened.
  • Page 41 INSTALLATION OF A RUBBER TRACK • Remove the two 255 mm wheels opposite to the track tensioner side (refer to Figure 26). Figure 26 • Install the rubber track NOTE: Compare with the other rubber tracks to find the correct orientation. •...

  • Page 42: Break-In Period

    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: asphalts, hay or straw field, etc).

  • Page 43: Replacement Of A Wheel With Extractor

    REPLACEMENT OF A WHEEL WITH EXTRACTOR WARNING Do not use air tools to remove the wheels. Use Camoplast extractor # 2000-00-1050, and the following procedure to make the replacement: Figure 27 • Remove the rubber cap of the wheel. If the wheel is retaining by a bolt, unscrew it and remove the wheel.
  • Page 44 REPLACEMENT OF A WHEEL WITH EXTRACTOR • Install the extractor under the wheel as shown on Figure 28 • Then screw the threaded rod to remove the wheel. Figure 28 • Hit the end of the threaded rod to shake the wheel loose.

  • Page 45: Tensioner Alignment

    Follow closely the next steps to align the tensioner. Use Camoplast alignment tool # 2000-00-1999 (item 1 on Figure 29) to align tensioner by means of the following procedure: Attach the alignment tool to system frame using the provided tie wraps.
  • Page 46 TENSIONER ALIGNMENT Position tensioner wheel shaft ends in the corners of the tool notches. Attach alignment tool to the track system frame using the provided tie wraps Refer to Figure Figure 30 WARNING Make sure that the wheel shaft ends are seated on all 4 surfaces of the alignment tool.
  • Page 47 TENSIONER ALIGNMENT IMPORTANT: If the wheel shafts are not perfectly seated on the alignment tool surfaces, pivot the tensioner to adjust the position. Refer to Figure 31. Figure 31 WARNING Make sure the wheel shaft ends are well seated on all 4 surfaces of the alignment tool before tightening the tensioner mounting bolt to its final position.
  • Page 48 TENSIONER ALIGNMENT Torque tensioner nut to 33 N-m. Refer to Figure 32. Figure 32 Remove the alignment tool from the track system frame.

  • Page 49: Maintenance Schedule

    MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE WARNING Do not insert hands nor feet into or near the system unless the engine is off, and the vehicle is stopped with the security brake engaged. For optimum performance and maximum durability, please refer to the maintenance grid on the following page:...
  • Page 50 MAINTENANCE SCHEDULE PRE-USE 10 HRS A: ADJUST C: CLEAN 20 HRS I: INSPECT L: LUBRICATE 25 HRS R: REPLACE 40 HRS 50 HRS 100 HRS / YEARLY LEGEND PART/TASK NORMAL WINTER CONDITIONS BOLTS TORQUE I, A I, A VEHICLE ALIGNMENT I, A I, A (1) REPLACE...
  • Page 51 NOTE: Do not use a brake cleaning solvent to clean the track system. This may damage sealing components and stickers CAUTION: When pressure washing the track systems, care must be taken to keep the water stream away from wheel bearing seals and rubber caps. CAUTION: If stabilizer rubber cone bores show sign of wear and oval deformation, they must be replaced along with the bolt and washer.

  • Page 52: Lubrication

    LUBRICATION LUBRICATION...
  • Page 53 LUBRICATION LUBRICATION...
  • Page 54 LUBRICATION LUBRICATION The Maintenance Schedule on page 46 includes lubrication maintenance that should be performed on track systems. Refer to the following recommendations for optimal lubrication. NOTE: Use a water-resistant anti-friction synthetic grease. Aerochem MF grease is recommended. REFERENCE “ A ” 132MM WHEEL BEARING SEAL LUBRICATION Apply evenly 1 to 1.5 CC (cubic centimeter) of grease on and between the wheel bearing seal lips.
  • Page 55 LUBRICATION REFERENCE “ B ” 255MM TIRE BEARING SEAL LUBRICATION Apply evenly 1 to 1.5 CC (cubic centimeter) of grease on and between the tire bearing seal lips. Apply over the entire circumference (360°).
  • Page 56 LUBRICATION REFERENCE “ C ” WHEEL SHAFT SEAL BEARING DIAMETER LUBRICATION Apply evenly 1 to 1.5 CC (cubic centimeter) of grease on the wheel shaft and seal bearing diameter over their entire circumference (360°) and width.
  • Page 57 LUBRICATION REFERENCE “ D ” HUB BEARING SEALS LUBRICATION Apply evenly 1.5 to 2 CC (cubic centimeter) of grease between the hub seal’s lips and over its the entire circumference (360°). IMPORTANT : the hub seal must not extend beyond the hub face.
  • Page 58 LUBRICATION REFERENCE “ E ” LUBRICATION OF THE HUB SPEED SLEEVE Apply 1 to 1.5 CC (cubic centimeter) of grease over the entire width and circumference (360°) of the hub speed sleeve.
  • Page 59 LUBRICATION REFERENCE “ F ” FRAME TUBING - TENSIONER SIDE WARNING Tensioner must always be realigned when is deassembly. Refer to Tensionner aligment section. Apply evenly a thin coat of grease, oil or spray lubricant inside the frame tubing, over the entire inner circumference (360°) and to a depth of about 12 to 15 cm (5 to 6 in).
  • Page 60 LUBRICATION REFERENCE “ G ” STABILIZER SHAFT LUBRICATION Apply evenly 1 to 1.5 cc (cubic centimeter) of grease all around (360°) the stabilizer shaft and over its entire length.
  • Page 61 LUBRICATION REFERENCE “ H ” STABILIZER SHAFT BORE LUBRICATION Apply evenly 1 to 1.5 cc (cubic centimeter) of grease inside the stabilizer shaft bore, over its entire length and circumference (360°).
  • Page 62 LUBRICATION REFERENCE “ I ” STABILIZER MOUNTING BOLT HEAD LUBRICATION Apply evenly 0.75 to 1.5 cc (cubic centimeter) of grease on the stabillizer mounting bolt head. Apply over the entire circumference (360°).
  • Page 63 LUBRICATION REFERENCE “ J ” BUSHING LUBRICATION - RIGID SUSPENSION ARM On vehicles with rigid rear suspension, apply evenly 0.5 to 1 CC (cubic centimeter) of grease on the inner o-ring of the rigid suspension arm bushing. Apply over the entire circumference (360°).
  • Page 64 LUBRICATION REFERENCE “ K ” FRONT TRACK SYSTEM STABILIZING ARM LUBRICATION Apply spray lubricant (e.g. motorcycle chain grease) all around the stabilizing arm compression spring and over its entire length.
  • Page 65 LUBRICATION REFERENCE “ L ” REAR TRACK SYSTEM STABILIZING ARM LUBRICATION (INDEPENDENT SUSPENSION) Apply spray lubricant (e.g. motorcycle chain grease) all around the stabilizing arm compression spring and over its entire length.
  • Page 66 LUBRICATION REFERENCE “ M ” REAR TRACK SYSTEM STABILIZING ARM LUBRICATION (RIGID AXLE SUSPENSION) Apply spray lubricant (e.g. motorcycle chain grease) all around the stabilizing arm compression spring and over its entire length.

  • Page 67: Storage

    TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Refer to the exploded views at the end of the Manual to obtain torque specifications applied to bolts at important points on the track system. NOTE: Use a threadlocker Loctite 263 type or its equivalent at the indicated places in the explode view of the system in this manual.

  • Page 68: Wear

    WEAR WEAR Wheel Verify the wear of the wheels especially on the interior guidance strip (Figure 34). The wheel must be replaced if the inner surface (1) is perforated or when the thickness of the wheel rolling band reaches a thickness of 45 mm. A wheel that is excessively worn will not offer enough support for the track's guidance.
  • Page 69 WEAR Urethane tire Verify the wear of the urethane tires especially on the interior guidance strip (1) and between the tire profiles (2). The wheel must be replaced if the inner surface is worn out or the tire is cracked between the tire profiles. A wheel that is excessively worn will not offer enough support for the track's guidance.
  • Page 70 WEAR Track Guide Verify the wear of the track guide by measuring the width of the guide. If dimensions of the guide illustrated in Figure 36 are lower than 5 mm, at any place, replace the part. If the guidance strip is worn so that the concave shape is no longer visible, replace the part.
  • Page 71 WEAR Sprocket Check the wear of the sprocket by measuring the part as illustrated on Figure 37. Replace the part when the dimension shown is less than 19 mm. An excessive wear could lower the efficiency of the drive of the track and reduce the system’s performance.
  • Page 72 WEAR Anti-rotation Verify the wear of anti-rotation system, mainly at the ball joint (Figure 38) to make sure that it is not seized or extremely loose. Ball joint damage could harm the performance of the track system. Figure 38...

  • Page 73: 2-Year Limited Warranty

    The UTV Camoplast UTV T4S track system is covered by a manufacturer warranty (warranty).
  • Page 74 (24) months from the date of original System purchase. In all cases, the warranty is limited to a maximum of the original purchase price or the fair market value of the System. Camoplast Hi-Performance Tracks will have final authority in determining the fair market value of a used System.
  • Page 75 System to the dealer location are the responsibility of the System owner. Camoplast Hi-Performance Tracks reserves its sole and exclusive right to update or modify this warranty without impact on end users. All previous terms and conditions of the warranty at time of...

  • Page 76: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING TROUBLE SHOOTING Problem Potential cause Correction Remove any debris which could Presence of debris in the system. prevent the proper operation of the system Severe and localized wear on a Replace the part wheel (flat spot) Remove ice/snow build-up.

  • Page 77: Serial Number Location

    SERIAL NUMBER LOCATION SERIAL NUMBER LOCATION The following pictures show the location of the serial numbers on the track system frame (Figure 39) and rubber track (Figure 40). Figure 39 Figure 40...

  • Page 78: Technical Support

    If your dealer or distributor is unable to solve a problem related with System, contact Camoplast Hi–Performance Tracks support team from Monday to Friday. Camoplast Solideal Inc. 4162, Burrill - Local A Shawinigan, (Québec) G9N 0C3 CANADA E-maill : atvtracksystems@camoplastsolideal.com Website : www.camoplastsolideal.com...

  • Page 79: Ce'' Declaration Of Conformity

    ’’CE’’ DECLARATION OF CONFORMITY ’’CE’’ DECLARATION OF CONFORMITY "CE" DECLARATION OF CONFORMITY 0$18)$&785(5  CAMOPLAST SOLIDEAL INC. $''5(66   %XUULOO /RFDO $ 6KDZLQLJDQ 4XpEHF  &DQDGD *1 & 3+21(  )$;  :(% 6,7(  ZZZFDPRSODVWVROLGHDOFRP HEREBY DECLARE THAT THE PRODUCT SERIES 352'8&7  879 7UDFN 6\VWHPV...
  • Page 80 This page is left intentionally blank.
  • Page 82 TRACK TENSIONER AND NUTS ASS'Y / TENSIONNEUR CHENILLE ET ÉCROUS ASSEMBLÉ 1083-00-8002 STICKER - WARNING / AUTOCOLLANT - AVERTISSEMENT STICKER - SERIAL NUMBER / AUTOCOLLANT - NO SÉRIE - TATOU UTV T4S 41-A 1083-00-8100 STICKER - FRONT LEFT PICTOGRAM / DÉCALQUE PICTOGRAMME AVANT GAUCHE...
  • Page 84 TRACK TENSIONER AND NUTS ASS'Y / TENSIONNEUR CHENILLE ET ÉCROUS ASSEMBLÉ 1082-00-7050 1083-00-8002 STICKER - WARNING / AUTOCOLLANT - AVERTISSEMENT STICKER - SERIAL NUMBER / AUTOCOLLANT - NO SÉRIE - TATOU UTV T4S 39-A 1083-00-8120 STICKER - REAR LEFT PICTOGRAM / DÉCALQUE PICTOGRAMME ARRIÈRE GAUCHE...
  • Page 86 ITEM # PART # DESCRIPTION TATOU UTV T4S MY2013 INDEPENDENT SUSPENSION (IS) 1000-00-8002 THREADED ROD, LONG / TIGE FILETÉE, LONGUE 1001-00-8005 STABILIZING ROD ASS'Y / BRAS STABILISATEUR ASSEMBLÉ - 480 LBS/IN 1015-00-7026 BACK PLATE (METRIC) / PLAQUE DE FIXATION ARRIÈRE (MÉTRIQUE) 1015-00-8250 UNIVERSAL BRACKET ANTI-ROT.
  • Page 88 ITEM # PART # DESCRIPTION TATOU UTV T4S MY2013 RIGID SUSPENSION (RS) 1015-00-7026 BACK PLATE / PLAQUE DE FIXATION ARRIÈRE 1015-00-8004 LH, BRACKET ANTI-ROTATION UTV (RS) / ANCRAGE ANTI-ROTATION UTV, GAUCHE (ER) 1015-00-8014 RH, BRACKET ANTI-ROTATION UTV (RS) / ANCRAGE ANTI-ROTATION UTV, DROIT (ER) 1035-12-A050 HEX SCR FLANGE / VIS HEX À...

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