All-Track Service: AT-80HD Operator Manual
All-Track Service: AT-80HD Operator Manual
All-Track Service: AT-80HD Operator Manual
SERVICE
AT-80HD
OPERATOR MANUAL
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................ 1
INTRODUCTION .................................................................................................. 2
SPECIFICATIONS
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ALL-TRACK SERVICE
AT-80 HD
Introduction
The All-Track Service machine which you have purchased is capable of providing
many hours of reliable service when maintained properly. The vehicle is the
result of many years in the All-Terrain vehicle industry. The vast amount of
engineering knowledge and technical skill gained from the past has been
combined to build vehicles which offer exceptional performance, reliability, and
durability.
The operator’s manual is presented to furnish you with the necessary information
for operating and maintaining your vehicle. Its primary purpose is to assist you,
the operator, in lubricating, and adjusting the vehicle for daily and seasonal
operations. You are urged to study its contents thoroughly in order to derive the
greatest benefit from the features built into this machine. While this vehicle is
designed with the safety of the operator in mind, the possibility of an accident
cannot be completely eliminated until you understand and practice all safety
precautions. The vehicle is designed to operate in severe conditions and
therefore operates differently than an automobile. Every vehicle operator should
become familiar with this manual, and its contents in order to safely operate the
machinery and to avoid downtime and repairs.
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ALL-TRACK SERVICE
AT-80 HD
Safety Precautions
Never refuel vehicle when engine is hot or running. Do not smoke when
refueling.
Never attempt to cross a body of frozen water unless you are absolutely
sure that it is safe to do so. Be sure to allow for the extra weight of
passengers and load.
On slippery surfaces like ice, loose gravel, etc… vehicle can slide into
obstacles or off path when operating on a sidehill.
You may not be able to traverse some hills that you can climb. Never
attempt to turn vehicle around on a hill. Drive up and back down if
necessary.
Never dismount from moving vehicles; wait until stopped and park brake is
engaged.
Always keep a first aid kit and fire extinguisher in vehicle in case of
emergency
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ALL-TRACK SERVICE
AT-80 HD
Investigate unknown terrain for large rocks, drop offs, etc….. which may
be hidden in plain sight.
Always park the vehicle traverse to slopes. Never park vehicle so that it is
headed up or down a steep hill.
Equipment and payload affect the performance of the vehicle and this
should be taken into account when negotiating marginal terrain, ground
conditions, or steep slopes.
Preventative Measures
Always match the speed of the vehicle to the terrain conditions in which
you are driving on. Striking hidden objects such as rocks or stumps may
cause damage to suspension and track tensioning system.
When operating on steep grades, special care must be taken to monitor
engine and hydrostatic oil pressure to prevent costly and serious repairs.
Tracks should not be run any tighter than necessary. Tracks that are run
too tight rob horsepower and cause track parts to wear much faster than
normal.
Watch out for obstacles which may damage suspension and track tension
assemblies. Even at slow speeds, sudden bumps can cause severe
impact on the machinery.
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ALL-TRACK SERVICE
AT-80 HD
Operating Instructions
Pre-Operation Checklist
Before the vehicle is driven, the operator should check the following to become
familiar with the vehicle and also avoid undue repairs and down time.
Check oil levels in engine crank case, gear drive and hydrostatic tank.
Be sure to check the radiator coolant level, crankcase oil level, as well as
hydraulic, pump drive, and hub oil prior to start up. Be sure that the direction
selector is in the neutral position and that the park brake is turned on. Remember
to turn on main battery switch located under driver seat. It is now safe to start
engine.
When operating in low temperatures, the engine and hydraulic system should be
pre- heated to avoid engine and hydrostatic transmission damage. You should
not use either, as the engine is equipped with glow plugs, and either could create
a premature ignition condition.
Once engine is started, check engine and hydrostatic vitals for out of the ordinary
readings. Shut down engine immediately and investigate cause of reading if
previously mentioned condition is encountered.
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ALL-TRACK SERVICE
AT-80 HD
As with all two track carriers, the AT-80HD is steered by applying differential
track speeds to turn vehicle. The vehicle is equipped with a digital electronic
steering wheel, direction selector, and foot pedal in order to simulate the
operation of a standard wheel driven motor vehicle. The vehicle is driven by two
infinitely variable hydrostatic transmissions which control the power, speed, and
torque of each track. The vehicle is equipped with two working ranges “high” and
“low”. High range provides 0-12 MPH of moderate torque and “low” provides 0-8
MPH of high torque. The vehicle is also equipped with a counter-rotate disable
switch. This feature is used to reduce the sensitivity in the steering wheel for
situations that do not require the vehicle to rotate on its axis such as driving on a
road or trail. If you require additional maneuverability, deactivate switch and the
vehicle will now counter rotate when the steering wheel is all the way to the right
or the left.
To steer the vehicle, simply choose direction of travel with the direction selector,
apply pressure to accelerator, and steer vehicle in desired direction of travel. The
machine steers similar to a regular truck or car. The vehicle will not move until
you select a direction of travel, and depress the accelerator pedal. To stop the
vehicle, slowly release accelerator and the hydrostatic systems acts as a brake.
Do not suddenly stop vehicle at high speeds as decelerating too quickly can
cause tracks to skip on drive sprockets as well as apply unnecessary shock
loading to hydrostatic system. When climbing a hill, and you wish to hold a
position, you must engage the parking brake or natural leakages within the
hydrostatic system will cause it to creep backwards.
If operating in very deep muskeg or mud, or operating with a very heavy load, it
may feel like the vehicle is not responding to steering input. This is because one
side of the hydrostatic transmission has surpassed maximum system pressure
and has begun to bypass motors through the relief valve. If such a situation is
encountered, be sure to check that the motors are in “low” and straighten
steering while pressing accelerator until both tracks begin to turn. Once the
vehicle is moving once again, it will be possible to complete the turn in smaller
increments.
In order to decrease the strain on undercarriage and drive system, try to avoid
making sharp turns in soft ground or on extreme grades. Rather, a series of
wider turns should be completed in order to decrease stresses encountered
when turning in soft ground.
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ALL-TRACK SERVICE
AT-80 HD
Models equipped with dual hydraulic joysticks are driven in a similar manner to
any hydrostatic skid steer vehicle. Pushing the joysticks forward or back control
the pumps independently which control the hydrostatic motors. Pushing the
joysticks to the farthest extreme gives you the most speed, but the least torque.
For maximum torque, press the levers only slightly in the direction of travel and
the vehicle should have enough torque in low speed for nearly any condition.
Models equipped with dual joysticks are also equipped with a control lockout
switch to be used to disable the controls when operating equipment like knuckle
boom cranes or other machine driven equipment. When operating a vehicle with
dual joysticks, it is important to maintain steady pressure and avoid jerky
operation as this can make for a rough ride as well as increase wear on drive
train and suspension components.
Do not attempt to make very sharp turns in extremely deep mud or ruts as this
may cause the tracks to be pulled off of the machine. It is better to make a series
of larger turns to navigate an obstacle if possible. If a situation is encountered
where the tracks begin to run off the machine, the situation can usually be
remedied by moving the vehicle slowly in the opposite direction of travel. This
maneuver will almost always return the tracks to their proper alignment. If tracks
persist to run off machine, it may be necessary to increase the track tension by
pumping some grease into the track adjusting cylinder.
Models equipped with a single hydraulic joysticks are controlled by pushing the
joystick in the direction you wish to travel. The further it is moved, the faster the
machine will travel. Pushing the joystick fully forward will provide straight forward
travel, and moving it in reverse will provide straight, rearward travel. By moving
the joystick to one side or the other while pushing the joystick forward will start to
initiate a turn in direction that it is pressed. Once the joystick reaches 45deg.
from the centerline, it will stop one track, and continue driving the opposite track
to allow a drag turn around the stopped track.. If the joystick is moved further up
to 90 Deg. from its centerline, it will counter-rotate by moving one track in a
forward direction, and the other in a reverse direction.
If a situation is encountered where the engine begins to bog down, bring the
joystick towards neutral until engine speed is recovered while continuing to travel
in a forward direction. This will allow the engine speed to increase and offer the
most torque possible.
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ALL-TRACK SERVICE
AT-80 HD
Operating (continued)
When approaching steep grades, it is recommended that the motors are in the
low speed position. This is to ensure that maximum torque is available to climb or
hold machine on incline and to avoid shifting the motors in a high stress situation.
If it is desired to hold a position on an incline, activate the park brake and ample
holding power will hold vehicle on any incline. In the event that the machine
experiences a loss of engine power, the park brakes will be automatically
activated to prevent a runaway situation.
Allow engine to run for at least five minutes at low engine RPM setting to
allow for uniform engine and turbocharger cooling.
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ALL-TRACK SERVICE
AT-80 HD
Engine
Consult manufacturer’s service manual
Cooling System
Frequent cleaning of outside of radiator is recommended. Clear often to allow
free flow of air to radiator. Check coolant level daily.
Pump Drive
Consult manufacturer’s service manual
Check oil frequently
Lubrication
Pump grease into the walking beam center cap daily to ensure that the bearings
are well lubricated. Wheel hubs are equipped with oil bath lubrication, but should
be inspected daily to check for low oil or leaky seals. Oil is only necessary to be
replaced if it appears to be contaminated or if the hub is removed from the
spindle.
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ALL-TRACK SERVICE
AT-80 HD
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ALL-TRACK SERVICE
AT-80 HD
Track Repairs
As a loss of control is experienced when a track is off, it is important that
the track be inspected daily for cuts, deteriorated sections, and tension
adjustment.
Track Tension
Proper track tension is very important when operating a tracked vehicle. Too
much track tension, and wear and tear is increased dramatically on the track and
drive sprockets. Too little track tension and the possibility of the vehicle leaving
its track become much higher and can cause the track to rub on suspension
components. Track tension is determined to be correct when slack is removed
from track and it just begins to rise off the top of the load wheels on flat ground. If
you notice excessive sprocket skipping when vehicle is in motion, it may be
necessary to increase track tension.
To release track tension, unscrew pressure release fitting until grease starts to
flow through the grease port. Doing this allows the idler wheel to swing back
releasing tension.
Tip: Driving the vehicle in a series of quick back and forth movements aids in
releasing track tension once pressure release fitting is backed off.
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ALL-TRACK SERVICE
AT-80 HD
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ALL-TRACK SERVICE
AT-80 HD
(NOTE: IDLER SPINDLE HAS ONLY 1 HOLE IN SPINDLE. PLEASE SPECIFY “IDLER SPINDLE” WHEN ORDERING
PARTS)
ITEM
PART NUMBER DESCRIPTION QTY.
NO.
1 75S-8003OB WHEEL SPINDLE 1
2 75S-8013OB OIL BATH SEAL HOUSING 1
3 3767, 3720 INNER SPINDLE BEARING 1
4 75S-8001OB 6 STUD H/D HUB 1
5 75S-8002OB OIL BATH HUB CAP 1
HX-SHCS 0.3125-
6 CAPSCREW 4
18x0.875x0.875-N
7 4964R WHEEL STUD 6
8 3578, 3525 OUTER SPINDLE BEARING 1
9 TP #2x1.5 PIN 1
10 75S-8002G HUB CAP GASKET 1
12 9W6647 METAL FACE SEAL 2
13 FW 1.25 TANG WASHER 1
14 HSNUT 1.2500-12-D-N CASTILLATED NUT 1
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ALL-TRACK SERVICE
AT-80 HD
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ALL-TRACK SERVICE
AT-80 HD
ITEM
PART NUMBER DESCRIPTION QTY.
NO.
1 75S-8011 WALKING BEAM 1
2 75S-8004 WALKING BEAM SPINDLE 1
3 HM212011 CUP, OUTER 1
4 HM212044 Cone, Outer 1
5 655 Cone, Inner 1
6 653 CUP, Inner 1
7 BB4254 W/BEAM SPINDLE NUT 2
8 OIT-1124 W/BEAM SPINDLE WASHER 1
9 spindle nut pin Spindle Pin 1
10 624-1-4281 GASKET, HUB CAP 1
11 624-6-4267 HUB CAP. W/B 1
HBOLT 0.2500-
12 Walking beam hub cap bolts 6
28x1.25x0.75-N
13 455041 National Seal 1
14 624-1-4290 skinner ring 1
15 #406 CLAMP 1
not Heavy Duty Wheel with Split
75S-8011 2
shown Ring
not
75S-8016 650X16 solid rubber tire 2
shown
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ALL-TRACK SERVICE
AT-80 HD
Track Assembly
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ALL-TRACK SERVICE
AT-80 HD
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ALL-TRACK SERVICE
AT-80 HD
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ALL-TRACK SERVICE
AT-80 HD
ITEM
PART NUMBER DESCRIPTION QTY.
NO.
1 75S-8008 Track tensioning cylinder 1
4 Washer 1
FW 7/8"
5 7/8" UNF Nut 1
6 20-2-217 pressure relief fitting 1
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ALL-TRACK SERVICE
AT-80 HD
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ALL-TRACK SERVICE
AT-80 HD
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ALL-TRACK SERVICE
AT-80 HD
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ALL-TRACK SERVICE
AT-80 HD
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ALL-TRACK SERVICE
AT-80 HD
LUBRICATION TABLE
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ALL-TRACK SERVICE
AT-80 HD
CONTACT INFORMATION
Visit us at www.all-track.ca
ALL-TRACK SERVICE
4281-23RD ST. N.E.
CALGARY AB. CANADA
T2E 6Y2
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