HD4/HD4PRO TRACK SYSTEM OPERATING, MAINTENANCE AND INSTALLATION MANUAL
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 1 OPERATING, MAINTENANCE AND INSTALLATION MANUAL HD4/HD4PRO TRACK SYSTEM
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 2 SYMBOLS USED WARNING These boxes warn of incorrect behavior that could result in serious injury or death. CAUTION: These paragraphs describe actions that may cause minor injury or damage to equipment. This logo indicates the optimal operation to maximize the use and lifespan of your product. This label is visible on the track system and warns of the danger posed by the rotating sprocket and wheels. Always be aware of these components. These symbols are visible on the frames and indicate the location of the tracks: front left, front right, rear left, and rear right. This label is visible on each frame of a track kit to show the part number and serial number.
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 3 TABLE OF CONTENT SYMBOLS USED ...................................................................................................................................................................................... 2 TABLE OF CONTENT ............................................................................................................................................................................ 3 INTRODUCTION..................................................................................................................................................................................... 4 PATENTS .................................................................................................................................................................................................. 4 Section 1. IMPORTANT INFORMATION ........................................................................................................................................ 5 1.1. Tools Required for Installation .....................................................................................................................................................5 1.2. Tools Required for Maintenance/Part Replacement ..........................................................................................................5 1.3. How the Vehicle is Affected ............................................................................................................................................................5 1.4. Dangerous Behaviors Related to the Use of a Track System ...........................................................................................6 1.5. Capacity ....................................................................................................................................................................................................7 Section 2. BREAK-IN AND MAINTENANCE ................................................................................................................................... 8 2.1. Break-in Period.....................................................................................................................................................................................8 2.2. Maintenance ...........................................................................................................................................................................................9 2.3. Maintenance Table ........................................................................................................................................................................... 11 2.4. Tracks.....................................................................................................................................................................................................12 2.5. Wheels ...................................................................................................................................................................................................12 2.6. Sprockets .............................................................................................................................................................................................. 12 Section 3. INSTALLATION ................................................................................................................................................................13 3.1. Before you Begin ...............................................................................................................................................................................13 3.2. When Lifting the Vehicle ...............................................................................................................................................................13 3.3. Unpacking ............................................................................................................................................................................................13 3.4. Bracket Installation .........................................................................................................................................................................14 3.5. Front Track Installation.................................................................................................................................................................14 3.6. Rear Track Installation ..................................................................................................................................................................16 Section 4. ADJUSTMENTS .................................................................................................................................................................17 4.1. Alignment of Steering with Tracks ...........................................................................................................................................17 4.2. Track Tension ..................................................................................................................................................................................... 18 4.3. Front Track Pitch Adjustment ....................................................................................................................................................19 4.4. Rear Track Preload Adjustment ................................................................................................................................................20 4.5. Suspension Preload Adjustment................................................................................................................................................20 Section 5. REMOVAL AND STORAGE ............................................................................................................................................21 Section 6. QUICK DIAGNOSTIC .......................................................................................................................................................22 Section 7. TIGHTENING TORQUE ..................................................................................................................................................23 Section 8. EXPLODED VIEWS ..........................................................................................................................................................24 8.1. Front Track System .........................................................................................................................................................................24 8.2. Front Track System Tightening Torque .................................................................................................................................26 8.3. Rear Track System ...........................................................................................................................................................................27 8.4. Rear Track System Tightening Torque ...................................................................................................................................29 Section 9. SPARE PARTS ...................................................................................................................................................................30 Section 10. REPLACEMENT PROCEDURE ...................................................................................................................................31 10.1. Before You Begin ............................................................................................................................................................................31 10.2. Replacement of the Tracks ........................................................................................................................................................31 10.3. Replacement of the Sprocket ....................................................................................................................................................33 10.4. Replacement of the Main Axle or its Bearing ....................................................................................................................33 10.5. Replacement of a Wheel Bearing ............................................................................................................................................36 10.6. Replacement of the Tensioner .................................................................................................................................................38 10.7. Replacement of the Comfort Slide ..........................................................................................................................................39 10.8. Replacement of a Pivoting Tandem .......................................................................................................................................41 10.9. Replacement of a Pivoting Axle ...............................................................................................................................................41 10.10. Replacement of Stub Axles ......................................................................................................................................................42 10.11. Greasing the Pivoting Tensioner ..........................................................................................................................................43
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 4 INTRODUCTION This HD4/HD4PRO track system, thanks to its performance and robust design, will give you peace of mind while you work and play all year round across forests, mountains, and snow. It is important to note that track systems allow for easier crossing where wheels may struggle. Under no circumstances should you exceed the limits specified for your vehicle and listed in its owner’s manual. These vehicles are designed for wheels, not tracks, so pushing the limits of the tracked vehicle is even more dangerous. Unlike wheels, tracks do not absorb impact. This could result in breakage or a loss of control, leading to serious injuries or death. All users of this product must be informed of and understand the following: • Refer to the vehicle manual for a comprehensive list of its particularities and limitations. • This manual outline all the features and limitations of the track system. Failure to follow the warnings in these manuals may result in situations with potentially fatal consequences. PATENTS Some technological aspects of the SOUCY HD4PRO / KIMPEX COMMANDER HD4 may be covered by one or more pending patent applications and/or granted patents. Refer to https://www.soucy.com/patents for more information.
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 5 Section 1. IMPORTANT INFORMATION 1.1. Tools Required for Installation • 3/8 drive wheel nut short socket(usually 17 or 19 or 21mm) with a 150 mm (6 in.) extension bar, 3/8 to ½ drive adapter, 22 mm socket wrench • 24 mm wrench and a crescent wrench • Spirit level • Measuring tape • Jack and jack stands When travelling, it is recommended to always have 17 mm, 19 mm, 22 mm, 24mm sockets and a crescent wrench. Bringing an axe, a shovel and a tow line can also be helpful in case of emergency. To ensure proper torque is applied to bolts, it is recommended to use a torque wrench. 1.2. Tools Required for Maintenance/Part Replacement • 3/8 drive wheel nut socket(usually 17 or 19 or 21mm), 10 mm, 17 mm, 19 mm, 22 mm, and 24 mm socket wrench, 3/8 to ½ drive adapter, with a 150 mm (6 in.) extension bar • 10 mm, 17 mm, 19 mm, 22 mm and 24 mm wrenches and a crescent wrench • 4mm and 10mm hex bit socket • Spirit level • Measuring tape • Jack and jack stands To ensure proper torque is applied to bolts, it is recommended to use a torque wrench. 1.3. How the Vehicle is Affected Installing a track system on your vehicle will alter your driving experience. The vehicle will have new dimensions (wider, longer, and higher), be heavier and have greater traction on hard surfaces, but not on slippery surfaces like ice or muddy clay. This will significantly affect braking distances and maneuverability. However, the vehicle will be more stable, and capable of handling snow, mud, and slopes like never before. Running on tracks reduces vehicle speed by around 35%-50% (ratio depends on vehicle’s OEM tire diameter and sprocket diameter) but does not affect vehicle’s payload or pulling capacities. Although loads can be handled more easily than with wheels, the vehicle is not designed for loads greater than those indicated in the vehicle manual. M6 : 10 mm M10 : 17 mm M12 : 19 mm M14 : 22 mm M16 : 24 mm
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 6 1.4. Dangerous Behaviors Related to the Use of a Track System WARNING 1. Do not attempt to skid the vehicle’s tracks. 2. Use the vehicle only in 4-wheel drive mode. 3. Operating the vehicle in snowy conditions can cause an ice film to form on the brake discs. Periodically apply the brakes while driving to remove it. 4. Keep in mind that braking distance may change (increase or decrease). 5. To avoid losing control, do not block the tracks while braking. 6. Before exploring new areas, ensure a safe return. 7. Prior to any inspection or use, verify that there is no mud, snow, ice, or debris obstructing the proper function of the track system or vehicle. 8. The vehicles are designed for wheels, not tracks, which makes it even more dangerous to push the limits of the vehicle. CV joints, tie rods and suspension arms are put to the test during sharp turns, even at low speeds, and can break down at higher speeds. 9. Never attempt jumps. While the wheels absorb some of the impact of a jump, the tracks do not. This can result in serious injury or death due to loss of control or breakage. 10. When getting your vehicle unstuck, do not attempt to press the accelerator pedal while standing beside it. This could cause you to fall under the vehicle. 11. When trying to climb in/on a vehicle taller than you, be careful of sloping terrain that could cause the vehicle or you to tip over. 12. Do not use the tracks as a footboard to prevent injury. 13. When using towed or pushed attachments, make sure to operate at low speeds. The use of attachments (sled, shovel, snowplow, rotary broom, etc.) can cause load levels that exceed those of a vehicle without attachments, which may result in sudden breakage. 14. Do not attempt to touch the track system components with your hands or feet while the vehicle is in motion, as this poses a serious risk of injury. Your hands could become caught between the components. For this reason, always stop the engine, remove the key from the ignition, and apply the handbrake if you need to check the track system. 15. Snow and mud can hide obstacles such as pits, branches, stumps, rocks, or fences which can destabilize the driver and cause them to lose control of their vehicle, even if they are small and unseen. 16. The rear track is not suitable for crossing large obstacles or driving in reverse on snow. Please exercise caution when reversing. 17. When reinstalling the vehicle’s original wheels, it is necessary to remove all track system components. The use of these parts is not recommended for wheeled vehicles. 18. After the first three hours of use, and after each repair or replacement of the track system components, it is important to check for any necessary tightening and adjustments. 19. In wet weather, tracks can be just as slippery as wheels, increasing the risk of skidding. 20. In winter, frozen bodies of water may seem tempting, but it is important to exercise caution. It is not safe to assume that just because snowmobiles can pass through, you can too. Vehicles with tracks are typically heavier, slower, and less maneuverable in deep snow than snowmobiles. 21. When navigating obstacles or rocky terrain, the steering system is put under significant strain. This can cause jerking of the handlebars/steering as the vehicle climbs over the obstacle. 22. Steep slopes may be more accessible with tracks than with wheels, but it is important to remember that they can still be dangerous. It is crucial to follow the safety guidelines outlined in your vehicle manual.
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 7 CAUTION: • When driving downhill, avoid turning the front tracks to prevent damage to your vehicle. Change direction when the weight of the vehicle is not concentrated on the front tracks. • Do not try to clear obstacles such as logs over 30 cm (12 in) in diameter, as they may get caught between the tracks or damage component under the vehicle. • Tracks have more traction on the ground and tend to throw stones or dirt. When driving, consider the safety of those around you. • On automatic transmission equipped vehicles, the High ratio should only be used on flat, hard surfaces. Use the Low engine ratio when pulling a load or driving through mud or deep snow. • Driving in ruts for long distances can cause the track to overheat, reducing its durability. • When towing, hauling or getting the vehicle unstuck, avoid attaching anything to the rubber tracks or track frames. Your vehicle’s chassis usually has specific areas for this operation. 1.5. Capacity The HD4/HD4PRO track system is designed to support a vehicle of 4000 lbs. The 4000 lbs(1814 Kg) limit is based on a wheeled vehicle including all payload and passengers that weighs not more than 4000 lbs when weighed on wheels. Once the wheels are swapped to track kits, the total weight of the vehicle including payload, passenger and tracks must not exceed 4500 lbs(2041 Kg). Speed limitations apply to the track kit with the same reasoning as the vehicle’s speed limitations to avoid overheating of components and reduce impact loads due to high speeds. The higher the payload, the lower the speed limit is on the track kit. Speed mentioned in the table is the actual speed of the vehicle (GPS speed) and may not be the speed shown on the speedometer of the vehicle. Most vehicle manufacturers allow high payloads only on Low transmission ratio, make sure you respect both the speed/payload limit of the vehicle and the track kit limit when working with heavy payloads. The table below lists the maximum permissible speed for each vehicle weight at 25°C (77°F). Reduce Max speed by 10% for each 5°C increment over 25°C. Max speed Total weight (vehicle +payload + track kit) Km/h mph Kg lbs 15 9 2041 4500 30 19 1814 4000 50 31 1588 3500 60 37 1361 3000 70 44 1134 2500 75 47 907 2000 Example: A vehicle including a driver, the track kit and a full tank of water and sprayer in the back weighs 4300 lbs. The ambient temperature is 40°C (104°F). Use the 4500 lbs rating with 15km/h max speed and reduce the top speed by 30% (15°C is 3 times 5°C increment). This gives 15-0.3x15=10.5 Km/h max speed
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 8 Section 2. BREAK-IN AND MAINTENANCE WARNING Perform a complete inspection every year. 2.1. Break-in Period WARNING 1. When using the track system for the first time, drive slowly on familiar ground and make turns on both sides to ensure correct installation and to become familiar with the new driving style. 2. After each rubber track replacement, a break-in period is necessary. During the first 3 hours of track use, some parts may stabilize due to vehicle weight and vibration, like causing the rubber track to become more flexible. Therefore, it is necessary to reapply tension to the track. Steel elasticity and painted surfaces can cause bolts to move and stabilize on their support, so it is important to tighten them during installation. After 3 hours or 75 km of use, the components should be stabilized. During this period, it is important to pay attention to the tracks and bolts. If any parts are moving or if the track is too loose, do not wait until the end of the break-in period to tighten them. WARNING 3. Pay close attention to the nuts or bolts holding the track kit axles on the vehicle hubs. If any bolt is loose, remove the kit, clean the surface of the vehicle hub and track kit axle, then re-install and tight the nuts or bolts to the specified torque from the vehicle owner manual. Sand, ice or dirt left between the parts during installation will cause the bolts to loosen. Clean surfaces are really important during installation. It is important to adjust the tension of the track to prevent it from de-tracking or skipping teeth on the sprocket which could cause premature wear of the track or the sprocket. It is normal to get a light plastic/rubber smell for the first 3 hours. The area under tandems will contact the rubber track and wear up to a certain point due to the weight of the vehicle.
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 9 2.2. Maintenance WARNING 1. The owner is responsible for enforcing the inspection and maintenance program to ensure safe use of the vehicle. 2. A damaged vehicle or track system can be dangerous for the driver and those in the surrounding area. 3. Perform a visual inspection of the components before each use. 4. Inspections should be conducted only after the engine has been turned off and the vehicle has been safely immobilized. 5. Before doing inspection or using the track system or vehicle, ensure there is no mud, snow, ice, or debris obstructing the proper functioning of the mobile parts. 6. Checking the level of tightening and making various adjustments should be done after three hours of use, as well as after any repair or replacement of the track system components. 7. The track tensioner functions by using a bolt secured in place by an anti-loosening nylon ring. It is crucial that this nylon ring is present and in good condition to prevent the track from becoming loose and detracking. 8. The arm of the anti-rotation system is the element that stabilizes driving and prevents tracks from turning around the main axles. During inspection on a flat surface, the components must be in good condition and free from any play. If there is excessive movement, replace the rod end that connects the arm attached to the brackets. CAUTION: 1. Driving with a component in poor condition will damage the other components. 2. Never use solvents to clean track assemblies: solvents can cause rapid deterioration of rubber and plastic. The track system has been designed to be safely washed using a pressure washer. Use only soapy water and/or a pressure washer for cleaning. 1. The wheel bearings are sealed and cannot be greased. In the long run, the seals will eventually fail and the wheel bearing will rust. Once you feel restriction to turn the wheels or the wheels can’t turn at all, replace the wheel bearings and seal assembly. 2. When performing rubber track inspection, do not forget to inspect the part of the track on the ground. Move your vehicle forward to check it. 3. By cleaning your vehicle and the track system after each use, you will ensure that no mud, snow, ice, or debris will clog moving parts, making the next inspection easier. 4. Bolts are visible on the brackets, sprockets, track tensioners and main axles (vehicle nuts). These nuts should be checked periodically by attempting to tighten them. 5. Make sure that the contact surfaces between the main axles of the vehicle and those of the tracks are clean before installing the kit. One way to get a tight fit between the track kit and the vehicle hub is to pretighten the four nuts in the order of top, bottom, right and left, and then apply the final torque in the same order. 6. Using the track system on rough terrain greatly increases the stress on the vehicle components, both the suspension and the drive system. Any play or breakage in any of these parts can cause a chain reaction of breakage.
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 10 7. The air filter tends to get dirty faster when using tracks (powdery snow, debris, dust, etc.). Clean it frequently. Some models are more efficient than others, check with your dealer. 8. CVT air intake may get clogged quickly in powdered snow. This could lead to overheating the cvt belt and blowing the belt. To avoid this potential issue, some manufacturers sell cvt air intake relocation kits to get air from the cab. It is strongly recommended to use a cvt air intake relocation kit if you intend to use the vehicle in powdered snow.
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 11 2.3. Maintenance Table ⚠ WARNING ⚠ Verification table During installation After break-in period (3h/75 km) At the beginning of the season Before each trip Every 40 hours of use Every 100 hrs and at the end of the season After a prolonged submersion Tightening of vehicle wheel nuts X X X Section 10.5 Sprocket bolts X Section 10.3 Anti-loosening nylon ring X Section 10.6 Mount kit bolts X X X X Arm of the anti-rotation system X X Vehicle alignment / loose in steering X X Section 4.1 Track tension X X X Section 4.2 Track wear X X Section 2.4 Are all the wheels turning? (bearing) X X Section 10.5 Wheel wear X Section 2.5 Sprocket wear X Section 2.4 Cracks and dents to the track frame X X Cracks and dents on the mount kit X X Comfort slide wear X Section 10.7 Tandem pivoting axle X Section 10.8 Pivoting axle X Section 10.10 Main axle bearing X X Section 10.4 Stub axles bent? (idler wheels) X X X Section 10.6 Grease main axle seal (zerk) X X Section 10.4 Grease pivoting tensioner X X X Section 10.11 Replace worn or broken parts
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 12 2.4. Tracks The tracks affect the vehicle’s adhesion, vibration, flotation on the snow, vehicle stability and the ability to cross obstacles, as well as safety. 1. Driving on surfaces with sharp objects such as metallic debris, steel ramps, rocks, and sharp branches can accelerate the formation of cracks and punctures. 2. Riding on uneven surfaces such as those that are convex, concave or have ruts, can cause tracks to wear unevenly and at a faster rate. 3. Installing studs or traction enhancing devices on the tracks is not advisable as it may damage the tracks, wheels, and sprockets and will void the warranty. 2.5. Wheels The wheels are used to guide the track and to distribute pressure on the ground. The main factors that cause wear on wheels are mud and violent impacts. 2.6. Sprockets To ensure maximum durability, it is recommended to invert the position of the sprockets from right to left when wear is visible on one side of the teeth. Rear sprockets will wear down faster than front sprockets so inverting position of the rear sprocket will happen sooner than the front sprockets. A sprocket should be switched to the opposite side (left / right) when there is only 1 mm of tooth remaining. Please refer to Figure 3 for further guidance. Rear sprockets are assembled using bolts and washers, it is normal to see the washers wearing down at some point as shown in Figure 2. The washers will not damage the rubber track even if they are showing trough the plastic teeth. A sprocket must be replaced when the teeth are 12mm or less in width as shown in Figure 1. For reference, a new sprocket is 18.4mm thick. Figure 3 Figure 2 Figure 1 12
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 13 Section 3. INSTALLATION 3.1. Before you Begin WARNING 1. The vehicle must be immobilized, engine switched off and allowed to cool. 2. Always wear safety glasses when installing, adjusting, or repairing. 3. Read and understand all warnings and instructions. CAUTION: 1. Assembled track corners are heavy and require two (2) people to carry them. When installing, make sure they are supported firmly to avoid unnecessary struggle. 2. Tracks are not stationary, so be careful when handling a corner assembly by a mobile part to avoid crushing your fingers. 3. Take care to use adequate tools and to use them properly. The manual indicates the right procedure. A tool can rip up and hurt you if the proper method is not followed. 1. Ensure that all necessary parts and tools are within reach before beginning the task. 2. Having a well-ventilated, clean, and well-lit workshop is the best practice for accident prevention. 3. To make installation easier, ensure that your vehicle is clean and free of debris. 4. Keep these instructions for future reference or inquiries. 5. Caution! The track system main axle may have several bolt patterns. Pay attention when installing the first main axle. Please refer to Figure 5. 6. During installation, ensure that left and right sets, as well as front and rear ones, are not inverted. Symbols on the track frames indicate the correct installation positions. 3.2. When Lifting the Vehicle WARNING Make sure the vehicle is secured in place by a system dedicated to this use (jack stands and hoist) and that it lies on or is fastened to areas that are not likely to break, bend or slip. A hydraulic jack is not safe, nor is a log. The vehicle must not be able to move. For installation, ensure that the vehicle is in two-wheel drive mode and that the gearbox is in neutral position. 3.3. Unpacking When unpacking, avoid using tools to handle the product as the packaging does not provide protection against sharp objects. Please use the proper containers to dispose of all packaging materials, including cardboard and plastic film. These materials will be recycled for future use.
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 14 3.4. Bracket Installation To install your HD4/HD4PRO mounting kit, please refer to the installation manual included in the mounting kit box. It is important to install the brackets first. WARNING Ensure that bolts are not overtightened as this may cause deformation of certain parts and compromise safety. 3.5. Front Track Installation 1. Lift the vehicle and remove one wheel. See section 3.2 2. Identify the frame corresponding to the removed wheel by using the correct symbol. When viewed from the side, the track should look like Figure 4. Figure 4 3. Refer to your bolt pattern to determine which hole corresponds to the main axle of your vehicle. There are four possible options on the 4 bolts axle. See Figure 5 (the measurements are in millimeters). Figure 5 Some vehicle require spacers. When needed spacers will be supplied in mounting kit, refer to your mounting kit instruction for spacer position before installing track kit on vehicle. 4. Align the main axles of the track with the hub of the vehicle. See Figure 6. Figure 6 5. Screw on the original wheel nuts or wheel bolts and tighten them according to the instructions for your vehicle. 6. Insert the rod end (#C) of the anti-rotation arm into the M12 bolt (#A) of the A-arm bracket (refer to Figure 7). You may need to adjust the frame to align the hole and bolt. FRONT
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 15 Figure 7 7. Tighten the M12 nut (#D) on the rod end (#C) to a torque of 83 N-m ± 4 (61 lbf-pi ± 3). 8. Install the rear tracks before adjusting front arms. WARNING Ensure that bolts are not overtightened as this may cause deformation of certain parts and compromise safety.
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 16 3.6. Rear Track Installation 1. Lift the vehicle and remove the wheel as described in Section 3.2. 2. Identify the frame corresponding to the removed wheel using the symbol on the frame. When viewed from the side, the rear track should look like Figure 8. Figure 8 3. Refer to your mount kit installation instructions to pre-assemble the anti-rotation arm to the track assembly and install the mount kit on the vehicle before continuing. 4. Align the main axle of the track with the hub of the vehicle. Figure 9 5. Screw on the original wheel nuts and tighten them according to the instructions of your vehicle. 6. Insert the rod end (#C) of the anti-rotation arm into its housing. Then, insert the M12 (#A) bolt (refer to Figure 10). It may be necessary to move the frame to align the hole and the screw. Figure 10 7. Install the M12 nut (#D) and tighten it to 83 N-m ± 4 (61 lbf-pi ± 3). 8. Adjust. See Section 4. WARNING Ensure that bolts are not overtightened as this may cause deformation of certain parts and compromise safety. FRONT
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 17 Section 4. ADJUSTMENTS WARNING 1. ALWAYS test the adjustment after making it and check that it has not changed during the test, and that it is identical between the right and left sides. 2. Adjustments must be made on a flat and level surface. 3. Make sure the steering/handlebar is not turning by itself when cornering or braking. If this is the case, the steering could rotate unexpectedly, and the vehicle could roll over. Risk of serious injury may occur. See Section 4.3 for more information. 4. If adjustments to the front anti-rotation require that the rod end must be unscrewed, make sure that a section of at least 20mm of the threaded rod remains inside the ball joint. Failure to do so may result in thread stripping, loss of control and injury. It is recommended that you take your vehicule to your dealer or a competent mechanic so that they can make these adjustements for you. In the following sections, when referring to part numbers, the first number corresponds to the front corners and the second number corresponds to the rear corners (front # / rear #). If only one number is given, it applies to both the front and rear corners. 4.1. Alignment of Steering with Tracks WARNING 1. Misaligned steering or improperly tightened steering components can cause loss of vehicle control. 2. During the break-in period, it is important to check the alignment as it may change. 1. Before adjusting, move back a few meters in a straight line and return to the initial position. 2. Make sure the steering wheel/handlebar is straight (front and rear tracks must be parallel) and that the steering components are in good condition and have no play. Otherwise, repair any damaged parts before adjusting. 3. Measure the distance at the front (measurement A, see Figure 11) and at the rear of the tracks (measurement B, see Figure 11). Ensure that the vehicle is resting on the tracks during measurement. Figure 11 4. The difference in length between measures A and B should not exceed 13 mm (0.5 in.). 5. If the difference is greater, have an authorized dealer adjust the alignment. A B
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 18 4.2. Track Tension WARNING Damage to the nylon anti-loosening ring could cause the tracks to become loose, leading to a loss of control. CAUTION: • A track that is too tight can lead to reduced performance or result in damage to some components. • Right/left tracks must have similar tension to avoid affecting driving. 1. To set the track tension, keep the vehicle on the ground. Turn the tensioning system screw (#22) counterclockwise until the spring is fully compressed (refer to Figure 14).Figure 14A simple way of validating if the spring is compressed enough is by pushing by hand perpendicular on the rubber track (see Figure 13) and validate that the coils are not moving. Once the coils stop moving when pushing the rubber track, the correct tension is reached. It is normal to see a small gap (.010”-.040” / 0.25-1mm) left between the coils on top of the bolt and no gap on the bottom coils. Figure 12 2. If you added too much tension by turning the screw too quickly, turn clockwise the tensioner screw to reduce tension until the coils start moving again then add tension until it stops moving. Figure 13 3. Move the vehicle forward to spread the tension equally in the rubber track and validate the spring is still fully compressed. Repeat until the tension stops changing when going forward. Figure 14 Push Small gaps Completely compressed
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 19 4.3. Front Track Pitch Adjustment 1. Before beginning, ensure that the vehicle is on a flat surface and that its weight is supported only by the tracks. Avoid any uneven ground or surfaces. If the vehicle was previously lifted in the air, crush the front and rear suspensions with your weight to bring it at ride height before continuing. 2. Ensure that the rubber components on the antirotation arms are not tightened on one side or the other of the support and that the steel protrudes from the rubber components. Figure 15 3. Tighten the lock nut (#E) against the rod end (#C) using a 24 mm wrench and a crescent wrench. 4. Place a bubble level on the horizontal anti-rotation area of the chassis. Screw nut (#Q) towards the rubber (#H) until the bubble level is horizontal. This will cause the track to lift at the front of the vehicle until only the tandem wheels touch the ground, refer to Figure 16). Figure 16 5. Tighten the M16 nylon nut (#M) until the steel slide is firmly secured between the nuts (#M) and (#Q). 6. Check the tightness of nut (#Q) by tightening it. 7. Tighten the lock nut (#E) against the nut (#Q). This adjustment affects the ease of steering rotation. If the wheel No. 5 is too close to the ground, the track system will be harder to turn. Conversely, if the wheel No. 2 is too close to the ground, the track system will turn too easily, causing abrupt and dangerous steering even at the slightest rock (refer to Figure 16).
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 20 4.4. Rear Track Preload Adjustment 1. The vehicle should be parked on a flat surface and only rest on the tracks. Figure 17 2. Ensure that the anti-rotation arm rubbers are not too tight on either side of the support, and that the slider sleeve extends beyond the rubbers. Figure 18 3. Insert between 20 and 25 mm of the threaded rod into the rod end. Tighten the rod end (#C) and its locknut (#E) using a 24-mm wrench and crescent wrench. 4. Screw the other nut (#Q) towards the rubber (#H) until the track system is flat on the ground. 5. Tighten the M16 nylon nut (#M) until the slider sleeve is firmly secured between the nuts (#M) and (#Q). 6. Check the tightness of the nut (#Q) by tightening it. 7. Tighten the lock nut (#E) against the nut (#Q). 4.5. Suspension Preload Adjustment Preload affects vehicle ground clearance and weight transfer during acceleration and braking. A firmer suspension limits the weight transfer and stabilizes the vehicle, while a softer suspension causes the tracks to move closer to the fenders and potentially scrape against them. A firmer setting helps going through thick snow by adding ground clearance and reduces occurrences of rubber track scraping with fenders. Figure 19 If vehicle weight changes a lot by adding heavy accessories or tools, suspension preload must be modified to compensate for the weight to keep the vehicle leveled. Then front track pitch adjustment (Section 4.3) must be done again to compensate for small vehicle pitch changes. Make sure the adjustment is done with the configuration the vehicle will be used in. Firm Soft
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 21 Section 5. REMOVAL AND STORAGE To shorten the next installation and avoid adjusting the anti-rotation arms, we recommend leaving the antirotation arm attached to the frame and removing the bolt (#A) and the nut (#D) that secure the rod end (#C) to the suspension bracket. CAUTION: • Clean the assembly before storing it. • Storage should be in a dry location, protected from UV rays (direct exposure to the sun) and heat sources. • If the assembly has been stored in a humid place or with water in the seal cavities, main axle or any other cavity with resting water for more than four weeks, corrosion may damage some components. • When storing the vehicle with the tracks installed, park it on a flat surface and ensure that only the weight of the vehicle rests on the tracks. Do not place any extra weight on luggage racks or on the vehicle seat. To prevent rust from appearing during storage, store the tracks in a vertical position. Figure 20
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 22 Section 6. QUICK DIAGNOSTIC Unusual vibration • De-tracking problem: See Section De-tracking problem (on the same page) • Damaged track: Check if an interior guide or if a track profile is ripped. See Section 2.4. • Sprocket bent, broken or worn (skip of tooth): Check the condition of the sprocket. See Section 2.6. • Sprocket tightening: Tighten all sprocket nuts at a torque of 64N-m (47lbs-pi). • Inadequate tightening of wheel nuts of the vehicle or eccentric tightening: Check tightening and positioning of the main axles. See Section 2.2. • Small or large wheel buckled: Check all wheels for distortion and replace any that are found. • Main axle bearing damage: If the sprockets turn erratically, the main bearing may need to be replaced. See Section 10.4. • Debris, mud or ice on the wheels, sprocket, or tracks: Clean all moving parts and the bottom of the frame. See Section 2.2. • Problem with the vehicle: First check suspension arms, ball joints and universal joints. Unstable drive • Problem with the vehicle: Check steering components, vehicle wheel bearings, suspension arms, ball joints and universal joints first. • Improper tightening of vehicle wheel nuts or off-center tightening: Check the tightening and positioning of the main axles. See Section 2.2. • Wrong transmission mode: The 2x4 mode should not be used. Differential lock mode should only be used at very low speeds. 4x4 mode is the recommended mode. • Vehicle load unevenly distributed on the front and rear: Uneven weight distribution can affect the adjustment of the anti-rotation arms, resulting in instable steering. Ensure weight is evenly distributed for optimal driving stability. If a substantial load is added to the vehicle for a specific task, suspension preload must be adjusted to compensate for the load to keep the vehicle level. • Vehicle alignment: See Section 4.1. • Adjustment of suspensions: A firmer suspension setting is recommended. • Angle of attack of one or both front tracks: An adjustment as described in Section 4.3. • Damaged main axle bearing: If the sprocket turns erratically, the bearings may need to be replaced. See Section 10.4. De-tracking problem • Vehicle alignment: See Section 4.1. • Debris preventing the large wheels from guiding: Clean the inside of the track and remove any debris. • Incorrect track tension or loosening of the tensioner: The track must be sufficiently tensioned, and the antiloosening nylon ring must absolutely be in good condition. See Section 2.2. • Condition of the guide lugs in the track: See Section 2.4. • Wheel alignment: Wheel bearing wear If a wheel has noticeable axial movement, either the wheel or its bearings must be replaced. See Section 10.5 Small or big bent wheel Check all the wheels for deformities and replace any that are found. Bent tensioner or idler wheel stub axle. Replace the bent part. See section 10.6 or 10.10 Power loss • Obstructed air inlet: Check the air filter. • Damaged main axle bearing: If the sprocket turns in a jerky manner, it may be necessary to replace the bearing. See Section 10.4. • Tension too high in the tracks: Excessive tension increases the required motor effort. • Debris, mud or ice on the wheels, sprocket, or tracks: Clean all moving parts and underside of chassis. See Section 2.2. • Wet or damaged transmission belt.
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 23 Section 7. TIGHTENING TORQUE Bolt size PITCH CLASS 4.6 CLASS 8.8 CLASS 10.9 CLASS 12.9 1 2 - 3 6 - 7 9 - 10 11 - 12 0.75 3 - 4 7 - 8 10 - 11 12 - 13 1.25 5 - 6 15 - 17 23 - 25 27 - 29 1 6 - 7 17 - 18 24 - 27 28 - 31 1.5 11 - 13 31 - 34 45 - 50 53 - 58 1 13 - 14 34 - 38 50 - 55 59 - 64 1.75 20 - 22 53 - 59 79 - 86 92 - 101 1.25 22 - 24 58 - 64 86 - 94 100 - 110 2 32 - 35 85 - 94 125 - 138 147 - 162 1.5 35 - 38 92 - 101 135 - 149 158 - 174 2 50 - 55 133 - 146 195 - 214 228 - 251 1.5 53 - 58 141 - 156 208 - 229 243 - 267 2.5 69 - 76 183 - 201 269 - 296 315 - 346 1.5 77 - 85 206 - 226 302 - 332 354 - 389 M16 M18 M10 M12 M14 TIGHTENING TORQUE (lbf-ft) M6 M8 • Reduce the tightening torque by 10% for lubricated hardware. • The torque values provided are only indicative and are based on the strength of the bolts. • Use these values only if they are not included in the instructions. Bolt size PITCH CLASS 4.6 CLASS 8.8 CLASS 10.9 CLASS 12.9 1 3 - 4 9 - 10 13 - 14 15 - 16 0.75 4 - 5 9 - 11 14 - 16 16 - 19 1.25 8 - 9 21 - 23 31 - 34 36 - 40 1 8 - 9 22 - 25 33 - 36 39 - 42 1.5 16 - 17 42 - 46 61 - 67 71 - 79 1 17 - 19 46 - 51 68 - 75 79 - 87 1.75 27 - 30 72 - 80 106 - 117 125 - 137 1.25 30 - 33 79 - 87 116 - 128 136 - 150 2 43 - 48 116 - 127 170 - 187 199 - 219 1.5 47 - 52 125 - 137 184 - 202 215 - 236 2 67 - 74 180 - 198 264 - 290 309 - 340 1.5 72 - 79 192 - 211 282 - 310 330 - 363 2.5 93 - 102 248 - 273 365 - 401 427 - 470 1.5 105 - 115 279 - 307 410 - 451 480 - 527 TIGHTENING TORQUE (N-m) M6 M8 M10 M12 M14 M16 M18
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 24 Section 8. EXPLODED VIEWS 8.1. Front Track System
OPERATING, MAINTENANCE AND INSTALLATION MANUAL TRACK SYSTEM SOUCY #2810703, 2810744, 2790234 SOUCY HD4PRO / KIMPEX COMMANDER HD4 SOUCY INTERNATIONAL / 5450, St-Roch Street / Drummondville (Quebec) Canada / J2B 6W3 1000023-EN revB • Printed in Canada 25 Figure 21 Front right corner shown Wheel bearings: 1x 6004-2RS (exterior) 1x 6005-2RS (interior)
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