Transcript
Operator’s Manual ZOMBY Un-Manned Ground Vehicle (UGV)
Invenscience LC www.invenscience.com
Document Number:
Rev:
i00578
01
Cage Code
54FP9
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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This Page Intentionally Left Blank
Operator’s Manual ZOMBY
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Operator’s Manual ZOMBY
Table of Contents 1.
OVERVIEW ............................................................................................................... 6
2.
SAFETY .................................................................................................................... 6
2.1
Operator’s Responsibilities ............................................................................................................... 6
2.2
Be conscious of the environment ..................................................................................................... 6
2.3 Safety Rules ......................................................................................................................................... 7 2.3.1 Safety Rules: General Operation ................................................................................................... 7 2.3.2 Safety: Slope Operation ................................................................................................................. 7 2.3.3 Safety: Children.............................................................................................................................. 8 2.3.4 Safety: Service ............................................................................................................................... 8 2.3.5 Other Safety Symbols .................................................................................................................... 8
3.
OPERATION ............................................................................................................. 9
3.1 Controls ................................................................................................................................................ 9 3.1.1 Emergency Stop Switches ............................................................................................................. 9 3.1.2 Keyed Power Switch .................................................................................................................... 10 3.1.3 Operator Control Unit (OCU) ....................................................................................................... 11 3.1.4 Joystick Driving ............................................................................................................................ 12 3.1.5 Throttle ......................................................................................................................................... 13 3.1.6 Choke ........................................................................................................................................... 13 3.1.7 Ignition Switch .............................................................................................................................. 13 3.2
Hour Meter ......................................................................................................................................... 13
3.3
Oil Temperature ................................................................................................................................. 13
3.4
Towing the Vehicle with Engine Off ................................................................................................ 13
3.5
Starting the Engine ........................................................................................................................... 13
3.6
Fuel ..................................................................................................................................................... 14
3.7
Seasonal Operation........................................................................................................................... 14
3.8
Towing ................................................................................................................................................ 14
3.9
Payload ............................................................................................................................................... 14
4.
MAINTENANCE ...................................................................................................... 14
4.1
Access Panels ................................................................................................................................... 14
4.2
Engine Maintenance.......................................................................................................................... 16
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4.2.1 Engine Oil and Filter .................................................................................................................... 16 4.2.1.1 Engine Oil Pressure and Steep Slopes ................................................................................ 16 4.2.2 Engine Air Filter............................................................................................................................ 17 4.3 Transmission Maintenance .............................................................................................................. 17 4.3.1 Transmission Fluid and Filter ....................................................................................................... 17 4.3.1.1 Fluid Type ............................................................................................................................. 18 4.3.1.2 Transmission Filter ............................................................................................................... 18 4.3.1.3 Oil Change Interval ............................................................................................................... 18 4.3.1.4 Changing Transmission Fluid ............................................................................................... 18 4.4 Track Tension .................................................................................................................................... 19 4.4.1 Track Tension Adjustment ........................................................................................................... 21 4.5 Track Toe-In ....................................................................................................................................... 21 4.5.1 Measuring Toe-In ......................................................................................................................... 21 4.5.2 Adjusting Toe-In ........................................................................................................................... 22
5.
TROUBLE SHOOTING ........................................................................................... 23
5.1 Engine Won’t Start ............................................................................................................................ 23 5.1.1 Engine Does Not Crank ............................................................................................................... 23 5.1.2 Engine Turns Over But Won’t Start.............................................................................................. 23 5.2 Transmission Troubleshooting ....................................................................................................... 23 5.2.1 Both Tracks Move Sluggishly or Do Not Move ............................................................................ 24 5.3
Track Problems, De-Tracking .......................................................................................................... 24
5.4
Electrical Problems ........................................................................................................................... 24
5.5
Other Engine Modifications ............................................................................................................. 25
6.
WARRANTY ........................................................................................................... 26
List of Figures FIGURE 1 REAR EMERGENCY SWITCH .................................................................................................... 10 FIGURE 2 FRONT EMERGENCY SWITCH.................................................................................................. 10 FIGURE 3 KEY POWER SWITCH ................................................................................................................ 11 FIGURE 4 OCU .............................................................................................................................................. 12 FIGURE 5 INSTRUMENT PANEL CONTROLS ............................................................................................ 12 FIGURE 6 ENGINE ACCESS COVER .......................................................................................................... 15 FIGURE 7 VETRONICS COVER ................................................................................................................... 15 FIGURE 8 ENGINE OIL ................................................................................................................................. 16 FIGURE 9 AIR FILTER .................................................................................................................................. 17 FIGURE 10 HYDRAULIC RESERVOIR ........................................................................................................ 19 FIGURE 11 TRACK TENSION MEASUREMENT ......................................................................................... 20
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FIGURE 12 TRACK TENSION ADJUSTMENT ............................................................................................. 21 FIGURE 13 REAR TOE MEASUREMENT .................................................................................................... 22 FIGURE 14 FRONT TOE MEASUREMENT .................................................................................................. 22 FIGURE 15 TOE ADJUSTMENT ................................................................................................................... 23 FIGURE 16 CORRECT LOCATION OF SNAP-RING ................................................................................... 24 FIGURE 17 FUSE BLOCK LOCATION ......................................................................................................... 25
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1.
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Operator’s Manual ZOMBY
OVERVIEW
This manual contains important safety precautions and information on the operation, maintenance, care and trouble shooting of your ZOMBY vehicle. A separate manual is supplied by the engine manufacturer detailing safety, use, and care of the engine.
BEFORE OPERATING VEHICLE, READ THIS MANUAL IN ITS ENTIRETY! Look for this symbol to indicate important safety precautions and warnings. This symbol indicates “Be alert! Your safety is at risk!”
2.
SAFETY
2.1
OPERATOR’S RESPONSIBILITIES Carefully read and follow the rules for safe operation. Inspect the unit. Make sure that the operator of the unit knows how to correctly use all standard and accessory equipment. Operate the unit only with guards, shields, and other safety items in place and working correctly. Correctly adjust the unit. Service the unit only with authorized or approved replacement parts. Complete all maintenance on the unit.
2.2
BE CONSCIOUS OF THE ENVIRONMENT
Do not fill the engine’s fuel tank completely full. Drain fuel for off–season storage. Use only unleaded gasoline. Service the air cleaner regularly. Change oil regularly. Observe oil recommendations in engine manual. Tune–up the engine regularly. Keep equipment in efficient operating condition. Dispose of used engine oil properly.
Shut-off engine before exiting or entering vehicle. Operate in clear area.
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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SAFETY RULES WARNING: This vehicle is capable of amputating hands and feet and may rollover. Failure to observe the following safety instructions could result in serious injury or death.
2.3.1
Safety Rules: General Operation
1)
Read, understand and follow all instructions in the Operator’s Manual, on the machine, the engine and with any attachments or accessories before starting.
2) 3) 4) 5) 6) 7)
Only allow responsible adults, who are familiar with the instructions, to operate the machine. Be sure the area is clear of other people before operating. Stop the machine if anyone enters the area. Never ride or carry passengers on the deck or other part of the vehicle. Slow down before turning. Never leave a machine unattended with the engine running. Always stop the engine, turn off power and remove the key before leaving the machine. Turn off power to attachment(s) when transporting or not in use. Stop the engine before inspecting or servicing. Do not operate the machine while under the influence of alcohol or drugs or when very tired. Watch for traffic when operating near or crossing roadways. Use extra caution when loading or unloading the machine onto a trailer or truck. Always wear eye protection when you make an adjustment or repair to the machine. Use care when pulling loads or using heavy equipment. Use only approved drawbar hitch points. Limit loads to those you can safely control. Do not turn sharply. Use care when backing. Do not operate this machine if you are taking drugs or other medication which can cause drowsiness or affect your ability to operate this machine. Do not use this machine if you are mentally or physically unable to operate this machine safely. The machine will not float. Do not operate on ice or in marshy areas where the machine may become submerged.
8) 9) 10) 11) 12) 13)
14)
15) 16) 17)
2.3.2
Safety: Slope Operation Slopes and rough terrain are major factors related to loss–of–control and tip–over accidents, which can result in severe injury or death. ALL slopes require extra caution. If you feel uneasy on the slope, do not operate on it.
DO
Travel up and down slopes, not across. Remove obstacles such as rocks, limbs, etc... Watch for holes, ruts or bumps. Uneven terrain could overturn the machine. Use slow speed on slopes. Do not make sudden speed changes. Use extra care with accessories or large loads. They can change the stability of the machine. Keep all movement on the slopes slow and gradual. Do not make sudden changes in speed or direction. Avoid starting or stopping on a slope. If machine loses traction, proceed slowly straight down the slope.
DO NOT
Do not turn on slopes unless absolutely necessary, then only turn slowly and gradually downhill, if possible. Do not travel across drop–offs, ditches or embankments. A track over the edge or an edge caving in could cause a sudden overturn and an injury or death.
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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Safety: Children Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine. NEVER assume that children will remain where you last saw them.
2.3.4
Keep children out of the operating area and in the watchful care of another responsible adult. Be alert and turn the engine off if children enter the area. Never allow children to operate the machine. Instruct children in the potential dangers of the machine. Use extra care when approaching blind corners, shrubs, trees or other objects that may obscure operator vision.
Safety: Service Use extra care when handling gasoline and other fuels. Fuels are flammable and the vapors are explosive. o Use only an approved container. o Never remove the gas cap or add fuel with the engine running. Allow the engine to cool for several minutes before refueling. Do not smoke. o Never refuel the machine indoors. o Never store the machine with fuel in the tank or fuel container inside where there is an open flame, such as a water heater. Never start or run the engine inside a closed area. Keep all nuts and bolts tight. Inspect the vehicle frequently for wear or damage. Damaged components must be immediately replaced with original equipment parts from an authorized service center. Keep the equipment in good condition. Never tamper with the safety devices. Check their proper operation regularly. To reduce fire hazards, keep the machine free of ice, grass, leaves or other debris build–up. Clean up oil or fuel spills. Allow the machine to cool before storing. Stop and inspect the equipment if the vehicle strikes an object. Repair, if necessary, before restarting. Never make adjustments or repairs with the engine running. However, the carburetor can be adjusted with the engine running. Do not change the engine governor settings or over–speed the engine. Wait for all movement to stop before servicing any part of the unit. Make sure all fluid lines and hoses are in good condition and all fittings are tight before starting vehicle.
Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury. If foreign fluid is injected into the skin, seek medical attention immediately.
2.3.5
Other Safety Symbols
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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3.
OPERATION
3.1
CONTROLS
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Operator’s Manual ZOMBY
Controls consist of Emergency Stop switches on the vehicle, key power switch, and the Operator Control Unit (OCU). Additional explanation on each item is provided below.
3.1.1
Emergency Stop Switches
The vehicle is equipped with push button “mushroom” style emergency shut-off switches at the front and rear of the vehicle. One is located on the top front of the vehicle (Figure 2 Front Emergency Switch) and the other is located on the rear of the vehicle (Figure 1 Rear Emergency Switch). Once pushed, the buttons must be twisted to be reset. When the button is pushed, it will kill the engine in the vehicle by grounding out the magneto and eliminating the spark. The engine can still turn over with either button depressed but will not start. The electrical systems will continue to operate on battery power with either button depressed.
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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Operator’s Manual ZOMBY
Rear Emergency Shut-Off
Figure 1 Rear Emergency Switch
Front Emergency Shut-Off
Figure 2 Front Emergency Switch 3.1.2
Keyed Power Switch
The vehicle is equipped with a keyed “power on” switch that enables the engine and all of the electrical systems. An LED indicator will illuminate when the power is on. See Figure 3 Key Power Switch.
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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Operator’s Manual ZOMBY
Figure 3 Key Power Switch 3.1.3
Operator Control Unit (OCU)
The ZOMBY is controlled with a 2.4 GHz COTS radio control unit. Only 5 channels are utilized in operating the vehicle. The COTS transmitter is the OCU. Controls are defined as follows: •
Left Side Joystick o Left position kills the engine o Right position will engage the starter o Up position increases throttle o Down position decreases throttle
•
Right Side Joystick o Up position will make the vehicle go forward o Down position will make the vehicle go backward o Left position will make the vehicle turn left o Right position will make the vehicle turn right Gear switch (Top left, toggle) o Back position, choke applied o Forward position, choke released, normal running
•
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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ZOMBY
Figure 4 OCU Figure 5 Instrument Panel Controls 3.1.4
Joystick Driving
The joystick for driving the vehicle is located on the right side. The joystick self centers to the neutral position. To make the machine move forward, simply move the joystick forward. To turn left while moving forward, move the joystick forward and slightly to the left. Angling the stick forward and to the right will perform a right hand turn while traveling forward. Pulling the stick rearward will move the vehicle in reverse. Moving the stick rearward and to the left will make the vehicle back-up and turn to the right. Moving the stick to the right while pulling back will cause the vehicle to back and turn left. A simple rule of thumb is to remember that the joystick controls the movement of the front of the vehicle. While backing or going forward, angling the stick to the left will move the front of the vehicle toward the left. Angling the stick to the right will cause the front of the vehicle to move to the right whether going forward or backward. Your ZOMBY vehicle is equipped with a dual path hydrostatic drive transmission enabling it to spin in place. With the joystick in the neutral position, it is possible to move it directly to the right or left thereby achieving a zero radius turn without forward or rearward displacement. This is called counter-rotation because the tracks drive in opposite directions. Counter-rotation results in a very quick turn. Avoid counterrotating on dirt or other un-even surfaces as track and idler damage may result. Braking is achieved by returning the joystick to the center “neutral” position. At slower speeds, the transmission provides more mechanical advantage for the engine. In situations where more torque is needed, it is advantageous to slow down. Moving the joystick nearer the neutral position will develop more climbing torque. Moving the joystick a greater distance from the center “neutral” position will develop more speed, but will provide less torque. The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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Operator’s Manual ZOMBY
Throttle
The throttle control increases engine RPM when moved up. It is preferable to select a throttle position based on the job at hand and then control vehicle speed through the control sticks rather than with the throttle control.
3.1.6
Choke
The engine choke is applied by flipping the “gear” toggle switch back (0 position). Choking the engine is generally only necessary during start up and for a few moments after the engine has been started. Return the choke switch to the “forward ” (1) position before engaging the transmission and moving the vehicle.
3.1.7
Ignition Switch
The ignition switch joystick (Left Stick) has three positions: Off On Start Off is in the extreme left position. The neutral position is the “run” position. The extreme right position will start the engine. Once the engine is started, the stick will spring back to the “on” position when released.
3.2
HOUR METER
The hour meter records actual operating time of the vehicle by totalizing the number of hours that the ignition switch has been on. Hours are recorded in 1/10 hour increments. The hour meter is useful for determining service intervals.
3.3
OIL TEMPERATURE
The transmission oil temperature becomes detrimental to the transmission components if the transmission oil temperature exceeds 230 degrees F. A thermostatically controlled fan cools oil. It may turn on without warning anytime the key switch is on. CAUTION: Operating the vehicle when the oil temperature is in excess of 230 degrees F will damage the transmission. CAUTION: Oil cooling fan may start without notice when key is on. Disconnect negative battery cable before servicing.
3.4
TOWING THE VEHICLE WITH ENGINE OFF
Do not tow the vehicle with the engine off unless the tracks are not in contact with the ground. Transmission damage will occur. CAUTION: Moving the vehicle with the engine off will damage the pumps and / or motors in the transmission.
3.5
STARTING THE ENGINE
For best results when starting the engine cold: 1. Set the choke to “on” (toggle back). 2. Set the throttle to 70% of full throttle (up). 3. Be certain that the right steering joystick is centered in the neutral position. 4. Moved the left joystick to the “start” position (right) until the engine starts. 5. Return the choke to the off (toggle forward) position. 6. Adjust throttle to a comfortable level and allow to stabilize for a few moments. 7. Beginning steering / moving the vehicle with the right joystick. If engine fails to start, see the trouble-shooting items in section 5.
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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3.6
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ZOMBY
FUEL
Use only unleaded gasoline fuel, 87 octane or higher.
3.7
SEASONAL OPERATION
Although your ZOMBY vehicle is designed primarily for snow operation, it performs well in any season. For satisfactory year-round performance, some precautions are in order.: Aggressive turning on dirt or rough terrain will significantly reduce the life of the track and idler wheel components. Operation in dusty conditions will require checking the air filter often. Temperature changes significantly affect the viscosities of oils. Use the proper oil in the engine and transmission for optimum performance and easy starting in cold temperatures.
3.8
TOWING
Your ZOMBY vehicle is equipped from the factory with a 2” receiver for towing. Do not exceed 50 pounds of tongue weight Do not exceed 750 pounds of gross trailer weight Do not tow on steep slopes Avoid sharp turns while towing WARNING: Towing can be dangerous. Trailer hitch and components may become wedged against track during turning causing dangerous instability.
3.9
PAYLOAD
The maximum allowable payload for the ZOMBY vehicle is 500 pounds. When operating in deep snow or soft material, performance will be degraded by adding weight as the overall ground pressure of the vehicle is increased. When transporting gear, snow and soft terrain performance will be improved if heavy items are transported near the rear of the vehicle or towed behind on a sled or trailer.
4.
MAINTENANCE
4.1
ACCESS PANELS
Access panels are provided for your protection and to facilitate service of the vehicle. Service access panels are as follows: Engine Access Cover: On the top rear of the vehicle is a large louvered cover. It covers basic drivetrain components including the engine and hydraulic pumps. It is held in place with screw around its perimeter. See Figure 6 Engine Access Cover. Vetronics Compartment: At the front of the vehicle on the top is a cover held in place with two black latches. The enclosure houses the vehicle electronics and battery. See Figure 7 Vetronics Cover. WARNING: Never operate the vehicle without all covers, guards and panels properly installed.
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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Operator’s Manual ZOMBY
Engine Access Cover
Figure 6 Engine Access Cover
Vetronics Cover
Figure 7 Vetronics Cover The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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4.2
Operator’s Manual
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ZOMBY
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ENGINE MAINTENANCE
For engine maintenance, refer to the engine manual provided with this manual. Access to the engine can be obtained by removing the engine cover. See section 4.1 for details.
4.2.1
Engine Oil and Filter
It is recommended that 5W-30 oil be used during cold weather to improve cold starting. See engine manual for additional recommendations for warmer temperatures. Once the engine cover is removed, check the oil level using the dipstick provided near the right hand side of the muffler. Add oil if necessary through the oil fill cap in the right hand valve cover. Change spin-on style filter per recommendations in the engine manual. The muffler assembly must be removed to access the oil filter. The oil filter is low on the left side of the engine. See Figure 8 Engine Oil. The engine drain plug has been replaced with a valve to facilitate draining the oil. The valve is equipped with a 2 ft hose. Plastic knock-out covers are provided on the side of the chassis to pull the oil hose through for draining to prevent draining the oil inside the chassis. Dispose of oil properly. WARNING: Muffler may be extremely hot. Let engine cool before servicing.
Oil Filter
Muffler
Oil Fill
Engine Oil Dipstick
Figure 8 Engine Oil 4.2.1.1 Engine Oil Pressure and Steep Slopes The engine uses a pressurize lubrication system. Low oil pressure will damage the engine. For additional information, see the engine manual. This condition may result from any of the following: Low oil level The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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Operator’s Manual ZOMBY
Excessively steep slope Oil pump failure or other oil system problem CAUTION: Running the engine with low oil pressure will damage the engine.
4.2.2
Engine Air Filter
The air filter for the engine is under a black plastic housing that lies directly under the engine access cover. The plastic housing is removable using four spring clips. The air filter is a disposable paper element and should be changed at regular intervals as defined in the engine manufacturer’s manual. See Figure 9 Air Filter.
Air Filter
Figure 9 Air Filter 4.3
TRANSMISSION MAINTENANCE
Your ZOMBY vehicle is equipped with a dual-path hydrostatic transmission. The transmission system consists of a tandem pump assembly, reservoir and filter that are mounted inside the engine compartment and hydraulic motors that are mounted in the tracks.
4.3.1
Transmission Fluid and Filter
It is necessary to check the fluid in the hydraulic reservoir before starting the vehicle. Carefully remove any dirt or dust that may have accumulated around the vented cap. Once the area is clean, carefully remove the vented cap. The cap is removed by pulling firmly upward. The correct fluid level is 1-2 inches below the bottom of the fill neck. Over-filling will cause the fluid to spill out when on steep slopes. Use Mobil 1 Synthetic 0W-30 engine oil only. Keep oil clean. The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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Operator’s Manual ZOMBY
4.3.1.1 Fluid Type Your ZOMBY vehicle ships from the factory with Mobil 1 0W-30 synthetic motor oil in the transmission. The viscosity / temperature performance of the synthetic oil is far superior to conventional motor oils and hydraulic fluids. The use of other oils in the transmission may cause damage to the transmission components and starting problems. 4.3.1.2 Transmission Filter The transmission oil filter must be changed every 150 hours of operation or yearly whichever comes first. Use only the factory approved filter available from your ZOMBY dealer. Use only Invenscience PN i00029. Use of any other filter will void the factory warranty. The transmission filter is located under the transmission reservoir cross-member on the left side of the vehicle.
CAUTION: Use of improper transmission oil filter will damage the transmission!
4.3.1.3 Oil Change Interval It is recommended that the transmission fluid and filter be changed every 150 hours of operation or annually whichever comes first. 4.3.1.4 Changing Transmission Fluid A valve is provided in the plumbing on the left side of the hydraulic reservoir. The valve is connected to a two foot piece of hose that can be pulled through the left side of the chassis after removing the plastic knock outs on the lower left side of the vehicle. Dispose of oil properly. Add fresh oil by removing the vented cap at the top of the reservoir. A complete change with filter change will require 9-10 quarts of oil. Optimum fluid level is 1-2 inches below filler neck. Measure the fluid level by inserting a clean dowel or other clean item into the transmission fluid reservoir. Do not overfill. Oil will expand when heated. Overfilling will cause the excess oil to leak out during operation. See Figure 10 Hydraulic Reservoir. WARNING: Oil and reservoir may be extremely hot. Let engine cool before servicing.
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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Operator’s Manual ZOMBY
Fill / Vent Cap
Reservoir
Transmission Filter
Drain Valve
Figure 10 Hydraulic Reservoir 4.4
TRACK TENSION
The tension of the tracks is critical to the performance of your ZOMBY vehicle. Too much tension will cause excessive rolling resistance. Too little tension can result in de-tracking. Operation in snow or slick conditions is more tolerant of a loose track than operation on dirt or rough terrain. As a general guideline, track tension should be .75 to 1.25 inches of free slack as measured by elevating the vehicle off the ground and measuring the free hanging gap from the track to the lower middle idler. Be sure that measurements are taken on both the inner and outer edges of the track. See Figure 11. WARNING: Make sure the vehicle is properly supported when lifted for service.
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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ZOMBY
Figure 11 Track Tension Measurement
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Figure 12 Track Tension Adjustment 4.4.1
Track Tension Adjustment
If the track is loose, increase the tension by adjusting the tensioning bolt on the inner and outer rear idler for each track. New tracks will tend to stretch somewhat in the first 10 hours of operation and should be checked for tightness. Track tension should be checked every 10 hours of operation. Track tension is adjusted as shown in Figure 12 using a ¾ inch wrench. Each track has two track tension adjustment bolts. Loosen the nuts on both before beginning adjustment. Increase track tension by turning the nut nearest the rear idler wheel in a clock-wise direction. Adjust inner and outer tensioners on one track at the same time. Once tension is correct, lock setting by tightening outer nut against bracket. Repeat for other track.
4.5
TRACK TOE-IN
The track toe-in is a measure of the parallelism between the two tracks. If the tracks are toed inward or outward, de-tracking problems may occur.
4.5.1
Measuring Toe-In
Measure the distance between the inner idlers at the rear of the machine. Record the distance. Measure the distance between the inner idlers at the front of the machine. Record the number. Now subtract the two. This is the toe-in. Acceptable toe-in is +/- .25 in. See Figure 13 and Figure 14.
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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Figure 13 Rear Toe Measurement
Figure 14 Front Toe Measurement 4.5.2
Adjusting Toe-In
If more toe-in exists, adjust the track struts at the front of the vehicle. Adjustment is made by loosening the jam nuts at each end of the strut and then turning the strut. Snug up the jam nuts to hold the adjustment. See Figure 15.
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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Operator’s Manual ZOMBY
Figure 15 Toe Adjustment
5.
TROUBLE SHOOTING
5.1
ENGINE WON’T START
Refer to the engine manual. The following troubleshooting tips are also provided as a guide.
5.1.1
5.1.2
5.2
Engine Does Not Crank Check battery condition. Charge if necessary. Check battery cables and terminals. Check connections at the battery and on the engine and chassis. Check starter relay.
Engine Turns Over But Won’t Start Check fuel level Check auxiliary fuel tank valve position if vehicle is so equipped. In cold weather, incorrect transmission and engine oil will cause starting difficulty Check engine choke position. Adjust cable if necessary to achieve full travel.
TRANSMISSION TROUBLESHOOTING
Solutions to common transmission problems are shown below. The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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ZOMBY
Both Tracks Move Sluggishly or Do Not Move
Check fluid level. See section 4.3.1 for details. Verify that correct fluid is used in the transmission. Improper fluid will cause poor performance in cold or hot weather. Change filter. Use correct filter. See section 4.3.1. If all of the above items have been verified, more serious problems may exist. Contact the ZOMBY factory or service center for additional help and service.
5.3
TRACK PROBLEMS, DE-TRACKING
If the track tends to walk off the idlers during turning, this is known as “de-tracking”. Your vehicle is equipped with track retainers that will tend to re-align the track if de-tracking occurs. When resolving detracking issues, check the following items:
Check track tension. Verify that both adjusters on a particular track are adjusted symmetrically. For additional details, see section 4.4. Inspect the idlers for damage. Replace any idlers that are bent or warped. Verify that the snap-rings are correctly installed in each idler. See Figure 16. Check track toe-in. Refer to 4.5 for details.
Figure 16 Correct Location of Snap-Ring 5.4
ELECTRICAL PROBLEMS
Your ZOMBY vehicle is equipped with a fuse block. The unit is located inside the vetronics cover on the bulkhead. Replace blown fuses with fuses of the same size and rating. Fuses are ATC type. The left fuse The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
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Operator’s Manual ZOMBY
block (facing the bulkhead) is 12VDC for engine and associated functions. The engine produces 20 Amps of 12 VDC regulated power. The fuse block on the right (facing the bulkhead) is 5 VDC for servo functions.
12 VDC Fuse Block 5 VDC Fuse Block
Figure 17 Fuse Block Location
WARNING: Always disconnect the battery before servicing the vehicle.
5.5
OTHER ENGINE MODIFICATIONS
Some adjustments have been made to the engine in your ZOMBY vehicle to optimize performance in the typical snow application. The following items have been altered from the original configuration provided by the engine manufacturer. Engine Oil: Since typical operation of the ZOMBY vehicle is in extremely cold climates, the engine oil has been changed to 5W-30. This improves cold weather starting performance. For operation in warmer environments, observe guidelines in engine manual. Spark Plugs: The engine has been fitted with NGK BPR2ES spark plugs for improved performance.
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
Page: 26 Date: 04/26/2010
6.
Document Number: i00578 Total Pages: 26
Operator’s Manual ZOMBY
WARRANTY
Invenscience LC warrants to the original purchaser that this unit shall be free from defects in material and workmanship under normal use and service for a period of 90 days or 30 hours of run time whichever occurs first.; however, this warranty does not cover engines, accessories, and Normal Wear Parts (except as noted below) as the companies that manufacture these items furnish their own warranties and provide service through their authorized field service facilities. For additional information, see the warranties covering these particular parts. If you are uncertain whether your unit contains or is equipped with one or more of these parts, consult your dealer prior to purchase. Subject to the terms and conditions noted in this Limited Warranty, we shall, at our option, repair or replace at no cost to the original purchaser any part covered by this Limited Warranty during the applicable warranty period. Normal Wear Parts are defined as belts, tracks, idlers, headlights and seat covers. These parts are warranted to be free from defects in material and workmanship as delivered with the product. Any claim for repair or replacement of Normal Wear Parts must be made within thirty (30) days of the date of purchase. No claims involving damage caused from material use, abuse or misuse will be honored. This Invenscience LC Limited Warranty is your exclusive remedy; however, this warranty is void or does not apply to any unit that has been tampered with, altered, misused, abused or used for rental or other commercial and/or professional (non–homeowner) uses. Your warranty does not cover minor mechanical adjustments which are not due to any defect in material or workmanship. For assistance in making such adjustments, consult your Operator’s Manual. To make a claim under this Invenscience LC Limited Warranty, return the unit (or if authorized in advance, the defective part) along with your proof of purchase to an Authorized Service Center near you. To locate the nearest Authorized Service Center, call the factory at the number shown below. If you return the entire unit, we will repair the unit. If we authorize the return of the defective part only, we will either replace or repair the part. In the case of a defect in hydraulic pumps or motors, the entire pump or motor must be returned since they do not include user serviceable parts. This Invenscience LC Limited Warranty gives you specific legal rights, and you may also have other rights which vary from state to state. This Limited Warranty is given in lieu of all other expressed and implied warranties including the implied warranty of merchantability and warranty of fitness for a particular purpose. If you need additional information on this written warranty or assistance in obtaining service, call: INVENSCIENCE LC,1–435-7532689 (435-753-BOTZ)
The information contained in this document is the sole property of Invenscience LC. Any reproduction in part or whole without the written permission of Invenscience LC is prohibited. All rights reserved. © 2010.
