This 134-page ASV HD 4500, HD 4520 Operator Manual PDF walks you through the full Posi-Track crawler, from pre-start checks to shutdown. Inside: an electrical schematic tracing the fuse panel, engine harness, and console wiring, plus a hydraulic schematic mapping the drive pumps, PTO motor, and directional valve. You also get the factory maintenance schedule with grease points, track tension adjustment, planetary oil changes, fuel system bleeding, and troubleshooting charts for both general and electrical faults. Re-torque the nine sprocket lug nuts to 115 ft.-lbs. after your first 10 hours; the 4520 engine peaks at 291 ft.-lb., the 4500 at 215. Guessing at maintenance intervals gets expensive fast. Bookmarked with a live text layer, so you can jump straight to a section or pull up any spec on your phone in the shop.
What's Inside This ASV HD 4500, HD 4520 Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction and Warranty | 1-4 | Welcome, Warranty Terms and Limitations, Gross Vehicle Weight |
| Specifications | 5-10 | General Dimensions, Engine, Tracks, Final Drive, Capacities, Loader Assembly, Electrical |
| Controls | 11-22 | Drive Control Console Definitions, Hydrostatic Drive, Loader Valve Control, Quick Attach Mount |
| Operation | 23-29 | Operating Capacity, Moving Dirt, Bi-Directional Operation, Side Hilling, Pre-Start Checklist, Starting and Shutdown |
| Maintenance | 30-47 | Maintenance Schedule, Engine and Hydraulic Oil and Filter Changes, Fuel System Bleeding, Track Tension, Radiator and Oil Cooler, Air Cleaner, Fuel Filter, Bogie and Wheel Service |
| Undercarriage Service | 48-66 | Sprocket Removal and Installation, Wheel Tube and End Tube Service, Undercarriage Rebuild |
| Parts Manual: Cover and Contents | 67-68 | Parts Manual Part #0401-707, Full Table of Contents |
| Parts: Service Items, Cab and Tower Assemblies | 69-83 | Service Items, Seat, Roll Cage, Fuel Tank, Tower with Filters and with Battery |
| Parts: Consoles, Linkage and Hydraulics | 84-95 | Main and Auxiliary Consoles, Transmission Linkage, PTO and Aux Valve, Neutral Lock, Charge Relief, Pumps, Hoses and Quick Couplers |
| Parts: Engine, Muffler and Air Cleaner | 96-103 | 4045D and 4045T Engine Assembly, Turbo and Natural Muffler and Air Cleaner Assemblies |
| Parts: Radiator, Oil Cooler and Chassis | 104-113 | Radiator and Oil Cooler Assembly, Chassis Assembly and Related Hardware |
| Parts: Undercarriage, Axles and Loader | 114-125 | LS Undercarriage, Carriage Assembly, Axle Assemblies 0307-022/023/024, Loader Assembly |
| Parts: Hydraulic and Electrical Schematics | 126-132 | Hydraulic Schematic Plus Electrical Schematics for Aux Console, Tower with Battery, Engine, Main Console, Roll Cage and Reservoir |
| Machine Schematics | 133-134 | HD4500 Series Auxiliary Console Wiring Sheet (Rev Jan 99) and Drive Motor/Transmission Hydraulic Sheet |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Peak Torque, 4520 | 291 ft.-lb. | p. 6 |
| Peak Torque, 4500 | 215 ft.-lb. | p. 6 |
| Lug nuts torque | 115 ft.-lbs. | p. 29 |
| Gross Vehicle Weight Limit | 12,000 lbs | p. 4 |
| Fuel Tank Capacity | 25 gal | p. 8 |
| Hydraulic Reservoir Capacity | 28 gal | p. 8 |
| Engine Oil Capacity | 14 qt | p. 8 |
| High Flow Auxiliary Pressure | 2,750 psi | p. 8 |
| HD 4500 | ||
| Engine Horsepower, 4500 | 80 hp | p. 7 |
| HD 4520 | ||
| Engine Horsepower, 4520 | 115 hp | p. 7 |
ASV HD 4500, HD 4520 Common Problems This Manual Covers
ASV Posi-Track HD 4500 bogs down under load, loses drive power, tracks slow to a crawl
Check the hydraulic reservoir level first; the system holds 28 gallons and low oil starves the drive circuit. Inspect the spin-on and canister filters for restriction and change them following page 34 if drive power fades as oil warms up. Then work through the track movement steps in the troubleshooting procedures starting on page 52.
Manual Section: General Troubleshooting p. 52Tracks run loose, sag between wheels, or derail when turning on side slopes
Adjust track tension with the screw jack until the track shows zero sag, following the procedure on page 36. Inspect wheels and the drive sprocket for uneven wear while the track is loose. Re-torque the nine sprocket lug nuts to 115 ft.-lbs. after the first 10 hours of operation, per page 29.
Manual Section: Track Tension p. 36Engine cranks but won't start after running the fuel tank dry or changing filters
Bleed air from the fuel system using the air bleed vent screw and primer lever, following page 35. Verify fuel level first; the tank holds 25 gallons and the pickup starves on slopes when it runs low. If the engine still won't fire, replace the fuel filter element using the steps beginning on page 41.
Manual Section: Bleeding the Fuel System p. 35Coolant temperature gauge climbs toward red during summer brush work or heavy grading
Open the hood and radiator door and blow debris out of the pre-cleaner and oil cooler grill with compressed air, following page 39. Check coolant level and verify engine oil on the dipstick; the crankcase holds 14 quarts. Clean cooling components daily in dusty conditions per the maintenance schedule on page 30.
Manual Section: Radiator and Oil Cooler p. 39Oil film on hydraulic hoses and wet fittings under the loader valve
Inspect all hydraulic lines and fittings during the pre-start check on page 27, wiping fittings clean so fresh seepage shows. Replace any damaged hose with the correct pressure rating; the valve inlet hose is rated 3,000 PSI, listed in the parts manual on page 94. Check reservoir level after any leak repair.
Manual Section: Pre Start Check List p. 27Frequently Asked Questions
What are the replacement specifications for the hydraulic filter?
The hydraulic filters should be changed every 250 hours. The system uses three filters: a three-inch filter, a five-inch filter, and a canister-type filter with an interior element (part number 0303-069 for the Hi-Flo filter). p. 35
What are the replacement specifications for the engine oil filter?
The engine oil and filter should be changed every 250 hours after the initial 100-hour break-in period. The ASV part number for the HD Engine Oil Filter is 0160-001. p. 34
What is the engine oil capacity for the HD 4500 / HD 4520?
The engine oil capacity for the HD 4500 and HD 4520 is 14 quarts. p. 31
What is the torque specification for the planetary lug nuts?
The 9 lug nuts that attach the sprocket to the planetary gearbox should be torqued to 115 ft.-lbs. after the initial 10 hours of operation. p. 30
What is the correct charge pressure for the hydrostatic drive?
At an idle, the charge pressure should be between 280 to 320 psi when the oil is warm. p. 50
How is this ASV HD 4500 Operator Manual delivered?
This is a 134-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Is printing allowed for this ASV HD 4500 Operator Manual?
Printing is allowed without restriction. Pull the pages you need for the job and bin them when they get greasy.
Reviews
There are no reviews yet.