BOGIE TRACK MANUAL. English version, effective date: August 2009

Transcription

1 English version, effective date:

2 CONTENTS Page Order Information 3 Track Models 4 Track Model Recommendations 7 Track Components and Description 8 Tire Inflation Pressure with Tracks 9 Ground Pressure 10 Why Tracks? 11 Service Life on Tracks 12 Track Shipping and Mounting 13 Mounting Instructions Ratchet Model 14 Mounting Instructions with Chain 16 Welding Instructions Recleating 17 Basics The tracks are made from carbon manganese steel, alloyed with boron by a special metallurgical treatment. After hardening with water, the steel has a 500 HB degree of hardness. All track components consist of the same material and are through hardened for good welding properties and wear characteristics. 2

3 Important order information to get the right track: 1. Tire dimension 2. Tire brand and model 3. Machine type and model 4. Ground conditions 5. Type of use (No 1 and 2 is very important) Order and Inquiry s North America: Olofsfors Inc. Phone: (519) Morton Ave. East, Fax: (519) Brantford, Ontario info@olofsfors.com Canada N3R 7J7 Website: Track Shipping Tracks are normally shipped in 4 rolls on one or two pallets. The joining track locks are either mounted on the ends of the rolls or in a joining set box. For every set of tracks you will need the correct tightening/ tensioning tool. Olofsfors has 3 types to offer; chains, a ratchet tool, and a geared tool. Please ensure that you have the right tool for your tracks. 3

4 ECO-TRACK TM The standard ECO-Track model is the most popular track for all-round traction and flotation. The ECO-Track cross member is one of the most environmentally friendly of all track offerings. The 26 mm linkage system is for heavier forestry machines, very aggressive soil conditions and demanding applications. ECO-Soft A very ground friendly track with improved flotation. Cross members are 915 mm (36 ) wide which protects both the tires and link system. The cross member end shape also minimizes ground disturbance when turning. The 26 mm linkage system is standard. ECO-OF The ECO-OF is an economical track suitable for rocky, muddy, rough terrain and demanding winter conditions where traction is the primary requirement. The 26 mm linkage system is available for heavier forestry machines, very aggressive soil conditions, and demanding applications. ECO-Max ECO-Max is a premium track for larger forestry machines. Heavier link system is standard with special side supports for maximum overall performance and longer service life. The cross members are closer together for very smooth travel and improved flotation. The cross member is the ECO-OF design for best traction and self cleaning. EX-Track The EX-Track has been designed for the most demanding operating conditions where traction is the primary requirement. The crossbar shape makes this track suitable in steep slopes, rocky terrain and deep snow. 4

5 ECO-Baltic ECO-Baltic is a track for very soft conditions. A smooth cross member profile helps protect the ground and brush mat. The 26 mm linkage system is available for larger machines and aggressive soil conditions. ECO-Magnum ECO-Magnum is a track for very soft conditions. A smooth cross member profile helps protect the ground and brush mat. The cross member end shape also minimizes ground disturbance when turning. Cross members are available in 923 mm (36 ) and 1023 mm (40 ) lengths. The 26 mm linkage system is available for larger machines and aggressive soil conditions. ECO-U This is a track with a U-shaped cross member for better traction and flotation. It is suitable for both wet and hilly terrain. EXW-Track A newly designed track for large forwarders and six wheel skidders. It offers excellent traction and good flotation in most applications. The heavy duty crossbar secures optimal track life. The cross member end shape also minimizes ground disturbance when turning. PRO-Track PRO-Track is a track model for harvesters and mid size forwarders up to 14 ton capacity. It is based on the ECO-Track system but with a longer distance between cross members. The overall performance is between conventional tracks and ECO-Tracks. 5

6 Conventional Tracks Standard Track Track for high traction in rocky, muddy and rough terrain, as well as in demanding winter conditions. Soft Ground Track Soft Ground Track is a track for increased flotation in wet conditions. Combi Track Combination track is good for mobility in difficult terrain, as well as increased flotation on soft ground. Conventional tracks Older style tracks. Higher power requirements and fuel consumption than ECO-Tracks. Not as smooth running or ground friendly as ECO-Tracks. 6

7 Track Recommendation List This list is only general recommendations or guidelines based on experiences in different countries or regions around the world. Other models may be suitable for special situations or conditions. Regions Normal terrain and ground conditions Wet conditions and thinning Operating Conditons Wet conditions with slopes Steep slopes and/or rocky terrain Deep snow Sweden 1 ECO-Track 1 ECO-Baltic 1 1 ECO-OF 1 ECO-OF 1 2 ECO-Soft 2 ECO-Track 2 2 ECO-Track 2 Standard Tr. 2 3 ECO-OF Standard Track 3 3 Finland 1 ECO-Track 1 ECO-Baltic ECO-OF 1 2 ECO-Soft 2 ECO-Track ECO-OF Norway 1 ECO-Track 1 ECO-Baltic 1 1 ECO-OF 1 ECO-OF 1 2 ECO-Soft 2 ECO-Track 2 2 ECO-Track ECO-OF Baltic 1 ECO-Baltic 1 ECO-Baltic ECO-OF 1 States 2 ECO-Track 2 ECO-Magnum ECO-Track 2 3 PRO-Track 3 PRO-Track Russia 1 ECO-Track 1 ECO-Baltic ECO-OF 1 2 ECO-OF 2 ECO-Magnum PRO-Track 3 PRO-Track Sticky clay Germany 1 ECO-Track 1 ECO-Baltic 1 ECO-Soft 1 ECO-OF 1 ECO-OF 1 Austria 2 ECO-OF 2 ECO-Track 2 ECO-Track 2 ECO-Track 2 2 Switzerland France 1 ECO-Track 1 ECO-Baltic 1 ECO-Soft 1 ECO-OF 1 1 ECO-OF 2 ECO-OF 2 ECO-Track UK/Ireland 1 ECO-Track 1 ECO-Baltic 1 ECO-U 1 ECO-OF 1 1 ECO-OF 2 ECO-U 2 ECO-Magnum 2 ECO-Soft 2 ECO-Track ECO-Soft 3 Soft Ground Tr North 1 ECO-Track 1 ECO-Soft 1 ECO-Soft 1 ECO-OF 1 ECO-OF 1 ECO-OF America 2 ECO-OF 2 ECO-Magnum 2 ECO-Track 2 ECO-Track ECO-Track 3 3 ECO-Max 3 3 South 1 ECO-Track 1 ECO-Soft 1 ECO-Soft 1 ECO-OF 1 1 ECO-OF America 2 ECO-OF 2 ECO-Magnum 2 ECO-Track ECO-Track Australia/ 1 ECO-Track 1 ECO-Soft 1 ECO-Soft 1 ECO-OF 1 1 ECO-OF New 2 ECO-OF 2 ECO-Track 2 ECO-Track Standard Tr. Zealand Standard Tr. 3 3 Indonesia 1 ECO-Track 1 ECO-Soft 1 ECO-Soft 1 ECO-OF 1 1 ECO-OF 2 ECO-Soft 2 ECO-Magnum 2 ECO-Track ECO-OF 3 ECO-Track 3 Soft Ground

8 Cleat/stud BOGIE TRACK MANUAL Track Components and Description ECO-Track Link Systems Machines/Maximum load Rim size Track mod. Link Ø Link hook Harvesters 22,5 08X- 20 mm (13/16 ) 40 x 15 mm (19/16 x 9/16 ) Forwarder 8-10 ton load 22,5 08X- 20 mm (13/16 ) 40 x 15 mm (19/16 x 9/16 ) Harvesters 26,5 09X- 22 mm (7/8 ) 45 x 15 mm (13/4 x 9/16 ) Forwarder ton load 26,5 09X- 22 mm (7/8 ) 45 x 15 mm (13/4 x 9/16 ) Harvesters 26,5 09X- 22 mm (7/8 ) 45 x 15 mm (13/4 x 9/16 ) Forwarder ton load 26,5 29X-, 39X- 26 mm (1 ) 45 x 18 mm (13/4 x 11/16 ) Forwarder 18 ton > 26,5 49X- 30 mm (1 1/5 ) 50 x 30 mm (2 x 1 1/5 ) Link Link hook Side support Cross member Track Locks Serial number plate The b-distance is impotant to verify the track type and part number if the identification is missing or unknown. 8 b - distance

9 Tires Dimension Brand Model Max pres. 600/50 x 22.5 Nokian ELS L-2(16) 4.3 bar/62 psi Nokian TRS LS-2(16) 4.3 bar/62 psi Trelleborg T bar/58 psi Trelleborg T bar/58 psi Trelleborg T /150 4,0 bar/58 psi Trelleborg T / bar/73 psi 650/45 x 22.5 Trelleborg T ,0 bar/73 psi 700/45 x 22.5 Nokian ELS L-2(16) 3.9 bar/57 psi Nokian TRS LS-2(16) 3.9 bar/57 psi 700/40 x 22.5 Trelleborg M bar/58 psi Trelleborg T bar/58 psi 710/40 x 22.5 Nokian FK F 3.9 bar/57 psi Trelleborg T /152 4,0 bar/58 psi Trelleborg T / bar/73 psi 600/55 x 26.5 Nokian ELS L-2(16) 4.6 bar/67 psi Nokian ELS L-2(20) 5.5 bar/80 psi Nokian TRS LS-2(16) 4.6 bar/67 psi Nokian FK F (16) 4.6 bar/67 psi Nokian FK F (20) 5.5 bar/80 psi Trelleborg T bar/73 psi Trelleborg T / bar/87 psi Trelleborg T / bar/73 psi Firestone Forestry EL 3.9 bar/56 psi 620/55 x 30.5 Trelleborg T / bar/73 psi 650/65 x 26.5 Nokian ELS L bar/80 psi 650/60 x 26.5 Trelleborg T / bar/73 psi 600/60 x 30.5 Trelleborg T bar/73 psi 700/50 x 26.5 Nokian ELS L-2(16) 4.6 bar/67 psi Nokian ELS L-2(20) 5.5 bar/80 psi Nokian TRS LS-2(16) 4.6 bar/67 psi Nokian TRS LS-2(20) 5.5 bar/80 psi Trelleborg T bar/73 psi Firestone Forestry EL 4.6 bar/66 psi 710/45 x 26.5 Nokian FK F (16) 4.6 bar/67 psi Nokian FK F (20) 5.5 bar/80 psi Trelleborg T /158 4,5 bar/65 psi Trelleborg T / bar/87 psi 750/50 x 26.5 Trelleborg T /170 5,0 bar/73 psi 750/50 x 26.5 Trelleborg T / bar/87 psi 700/50 x 30.5 Trelleborg T bar/73 psi 750/55 x 26.5 Nokian ELS L-2(20) 5.5 bar/80 psi Nokian TRS L-2(20) 5.5 bar/80 psi Nokian FK F(20) 5.5 bar/80 psi 750/45 x 30.5 Trelleborg T / bar/87 psi 800/40 x 26.5 Nokian FK F(20) 5.0 bar/73 psi Trelleborg T bar/73 psi This list is recommendations from the tire manufacturer when using tracks. Ref: Recommendations from Nokian: The importance of inflation pressure is further emphasized in forestry machines because working in difficult environments, and with varying wheel loads places added strains on the tires carrying capacity. This is why Nokian Tires provides inflation pressure recommendations for the most common forestry machine types. Using these recommendations will increase the durability of forestry tires and prolong their lifetime. The use of correct air pressure and checking it regularly is the best way to make sure that your tires provide reliable performance, prevent any damage caused by incorrect air pressure and prolong your tires service life. Insufficient air pressure can cause damage and rim chafing, and possibly even the tire slipping on the rim. Nokian Tires air pressure recommendations are based on the forestry machines own weight as well as their load, traction power (forwarders) and stability (harvesters). When conducting air pressure maintenance, temperature must be also be taken into account: as the air s temperature inside the tire decreases, air pressure decreases by approximately 10 kpa / 10 C = 1.45 psi / 10 C = 1.45 psi / 18 F When using tracks, always adhere to the maximum air pressure allowed to tire. The inflation pressure has to be measured from a cold tire. 9

10 Ground Pressure The main advantage of tracks is that the cross members distribute the load over a large area instead of being concentrated on two small surfaces. Branches, roots, etc often cover the ground, which help to support a tracked vehicle. Tires however, tend to sink into and compact the ground. The advantages of using the right tracks: Protect ground against damage Reduced ground pressure and increased flotation Less ground compaction Increased traction Less wear on power train of the machine Reduced fuel consumption Increased load capacity Greater stability when loading and unloading Greater stability when driving Machines with maximum load of 12 metric tons Total weight on rear bogie = kg ( lb) Dimension Tires ECO-Track ECO-Soft PSI / kpa PSI / kpa PSI / kpa 600 x / 104, / 54, / 43, x / 89, / 47, / 43, x / 78,41 Machines with maximum load of 14 metric tons Total weight on rear bogie = kg ( lb) Dimension Tires ECO-Track ECO-Soft PSI / kpa PSI / kpa PSI / kpa 600 x / 129, / 67, / 53, x / 111, / 58, / 53, x / 97,50 Machines with maximum load of 18 metric tons Total weight on rear bogie = kg ( lb) Dimension Tires ECO-Track ECO-Soft PSI / kpa PSI / kpa PSI / kpa 20,5 x / 163, / 81, / 59,11 25/65 x / 140, / 71, / 59,11 650/65x / 143, / 74, / 59,11 (600 x 30.5 ) 750/55x / 122, / 65, / 59,11 (700 x 30.5 ) 800 x / 106,26 10

11 Why Tracks? BOGIE TRACK MANUAL Soil is one of the most important components of a forest ecosystem. All plant life in the forest depends on the soil supply nutrients, gases, moisture and support for roots. Soil forming processes take time, and soil structure can be fragile. Undamaged soil with pore space almost half the volume, gives good growth and undisturbed water and air transportation. Compacted soil with less porosity and future less growth. The best solution to minimize soil compaction and rutting is widening the contact area against the ground by putting bogie tracks on the machine. Tracks on the machine is the big difference between a successful operation and a damaged logging area with deep ruts! 11

12 Service Life Considering the large variety and types of machines, wide range of applications and different ground conditions, it is impossible to provide exact length of service life on tracks. In general, a track is considered as being worn out if the links, link hooks, or cross members are worn to the point that they begin to break down. The following conditions or factors directly affect service life: Snow Reduces wear of the track Increased service life Sand / clay Increased wear on links and link hooks Significantly reduced service life Rocks Increased wear on cross members Reduced service life. Harvesters Travel short distances at low speed Increased service life Forwarders Travel with load long distances Reduced service life Bogie skidders Continual travel at high speed Significantly reduced service life Scarification Continual travel at high speed Significantly reduced service life Small machine Less wear of the tracks Increased service life Large machine Increased wear of the tracks Reduced service life These factors decisively influence the tracks service life. Variations of 15 to 20 times can be noted. X % X Hours The steel type is of decisive importance for service life. Hard steel types withstand hard minerals. There are two types of wear. Heavy and fast wear as well as a milder and slower wear. Tests have shown that if the minerals are 1.8 times harder than the steel, the steel wears fast. If you choose sufficiently hard steel, you get slower wear. Every rock type wears in its own unique way. 500 Brinell gives 25% better wear strength than 400 Brinell (see diagram). Brinell (HB) 12

13 Track Shipping and Mounting Tracks are normally shipped in 4 rolls on one or two pallets. The joining track locks are either mounted on the ends of the rolls or in a joining set box. MOUNTING INSTRUCTIONS Each pair of tracks consist of: 2 Sections without removable track locks 2 Sections with track locks at one end For every set of tracks you will need the correct tightening/ tensioning tool. Olofsfors has 3 types to offer; chains, a ratchet tool, and a geared tool. Please ensure that you have the right tool for your tracks. Layout the track with the top of the cross members facing up. Using a long track lock from the joining set, connect one section that does not have track locks with a section that has track locks. Note: Join the section that has track locks so that the track locks are at a loose end. This will make it easy to remove a cross member if necessary. A cross member may need to be removed if the tracks are being installed on used (worn) tires. For further instructions on mounting tracks, please look at the next pages depending on type of mounting tool. 13

14 Mounting Instructions with Ratchet Tool 1 Roll out the track and join the sections with long track locks. Drive over the track on the bogie. 2 When the track is on the bogie make sure that the ends are at one end of the bogie. Mount the two clamps 3from the outside into the link hooks. Drive slowly forward 4until the clamps are between the bogie wheels. Mount the installation 5tool on the cross members from below. Make sure that it is in the middle. Use a ratchet wrench 6to tighten the track. 14

15 Mounting Instructions with Ratchet Tool 7 When the clamps are loose, remove them from the track. 8 Tighten the track until you can install the track lock. Mount the track lock 9plate. Mount the bolt from 10 above because of the risk of damage the nut during driving. Take out the tool. 11 The proper tensioning of the track is when slack between tires is between 25 mm (1 ) and 50 mm (2 ). For Track 12 Model Part no ECO-Track & ECO-Soft ECO-OF & ECO-Max ECO-L ECO-U & ECO-Wide ECO-Baltic & ECO-Magnum PRO-Track Note! Make sure that the tool is greased and free from mud and sand. 15

16 Mounting Instructions with Chains Roll out the track and 1join the 2 sections with the long track locks included in the joining set. Drive over the track and bring the other end over the top of the tires so that both ends are at one end of the bogie. Insert the mounting chain 2through one of the longer track links on the ground section (see illustration). Insert the other end of 3the mounting chain through one of the longer track links on the top section. Pull the chain tight. Lock the chain by inserting 4the free end through a link as shown. After both chains are installed, check that they have the same length on either side. Drive forward until the chains are between the bogie wheels. Connect the track ends together with the track locks included in the joining set. Caution! When driving forward to stretch the track you must stay outside the risk area. Mounting chain Part. no

17 Welding General: All track components are made from special carbon manganese steel alloyed with boron. It is important that the material being welded is clean and dry. It is extremely important that only new and dry electrodes be used. The overall temperature of the tracks must be at least 18 C (65 F) prior to welding. Recommended pre-heating temperature is C ( F) to a maximum of 250 C (480 F). Recommended Welding Materials: Manual Welding Electrode (Stick Welding) OK 48.30, OK (E7018), OK or equivalent MAG Welding (Gas Metal Arc Welding) OK Autorod 12.51, OK Autorod (ER70S-6), OK Autorod Argon gas with 16% CO2 or 23% CO2 is recommended as protection gas. Note: Maximum electrode size is 3.25 mm (1/8 ) Welding Cleats: Never weld cleats on the centre section of the cross-member. See Figure 1 below. All welding passes are to be parallel with the cross-member. Position cleats and tack weld in place. (Never weld cleats on the centre section of the cross-member). Weld cleats in place on the opposite side of the tack weld. This will prevent a localized over-heating of the cross-member material, at this point return to the previous cleats and complete the welding on the opposite side of the cleat. Consult your local dealer for the correct replacement cleat. It is highly recommended to use the replacement cleats because they are made of the same material as the cross members. Fillet welds are to be a maximum of 3/16. 17

18 This is a sample of a welding procedure specification. WPS for ESAB OK 67, 45 (Stainless) and OK Autrod 12,50/12,51 (Gas Metal Arc Welding), can be found at our home page: WPS111PA01-02 Svetsdatablad WPS Welding Procedure Specification SVETSMETOD WELDING PROCESS 111 Look at WPAR no. WPAR111PA01-00 FOGUTFORMNING/ GROOVE DES. SVETSFÖLJD/ WELDING SEQ. GRUNDMATERIAL BASE MATERIAL MATERIALTYP MATERIAL TYPE OR GRADE TJOCKLEKSOMRÅDE TH. RANGE QUALIFIED KOLEKVIVALENT Cew ( IIW) CARBON EQUIVQLENT Cew W02 50mm 0,58 TILLSATSMATERIAL FILLER MATERIAL FABRIKAT TRADE NAME BENÄMNING DIN / EN CODE TORKNING AV ELEKTRODER DRYING OF ELEKTRODES PULVER FLUX ROTSTÖD BACKING SKYDDSGAS TYPE OF SHIELDING ESAB OK EN 499: E 42 4 B 42 H5 Distributor recom. POS FÖRVÄRMNING PREHEAT GILTIGHETSOMRÅDE RANGE OF POSITION QUA. FÖRVÄRMNINGSTEMP. PREHEAT TEMP. MELLANSTRÄNGSTEMP. INTERPASS TEMP. VÄRMNINGSMETOD APPL. METHOD MÄTMETOD METHOD OF MEASUREMENT PA, PB 75º C º C Acetylene/ Propane Chalk, thermometer SAMMANSÄTTNING SKYDDSGAS TEKNIK SHIELDING GAS TECHNIQUE COMPOSITION FLÖDE FLOW RATE ROTGAS GAS BACKING FABRIKAT TRADE NAME STRÄNG, PENDLING STRING, WEAVE BEAD RENGÖRINGSMETOD CLEANING METHOD HÄFTNINGSMETOD FIT UP METHOD ROTSIDANS BEHANDLING VÄRMNING/KYLN. HAST. HEATING/COOLING RATE HÅLLTEMPERATUR SOAKING TEMP. HÅLLTID SOAKING TIME VÄRMNINGSMETOD APPLICATION METHOD Weld Anmärkning/ remarks Remove snow/ice, dirt and rust Do not fasten cleat on the short side ROOT PREPARATION Rightward welding for best deep 5-10 degree ENKEL/DUBBELELEKTROD penetration angle SINGLE/MULTIPLE ELECTRODE String Grinding Similar welding rod compared with AWS is: SFA/AWS A5.1 / E7018 STRÄNG METOD TILLSATSMATERIAL BEAD PROC. FILLER MATERIAL StickOut VARUNAMN DIAM. AC POL. AMPERE VOLT CM/ MIN STRÄCKENERGI mm TRADENAME DC MIN MAX MIN MAX TRAVELSP. HEATINPUT OK ,2 DC (+) , OK ,2 DC (+) ,2 VÄRMEBEHANDLING POST WELD HEAT TREATM. GODKÄNNANDE APPROVALS OLOFSFORS KUND MYNDIGHET CLIENT DATUM DATUM DATUM DATE DATE DATE 18

19 19

20 QUALITY AND KNOWLEDGE A quality track must combine hardness with toughness. It must have a long life and be resistant to everyday wear and tear. The track must be able to withstand severe strain and also be able to protect tires and sidewalls in rough terrain. Olofsfors therefore use a carbon manganese steel that is alloyed with boron through a special metallurgical treatment. Boron steel has just the right qualities - it is hard and tough. Boron steel can be welded like conventional high strength, structural steel. After hardening, the steel is about 500 Brinell. Inc. 22 Morton Ave. East, Brantford, Ontario, Canada N3R 7J7 Phone (519) Fax: (519) info@olofsfors.com Internet: Återförsäljare / Dealer / Händler / Revandeur