global track china co., ltd

Richard DURAND – Arnaud MOUSNIER AVON SPENCER MOULTON, France Product Management & Support 02/07/02 18:50

S E R V I C E - I N F O R M A T I O N Reference-N°: AvonTechnicalBooklet2 - instruction book

Typical Rubber Crawler Failures – Causes – Prevention

Models

Mini-Excavator type tracks

Subject Rubber tracks are being used for various applications under a wide variety of operating conditions in the world. During a rubber track’s service life, various types of damage might occur. Some of them do not affect continued usage of the rubber tracks; however, others cause fatal damage to the rubber tracks, requiring their replacement. This manual will at first explain what is a rubber track, what are the different types of rubber tracks for Mini-Excavators that exist and how it is made. It will also show actual examples of different types of damage illustrated by pictures to describe the causes and recommend prevention to extend the service life of rubber tracks. It will also remind you some essential rubber crawler maintenance procedures. We would like customers / operators to be informed about the prevention of track damage and the consequences of a bad usage.

AvonTechnicalBooklet2 - instruction book / 37 QUAL1999013010104/01

Richard DURAND – Arnaud MOUSNIER AVON SPENCER MOULTON, France Product Management & Support 02/07/02 18:50 1- What is a rubber track ? Introduction 1.1 Structure 1.2 Specifications 1.3 Manufacturing method 1.4 The undercarriage components 2 – The different types of rubber tracks 2.1 Examples of use 2.2 Description of the track main components 2.3 Different Types of rubber track 3- Fitting the track onto the machine 3.1 Removing the old track 3.2 Fitting the new track 3.3 Tension of the track 4 - Field Service Information : Typical Rubber Track Failures 4.1 Cut of steel cords (transversal crack) 4.2 Longitudinal cracks and cuts on the lug side rubber 4.3. Cut on the lug side rubber 4.4. Separation of embedded core bars due to external forces 4.5 Separation of core bars due to corrosion 4.6 Cuts on the edges of track roller side rubber 4.7. Lug abrasion 4.8. Abrasion of embedded metals 4.9. Cracks of the lug side rubber due to fatigue 4.10. Cracks of the innerside (roller side) rubber due to fatigue 4.11. Exposure of steel cord 5- Rubber Crawler Tension Checking / Adjusting Procedure 5.1. Correct Tension : 5.2. Rubber Crawler Repair Manual 6 - Precautions for use 6.1. In operation 6.2 Storage and transport 7 - Claims 7.1 Warranty conditions 7.2 Warranty Claims procedure 7.3. Necessary Information to be provided to ASM : 7.4. Where to find Necessary Information related to Tracks ? 7.5. What kind of pictures to provide ? 7.6. Claim form : Avon advises you to use the following claim form



1- What is a rubber track ? Introduction There are two types of tracks for construction equipment undercarriages : steel tracks and rubber tracks. The steel tracks have been developed first and are today widely used. Rubber tracks were developed later and their use has rapidly spread because of the quality of their performance : they don't damage the roads as much as steel tracks and they work more easily in urban areas. 1.1 Structure The basic structure of the AVON rubber track is one of solid parts (wheel guide and steel cord) ensuring the internal strength and the engaging of the sprocket as well as rubber that ensures the flexibility and cohesion of the track.

1.2 Specifications

Compared to steel tracks, characteristics of materials used for rubber tracks bring about significant improvements. They don’t damage paved or fragile surfaces, they offer more comfort to the user and are much quieter than steel tracks.

1.3 Manufacturing method The tracks are first moulded flat and then the junction is made on a specific press. At the junction the track is thicker because 2 layers of steel cord are superimposed.



1.4 The undercarriage components

* THE SPROCKET (A) : It is the cogwheel usually situated at the back of the undercarriage which pulls the track. The number of teeth of the sprocket and its root diameter are important to choose the right track type.

* THE IDLER (B) : It is situated opposite the sprocket. The idler allows the track to be maintained at the right tension.

* THE IDLER SPRING (C) : It is designed to absorb the shocks and jolts of the machine. You only have to make sure that it is maintained in a good condition of work, meaning that it is operational.

* THE TRACK TENSION DEVICE (D) : It is situated in line with the spring and the idler. This component of the undercarriage is essential because it allows for adjustment of the tension. Having a good tension can avoid lots of problems.

* THE ROLLERS : The track rollers (E) situated all along the undercarriage support the weight of the machine and distribute it evenly on the track. As for the upper roller (F) it prevents the track from sagging



2 – The different types of rubber tracks 2.1 Examples of use


Richard DURAND – Arnaud MOUSNIER AVON SPENCER MOULTON, France Product Management & Support 02/07/02 18:50 2.2 Description of the track main components

* THE EMBEDDED METAL (CALLED ALSO THE CORE BAR) : They can either be made of cast-iron or of steel. There are 2 types of shape :

a) Oblong core bar, flat on top for the interchangeable tracks.

b) Smaller and more pointed core bar for conventional tracks. * THE STEEL CORD : This is an essential element of the track situated between the core bar and the lug moulded in the rubber. It ensures the longitudinal rigidity of the track and makes it more resistant to tension. * THE RUBBER : The compounds used in AVON tracks are specially designed to meet the requirements of the product. This is the reason why their compositions are different depending on whether it is for the lug or the innerside of the track. For example, lug rubber is designed to have a greater resistance to abrasion and tearing, whereas the innerside rubber is designed to resist rubbing of the track roller and tearing.

* THE UNDERLAYER OF RUBBER : It is a layer of rubber situated between the core bar and the steel cord which ensures the adjustment of a measure called "Z" (see above) and which allows the good engaging of the track onto the sprocket.


Richard DURAND – Arnaud MOUSNIER AVON SPENCER MOULTON, France Product Management & Support 02/07/02 18:50 2.3 Different Types of rubber track * Conventional : The first-generation tracks were called conventional, meaning that they were to be fitted on miniexcavators only designed for rubber tracks and not for steel tracks, unless the components of the undercarriage were modified. The particular form of the top of the core bar makes it easily recognisable.

* Interchangeable : The improvement on the wheel guide led to the development of the interchangeable track which, as the name indicates, is interchangeable with steel tracks without modifying anything on the machine and offers more comfort to the user. The oblong and flat on the top core bar differentiates the interchangeable from the conventional.

There are 2 types of interchangeable tracks : - Long Pitch (standard pitch)

Every other tooth of the sprocket matches with the core bar as is shown on this drawing. This is the standard interchangeable track which was developed first.

Short Pitch

Long Pitch

- Short Pitch

All teeth of the sprocket match with the core bars, which decreases significantly the vibrations and greatly improves the comfort for the user.



machine

3.1 Removing the old track

Worn out track to be changed

Move the machine up, so that the track does not touch the ground

Remove the plate protecting the track tension device

Unscrew the grease cylinder cap

Remove the cylinder grease (for example by standing on the track).

When the idler is moved back at its maximum, move the track down and take it away.

3.2 Fitting the new track

Engage the track first around the sprocket

Engage the track then around the idler

You can use a steel rod to fit the track, but you must be careful not to damage or to hurt the track.

3.3 Tension of the track

Pull up the track tension device with a grease pump until the sagging reaches ~ 15mm a and screw the cap of the track tension device back again. GOOD TENSION = SAGGING OF 15MM or width of a finger (between the top of the core bar and the roller) provided that :

- The track does not touch the ground (Cf photo) - The thickest part of the track is on the opposite side, closest to the cabin.

Attention : the track must not be too few or too much tensioned to avoid risk of core bar pullout or of core bar middle part breaking.


3- Fitting the track onto the


4 - Field Service Information : Typical Rubber Track Failures

4.1 Cut of steel cords (transversal crack) Damage: steel cords are cut off Replacement: Replacement is required

4.1.1 Causes of the damage When applied to rubber tracks under following circumstances, tension in excess of the breaking strength of the embedded steel cords causes steel cords to be cut:

(a) When the rubber track is detracking, the idler or sprocket rides on the projections of the embedded metal. (see the sketch below)

Projection of core bar

Sprocket or idler

(b) When the rubber track is detracked, projections of core bars get stuck between

the frame of the undercarriage.

(c) The rubber track is clogged with stones or foreign obstacles.



embedded steel cords will corrode. The deterioration of the design strength may lead to the breaking off of the steel cords.

4.1.2. Prevention

The following prevention should be taken to minimize the risk of this damage:

(a) Periodical checking on site of the recommended tension level.

(b) Avoiding quick turns on bumpy and rocky fields.

(c) Making machine operators carefully drive as to avoid having stones and other articles clog to the rubber tracks.

(d) Driving over sharp objects in the fields is to be avoided. If such is impossible,

making turns while driving over such objects is to be avoided at the least.

4.2 Longitudinal cracks and cuts on the lug side rubber Damage: Sometimes cracks and cuts on the lug side rubber at the edges of

the embedded metals can be observed. Replacement: Basically, no replacement is required unless the cuts on the lug side

rubber are discovered all around the edges of the embedded core bars, as this will result in a complete cut off.


Furthermore, when moisture invades through a cut on the lug side rubber surface, the


When rubber tracks drive over sharp projections, intensive stress is applied to the lug side rubber surface, especially at the edges of embedded metals, causing longitudinal cracks and cuts along the embedded metals area limit.

4.2.2. Prevention To avoid intensive stress applied to the lug root where metals are imbedded, machine operators are requested to avoid driving over stumps and ridges. 4.3. Cut on the lug side rubber Damage: Cut on the lug side rubber often occurs as one of the most

typical failure modes. Replacement: When a cut on the lug side rubber reaches the embedded steel

cords, it should be immediately repaired in accordance with our repair manual.


4.2.1 Causes of the damage


4.3.1. Causes of the damage When the rubber tracks drive over projections or sharp stones in the fields, the concentrated forces applied cause cuts on the lug side rubber surface. In case of making turns on projections, the lug side rubber surface will have an even higher chance to be cut. If the cuts run through the embedded steel cords, it might result in the steel cords’ breakage due to their corrosion. It is highly recommended to repair the cuts with cold vulcanisation rubber as soon as they are observed.

4.3.2 Prevention

Machine operators are requested to drive with great attention to the ground’s surface especially in terrain of the following type:

• Construction sites • Demolition sites • Paths covered with rocks and woods • Concrete ridges • Stumpy fields

When operating on terrain as mentioned above, high-speed drive, quick turns and overloading should be avoided. 4.4. Separation of embedded core bars due to external forces Damage: Extraordinary outer forces applied to embedded metals cause

their separation from the rubber track’s body. Replacement: Even a partial separation of embedded metals requires

replacement of the complete track.

Rubber came off together with steel links



4.4.1 Causes of the damage Core bars are adhered between steel cords and rubber body. The following cases generate external forces greater than the adhesion strength, causing their extraction

(a) When the idler rides onto their projections, core bars might ultimately peel off.

(b) When machine moves onto kerbs, obstacles, especially when tension is too

low, the core bars are likely to hit the frame of the undercarriage or the rollers

Core bar gets closer to Core bar projection Extraction effort METAL CORE BAR frame, while on pavement hits frame edge applied to core bar IS PULLED OUT !!

(c) When a rubber track is detracked, it becomes stuck between the guide frame or

the undercarriage frame, causing the separation of core bars.

Extraction force

Crack progressing alongside edge of core bar due to many contacts of insert against frame

Clear sign that

undercarriage was hit

by the metal cleat (due to

loose tension)

(d) Abnormally abraded sprockets as shown above will pull core bars out.



4.4.2 Prevention Similar to the prevention against the cut of steel cords:

(a) Recommended to the prevention against the cut of the steel cords: (b) Quick turns on bumpy and rocky fields should be avoided. (c) If abnormal abrasion of sprockets is seen, they should be immediately replaced.

4.5 Separation of core bars due to corrosion Damage: Due to corrosion of core bars, the adhesion to the rubber

body deteriorates, resulting in complete separation. Replacement: Even a partial separation of the core bars requires a

complete replacement.


Core bars are adhered to the rubber body. The following operating conditions cause them to corrode, causing deterioration of the adhesion, and finally resulting in their separation from the rubber body.

(a) Excessively salty fields, like the seashore (b) Strongly acidic or alkali containing terrain (c) Compost spread grounds

Particular remark : In case of outside flange trackrollers, the rubber surface of the innerside will gradually be abraded, ending in partial exposure of core bars. This may lead to on-spot corrosion, but generally does not result in pulling out the core bars from the rubber body. Such punching is indeed generally only a “cosmetic problem”. Advice on risk taken depending on machine should be however requested from Avon.



4.5.2 Prevention If rubber tracks are used under such field conditions as described under 4.5.1. above, they should be washed with plenty of water, as described in 4.1.2. After being completely dried, they should be stored properly.

When core bars start to pull out of rubber body and become loose, replacement of rubber track should be considered. 4.6 Cuts on the edges of track roller side rubber Damage: Both edges of rubber tracks have no special reinforcements. Under

operation, it may happen that they are cut or torn off. Replacement: In such case, the rubber track does not have to be replaced.


This damage is caused by objects on field or interference with the machine frame. (1) In case of damage by objects on the operating ground: The edges of rubber track

are often deformed largely due to a bumpy ground surface, stones and other objects, which cause intensive stress on the edges resulting in the damage. Especially, when a machine drives over concrete pavements, this type of damage easily occurs.



(2) In case of damage by interference with machine

frame : If machine continues operating with rubber tracks being detracked, the tracks may get caught up in machine frame or undercarriage parts, resulting in damage. Furthermore, when a machine travels along side slopes, rubber tracks get so much deformed that they hit the machine frame and undercarriage parts, which causes cutting, gouging and rubbing of rubber tracks in the end.

4.6.2 Prevention

When travelling, operator should be careful not to drive over any sharp projections on the ground. He should also prevent rubber tracks from coming into contact with concrete walls, ditches and ridges. If rubber tracks are detracked, the machine should be stopped immediately for retracking. The detracking cause should be checked : check crawler tension and retighten if necessary. Please see point 4.1.2.


Richard DURAND – Arnaud MOUSNIER AVON SPENCER MOULTON, France Product Management & Support 02/07/02 18:50 4.7. Lug abrasion Damage: Over time, the lug side inevitably undergoes abrasion. Replacement: No replacement is required.


Lug abrasion is more or less inevitable. Even if lug abrasion is proceeding, the rubber track can be used. However, as the traction performance deteriorates accordingly, it is highly recommended to replace the abraded tracks with new ones when the remaining lug height becomes less than 5 mm.

4.7.2.Prevention In order to prevent the rubber track from abnormal or premature abrasion, following operating conditions should be avoided :

• Making quick and repeated turns on concrete and asphalt roads • Driving up and down mountain paths with slippage • Making frequent turns on paths covered with rocks and wood

4.8. Abrasion of embedded metals Damage: Over time, core bars are gradually abraded. Replacement: Replacement is required when the width of the core bars reaches

under 80 % of their original width (D)



When trackrollers roll over core bars, and sprocket and idler gears with them, their abrasion is inevitable. The following cases sometimes accelerate their abrasion:

(a) Too old and already abraded sprockets, which pitch does no longer matches rubber track pitch.

(b) Sprocket design or pitch do not correspond to track design or pitch.

(c) Rubber tracks are driven with an extraordinary heavy load on them.

(d) Rubber tracks are used on sandy fields.

4.8.2 Prevention As long as rubber tracks are used under normal operating conditions, abnormal abrasion is unlikely to occur. The level of abrasion (A) should be carefully checked when the machines are mainly operated for towing and dozing works, which generate a heavy load for rubber tracks, and when they are operated under a sandy field condition for a long time.

4.9. Cracks of the lug side rubber due to fatigue Damage: Small cracks around the root of the lug as a result from

operation fatigue. Replacement: When cracks reach so deep that they expose the steel cords,

whole track replacement is required.

Fatigue crack

(by aging) Ozone crack AvonTechnicalBooklet2 - instruction book / 37 QUAL1999013010104/01



Because of wound stress applied to rubber tracks around the undercarriage parts during operation, the fatigue especially causes cracks on the lug side rubber surface. Once the cracks occur, they gradually deteriorate with even small external injuries. Also when operating near seashores or under cold temperatures, rubber tracks are more likely to suffer from ozone cracks.

4.9.2 Prevention Rubber tracks are designed with special rubber compounds as to prevent cracks due to fatigue. However, external injuries on the lug side rubber sometimes cause more chance of cracking. Machine operators should take care when driving, so as not to cause external injuries to the lug side rubber. In order to minimize the occurrence of ozone cracks, attention should be paid to the following instructions for maintenance:

• Avoid exposing stored tracks to direct sun light • Avoid exposing stored tracks to direct rain and snow fall • Store tracks in well ventilated warehouses • Use the tracks at least once a month

4.10. Cracks of the innerside (roller side) rubber due to fatigue Damage: Small cracks in the rubber directly above the core bars, resulting

from operation fatigue. Replacement: No replacement required unless core bars become loose in the

rubber body and are about to pull out (cf points 4.5.1 & 4.5.2).


Making vibrations without moving the machine increases fatigue on rubber, leading to cracks in the rolling path for machines fitted with flange rollers

4.10.2 Prevention

Don’t let machine sit too long in the same position when you operate in these conditions. Move the machine from time to time to balance pressure of vibrations.




Damage: Exposure of cords between the lugs Replacement: No replacement required at this stage, but such problem will result

in steel cord corroding and finally breaking. Repair of track can increase track life.

4.11.1 Causes of the damage : This problem results from normal machine operation, especially on hard & abrasive grounds

4.11.2 Prevention : Machine operator is requested to drive carefully on construction or demolition sites, on concrete grounds and stumpy fields (please see point 4.3.1 and 4.3.2.)

Special Remark : Strand of steel cord may sometimes stick out of the rubber track. This is no problem for the integrity of the track. Such problem results from the friction of the sprocket against the edges of the track sprocket holes.

Solution : Cut the strand. This will have no consequence as the number of cords in the Avon tracks is always overspecified.


4.11. Exposure of steel cord


5- Rubber Crawler Tension Checking / Adjusting Procedure

(after the first 30hrs, then every 50hrs) 5.1. Correct Tension : Correct tension is a determining factor for the lifetime of rubber crawlers. It is highly recommended to the operator to check/ adjust the tension regularly. Too loose rubber crawlers are source of:

• Contact between rubber crawler and track frame at several places when riding over some obstacles. The results are:

Damages

- Core bar projection hits the edge of the frame and can be easily ripped out.


- Damages to the inside surface of the crawler causing core bar or steel wires corrosion and resulting in fatal damages.


• “Detracking”: rubber crawler comes off. In this case, the sprocket rides on the inside surface of the crawler causing deep cuts/damages and allowing water to penetrate resulting in metal core or steel wires corrosion and finally in fatal damages.

Damages due to sprocket teeth

Metal core already visible

• Track rollers pushing out the steel links

AvonTechnicalBooklet2 - instruction

Force

book / 37 QUAL1999013010104/01

Richard DURAND – Arnaud MOUSNIER AVON SPENCER MOULTON, France Product Management & Support 02/07/02 18:50 Lift the machine or, at least one side of the machine, so that the crawler(s) has no contact with the ground anymore.

• Operate the corresponding travel lever till the infinity symbol (∞) is located at the top

roller or at the middle distance between the idler and the sprocket, at top side. This infinity symbol shows where the rubber crawler seam is located. This sign is generally visible at the inner face of the rubber crawler. It is generally where the Avon logos and serial numbers are located.

Top roller

∞



• Check the rubber crawler tension level, by measuring its sag distance between the

steel link and the center track roller contact surfaces.

sag

dist

ance

• If this distance is bigger than 25mm, the tension level must be readjusted.

Remove the grease nipple protection plate on the side of the frame. Using a grease gun, apply grease in tension cylinder till this sag distance is 10 ~ 15 mm.


Richard DURAND – Arnaud MOUSNIER AVON SPENCER MOULTON, France Product Management & Support 02/07/02 18:50 5.2. Rubber Crawler Repair Manual 5.2.1. Repairable cut (1) Only cuts occuring between the lugs (as per drawing –1) can be repaired.

Repair is not necessary for the small cut (not longer than 30mm and not deeper than 10mm), but if the steel cord is seen, quick repair is advisable regardless of the size of the cut.

(2) The drawing –2 shows the cut at the edge. In some cases, the repair is advisable soon after the cut is made. The procedure of repair is shown underneath for your reference.

5.2.2 Repair Procedure (Preparation) (1) Cleaning of the cut: -1-

To achieve a good adhesion, the dirt (soil, sand and dust) should be cleaned. The cut area should be moved to a round area (around sprocket or idler) to make the cut open as much as possible, then all the dirt should be eliminated by using the brush. Using a compressor is very effective.

(2) Cleaning of the cut -2-

Using specific solution such as Toluene should eliminate dirt such as soil. Enough quantity of solution should be put on the cut, before brushing it all to eliminate the excess. To make the solution dry well, please don’t touch the cut for 5 to 10 minutes.

(3) Enlarging the cut:

For easier buffing, you can enlarge the cut with a cutter knife. All around the cut, also the depth of the cut, tapering should be done at 45°.

(4) Buffing of the cut:

To achieve a good adhesion, the surface of the cut should become rough, by buffing inside of the cut with sand paper or wire brush. This procedure is important to have a good adhesion between the compound and rubber track. All the surface of the cut should be buffed well. Also buffing should be made 30-40mm wider than cut, as adhesive will be put.


Richard DURAND – Arnaud MOUSNIER AVON SPENCER MOULTON, France Product Management & Support 02/07/02 18:50 (5) Cleaning the cut:

Refuse and waste of rubber and sandpaper generated during the buffing procedure (4) can account for an obstruction for the adhesion. It should be properly eliminated by using the compressor.

5.2.3 Repair work (1) Putting the adhesive: -1-

The adhesive (Special Bond) should be put into the cut carefully by using the brush. The area on which adhesive is put should be wide (to all buffed area).

(2) Mixture of compound A and B.

aa. Mix the compound A (black) and B (white) with the same volume by hand. bb. Mix until the white line is eliminated and the entire colour becomes black.

Note : The compound soon after taken from the can is sticky to the hand, but becoming less sticky while mixing which is the sign of the mixture.

(3) Putting the adhesive: -2-

After you’ve checked that the adhesive referred to in procedure (1) above is dry, you should apply a 2nd coat and wait until it is half dry. Then, you should put the mixed compound according to following procedure (4).

(4) Putting the mixed compound:

The A+B mixed compound under procedure (2) should be put into the cut using the thumb or a pick. The compound to be put should be torn several times until complete homogeneity and spread in sheets. By taking care that air is not trapped, mixed compound should be put until 2-3 mm higher than original rubber level.

(5) Hardening the compound:

Repair is completed after hardening the compound by leaving the applied compound in the room temperature. Note : The index of time under room temperature and hardness of the compound is as under : 24 to 48 hours under room temperature 30°C 4 to 5 days in cold days or winter

The heat over 50°C must not be applied in any case.

5.2.4. Others Just soon after a cut at the edge is made (see sketch 2- above), it can be repaired in some cases by the strong and special bond after cleaning the cut surface carefully.



1) Brush Big: 1 Small: 2 2) Wire brush 1 3) Knife 1 4) Sandpaper (#60) 1 5) Driver 1 6) Solution Small qty 7) Compound A + B As much as necessary Special bond As much as necessary 8) Hand grinder 1 9) Compressor 1

REMARK: The set including compounds A + B (for cold vulcanisation) can be ordered, for example from: • Rema Tip – Top

(Their Part/Nr n°516 9087).

Informations and closest dealer address can be got through Internet (http:\www.tiptop.de) or at following address:

STAHLGRUBER Otto Gruber GmbH & Co.

D-81675 München Germany

Phone: (0049) 89 41 51 - 1 Fax: (0049) 89 47 10 41

5.2.6 Detailed Description of Repair Steps


Einsteinstraße 130

5.2.5 Repair materials and tools

N° Designation Lot


5.2.6.1. Cleaning of the cut with solvant (ex. : toluene).

The dirt (soil, sand and dust) should be eliminated

5.2.6.2 Enlarge the cut by

widening the damage (cut all around the

damage at a 45° angle)

5.2.6.3. Buffing of the cut :

inner surface of damage must be made rough with a wire brush (or sandpaper) for

complete adhesion. This step

efficiency of the sticking will depend from the roughness of

the innerside of the area.

must be carefully done since the

Also sand around the area (5 mm wide) because it will be

coated with adhesives



5.2.6.4. Wash the area :

Rubber and sandpaper dust which appeared in step 5.2.6.3. must be washed away with an

air compressor

5.2.6.5. Putting the adhesive.

Wait until it is dry

5.2.6.6. Mixture of compounds A+B. Take same quantity, mix and press them a few times until

complete homogeneity (when mixing is not sticky any more)



5.2.6.7 Putting the adhesive :

Apply a 1st coat, wait until it is dry. Apply a 2nd coat, wait until it is half

dry.

5.2.6.8. Fill damage with A+B mixture

when 2nd coating is half dry. Push firmly with the thumb to avoid trapping air. Then, rub surface with fingers wet with

solvent so that surface becomes smoother

5.2.6.9 Cold Vulcanisation :

Apply on fix on surface a plate or pipe to pack mixture to rubber. Do not

remove until vulcanisation is complete = 2 days in room

temperature or 4-5 days in winter. Vulcanisation is done when you cannot mark with a fingernail.

Finishing = Remove surplus around flaw with a cuttting knife.


Richard DURAND – Arnaud MOUSNIER AVON SPENCER MOULTON, France Product Management & Support 02/07/02 18:50 5.2.7 Particular case of cracks or cuts at the edge of track : This method applies only if the rubber is not totally torn out from the track

5.2.7.1. Clean up the dirt (soil, sand,

dust,...) using compressor Wash inside cut with solvent

5.2.7.2. Coat quick drying glue onto the cut and press it

for adhesion Wash inside cut with

solvent



6 - Precautions for use 6.1. In operation

the do's and don'ts

Sharp stone, bedrock, iron scrap Machine astride a trench

Risk of damaging the lugs and breaking the steel cord Damages to the lugs – Breaks of the core bars

Light / flooded soil Pavements

Risk of detracking (unsteady surface) Don't climb kerbs at a right angle, use a ramp. Track damaged by rocks

High temperature surfaces Turning on a slope

Don't stay too long on hot ashes or fresh asphalt. Don't turn on hillsides at a right angle. Risk of damage on the lugs.



Uneven surfaces Only one track is in contact with the ground

Risk of detracking especially if the track is partly in contact with the ground when you turn. Both tracks must be in contact with the

ground so as not to damage the lugs or break the core bars

Turning without driving

Slipping

Risk of excessive abrasion of the lugs

Load and speed must be appropriate for the machine otherwise tracks will slip and lugs abrade quickly

Fall Hitting with the bucket

Drive carefully on very uneven surfaces Risk of breaking core bars and steel cord so as not to damage the core bars



6.2 Storage and transport

6.2.1. Storage of the track alone : Keep away from direct sunlight and bad weather. 6.2.2. Storage of the machine : Wipe off mud, soil, ... stuck between the track and the undercarriage. Remove oil, solvent stain, ...from the track. Always clean the track after operation in salty area to avoid oxidation. Keep away from direct sunlight

6.2.3. Loading on a truck : Use ladder rail or ramp to load the machine on a truck or a trailer. Do not load on a truck by using the arm of the machine.

7 - Claims

7.1 Warranty conditions

The AVON FUKUYAMA tracks are guaranteed for 1 year or 1000 hours of operation, whichever comes first, from the date of selling to the final user subject to: - Tracks are used according to recommendations given in this instruction book. - The claim must occur within 3 years after the sale to the dealer/manufacturer. To make it easier, we strongly recommend you to have our serial numbers printed on your invoices and packing lists to your customers. The claim will be accepted only if the problem on the track comes from a manufacturing default of AVON SPENCER MOULTON.

The claims will under no circumstances be accepted if the tracks are damaged because of misuse.


Richard DURAND – Arnaud MOUSNIER AVON SPENCER MOULTON, France Product Management & Support 02/07/02 18:50 7.2 Warranty Claims procedure

The decision is taken jointly by the technical dept, the quality dept and the sales dept according to the information and photographs provided by the user. The claims can only be examined once AVON SPENCER MOULTON has all the elements in hand. 7.2.1. If the elements provided are not sufficient or clear enough, AVON SPENCER

MOULTON can ask for the track to be returned for a complementary examination. AVON SPENCER MOULTON will not pay transport costs for the tracks that were not asked to be returned.

7.2.2. If the claim is accepted AVON SPENCER MOULTON gives a credit note or

replaces the track. The credit note can be deducted from a future invoice.

. 7.3. Necessary Information to be provided to ASM : - Customer name and location (city + area). - Machine model and Serial number. - Hours worked of machine with the track(s). - Date of installation onto machine (or date of sale to customer) - Repair date. - Customer comments and complaint/defect code if applicable. - Serial number of part (embossed inside track next to logo) + production date - Several clear pictures, possibly in digital form, of whole track + damage area 7.4. Where to find Necessary Information related to Tracks ?


Richard DURAND – Arnaud MOUSNIER AVON SPENCER MOULTON, France Product Management & Support 02/07/02 18:50 7.5. What kind of pictures to provide ? AVON requests 4 to 5 good quality photos to the claimed part : • 1 photo giving a general view of the failed crawler.

• 2 photos showing the 2 halves of the inside surface of the rubber crawler.

• 1 photo (magnified) of the damage area

In case of cleat pull out, please also provide one large picture of the metal link surface (if still available)

7.6. Claim form : Avon advises you to use the following claim form


Richard DURAND – Arnaud MOUSNIER AVON SPENCER MOULTON, France Product Management & Support 02/07/02 18:50 AVON FUKUYAMA RUBBER TRACK : CUSTOMER COMPLAINT REPORT FROM........................................................................................................ TO ASM By Fax to +33 (0)2 38 34 73 42 or by E-mail : [email protected]

Please complete this box For use only by AVON SPENCER MOULTON

DRAWN UP BY: DATE: NAME OF CUSTOMER: ADDRESS: COUNTRY: ACTION REQUESTED: CREDIT NOTE: REPLACEMENT

PLAINTE N° : N° CLIENT : NOTE DE DEBIT N° :

ESSENTIAL INFORMATION TRACKS MODEL (width)x(pitch)x(nb of teeth) ASM REF SERIAL N° DURATION OF USE DATE WHEN SOLD TO CUSTOMER DATE OF PURCHASE FROM ASM

1st track

- - - - - -

2nd track (Claim affecting a pair of tracks)

- - - - - -

PROBLEMS NOTED

MACHINE MODEL + TYPE Operating Hours (since commissioning)

- -

- -

(For use by ASM)

Retour demandé Prise en garantie Avoir / Remplacement

OUI NON Reçu le : OUI NON n° Soldé le :

OUI NON Reçu le : OUI NON n° Soldé le :

IMPORTANT INFORMATION

OPERATING CONDITIONS OF MACHINE CONSTRUCTION QUARRY

TARMAC, ROAD SAND

AGRICULTURE CLAY

OTHER (Please give details) ........................................

DESCRIPTION OF TRACKS AND CHASSIS COMPONENTS ROLLERS % WEAR: ................. WORN ABRASION

IDLER NORMAL (as new) WORN OVALISED OTHER: ........................

SPROCKET NORMAL (as new) WORN OTHER: ........................

TRACK ADJUSTMENT(SAG DISTANCE) 0 to 10 mm 10 to 20 mm > 20 mm

CUSTOMER COMMENTS


global track china co., ltd

Automotive