Technical Handbook RH 120 E 4. Undercarriage TEREX Germany GmbH & Co. KG
2 803 229.00 en
Editor:
TEREX Germany GmbH & Co. KG Department 910 – Product Support D-44149 Dortmund, Karl-Funke-Str. 36 Phone:
++49 / 231 / 922-4901
Fax:
++49 / 231 / 922-5900
ã Copyright by O&K, Printed in Germany
CONTENTS
4.
UNDERCARRIAGE 4.1
4.2
4.3
4.4
4.5
Introduction...................................................................................... 4.1 - 1 4.1.1
Foreword........................................................................... 4.1 - 1
4.1.2
Safety................................................................................ 4.1 - 1
4.1.3
General ............................................................................. 4.1 - 5
Travel system................................................................................... 4.2 - 1 4.2.1
General ............................................................................. 4.2 - 1
4.2.2
Components of travel system ........................................... 4.2 - 1
4.2.3
Wear limits ........................................................................ 4.2 - 4
Track chain....................................................................................... 4.3 - 1 4.3.1
General ............................................................................. 4.3 - 1
4.3.2
Components of Track chain .............................................. 4.3 - 1
4.3.3
Assembly .......................................................................... 4.3 - 2 4.3.3.1
Opening the track chain ................................... 4.3 - 2
4.3.3.2
Closing the track chain..................................... 4.3 - 3
Idler ................................................................................................... 4.4 - 1 4.4.1
General ............................................................................. 4.4 - 1
4.4.2
Components of the idler.................................................... 4.4 - 1
4.4.3
Assembly of the idler......................................................... 4.4 - 3
Bottom roller .................................................................................... 4.5 - 1 4.5.1
General ............................................................................. 4.5 - 1
4.5.2
Components of the bottom roller....................................... 4.5 - 1
4.5.3
Bottom roller installation.................................................... 4.5 - 4
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Page 4 - 1
CONTENTS 4.6
Top roller .......................................................................................... 4.6 - 1 4.6.1
General ............................................................................. 4.6 - 1
4.6.2
Components of the top roller............................................. 4.6 - 1
4.6.3
Top roller installation......................................................... 4.6 - 4
4.7
Sprocket ........................................................................................... 4.7 - 1
4.8
Travel gearbox – removal and installation .....................see chapter 7.2
4.9
Track pads........................................................................................4.9 – 1
4.10
Hydraulic track tensioning system ..............................................4.10 – 1
4.11
Page 4 - 2
4.10.1
General ...........................................................................4.10 – 1
4.10.2
Components ...................................................................4.10 – 1
4.10.3
Releasing the track tension.............................................4.10 – 4
4.10.4
Checking the accumulators............................................. 4.10 - 4
Duo cone seals .............................................................................. 4.11 - 1
RH 120 E Diesel - 2803243e - (00) – 11.99
4.1
UNDERCARRIAGE
4.1
Introduction
4.1.2
Safety Instructions
4.1.1
Foreword
4.1.2.1
Danger in the event of non-observance of the safety instructions
The Technical Handbook contains important information for personnel servicing the machine. Machine specifications listed elsewhere in the machine documents are not always repeated in this book. The documentation of an TEREX Mining machine includes:
This TEREX hydraulic excavator has been built in accordance with state-of-the-art standards and the recognized safety rules.
•
the operating instructions
However, operating the machine if a fault is suspected or has occurred, or carrying out repair work inexpertly may
•
the spare-parts list
•
•
the technical handbook
The present brochure does not contain the specifications of auxiliary units for the operation of additional or optional equipment or the specifications of individual machines. The refilling quantities specified for consumables are approximate quantities which are intended as a help for planning consumable requirements. Each unit is equipped with suitable checking devices, e.g. dipstick or checking plugs, permitting the operator to check proper filling of the units.
2440558e.doc - (00) - 11.96
•
endanger the lives of persons in contact with it damage the machine and other property.
The hydraulic excavator must be stopped immediately on any damage being suspected or occurring to ensure that the safety of the operator, of other persons at the place of use or of other material property is not compromised. All components of TEREX machines are carefully co-ordinated. Trouble-free operation and a long service life can only be achieved with original TEREX spare parts.
Page 4.1 - 1
4.1
UNDERCARRIAGE
4.1.2.2
Rules for safety at work
Personnel
Personnel
Personal protective working clothing:
The machine must not be started by unauthorized persons.
Wear a safety helmet, safety footwear and gloves.
It must therefore be secured.
Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in injury.
Observe the accident prevention regulations. The hydraulic excavator may be operated, serviced or repaired only by specially trained and authorized personnel with the appropriate technical know-how. If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from TEREX.
gear
and
If the work to be carried out requires auxiliaries, e.g. marshallers, the competences of each individual helper must be clearly defined beforehand. The individual responsibilities must be meticulously observed to avoid unclear competences endangering safety.
The personnel must have read and understood the operating instructions and in particular the chapter ‘Fundamental Safety Instructions.’ Only such persons may start up the machine during assembly work in order to adjust the attachments. Incorrect operation of the machine or the attachments may give rise to life-threatening situations. During all works, always observe the start-up and shut-down procedures prescribed in the operating instructions.
Page 4.1 - 2
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4.1
UNDERCARRIAGE
Tools and auxiliaries Tools, hoists, slings, trestles and other devices must be in a reliable, safe state. Metal splinters may cause injury when attachment bolts are being driven in or out. A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn. For climbing onto or off the machine, use only the ladders, steps, platforms and handrails provided for this purpose. Always keep ladders, steps and platforms in a non-slip state. Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.
Securing the working equipment Before carrying out assembly work, the machine and the attachments must be secured against inadvertent and unauthorized starting, e.g. by placing chocks under the wheels or tracks and by standing the working equipment on the ground. Stand the working equipment on the ground in such a way that no movements can be made when mechanical or hydraulic connections become detached. Secure any equipment or component which is to be mounted or dismantled or whose position is to be changed using hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.
2440558e.doc - (00) - 11.96
Systems and units (e.g. pipes, accumulators, etc.) must be properly depressurized before being opened. Protective devices on moving machine parts may be opened or removed only when the drive unit is stationary and protected against inadvertent starting. Before recommissioning, all protective devices must be refitted. Before carrying out assembly work, the machine and the equipment must be secured against inadvertent starting, e.g. by placing chocks under the wheels or tracks and by standing the working equipment on the ground.
Hydraulic and lubricating system: Always observe the safety regulations applicable to the product when handling oils, greases and other chemical substances. Unused but open bores, pipelines and hose connections must be closed in a pressure-tight manner. Refill collected hydraulic oil back into the hydraulic system only through the return-flow filters. Dispose of waste oil without polluting the environment. Observe the correct working sequence when fitting or replacing components or equipment. The working sequence has been specified and tested by qualified experts.
Page 4.1 - 3
4.1
UNDERCARRIAGE
Replace defective, mechanically prestressed units only as an entirety. Never open them. In exceptional cases, open only when the system and the operating sequence are precisely known. The Technical Manual contains no information on such work.
4.1.2.3
Unauthorized conversions or modifications of the hydraulic excavator are forbidden for reasons of safety. The nominal pressure of pressure relief valves must not be modified without explicit approval from TEREX. Do not remove the lead seals from pressure-relief valves and pressure accumulators.
When the machine is at operating temperature, the consumables are at least at the same temperature. Precautions must therefore be taken to prevent burning or scalding. Be careful when handling acids, e.g. battery acid. Acid splashes may injure the eyes and the skin. Do not smoke when flammable liquids.
Conversions or modifications to the machine
4.1.2.4
Recommissioning
handling
Be careful with naked flames and unprotected light. Not only fuel but also other consumables often have a low flash point and catch fire easily.
Prior to recommissioning:
• • • •
Page 4.1 - 4
Grease all lubricating points. Check all oil levels and make the necessary corrections. Carry out function checks of all repaired components Check all functions of the excavator including the brakes during a test run. Release the hydraulic excavator for recommissioning only after all functions have been found to work perfectly.
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4.1
UNDERCARRIAGE
4.1.3
General
In addition to the operating instructions and the spare-parts list, the present Technical Manual contains information enabling the user of the TEREX hydraulic excavator to safely operate, maintain and repair the machine in accordance with the specifications. The information supplied in the Technical Manual represents the standard version of the machine as delivered. All sketches and drawings are merely schematic. They do not necessarily represent the machine's actual state of design and must not be used as manufacturing documents. No reference is made to special versions.
2440558e.doc - (00) - 11.96
After delivery, the Technical Manual is not subject to revision. Technical changes introduced into the series production after delivery of the machine may also be implemented in machines already in use. In such case, already delivered Technical Manuals are normally not automatically updated. All technical documents issued by TEREX Mining GmbH are written in German and then translated. Even a good translation may give rise to questions which your TEREX dealer or your TEREX distributing centre will be pleased to answer. This Technical Manual has been carefully prepared by the competent divisions. If any points are nevertheless unclear or incorrect, please contact your local TEREX dealer or your TEREX distributing centre.
Page 4.1 - 5
4.1
UNDERCARRIAGE
Page 4.1 - 6
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4.2
TRAVEL SYSTEM
4.2
Travel system
4.2.1
General
The hydraulic excavator is equipped with a lowmaintenance undercarriage.
4.2.2
Track pad and chain link are forming one unit.
Components of travel system
Table for Fig. 1 Ref. no.
Quantity
Designation
1
1
Carbody
2
2
Track frame
3
2
Travel gearbox
4
2
Track tensioning system
5
14
Bottom roller
6
2
Support roller
7
94
Track link (2 x 47)
8
2
Idler
9
2
Sprocket
10
4
Travel motor
Further remarks
Weight [kg]
Table 1
Fig. 1
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Travel system
Page 4.2 - 1
4.2
TRAVEL SYSTEM
Table for Fig. 2 Designation
Further remarks
Weight [kg]
1
Track chain 1 000 mm
47 links
311 each
2
7
Bottom roller
434 each
3
2
Top roller
166 each
4
28
Spacer
5
8
Washer
6
28
Hex bolt M 30 x 190 – 12.9
7
8
Hex bolt M 24 x 160 – 12.9
Ref. no.
Quantity
1
Table 2
Page 4.2 - 2
RH 120 E - 2803244e - (00) – 11.99
4.2
TRAVEL SYSTEM
A
B A-B Y 3 7 5
Z
Y
4
Z
6 2 1
2 4 5 0 9 2 8 A .S K D 6, 7
Fig. 2
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Travel system
Page 4.2 - 3
4.2
TRAVEL SYSTEM
4.2.3
Wear limits
Wear on the track components is due to movement, loading and ground contact, as well as to the hardness (abrasiveness) of the ground. Wear can also be increased by the following factors: 1. unstable position of excavator because of uneven ground. 2. one-sided stressing of the tracks when turning on the spot. 3. Driving over obstacles. 4. High amount of travelling of more than 10% of the operating hours.
Page 4.2 - 4
Track components must be replaced when they have worn down to between 75 and 100%. Sudden failure is otherwise pre-programmed. Careful and regular measurements are necessary to determine the extent of wear and to be ready for component exchange when it is necessary. Before measuring components, clean them thoroughly. Measure at several points. It is not the average, but the maximum wear value that is to be taken as wear limit. Because the wear life between 75 and 100% is low, we recommend that components be changed as a preventive measure as soon as the 75% limit has been reached. Exchange can take place while other servicing is being carried out.
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4.2
TRAVEL SYSTEM
Wear limits for travel system Component
Wear limits [mm] W W W 75 % 100 % 50 %
N New
W 25 %
350
352,5
355
358,5
363
1 401
1 410
1 420
1 434
1 452
A
106
103,5
100,5
96,5
92
B
235
224,5
213,5
201,5
189
C
45
37
29
21
13
Ø
80,4
81,6
83
84,8
87
Ø
80
78,9
77,6
75,9
74
114
109,5
104
97
89
188
182,5
178
172,5
166
measured
Track pad
Track chain (4 links)
Track pad
Pad bush
Pad pin
Pad cam
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Page 4.2 - 5
4.2
TRAVEL SYSTEM
Component
Bottom roller
Top roller
Idler rim
Sprocket rim
Sprocket tooth
Page 4.2 - 6
Ø
Ø
Ø
Ø
Wear limits [mm] W W W 75 % 100 % 50 %
N New
W 25 %
340
334
325
315
302
51
54
58,5
63,5
70
260
255
249
241
232
25
27,5
30,5
34,5
39
1 120
1115
1109
1101
1092
50
52,5
55,5
59,5
64
1208
1203
1197
1189
1180
50
52,5
55,5
59,5
60
138
134
129
123
116
177
174
170
165,5
162
measured
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4.3
TRACK CHAIN
4.3
Track chain
4.3.1
General
Proportionate weight transmitted through the sprocket does not strain the pins and bushings connecting the pad-links.
The “combined pad-link” type track chain combines a chain link and a track pad into one unit. The drive forces are directly transferred from the sprocket into the massive pad-link unit.
4.3.2
The track pins are full-floating.
Components
The quantities are valid for 1 track chain. Designation
Further remarks
Weight [kg] 281 each 1,2 each
Ref. No.
Quantity
1 2
47 376
Pad-link Bushing
3
94
Pin
8,6 each
4
94
Cover plate
1,5 each
5
94
Circlip
Table 1
A-A 1:2
3 2 A
A
1 5 Fig. 1
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4
2450906A.SKD
Track chain
Page 4.3 - 1
4.3
TRACK CHAIN
4.3.3
Assembly
4.3.3.1
Opening the track chain
The track chain can be opened as follows: 1. Position the excavator in such a way that the chain link which is to be removed is positioned at the lower section of the sprocket (Arrow A in Fig.2).
Before opening the track chain has to be slackened in accordance with the operating instructions. The ball valve in the line to the track tensioning cylinder must be closed to avoid the piston being completely pushed out of the barrel when an engine is started.(see chapter 4.10).
2. First open the connection above the track link which is to be removed. (Arrow A in Fig. 1). 3. Remove both circlips (5, Fig. 1). 4. Remove both cover plates (4, Fig. 1). 5. Remove both track pins (3, Fig. 1).
Avoid uncontrolled movement of the opened track by fixing the track with help of appropriate means, e.g. chain hoists or forklift.
6. Afterwards remove the other two track pins accordingly.
Secure against falling down! When the chain is not engaged with the sprocket the whole upper section of the chain may roll off from the idler and create injury and damage! Therefor uncontrolled rolling of the chain has to be avoided by securing the chain by appropriate means!
Page 4.3 - 2
RH 120 E - 2803245e - (00) – 11.99
4.3
TRACK CHAIN
A
2760067A.SKD Fig. 2
4.3.3.2
Opening the track chain
Closing the track chain
1.
Align the track chain so that the links which are to be connected are positioned in front of the sprocket (Fig. 1).
2.
Clean bushings in the track link and the track pins with degreaser.
3.
Cover the track pins with a thin layer of assembly paste part-no. 271 554.
4.
Install both track pins, cover plates and circlips.
5.
Tension the track according to the ‘Operating Instructions’.
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Page 4.3 - 3
4.3
TRACK CHAIN
Page 4.3 - 4
RH 120 E - 2803245e - (00) – 11.99
4.4
IDLER
4.4.
Idler
4.4.1
General
With the idler the track is hydraulically tensioned via spacer piece and track tensioning cylinder.
The idler is mounted in the two slider pieces, which are guided in the track frame.
4.4.2
Components of the idler
The reference numbers are related to Fig. 1 and Fig. 2 Ref. no.
Quantity
Designation
1 2
1 2
Idler Slider piece
3
1
Shaft
4
2
Disk
5
Further remarks
Weight [kg] 1 533 138 each 133
----
6
2
Bushing
7
2
Duo-cone seal
8
2
O-ring
9
2
Locking pin
10
----
11
12
Dowel pin
12
2
Locking pin
14
1
Spacer piece
15
----
16
4
Hex. bolt M 24 x 160
17
4
Sleeve
30
0,6 kg
Grease
Tightening torque Md = 670 Nm KPF2K - 30
Table 1
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Page 4.4 - 1
4.4
IDLER
Fig. 1
Idler
1
11
8
9; 12
3
4
7
2
A-A
90°
A 9; 12
6
30
2451815A.SKD
A
Fig. 2
Page 4.4 - 2
Idler
RH 120 E - 2803246e - (00) – 11.99
4.4
IDLER
4.4.3
Assembly of the idler
3. Pick up idler shaft with lifting device (6, Fig. 3) and install into the idler.
When assembling the idler the working sequence has to be as follows: 1. Place idler onto suitable support (1, Fig. 1) and completely press, respectively drive in bushing (2, Fig. 1).
Fig. 3
Fig. 1
Installation of bushings
2. Fit two halves of duo-cone seals (5, Fig. 2) into idler (see chapter 4.11 ‘Duo-cone seals’).
Installation of idler shaft
4. Insert labyrinth ring into the groove in the idler (5, Fig. 2). The seal must not be pressed into the grove but move freely. Grease the surface on both sides of the seal with high pressure grease (30, Fig. 2).
Grease must not penetrate into the oil channels of the idler.
5. Grease seal ring (7, Fig. 4) and place into slider piece (8, Fig. 4).
Fig. 2
Installation of duo-cone seal
Fig. 4
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Installation of seal
Page 4.4 - 3
4.4
IDLER
6. Place disk (3, Fig. 5) with grease into slider piece (8, Fig. 5) and secure by knocking in dowel pins (4, Fig. 5).
8. Clean indicated area of the idler shaft (arrow, Fig. 2) with degreaser and cover with a thin layer of anti-seize paste part-no. 271 554. Assemble the first slider piece (8, Fig. 7) and the shaft (6, Fig. 7) with help of a lifting device. Ensure that the slider piece is brought exactly into position and the borings for the locking pins (9 + 10, Fig. 8) in the slider piece and the shaft are aligned. Before assembling the duo-cone seal clean the contact surface carefully and cover the contact surface slightly with oil. Do not oil the other areas of the duo-cone seals..
Fig. 5
Installation of disc
7. Fit half of duo-cone seal (5, Fig. 6) into slider piece (8, Fig. 6).
Fig. 7
Fig. 6
Page 4.4 - 4
Installation of slider piece
Installation of duo-cone seal
RH 120 E - 2803246e - (00) – 11.99
4.4
IDLER
9. Install the locking pins (9 + 10, Fig. 8). The grove in the locking pin has to show into the direction of the shaft.
Fig. 8
Installation of locking pins
10. Turn idler and fill idler housing with oil according to Service Manual.
Fig. 9
Filling with oil
For oil quantity and -quality refer to the ‘Operating Manual’.
11. Install second slider piece according to section 8.
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Page 4.4 - 5
4.4
IDLER
Page 4.4 - 6
RH 120 E - 2803246e - (00) – 11.99
4.5
BOTTOM ROLLER - RH 120 E - SERIAL NUMBERS
To find the valid section place the cursor on the box with the machine serial number and click.
Machine serial number
Valid document (file name)
Revision
120 001 - 120 024
2803247e
01
from 120 025
3657707e
00
RH 120 E - chapter 4.5 - serial numbers.doc - (00) – 02.03
Page 4.5 - 1
4.5
BOTTOM ROLLER - RH 120 E - SERIAL NUMBERS
Page 4.5 - 2
RH 120 E - chapter 4.5 - serial numbers.doc - (00) – 02.03
4.5
BOTTOM ROLLER
4.5
Bottom roller
4.5.1
General
1. Bottom rollers have lifetime lubrication. They do not require any maintenance until the wear limits have been reached.
4. The roller can be made fully operational by removing and cleaning it, and then filling it with fresh oil. 5. Loose fastening bolts will immediately result in leaks and further damage to the bottom rollers.
2. The rollers are sealed with duo-cone seals (6). Function and assembly of duo-cone seals - see chapter 4.11. 3. The majority of roller leaks is due to dirt that enters through the labyrinth (see arrow, Fig. 2) and penetrates into the duo-cone seals.
4.5.2
Components of the bottom roller
The parts listed in table 1 refer to Fig.1, 2 and 3. Components of the bottom roller Designation
Quantity
1 2
1 2
Roller body Support
286 33 each
3
2
Bushing
1,9 each
4
2
Disk
0,7 each
5
2
Ring
6
2
Duo-cone seal
7
1
Plug
8
2
Sealing ring
9
----
10
----
11
1
Washer
12
1
Hex. bolt M 16 x 65
13
8
Hex. bolt M 30 x 190
14
8
Washer
61
0,2 kg
Grease
Further remarks
Weight [kg]
Ref. no.
see chapter 2.9
Table 1
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Page 4.5 - 1
4.5
BOTTOM ROLLER
Fig. 1
Bottom roller
3 2
5
6
1
11
4
12
7 8
7 8
15
24 166 90A.SKD
Fig. 2
Page 4.5 - 2
Bottom roller
RH 120 E - 2803247e - (00) – 11.99
4.5
BOTTOM ROLLER
A
B A-B Y
Z
Y
14
Z
13 1 2 45 09 2 8B .S K D 13 Fig.3
RH 120 E - 2803247e - (00) – 11.99
Bottom roller - Installation
Page 4.5 - 3
4.5
BOTTOM ROLLER
4.5.3
Bottom roller installation
Sequence of assembly for bottom roller installation 1. Position roller under the track frame and threat in mounting bolts (13) with washers (14).
4. ** ATTENTION ** Bearing has to lay at the whole connecting surface of the track frame without any axial tolerances. 5. Torque - tighten mounting bolts with torque according to chapter 2.9 - ‘Tightening procedures’.
2. Remove items 8, 9, 10, 11 on both bearings. 3. Press bearing with
6. Fill in oil according to the service- and operating instructions and plug bearing with items 7 and 8.
auxiliary bolt Part-no. 2 157 689 (Fig. 4) Fill oil container to the marked level against connecting surface of the track frame.
Fig. 4
Page 4.5 - 4
Auxiliary bolt Part-no. 2 157 689
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4.5
BOTTOM ROLLER
4.5
Bottom roller
4.5.1
General
•
Bottom rollers have long term lubrication. If installed the rollers are connected to the undercarriage central greasing system.
•
The rollers are sealed with duo-cone seals (6). Function and assembly of duo-cone seals see chapter 4.11.
•
The majority of roller leaks is due to dirt that enters through the labyrinth (see arrow, Fig. 2) and penetrates into the duo-cone seals.
4.5.2
•
The roller can be made fully operational by removing and cleaning it, and then filling it with fresh oil.
•
Loose fastening bolts will immediately result in leaks and further damage to the bottom rollers.
Components of the bottom roller
The parts listed in table 1 refer to Fig.1, 2 and 3. Components of the bottom roller Ref. no.
Quantity
1
Weight [kg]
Designation
Further remarks
1
Roller body
∅ 360 mm
2
2
Support
52 each
3
2
Bushing
6,5 each
4
2
Disk
1,4 each
5
2
O-Ring
6
2
Duo-cone seal
7
1
Plug
8
2
Sealing ring
9
321
----
10
2
O-Ring
11
2
Plug
12
----
13
4
Hex. bolt M 30 x 220
14
4
Washer
20
1
Securing device for transport
30
0,2 kg
Tightening torque Md = 2 250 Nm
Grease
Table 1
RH 120 E - 3657707e.doc - (00) – 02.03
Page 4.5 - 1
4.5
BOTTOM ROLLER
Fig. 1
Bottom roller
13 Fig. 2
Page 4.5 - 2
A Bottom roller
RH 120 E - 3657707e.doc - (00) – 02.03
4.5
BOTTOM ROLLER
A
B A-B Y
Z
Y
14
Z
13 1 2 45 0 9 2 8B .S K D 13 Fig.3
RH 120 E - 3657707e.doc - (00) – 02.03
Bottom roller - Installation
Page 4.5 - 3
4.5
BOTTOM ROLLER
4.5.3
Bottom roller installation
Press bearings against connecting surface of the track frame.
Sequence of assembly for bottom roller installation •
Position roller under the track frame and threat in mounting bolts (13) with washers (14).
•
Remove securing device (20, Fig. 4).
Because of the securing device for transport the roller body and the supports have been pre-loaded. Therefore it is important to press the supports against the contact surface of the frame before The mounting bolts (13) are tightened. So the axial clearance of 1,0 to 2,0 mm is achieved.
•
Tighten mounting bolts with torque according to chapter 2.9 - ‘Tightening procedures’.
•
Fill in oil according to the service- and operating instructions and plug bearing with items 7 and 8.
•
Fill oil container to the marked level
The supports have to contact the whole connecting surface of the track frame without any axial tolerances.
Fig. 4
Page 4.5 - 4
securing device for transport
RH 120 E - 3657707e.doc - (00) – 02.03
4.6
TOP ROLLER
4.6
Top roller
4.6.1
General
3. The majority of roller leaks is due to dirt that enters into the duo-cone seals.
Onto each track frame 2 top rollers are installed. 1. Top rollers have lifetime lubrication. They do not require any maintenance until the wear limits have been reached.
4. The roller can be made fully operational by removing and cleaning it, and then filling it with fresh oil. 5. Loose fastening bolts will immediately result in leaks and further damage to the bottom rollers.
2. The rollers are sealed with duo-cone seals (4). Function and assembly of duo-cone seals - see chapter 4.11.
4.6.2
Components of the top roller
The parts listed in table 1 refer to Fig.1, 2, 3. Components of the top roller Ref. no.
Quantity
Designation
1
1
Top roller body
2
2
Support
3
2
O-ring
4
2
Duo-cone seal
5
2
Bushing
6
1
Shaft
7
2
Locking pin
8
2
Locking pin
9
1
Sealing ring
10
1
Plug
11
4
Washer
12
4
Hex. bolt M 24 x 160
Further remarks
Weight [kg] 109 9,4 each
4,6 each 25
Table 1
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Page 4.6 - 1
4.6
TOP ROLLER
Fig. 1
Top roller
Fig. 2
Top roller
Page 4.6 - 2
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4.6
TOP ROLLER
1 12 11
2450928C.SKD
12 Fig. 3
4.6.3
Top roller - installation
Top roller installation
•
Torque - tighten mounting bolts with torque according to chapter 2.9 - ‘Tightening procedures’.
•
Fill in lubricant according to the service- and operating instructions and install sealing ring (9) and plug (10).
Sequence of assembly for top roller installation •
Position roller onto the track frame and threat in mounting bolts with spacers.
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4.6
TOP ROLLER
Page 4.6 - 4
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4.7
SPROCKET
4.7
Sprocket
•
For Installation of the travel gearbox see chapter 7.2 ‘Travel gearbox’.
The sprocket is bolted to the travel gearbox.
Ref. no.
Quantity
1 2
1 41
Travel motor cover Washer
3
48
Washer
4
48
Hex. bolt M 30 x 2 x 190
5
1
Sprocket
6
Designation
Weight [kg]
Further remarks
Tightening torque Md = 2 500 Nm 1 423
----
7
41
Hex. bolt M 30 x 2 x 240
8
2
Plug
9
1
Plug
10
2
Travel motor
11
1
Travel gearbox
12
4
Hex. bolt M 20 x 50
13
4
Washer
Tightening torque Md = 2 500 Nm
72 each 2 600 Tightening torque Md = 350 Nm
Table 1
A
Fig. 1
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Opening of track
Page 4.7 - 1
4.7
SPROCKET
1 5 11
C
E
F
3,7
3,4 D
2450925B.SKD
4, 7 Fig. 2
Sprocket drive
Fig. 3
Travel gearbox and sprocket
Page 4.7 - 2
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4.7
SPROCKET
Removal and installation of the sprocket can be done while the travel gearbox is installed in the track frame.
•
When the sprocket has been prepared for installation, apply adhesive Part-no. 1 991 417 to one of the contact surfaces (arrow E, Fig. 2).
The track has to be opened according to chapter 4.3.
Apply the adhesive with ca. 10 mm clearance from the threaded holes to ensure that no adhesive can be forced into the threaded holes when the gearbox is set down. Penetration of adhesive into a threaded hole leads to increased friction and thus to invalidation of the starting power data.
Avoid uncontrolled movement of the track by fixing it with help of appropriate means, e.g. chain hoists or forklift before it is opened.
Removal of the sprocket •
Pick up sprocket with lifting device.
•
Unscrew all mounting bolts (4, Fig. 2)
•
Insert 2 bolts ISO 4017 - M 30 x 150 - Part-no. 157 699 into the holes of the sprocket.
•
Screw in all 4 bolts equally to separate the sprocket from the gearbox.
Installation of the sprocket •
Mounting bolts The threads and the heads of the mounting bolts have to be slightly oiled and must not come into contact with the adhesive.
•
Contact surface Prior to installing the sprocket, all traces of paint and grease must be removed from the contact surfaces between sprocket and travel gearbox with solvent Part-no. 216 405 (arrows E and F, Fig. 2). Check the contact area of sprocket and gearbox carefully for mechanical damages. The contact surface (arrow F, Fig. 2) must be coated with mounting paste Part-no. 244 905.
•
Adhesive
•
Sprocket Pick up sprocket with lifting device. Align sprocket and gearbox, insert all mounting bolts and tighten hand-tight.
•
Tightening of bolts
Start sprocket installation as soon as the adhesive has been applied. The adhesive starts hardening when the metal surfaces have been joined without any air being admitted and is completed after approx. 48 hours at an ambient temperature of approx. 20°C. The hardening process is initially strongly delayed, so that the installation time can be extended to a maximum of 8 hours. At temperatures below -10°C, activator Part-no. 1 991 468 must be sprayed onto the second joining surface - the surface with no adhesive.
Threads Clean all threads from paint, rust and grease and blow out with compressed air. Check for damage and tap threads again if required.
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Page 4.7 - 3
4.7
SPROCKET
After installing the sprocket screw in all bolts and tighten all bolts (4, Fig. 3) crosswise with a torque of 2500 Nm. •
Closing of track Bring track to a suitable position (A, Fig. 1) by moving the excavator and close track.
After closing the track the ball valve at the track tensioning cylinder has to be opened and the pressure relief valve in the carbody has to be adjusted (see chapter 4.10).
Page 4.7 - 4
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4.8 4.8
TRAVEL GEARBOX - REMOVAL & INSTALLATION Travel gearbox removal and installation
The removal and installation of the travel gearbox is described in chapter 7.2
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Page 4.8 - 1
4.8
TRAVEL GEARBOX - REMOVAL & INSTALLATION
Page 4.8 - 2
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4.9
TRACK PAD
4.9
Track pad
The “combined pad-link” type track chain combines a chain link and a track pad into one unit. For further details see chapter 4.3 ‘Track chain‘.
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4.9
TRACK PAD
Page 4.9 - 2
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4.10
HYDRAULIC TRACK TENSIONING SYSTEM
4.10
Hydraulic track tensioning system
4.10.1 General Technical data: Track tensioning pressure
80 bar
Setting of pressure relief valve:
330 bar
Nitrogen pre-charge of accumulator:
48 bar
Suspension travel:
100 mm
Maximum retensioning distance:
120 mm
4.10.2 Components of the track tensioning system The reference numbers are related to Fig. 1 and Fig. 2 Ref. no.
Quantity
Designation
Further remarks
Weight [kg]
1
1
Idler-unit
1 953
2
2
Plug
3
2
Sealing ring
4
2
Bushing
5
1
Shaft
6
2
Thrust washer
7
1
Pin
8
2
Duo cone seal
9
2
O-ring
10
2
Sealing ring
11
2
O-ring
12
2
Sliding piece
13
2
Locking pin
14
2
Locking pin
15
1
Spacer piece
225
16
1
Tensioning cylinder
363
17
4
Sleeve
18
8
Hex. bolt M 24 x 160
19
1
Accumulator
20
1
Filling and testing port
21
4
Hex. bolt M 8 x 20
22
4
Spring washer
23
1
Plug
24
1
Ball valve
133
Md = 670 Nm
Md = 21 Nm
Table 1
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4.10
HYDRAULIC TRACK TENSIONING SYSTEM
Fig. 1
Page 4.10 - 2
Idler with track tensioning cylinder
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2450926A.SKD
HYDRAULIC TRACK TENSIONING SYSTEM
16
19
24
1
17
18
15
16
18
24
19
21
4.10
18, 21 Fig. 2
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Idler with track tensioning system
Page 4.10 - 3
4.10
HYDRAULIC TRACK TENSIONING SYSTEM
4.10.3 Releasing the track tension
4.10.4 Checking the accumulators
Before carrying out repair work the tracks have to be slackened.
The procedure how to check the accumulators is described in chapter 8.6.4.8 ‘Track tensioning system’.
Procedure: •
Shut down the engines
•
Open both pressure relief valves (3, Fig. 3); the track is slackening (each track is related to a pressure relief valve).
•
Before opening the track the ball valve (10. Fig. 2) in the line to the track tensioning cylinder must be closed to avoid the piston being completely pushed out of the barrel when an engine is started.
•
After completion of the repair close the pressure relief valves (turn in completely).
Fig. 3
Track tensioning system
Each pressure relief valve (3, Fig. 3) is adjusted to 330 bar and sealed in this position. The seal must not be removed and the pressure setting of 330 bar must not be changed.
Attention! Tensioning of the tracks: See operator’s manual.
Pressure setting: See chapter 8.6 ‘Checking and setting pressures’
Page 4.10 - 4
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4.11
DUO-CONE SEALS
4.11
Duo-cone seals
Duo-cone seals (also referred to as steel-on-steel seals) are used as shaft seals. The arrangement of the seal is such that one steel ring, elastically mounted in the fixed component, lies/runs axially against a second steel ring that is also elastically mounted, but this time in the rotating component. Duo-cone seals are used in the excavator's bottom rollers, support rollers and idlers. Leakages in such components are usually due to damaged duo-cone seals. In case of leakages, the duo-cone seals are to be changed immediately. Fig. 2
Observe the following points when assembling duo-cone seals: 1. The running surfaces ‘’A’’ of the steel rings (1, Fig. 1) must be completely free of scratches and scores. Clean all traces of oil and dust from running surfaces "A" and seating bevels ‘’B’’. All surfaces must be dry and free of rust, slag and scale.
3. Place one complete half (1) and (2) of the duocone seal into/onto the rigid component and one complete half into/onto the rotating component (Fig. 3) - but without using any oil. Make sure that distance ‘’C’’ is equal all the way around the seal.
Fig. 3 Fig. 1
Duo-cone seals
2. Draw rubber seal (2) onto steel ring (1, Fig. 2). The rubber ring (2). is correctly positioned when it sits twist-free parallel to the surface of the steel ring (1)..
Duo-cone seals
Duo-cone seals
4. Before fitting the two machine components (rigid and rotating) together, carefully wipe the surfaces ’’A’’ of the steel rings (1) to remove any foreign bodies or even finger-prints. Then apply a drop of thin oil between the running surfaces, but without allowing oil to get onto the other parts. Attention: NEVER fit a new half of a duo-cone seal to a used half. When re-assembling used duocone seals, make sure that pairs that were previously installed together are kept together.
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Page 4.11 - 1
4.11
DUO-CONE SEALS
Page 4.11 - 2
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