Anleitung Hinowa Fahrwerk Englisch

TABLE OF CONTENTS
MANUFACTURERS STATEMENT Page 32

INTRODUCTION Page 33
TRACKED UNDERCARRIAGE IDENTIFICATION DATA Page 34
TERMINOLOGY Page 35
SAFETY INFORMATION Page 36
PICTOGRAMS Page 37
SAFETY AND ACCIDENT PREVENTION
1. GENERAL PRECAUTIONS Page 38
1.1 Read these instructions with care Page 38
1.2 Unauthorized modifications Page 38
1.3 Safety valves Page 38
OPERATING PRECAUTIONS
2. INSTALLATION PRECAUTIONS Page 38
2.1 Remove paint before welding Page 38
2.2 Avoid welding near to pressurized pipelines Page 39
2.3 Avoid contact with high pressure fluids Page 39
2.4 Structural connection of the undercarriage Page 39
2.5 Hydraulic connections to the tracked undercarriage Page 40
2.6 Procedure for the first undercarriages starting Page 41
2.7 Installing tracked undercarriages with hydraulic widening Page 42
3. TECHNICAL DATAAND CONNECTION DIAGRAMS Page 43
O OP PE ER RA AT TI I N NG G A AN ND D M MA AI I N NT TE EN NA AN NC CE E M MA AN NU UA AL L SERIES PT TRACKED UNDERCARRIAGES
Pagina 30
4. PRECAUTIONS TO ENACT WHEN STARTING
TO USE THE UNDERCARRIAGE INSTALLED Page 44
4.1 Work with your machine in conditions of safety Page 44
4.2 Parking the machine Page 44
4.3 Working in streams Page 44
4.4 Use of rubber tracks Page 45
4.5 Rubber track tension Page 45
4.6 Steel track tension Page 46
4.7 Use of hydraulic widening Page 46
5. MAINTENANCE Page 47
5.1 Correct inspection and maintenance procedures Page 47
5.2 Maintenance of drive geared motors Page 48
5.2.1 Checking the oil level in the reduction unit Page 48
5.2.2 Replacement of oil in the reduction unit Page 48
5.2.3 Choice of type of reduction unit oil Page 48
5.2.4 Hydraulic circuit oil Page 49
5.3 Rubber track maintenance Page 49
5.3.1 Checking track tension Page 49
5.3.2 Track loosening/tightening procedures Page 50
5.3.3 Checking the rubber tracks Page 51
5.3.4 Replacement of rubber tracks Page 53
5.4 Steel track maintenance Page 55
5.4.1 Checking track tension Page 55
5.4.2 Checking pin and bush wear Page 55
5.5 Checking sprocket wear Page 56
5.6 Checking bolt tightness Page 57
5.7 Grease points Page 57
APPENDIX 1 Page 88
APPENDIX 2 Page150
Pagina 31
MANUFACTURERS STATEMENT
The tracked undercarriage product is an incomplete part of a machine
and cannot be used directly in a self-contained and independent man-
ner because it is lacking the tool, implement or other instrument finali-
zed for a specific application. It consequently does not fall within the
range of application of Machine Directive Chap. I, Art. I and does not
need to comply with the provisions stipulated in Chap. I, Art. 5 and
Chap. II, Art. 8. Its destination, as indicated in attachment II, point B
(see Chap.I, Art. 4, point 2), is to be incorporated in a machine or to be
assembled with other machines in order to compose a machine where
the Machine Directive is applied. Given the above,
The HINOWA S.p.A. Company
Via Fontana - 37054 NOGARA (VR) - ITALY
Tel. 0442/539100 - Fax 0442/539075
STATES
that it is forbidden to put HINOWA series PT and series PT-ALL
tracked undercarriages in service before the machine in which they
have been incorporated has been stated to comply with the provisions
of MACHINE DIRECTIVE (EEC directive 98/37) and subsequent modi-
fications.
Pagina 32
INTRODUCTION
This manual is made to permit customers to properly employ Hinowa tracked
undercarriages on the machines that they have designed and where they intend
installing the undercarriages.
Read this manual with care before making mechanical and hydraulic connections
between the tracked undercarriage and your machine.
Continuous improvements in Hinowa products may create illustrations in the
manual that do not match exactly with the parts that are used.
No matter where you live or work do not hesitate to contact our engineering
department which is at your full disposal for all useful information and, in case, to
furnish you with any genuine spare parts you may require: these are the only
spare parts that guarantee quality and perfect interchangeability.
It is necessary, to correctly request spare parts, that every order be preceded by
the serial nof the tracked undercarriage.
The technical data and connection layouts illustrated in Chapter 3 refer to stan-
dard versions and the main special versions of Hinowa tracked undercarriages.
Consult with our engineering department regarding special versions not contem-
plated in this manual.
Pagina 33
TRACKED UNDERCARRIAGE IDENTIFICATION DATA
The drawing shows the position of the serial non the tracked undercarriage.
CLASSIFICATION
Pagina 34
Matricola
520202BH197
520202BH197
PT20 G L / ***
Type of undercarriage
G: rubber tracks
A: steel tracks
C: short type undercarriage length
L: long type undercarriage length
Undercarriage version
Example:
Example:
TERMINOLOGY
The following names for the various assembly components are given to make it
easier to understand safety warnings and operation and maintenance instructions
for the tracked undercarriage.
1 Track
2 Track-stretching wheel
3 Track-stretching wheel support
4 Spring
5 Track-stretching cylinder
6 Valve
7 Truck
8 Motor protection cover
9 Cover
10 Reduction gear drive
11 Sprocket
12 Roller
13 Track guide
Pagina 35
11
1
2
3
4
5
6
7
8
9
10
12
13
SAFETY INFORMATION
To prevent accidents you must carefully read and comply with all the precautions
and warnings contained in this manual before starting to work and before perfor-
ming any maintenance.
This is the safety warning signal. Pay attention
when you see this symbol on the tracked under-
carriage or in this manual since there is potential
danger for personal injury.
Comply with recommended instructions and pre-
cautions.
The words DANGER and WARNING are used
together with the safety warning symbol.
The word DANGER indicates potential danger
situations that can quite probably cause severe
injury or death if the danger is not avoided and
can also cause serious damage to the undercar-
riage.
The word WARNING indicates potential danger
situations which, if they are not avoided, can
cause minor harm or injury to the operator. This
word can also be used only to indicate dangers
which can cause damage to the tracked under-
carriage.
This message is used in situations where failure
to take due measures can shorten the working
life of the tracked undercarriage.
Pagina 36
IMPORTANTE
PERICOLO
ATTENZIONE
DANGER
WARNING
IMPORTANT
PICTOGRAMS
CONSULT THE MANUAL
Read the contents of this manual with care before connecting the tracked undercar-
riage to your machine or before performing maintenance.
DIRECTION OF MOVEMENT
Make sure that forward movement by the tracked
undercarriage is always with the drive geared motors
located in the rear part of the undercarriage.
DIRECTION OF ROTATION OF DRIVE GEARED MOTORS
The pictogram shows an example of direction of the reduction gear drive for the
connection of your machine to the hydraulic circuit. The rotation directions for each
model are indicated in the diagrams of this booklet (see chapt. 3).
Pagina 37
SAFETY AND ACCIDENT PREVENTION
1 GENERAL PRECAUTIONS
1.1 Read these instructions with care
Enact all possible safety regulations, precautions and instructions when installing
and/or performing maintenance on the tracked undercarriage.
1.2 Unauthorized modifications
It is strictly forbidden to bring modifications to the tracked undercarriage which
could compromise proper operation and safety. The Hinowa company is not
responsible for any injury or damage caused by unauthorized modifications.
1.3 Safety valves
It is strictly forbidden to modify or tamper with hydraulic geared motor control and
safety valves whenever these are present. The Hinowa company is not responsi-
ble for damage to persons or property, to your machine or to tracked undercarriage
components when standard settings for hydraulic valves are tampered with.
OPERATING PRECAUTIONS
2 INSTALLATION PRECAUTIONS
2.1 Remove paint before welding
Whenever you weld your machine to the frame of the
tracked undercarriage you must first remove the paint in
the welding zone. Heated paint in the welding zone, if it
is not removed, can generate toxic fumes. Avoid poten-
tially toxic fumes and dusts.
Avoid inhaling dust if you sand or grind the paint to remo-
ve it. Wear an approved breathing set.
If you use solvents or similar substances for paint remo-
Pagina 38
PERICOLO
PERICOLO
DANGER
DANGER
PERICOLO DANGER
val be sure to eliminate this substance with soap and water before welding the bare
section.
Remove solvent or paint removal containers from the welding zone. Wait at least
15 minutes before starting to weld to make sure fumes disperse.
Perform the entire job in a well-ventilated work zone.
Dispose of paint and solvent in an environmentally-safe manner according to cur-
rent local regulations.
2.2 Avoid welding near to pressurized pipelines
Never heat by welding near pressurized hydraulic pipeli-
nes or other flammable materials. Excessive heating
near to pressurized hydraulic pipelines can cut them and
generate flammable spatter with consequent severe
burns for yourself and for other nearby persons. Install
heat-resistant screens if you cannot avoid welding near
to pressurized pipelines.
2.3 Avoid contact with high pressure fluids
Fluids which exit under high pressures can penetrate into
the skin and cause very severe injuries.
Avoid this danger by eliminating pressures before con-
necting hydraulic pipelines. Tighten all connections well
before pressurizing the circuit.
When inspecting the system and looking for leaks use a
piece of cardboard and protect the hands with gloves
and the eyes with safety goggles. Consult a doctor
immediately if an accident happens. Fluid injected into
the skin must be surgically removed within a few hours
since otherwise it can cause serious diseases.
2.4 Structural connectin of the undercarriage
Weld the structures of the undercarriage such as cross-members and side frames
as near as possible to the reinforcement points, as indicated in the picture.
Do not weld outside the sketched area, in order to prevent structural failures of the
side frames and/or of components such as rollers, wheels, reduction gear drives.
Pagina 39
NOTE: The undercarriages that are sup-
plied without cross-members are
assembl ed through a j uncti on
reinforcement between the plate
fixing the reduction gear drives sup-
port and the main structure. Such
reinforcement is ONLY little welded
(see pi cture). Before usi ng the
undercarriage, weld this reinforce-
ment by fixing it also to the machi-
nes structure.
2.5 Hydraulic connections to the tracked undercarriage
Always make sure you connect the hydraulic components of the tracked undercar-
riage to your machines system according to the diagrams given in this manual.
Pay attention to the type of undercarriage you have purchased because series PT
undercarriage connection circuits are not all the same since various types of
hydraulic geared motors are used.
It is important to check, when connecting the hydraulic geared motors, what the
geared motors direction of rotation corresponds to forward movement by the machi-
ne when the geared motors are positioned in the rear part of the undercarriage.
Some versions of tracked undercarriages may be furnished without the drive control
valve flanged to the geared motors. In this case it is your task to install the valve,
complying with the diagrams indicated in this manual. If you choose to use in-line
drive control valves then the connection between hydraulic geared motors and val-
Pagina 40
ves must be made using pipelines of appropriate dimensions for the working
hydraulic pressure and the peak pressure.
Adjustment of the drive control valves and the max. pressure valves that control the
circuit, must be according to the settings indicated in the technical data card.
We remind you that the function of the control valves that are flanged to the
motor is to prevent pressure peaks due to the inertial force and to allow con-
trolling the undercarriage when driving on a slope. The installer is responsi-
ble for mounting under his machine a PT undercarriage which is not equip-
ped with control valves.
In addition to this, we remind you that a hydraulic motor not equipped with
negative brake always leaks, which can cause movements of the machine if
parked on a slope.
IMPORTANT
The standard Hinowa undercarriages are usually installed on open circuits
(see attachments). For different applications (for example closed circuits)
please contact the Hinowa engineers.
For the hydraulic connections, in particular the drain connections, please refer to
what stated in the specific schemes for each model.
2.6 Procedure for the first undercarriages starting
Before putting the undercarriage into service, do what follows:
1) Oil fluxing: max. contamination allowed: absolute class NAS 9 1638 or 18/18 SO
DIS 4406
2) Operate the reduction gear drive idle for about 5 minutes (machine lifted) at low
load and in one direction, in order to ensure a good cleaning of the system and a
perfect filling.
Pagina 41
U
M
S
0
1
0
2
4
PERICOLO
2.7 Installing tracked undercarriages with hydraulic widening
Be careful not to ruin the antifriction slide guides placed inside the central structure
if you need to install your machine on a tracked undercarriage with hydraulic wide-
ning. Perform the following operations before welding your structure to the central
frame of the tracked undercarriage:
1) support the central part of the tracked
undercarriage with blocks that lift the
tracks off the ground and permit you to
work in safe and secure conditions;
2) remove the pins from the hydraulic
widening cylinder stems;
3) pull out the 2 longitudinal members of
the tracked undercarriage that are no
longer connected to the central structu-
re;
Pagina 42
ATTENZIONE WARNING
4) unscrew the sixteen screws from the
4 protective covers (a) and remove
the 4 slide guides (b) located inside
each cover.
At this point you can proceed to weld your machine onto the central frame of the
tracked undercarriage. Be sure to make intermittent welds that do not deform the
central structure of the undercarriage. Subsequently, to reassemble the undercar-
riage, repeat procedures for removing the longitudinal members from the central
structure in reverse order. Start by repositioning the slide guides inside the central
structure. Close them with the 4 protective covers. Insert the 2 longitudinal mem-
bers in the central structure and clamp everything together by inserting the pins of
the widening cylinder stems into their seats on the longitudinal members.
3 TECHNICAL DATA AND CONNECTION DIAGRAMS
Be extremely careful to make sure you comply with the
hydraulic connection diagram for the type of tracked
undercarriage that you use, as indicated below.
First discover, as indicated in the manual, the exact input positions (A and B) for oil
to the geared motor, the drainage connection and the two speed drive control
(when furnished). A and B inlets of drive geared motors equipped with negative
brakes and/or translation control valves must always be connected to open center
sections of hydraulic distributors.
The Hinowa company will not be responsible for damage to persons and/or pro-
perty caused by failure to comply with this rule.
For the max. performances of your undercarriage, please always refer to what sta-
ted in the technical data section of the drawing attached to the order confirmation
of the undercarriage you have purchased.
In particular the maximum stated operating slope refers to maximum technical
performance data expressed for the tracked undercarriage and may not coincide
with the actual slopes that can be climbed by your machine while still remaining in a
situation of safety.
Pagina 43
PERICOLO
a
b
DANGER
4 PRECAUTIONS TO ENACT WHEN STARTING TO USE THE UNDERCARRIA-
GE INSTALLED
4.1 Work with your machine in conditions of safety
Make sure that the work site terrain is strong enough to
firmly support your machine. When you work near an
excavation position the tracked undercarriage with its
drive geared motors to the rear. Be careful not to tip
over when working on frozen terrain. A rise in tempe-
rature can soften the terrain and make it unstable.
4.2 Parking the machine
Park your machine on solid and flat terrain with enough
room to permit inspection. If you cannot do this and
must park on a slope then insert safety wedges below
the tracks.
4.3 Working in streams
If the bottom is level and the water flows slowly then
the tracked undercarriage can work in water up to the
top surface of the track pads. Be very careful about
the type of bottom of the stream since if it is very soft
the machine may slowly sink down.
Pagina 44
PERICOLO DANGER
PERICOLO DANGER
4.4 Use of rubber tracks
Avoid the following situations when working with an undercarriage with rubber
tracks:
1. Do not maneuver on hard, stony and uneven surfaces such as streambed rock,
gravel, etc.
2. Dont keep the rubber tracks lying in the direct sun light for more than 3 months
time.
3. Avoid improper steering maneuvers on asphalt and cement since these cause
excess pad wear. Avoid working on asphalt surfaces when their temperature
exceeds 60C since this causes both excess pad wear and damage to the
asphalt surface.
4. Maneuvers with a loose track on an irregular surface can cause the pad to deta-
ch and/or damage to the rubber track.
5. Rubber tracks are designed only for use on soft terrain, not for hard and abrasive
surfaces such as sand, stone, minerals, etc. Use of rubber tracks on these sur-
faces can cause premature wear and deformation.
6. Avoid contact between sharp concrete edges etc. and the rubber track.
7. Fuels or synthetic oils must never come in contact with the rubber track. If this
does happen then they must immediately be cleaned.
8. Avoid using rubber tracks in marine and seaside environments since saline air or
salt in general corrode adhesion between rubber and metal inner core.
4.5 Rubber track tension
When the tracked undercarriage is lifted the rubber track must deflect 1015 mm as
indicated in the illustration. When tension decreases it must be re-tightened to pre-
vent the machine from losing its tracks because they are too loose (see paragraph
5.3.2).
Pagina 45
10 15 mm
ATTENZIONE WARNING
4.6 Steel track tension
The chain tension must always be correct. This is correct when, in the top part of
the track, the longest section of unsupported chain deflects about 20 mm.
The chain must be re-tightened when deflection exceeds this value (see paragraph
5.3.2).
4.7 Use of hydraulic widening (only for tracked undercarriages with hydrau-
lic widening)
Before widening or narrowing the tracks using the
hydraulic widening mechanism first lift the machine off
the ground to prevent friction between tracks and ter-
rain, caused by the weight of the machine, from cau-
sing damage to the undercarriage structure.
Pagina 46
IMPORTANTE
IMPORTANT
5. MAINTENANCE
5.1 Correct inspection and maintenance procedures
Learn how to perform correct maintenance on the tracked undercarriage and how
to perform the inspection procedures described in this manual.
Always perform maintenance on a solid and level surface.
Never grease or lubricate or perform maintenance on the machine while it is in
motion.
Solidly support the undercarriage if it needs to be lifted up for maintenance.
Use great care when maintaining the hydraulic system since oil is very hot when
the machine has just finished working.
Circuits are under high pressures not only when working but also when work is
Keep all components properly installed and in good condition.
Immediately repair all damage and replace worn or broken parts.
Remove any build-ups of grease, oil or debris.
Check for oil leaks and/or damaged hydraulic hoses.
Use recommended lubricants. Do not mix different brands of lubricants.
Use only original Hinowa spare parts.
Keep undercarriage widening cylinder and track-stretcher grease nipples clean.
Intervals for periodic maintenance are indicated for normal work conditions. If the
tracked undercarriage is used in severe work conditions then maintenance must
be performed at shorter intervals.
Dispose of lubricants in an ecologically safe way. Thoughtless disposal of lubri-
cants can damage the environment. Become familiar with local anti-pollution
laws and regulations before disposing of lubricants.
Use suitable containers when draining lubricants. Do not use beverage or food
containers that might tempt someone to drink from them. Never pour lubricants
on the ground or in a canal, pond or watercourse. Comply with current environ-
mental protection regulations when disposing of lubricants.
Pagina 47
5.2 Maintenance of drive geared motors
5.2.1 Checking the oil level in the reduction unit
Every 100 hours check the oil level in the reduction
unit gearbox. Usually on the external side of the
reduction gear drive there are two plugs: A1 and B
or A2 and B, depending on the type of reduction
gear drive, as indicated in the picture. Stop the
reduction gear drive when the plug B is in the
upper position. Remove the plugs A1 or A2 and
check that the oil level is aligned with them. If this
was not the case, re-fill from B using A1 and A2 as
a level check.
5.2.2 Replacement of oil in the reduction unit
Replace the oil after the first 100 operating hours
and then at subsequent 1000 hour intervals.
Proceed as follows to perform the replacement:
- stop the reduction gear drive when the B plug is
in the lower position, as indicated in the picture;
- remove both plugs, A1 and B or A2 and B and let
the oil come out completely;
- then put the reduction gear drive as indicated in
5.2.1 and fill using the B plug and A1 or A2 as a
level check
Avoid using oils with different characteristics and
brands.
5.2.3 Choice of type of reduction unit oil
We recommend, for reduction units, using gear oils with E.P. additives and viscosity
class according to ISO VG 150 or SAE 80W/90.
When temperature variation ranges are very high we recommend using synthetic
oils with E.P. properties and minimum 165 viscosity index and viscosity class VG
150 and VG 220.
Pagina 48
B
A2
A1
VG100 VG150 VG320 VG150-200
-20C +5C +5C +40C +30C +50C -30C +65C
IV 95min IV 95min IV 95min IV 165min
ISO 3448
A1
A2
B
IMPORTANTE IMPORTANT
In all cases select oils that are not subject to rapid aging at their operating tempera-
tures. Continuous duty temperature must not exceed 90C.
5.2.4 Hydraulic circuit oil
Use mineral oil with anti-wear additives such as HLP (DIN 51524) or HM (ISO
6743/4) and viscosity according to ISO VG46. Recommended filtration must be 10
m absolute or b1075.
5.3 Rubber track maintenance
5.3.1 Checking track tension
Stop your machine on a flat and solid surface. Lift it in safe conditions and put sta-
ble supports under the undercarriage frame to properly support it. Measure distan-
ce A at the central roller of the undercarriage from the bottom of the roller to the
rigid inside surface of the rubber track. Track tension is normal if dimension A is
between 10 and 15 mm.
Adjust tension as described in the following paragraph if track tension does not
comply with these dimensions (loose or too tight).
Pagina 49
A
5.3.2 Track loosening/tightening procedures
1. Remove the screws and take off cover 3 to access the adjustment system.
2. To loosen the track turn valve 1 counter-clockwise no more than 1 turn. One
turn of valve 1 is sufficient for loosening the track.
3. If grease does not start to drain out then slowly rotate the track.
4. When you have obtained correct track tension then turn valve 1 clockwise and
tighten it. Clean all traces of extruded grease.
5. To stretch the track connect a grease gun to grease nipple 2 and add grease
until track tension falls within specified values.
The grease contained in the hydraulic track is pressurized. Never loosen grease
valve 1 for more than one turn. If the valve is loosened too much you risk expelling
grease under pressure and possible serious injury to the machine operator. Also
never loosen grease nipple 2.
Remove gravel or mud when they are jammed between the sprocket and the track
link before loosening the track.
It is not normal for the track to remain too tight after turning valve 1 counter-clockwi-
se or for it to remain loose after introducing grease into grease nipple 2. Never try
to remove the tracks or disassemble the track-stretching cylinder since pressure of
the grease inside the track tension cylinder is extremely dangerous.
Pagina 50
PERICOLO
520202BH197
3
1
2
PERICOLO
DANGER
DANGER
5.3.3 Checking the rubber tracks
The structure of the rubber track is shown in fig. A. The steel cables and metal core
are embedded in the rubber. The carved profiles function to give stability on soft
terrain. They are made on the bottom part that rests on the ground. The wheel gui-
des, located on the inside of the track, prevent the track from sliding off the guide
rollers.
Causes of damage
A) Breakage of steel cables
Excess track tension can cause steel cables to break in the following conditions:
- when stones or foreign matter accumulate between the track and the undercarria-
ge frame;
- when the track slips off its guide system;
- in case of great friction such as rapid changes in direction.
B) Wear and breakage of metal cores
Excess track tension can cause the metal cores to bend or break just like the steel
cables as stated above. Other causes include:
- improper contact between track and sprocket;
- rotation of internal rollers;
- operation on sandy terrain.
Pagina 51
Fig. A
CORDE
D'ACCIAIO
SCULTURA
LATO RUOTA
FORO RUOTA
DENTATA
ANIMA METALLICA
CARVED
PROFILE
STEEL
CABLES
SPROCKET
HOLE
WHEEL SIDE
METAL CORE
C) Detachment of metal cores
The metal core functions as an adhesive for
the rubber, especially between the core itself
and the steel cables. Detachment can be
caused by excess track tension or by cable
breakage for the following reasons:
- metal cores have been rolled by a worn
sprocket as indicated in the figure. When
this type of wear or abrasion is encounte-
red the sprocket must be replaced as soon
as possible.
Rubber abrasion resulting on surfaces where guide rollers work incorrectly is illu-
strated in photo 9 (see appendix 2).
This type of breakage, like that indicated in paragraphs A-B-C, leads to total functio-
nal inefficiency and the track must be replaced.
D) Fatigue cracks and abrasion
1. Cracks at the base of the carved profiles are caused by fatigue due to rubber
bending caused by the sprocket or the track-stretching wheel as indicated in
photo 4 (see appendix).
2.Cracks and bends on the edge of the rubber are cau-
sed by maneuvering the track on concrete edges and
curbs.
3. Cracks and abrasions in the rubber on the guide roller paths are caused by com-
pression fatigue of the rubber due to the weight of the wheel combined with ope-
ration on sandy terrain or repeated sudden changes in direction. These are illu-
strated in photos 6-8-9 (see appendix).
4. Abrasion of the carved profile may be caused, in particular, by rotation on con-
crete or gravel surfaces or hard surfaces (see photo 7 in the appendix 2).
Damage as indicated in paragraph D, points 1, 2 and 3, is not fatal for the track and
the track can continue to work even in the presence of gradual and progressive
damage.
Continuation of the damage indicated at point 3 leads to exposure of the metal
cores. If this exposure extends for more than half of the circumference of the track
then it is time to replace the track, even though it can still be used.
Pagina 52
PARTI USURATE
CRACK
WORN PARTS
E) Cracks caused by external factors
Cracks on the outside surface of the track (the surface in contact with the terrain)
are often due to contact with gravel, sharp stones, sharp materials such as sheet
metal, nails, glass. These cause cuts as illustrated in photo 10 (see appendix 2).
This type of damage is inevitable given the very nature of rubber itself, although the
entity depends on how the track is used.
Cracks on the inside surface of the circumference and on the edge of the rubber
are caused by contact between track and the undercarriage structure or with sharp
concrete edges. These are indicated in photos 12 and 13 (see appendix).
Even though it does not look very good the track can still be subjected to severe
working conditions.
5.3.4 Replacement of rubber tracks
The grease contained in the hydraulic cylinder is under
pressure. Never loosen grease valve 1 for more than 1
turn. If the valve is loosened too much then pressurized
grease may exit and cause severe injury to the machine
operator. Never loosen grease nipple 2.
Remove gravel or mud when they are jammed between
the sprocket and the track link before loosening the track.
Removing the rubber track
1. Stop your machine on a solid and level surface. Lift it up and support it in safe
conditions as described in paragraph 5.3.1.
2. Remove the screws and take off cover 3 that gives access to the adjustment
system.
Pagina 53
1
2
520202BH197
3
PERICOLO DANGER
3. To loosen a track slowly unscrew valve 1 counter-clockwise for no more than 1
turn. One turn of valve 1 is sufficient for loosening the track.
4. If grease does not start to drain out then slowly rotate the track.
5. Insert 3 steel tubes (4) inside the track in
the space between the rollers. Rotate the
driving gear in reverse (5) so that the steel
tubes proceed wi th the track and are
between the track tension wheel and the
track tensi oner. Exerci se force (6)
sideways to slide the track and and relea-
se it from the track-stretching wheel.
Installing the rubber track
1. Make sure that you are always in safe conditions with
the machine lifted so to perform the operation for
track installing.
2. Check that the grease contained in the hydraulic cylinder has been removed.
3. Mesh the track links in the sprocket and
place the other end of the track on the
track-stretching wheel.
4. Rotate the driving gear in reverse (7) and
pull the track soles inside the frame (8)
5. Position the track using a steel tube and
turn the driving gear again.
6. Make sure track links mesh correctly in
the sprocket and in the track-stretching
wheel.
7. Adjust track tension (see paragraph 5.3.2 - Track loosening procedures).
8. Set the tracked undercarriage on the ground.
Pagina 54
PERICOLO
8
7
520202BH197
4
5
6
520202BH197
DANGER
5.4 Steel track maintenance
5.4.1 Checking track tension
Stop your machine on solid and level terrain. Check that there is a 1520 mm
deflection on the top part of the track in the longest section of unsupported track.
If track tension is not within the above-specified dimensions then follow the proce-
dures described in paragraph 5.3.2 to tighten or loosen tension.
5.4.2 Checking pin and bush wear
This type of wear can prevail compared to wear of other chain parts when work is
done on terrain that is too abrasive. Replace these units when the length of 4 chain
links exceeds the nominal value by more than 2%. Check the number on the tracks
reference reported in the order confirmation of your undercarriage.
Pagina 55
5.5 Checking sprocket wear
Measuring wear on sprocket and driving gear teeth is one of the most difficult mea-
surements to be done.
In normal operating conditions, in fact, wear takes place so that no trace of preexi-
sting tooth remains to furnish a clear reference for determining tooth wear. As a
consequence precise data cannot be furnished and it is always necessary, to make
any type of judgement, to refer to a new sprocket or wheel of the same type. As a
general rule a sprocket should be replaced when wear reaches the illustrated limits.
Since wear is never uniform you must always consider the point where wear is
greatest.
Calculate, in order to determine the maximum admissible wear for each sprocket or
driving gear, that this maximum wear must not exceed 3% of the pitch of the chain
that meshes with the gear itself.
Pagina 56
5.6 Checking bolt tightness
Check the tightness of bolts and components which may become loose depending
on the tracked undercarriages type of use.
Pay particular attention to frame components such as track-stretching wheels, drive
geared motors, driving gears and guide rollers. Make sure these are adequately
tightened according to the following table.
Threading diameter Pitch kgm
mm. mm.
6 1 1,3 0,15
8 1,25 3,2 0,3
10 1,5 6,5 0,6
12 1,75 11 1
14 2 17,5 2
16 2 27 3
18 2,5 37 4
20 2,5 53 6
22 2,5 73 8
24 3 92 10
27 3 135 15
30 3,5 184 20
5.7 Grease points (only for tracked undercarriages with hydraulic
widening only)
Perform this maintenance procedure every 100 work hours, using lithium grease
with EP2 consistency.
Clean grease nipples before connecting them to the
grease gun.
Clean all grease that exits out after greasing.
Lubrication should be at more frequent intervals if the
tracked undercarriage is used in particularly severe
operating conditions.
The grease points for the tracked undercarriage widening cylinder pins are illustra-
ted below.
Pagina 57
IMPORTANTE IMPORTANT
1
2
PT8
Pagina 92
1
R
R
Impianto idraulico sottocarro cingolato PT8 con freno di stazionamento versione fissa
Hydraulic diagram of the PT8 with brake, fixed width version
Hydraulische Anlage Unterwagen PT8 mit Bremse fixe Breite
1
R R
Impianto idraulico sottocarro cingolato PT8 con freno di stazionamento versione allargabile
Hydraulic diagram of the PT8 with brake, variable width version
Hydraulische Anlage Unterwagen PT8 mit Bremse mit Spurverbreiterung
APPENDICE 1 - APPENDIX 1 - ANHANG 1
Pagina 93
Motoriduttore sottocarro serie PT8 senza freno
C
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Sottocarri Serie PT8 con freno
Pagina 94
1
R
A B
R
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Impianto idraulico sottocarro cingolato PT8 con freno di stazionamento versione allargabile
A
Impianto idraulico sottocarro cingolato PT8 con freno di stazionamento versione fissa
1
B A
R
B
R
Pagina 95
Motoriduttore sottocarro serie PT8 con freno
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APPENDICE - APPENDIX - ANHANG 2
Pagina 150
FOTO - PHOTO N. 1
CORDE D'ACCIAIO CHE
SONO STATE TAGLIATE
STEEL CORDS WHICH
HAVE BEEN CUT
ZERRISSENE
DRAHTSEILE
FOTO - PHOTO N. 2
ABRASIONE E ROTTURA
DELLE ANIME IN ACCIAIO
ABRASION AND
BREAKAGE OF CORE
METALS
ABNTZUNG UND
VERSCHLEISS
DER METALLKERNE
FOTO - PHOTO N. 3
SEPARAZIONE
DELL'ANIMA IN ACCIAIO
SEPARATION OF
CORE METAL
ABLSUNG DER
METALLKERNE
Pagina 151
FOTO - PHOTO N. 4
ROTTURA DELLA BASE
SCULTURA CAUSATA DALLO
SFORZO DI PIEGAMENTO
(CURVATURA) DELLA GOMMA
CRACK ON LUG FOOT
CAUSED BY BENDING
FATIGUE OF THE RUBBER
DEFEKTE PROFILE ALS
FOLGE EXTREMER
RICHTUNGSNDERUNGEN
MIT REIBWIDERSTAND
FOTO - PHOTO N. 5
ROTTURA SULLA PARTE
ESTERNA DELLA GOMMA
SOTTO IL BORDO DELLA
ANIMA IN ACCIAIO
CRACK ON OUTER SIDE
RUBBER UNDER THE
EDGE OF CORE METAL
DEFEKTE AN DER
AUSSENSEITE
BER DEM METALLKERN
FOTO - PHOTO N. 6
ROTTURA SULLA PARTE
INTERNA DELLA GOMMA SUL
LATO DELL'ANIMA IN ACCIAIO
CRACK ON INNER SIDE
RUBBER ON SIDE OF
CORE METAL
DEFEKT AN DER INNENSEITE
BEI DEN METALLKERNEN
Pagina 152
FOTO - PHOTO N. 7
ABRASIONE DELLE
SCULTURE
ABRASION OF LUGS
ABNTZUNG DES PROFILS
FOTO - PHOTO N. 8
ABRASIONE DELLA GOMMA
DOVUTAALLE RUOTE GUIDA
(STADIO INIZIALE)
ABRASION OF RUBBER
RUN OVER BY GUIDE
WHEELS
(BEGINNING STAGE)
ABNTZUNG
DES GUMMIS UND DER
FHRUNGSNOCKEN
(ANFANGSSTADION)
FOTO - POTO N. 9
ABRASIONE DELLA GOMMA
DOVUTAALLE RUOTE GUIDA
(STADIO FINALE)
ABRASION OF RUBBER RUN
OVER BY GUIDE WHEELS
(TERMINAL STAGE)
ABNTZUNG DES GUMMIS
UND DER
FHRUNGSNOCKEN
(ENDSTADION)
Pagina 153
FOTO - PHOTO N. 10
TAGLIO DI MATERIALE
TAGLIENTE SULLA PARTE
ESTERNA DELLA GOMMA
CUT ON OUTER SIDE
RUBBER FROM A SHARP
MATERIAL
SCHNITTSCHDEN AM
RAUPENPROFIL
VERURSACHT DURCH
SCHARFE GEGENSTNDE
FOTO - PHOTO N. 11
ROTTURA E ABRASIONE
SULLA PARTE ESTERNA
DELLA GOMMA CAUSATA
DA RIGIDE CONDIZIONI
DEL TERRENO
CRACK AND ABRASION
ON OUTER SIDE RUBBER
CAUSED BY SEVERE
GROUND CONDITIONS
VERLETZTES PROFIL ALS
FOLGE VON HARTEM U.
SCHNITTIGEM MATERIAL
Z. B. ABBRUCH
FOTO - PHOTO N. 12
TAGLIO AL BORDO SULLA
PARTE INTERNA DELLA
GOMMA DOVUTO MATERIALI
TAGLIENTI O A SPIGOLI RIGIDI
EDGE CUT ON INNER SIDE
RUBBER BY SHARP MATE-
RIALS OR CONCRETE RIDGES
SCHNITTSCHDEN AN DER
AUSSENSEITE VERURSACHT
DURCH SCHARFKANTIGE,
UNVERPUTZTE
BETONMAUERN
Pagina 154
FOTO - PHOTO N. 13
ROTTURA DELLA PARTE
INTERNA DELLA GOMMA
CAUSATA DAL CONTATTO
CON IL TELAIO DEL
SOTTOCARRO
CRACK ON INNER SIDE
OF RUBBER CAUSED BY
CONTACT WITH FRAME
OF UNDERCARRIAGE
SCHDEN AM RAUPEN-
INNERN VERURSACHT
DURCH ANSTOSSEN AM
FAHRWERK

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