RH120E Undercarriage Technical Handbook

Technical Handbook

RH 120 E

4. Undercarriage

TEREX Germany GmbH & Co. KG

2 803 229.00 en

Editor: TEREX Germany GmbH & Co. KGDepartment 910 – Product SupportD-44149 Dortmund, Karl-Funke-Str. 36

Phone: ++49 / 231 / 922-4901Fax: ++49 / 231 / 922-5900

� Copyright by O&K, Printed in Germany

CONTENTS

RH 120 E Diesel - 2803243e - (00) – 11.99 Page 4 - 1

4. UNDERCARRIAGE

4.1 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

4.2 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

4.3 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

4.4 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

4.5 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

CONTENTS

Page 4 - 2 RH 120 E Diesel - 2803243e - (00) – 11.99

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

4.10.1 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

4.11 Duo cone seals .............................................................................. 4.11 - 1

4.1 UNDERCARRIAGE

2440558e.doc - (00) - 11.96 Page 4.1 - 1

4.1 Introduction

4.1.1 Foreword

The Technical Handbook contains important in-formation for personnel servicing the machine.Machine specifications listed elsewhere in the ma-chine documents are not always repeated in thisbook.

The documentation of an TEREX Mining machineincludes:

• the operating instructions • the spare-parts list • the technical handbook

The present brochure does not contain the specifi-cations of auxiliary units for the operation of addi-tional or optional equipment or the specifications ofindividual machines.

The refilling quantities specified for consumablesare approximate quantities which are intended as ahelp for planning consumable requirements. Eachunit is equipped with suitable checking devices,e.g. dipstick or checking plugs, permitting the op-erator to check proper filling of the units.

4.1.2 Safety Instructions

4.1.2.1 Danger in the event of non-obser-vance of the safety instructions

This TEREX hydraulic excavatorhas been built in accordance withstate-of-the-art standards and therecognized safety rules.

However, operating the machine ifa fault is suspected or has oc-curred, or carrying out repair workinexpertly may

• endanger the lives of persons incontact with it

• damage the machine and otherproperty.

The hydraulic excavator must bestopped immediately on any dam-age being suspected or occurringto ensure that the safety of the op-erator, of other persons at theplace of use or of other materialproperty is not compromised.

All components of TEREX ma-chines are carefully co-ordinated.Trouble-free operation and a longservice life can only be achievedwith original TEREX spare parts.

4.1 UNDERCARRIAGE

Page 4.1 - 2 2440558e.doc - (00) - 11.96

4.1.2.2 Rules for safety at work

PersonnelThe machine must not be startedby unauthorized persons.

It must therefore be secured.

Observe the accident preventionregulations.

The hydraulic excavator may beoperated, serviced or repaired onlyby specially trained and authorizedpersonnel with the appropriatetechnical know-how.

If such know-how is lacking, me-ticulous instruction must be givenby experienced personnel, e.g.from TEREX.

The personnel must have read andunderstood the operating instruc-tions and in particular the chapter

‘Fundamental

Safety Instructions.’

Only such persons may start upthe machine during assembly workin order to adjust the attachments.

Incorrect operation of the machineor the attachments may give rise tolife-threatening situations.

During all works, always observethe start-up and shut-down proce-dures prescribed in the operatinginstructions.

PersonnelPersonal protective gear andworking clothing:

Wear a safety helmet, safety foot-wear and gloves.

Wear closely fitting working cloth-ing when working on the machine.Loose, wide garments may catchon machine parts and result in in-jury.

If the work to be carried out re-quires auxiliaries, e.g. marshallers,the competences of each individualhelper must be clearly defined be-forehand. The individual responsi-bilities must be meticulously ob-served to avoid unclear compe-tences endangering safety.

4.1 UNDERCARRIAGE

2440558e.doc - (00) - 11.96 Page 4.1 - 3

Tools and auxiliariesTools, hoists, slings, trestles andother devices must be in a reliable,safe state.

Metal splinters may cause injurywhen attachment bolts are beingdriven in or out. A brass or coppermandrel should therefore be usedfor this purpose, and goggles mustbe worn.

For climbing onto or off the ma-chine, use only the ladders, steps,platforms and handrails providedfor this purpose.

Always keep ladders, steps andplatforms in a non-slip state. Re-move any oil, grease, earth, clay,snow, ice and other foreign matterimmediately.

Securing the working equip-mentBefore carrying out assembly work,the machine and the attachmentsmust be secured against inadver-tent and unauthorized starting, e.g.by placing chocks under thewheels or tracks and by standingthe working equipment on theground.

Stand the working equipment onthe ground in such a way that nomovements can be made whenmechanical or hydraulic connec-tions become detached.

Secure any equipment or compo-nent which is to be mounted ordismantled or whose position is tobe changed using hoists or appro-priate slinging/supporting devicesto prevent them from moving, slip-ping or falling inadvertently.

Systems and units (e.g. pipes, ac-cumulators, etc.) must be properlydepressurized before beingopened.

Protective devices on moving ma-chine parts may be opened or re-moved only when the drive unit isstationary and protected againstinadvertent starting.

Before recommissioning, all pro-tective devices must be refitted.

Before carrying out assembly work,the machine and the equipmentmust be secured against inadver-tent starting, e.g. by placingchocks under the wheels or tracksand by standing the workingequipment on the ground.

Hydraulic and lubricating sys-tem:Always observe the safety regula-tions applicable to the productwhen handling oils, greases andother chemical substances.

Unused but open bores, pipelinesand hose connections must beclosed in a pressure-tight manner.

Refill collected hydraulic oil backinto the hydraulic system onlythrough the return-flow filters. Dis-pose of waste oil without pollutingthe environment.

Observe the correct working se-quence when fitting or replacingcomponents or equipment. Theworking sequence has been speci-fied and tested by qualified ex-perts.

4.1 UNDERCARRIAGE

Page 4.1 - 4 2440558e.doc - (00) - 11.96

Replace defective, mechanicallyprestressed units only as an en-tirety. Never open them. In excep-tional cases, open only when thesystem and the operating se-quence are precisely known. TheTechnical Manual contains no in-formation on such work.

When the machine is at operatingtemperature, the consumables areat least at the same temperature.Precautions must therefore betaken to prevent burning or scald-ing.

Be careful when handling acids,e.g. battery acid. Acid splashesmay injure the eyes and the skin.

Do not smoke when handlingflammable liquids.

Be careful with naked flames andunprotected light. Not only fuel butalso other consumables often havea low flash point and catch fireeasily.

4.1.2.3 Conversions or modifications to themachine

Unauthorized conversions or modi-fications of the hydraulic excavatorare forbidden for reasons of safety.

The nominal pressure of pressurerelief valves must not be modifiedwithout explicit approval fromTEREX. Do not remove the leadseals from pressure-relief valvesand pressure accumulators.

4.1.2.4 Recommissioning

Prior to recommissioning:

• Grease all lubricating points.

• Check all oil levels and make thenecessary corrections.

• Carry out function checks of allrepaired components

• Check all functions of the exca-vator including the brakes duringa test run. Release the hydraulicexcavator for recommissioningonly after all functions have beenfound to work perfectly.

4.1 UNDERCARRIAGE

2440558e.doc - (00) - 11.96 Page 4.1 - 5

4.1.3 General

In addition to the operating instructions and thespare-parts list, the present Technical Manualcontains information enabling the user of theTEREX hydraulic excavator to safely operate,maintain and repair the machine in accordancewith the specifications.

The information supplied in the Technical Manualrepresents the standard version of the machine asdelivered.

All sketches and drawings are merely schematic.They do not necessarily represent the machine'sactual state of design and must not be used asmanufacturing documents.

No reference is made to special versions.

After delivery, the Technical Manual is not sub-ject to revision.Technical changes introduced into the series pro-duction after delivery of the machine may also beimplemented in machines already in use.In such case, already delivered Technical Manu-als are normally not automatically updated.

All technical documents issued by TEREX MiningGmbH are written in German and then translated.

Even a good translation may give rise to questionswhich your TEREX dealer or your TEREX distrib-uting centre will be pleased to answer.

This Technical Manual has been carefully pre-pared by the competent divisions.

If any points are nevertheless unclear or incorrect,please contact your local TEREX dealer or yourTEREX distributing centre.

4.1 UNDERCARRIAGE

Page 4.1 - 6 2440558e.doc - (00) - 11.96

4.2 TRAVEL SYSTEM

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4.2 Travel system4.2.1 GeneralThe hydraulic excavator is equipped with a low-maintenance undercarriage.

Track pad and chain link are forming one unit.

4.2.2 Components of travel systemTable for Fig. 1

Ref. no. Quantity Designation Further remarks Weight[kg]

1 1 Carbody2 2 Track frame3 2 Travel gearbox4 2 Track tensioning system5 14 Bottom roller6 2 Support roller7 94 Track link (2 x 47)8 2 Idler9 2 Sprocket10 4 Travel motor

Table 1

Fig. 1 Travel system

4.2 TRAVEL SYSTEM

Page 4.2 - 2 RH 120 E - 2803244e - (00) – 11.99

Table for Fig. 2


1 1 Track chain 1 000 mm 47 links 311 each2 7 Bottom roller 434 each3 2 Top roller 166 each4 28 Spacer5 8 Washer6 28 Hex bolt M 30 x 190 – 12.97 8 Hex bolt M 24 x 160 – 12.9

Table 2

4.2 TRAVEL SYSTEM

RH 120 E - 2803244e - (00) – 11.99 Page 4.2 - 3

6, 7

Fig. 2 Travel system

2450928A.SKD

ZY

Z6

2

1

A

4

7

5

3

B

A-B Y

4.2 TRAVEL SYSTEM

Page 4.2 - 4 RH 120 E - 2803244e - (00) – 11.99

4.2.3 Wear limitsWear on the track components is due to move-ment, loading and ground contact, as well as to thehardness (abrasiveness) of the ground.

Wear can also be increased by the following fac-tors:

1. unstable position of excavator because of un-even 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% ofthe operating hours.

Track components must be replaced when theyhave worn down to between 75 and 100%.Sudden failure is otherwise pre-programmed.

Careful and regular measurements are necessaryto determine the extent of wear and to be ready forcomponent exchange when it is necessary.

Before measuring components, clean them thor-oughly. Measure at several points. It is not theaverage, but the maximum wear value that is to betaken as wear limit.

Because the wear life between 75 and 100% islow, we recommend that components be changedas a preventive measure as soon as the 75% limithas been reached. Exchange can take place whileother servicing is being carried out.

4.2 TRAVEL SYSTEM

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Wear limits for travel system

Component Wear limits [mm]N

NewW

25 %W

50 %W

75 %W

100 %measured

Track pad

350 352,5 355 358,5 363

Track chain (4 links)

1 401 1 410 1 420 1 434 1 452

Track pad A 106 103,5 100,5 96,5 92

B 235 224,5 213,5 201,5 189

C 45 37 29 21 13

Pad bush

Ø 80,4 81,6 83 84,8 87

Pad pin

Ø 80 78,9 77,6 75,9 74

Pad cam 114 109,5 104 97 89

188 182,5 178 172,5 166

4.2 TRAVEL SYSTEM

Page 4.2 - 6 RH 120 E - 2803244e - (00) – 11.99

Component Wear limits [mm]N

NewW

25 %W

50 %W

75 %W

100 %measured

Bottom roller Ø 340 334 325 315 302

51 54 58,5 63,5 70

Top roller Ø 260 255 249 241 232

25 27,5 30,5 34,5 39

Idler rim Ø 1 120 1115 1109 1101 1092

50 52,5 55,5 59,5 64

Sprocket rim Ø 1208 1203 1197 1189 1180

50 52,5 55,5 59,5 60

Sprocket tooth 138 134 129 123 116

177 174 170 165,5 162

4.3 TRACK CHAIN

RH 120 E - 2803245e - (00) – 11.99 Page 4.3 - 1

4.3 Track chain4.3.1 GeneralThe “combined pad-link” type track chain combinesa chain link and a track pad into one unit.The drive forces are directly transferred from thesprocket into the massive pad-link unit.

Proportionate weight transmitted through thesprocket does not strain the pins and bushingsconnecting the pad-links.

The track pins are full-floating.

4.3.2 ComponentsThe quantities are valid for 1 track chain.

Ref. No. Quantity Designation Further remarks Weight[kg]

1 47 Pad-link 281 each2 376 Bushing 1,2 each3 94 Pin 8,6 each4 94 Cover plate 1,5 each5 94 Circlip

Table 1

Fig. 1 Track chain

A

1 45

A

23

2450906A.SKD

A-A 1:2

4.3 TRACK CHAIN

Page 4.3 - 2 RH 120 E - 2803245e - (00) – 11.99

4.3.3 Assembly4.3.3.1 Opening the track chain

The track chain can be opened as follows:

1. Position the excavator in such a way that thechain link which is to be removed is positionedat the lower section of the sprocket (Arrow A inFig.2).

Before opening the track chain hasto be slackened in accordance withthe operating instructions.The ball valve in the line to thetrack tensioning cylinder must beclosed to avoid the piston beingcompletely pushed out of the bar-rel when an engine is started.(seechapter 4.10).

Secure against falling down!When the chain is not engagedwith the sprocket the whole uppersection of the chain may roll offfrom the idler and create injury anddamage!Therefor uncontrolled rolling of thechain has to be avoided by secur-ing the chain by appropriatemeans!

2. First open the connection above the track linkwhich 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 ofthe opened track by fixing the trackwith help of appropriate means,e.g. chain hoists or forklift.

6. Afterwards remove the other two track pinsaccordingly.

4.3 TRACK CHAIN

RH 120 E - 2803245e - (00) – 11.99 Page 4.3 - 3

Fig. 2 Opening the track chain

4.3.3.2 Closing the track chain

1. Align the track chain so that the links whichare to be connected are positioned in front ofthe sprocket (Fig. 1).

2. Clean bushings in the track link and the trackpins with degreaser.

3. Cover the track pins with a thin layer of as-sembly paste part-no. 271 554.

4. Install both track pins, cover plates and cir-clips.

5. Tension the track according to the ‘Operating

Instructions’.

A

2760067A.SKD

4.3 TRACK CHAIN

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4.4 IDLER

RH 120 E - 2803246e - (00) – 11.99 Page 4.4 - 1

4.4. Idler4.4.1 GeneralThe idler is mounted in the two slider pieces, whichare guided in the track frame.

With the idler the track is hydraulically tensionedvia spacer piece and track tensioning cylinder.

4.4.2 Components of the idlerThe reference numbers are related to Fig. 1 and Fig. 2


1 1 Idler 1 5332 2 Slider piece 138 each3 1 Shaft 1334 2 Disk5 ----6 2 Bushing7 2 Duo-cone seal8 2 O-ring9 2 Locking pin10 ----11 12 Dowel pin12 2 Locking pin14 1 Spacer piece15 ----16 4 Hex. bolt M 24 x 160 Tightening torque Md = 670 Nm17 4 Sleeve30 0,6 kg Grease KPF2K - 30

Table 1

4.4 IDLER

Page 4.4 - 2 RH 120 E - 2803246e - (00) – 11.99

Fig. 1 Idler

Fig. 2 Idler

6

30A

A

1 11 8 9; 12 3

9; 12

2451815A.SKD

4 27

A-A 90°

4.4 IDLER

RH 120 E - 2803246e - (00) – 11.99 Page 4.4 - 3

4.4.3 Assembly of the idlerWhen assembling the idler the working sequencehas to be as follows:

1. Place idler onto suitable support (1, Fig. 1) andcompletely press, respectively drive in bushing(2, Fig. 1).

Fig. 1 Installation of bushings

2. Fit two halves of duo-cone seals (5, Fig. 2) intoidler (see chapter 4.11 ‘Duo-cone seals’).

Fig. 2 Installation of duo-cone seal

3. Pick up idler shaft with lifting device (6, Fig. 3)and install into the idler.

Fig. 3 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 butmove freely.

Grease the surface on both sides of the sealwith high pressure grease (30, Fig. 2).

Grease must not penetrate into theoil channels of the idler.

5. Grease seal ring (7, Fig. 4) and place into

slider piece (8, Fig. 4).

Fig. 4 Installation of seal

4.4 IDLER

Page 4.4 - 4 RH 120 E - 2803246e - (00) – 11.99

6. Place disk (3, Fig. 5) with grease into sliderpiece (8, Fig. 5) and secure by knocking indowel pins (4, Fig. 5).

Fig. 5 Installation of disc

7. Fit half of duo-cone seal (5, Fig. 6) into slider

piece (8, Fig. 6).

Fig. 6 Installation of duo-cone seal

8. Clean indicated area of the idler shaft (arrow,Fig. 2) with degreaser and cover with a thinlayer of anti-seize paste part-no. 271 554. Assemble the first slider piece (8, Fig. 7) andthe shaft (6, Fig. 7) with help of a lifting device. Ensure that the slider piece is brought exactlyinto position and the borings for the locking pins(9 + 10, Fig. 8) in the slider piece and the shaftare aligned.

Before assembling the duo-cone seal clean thecontact surface carefully and cover the contactsurface slightly with oil. Do not oil the other areas of the duo-coneseals..

Fig. 7 Installation of slider piece

4.4 IDLER

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9. Install the locking pins (9 + 10, Fig. 8). Thegrove in the locking pin has to show into the di-rection of the shaft.

Fig. 8 Installation of locking pins

10. Turn idler and fill idler housing with oil ac-

cording 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 section8.

4.4 IDLER

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4.5 BOTTOM ROLLER - RH 120 E - SERIAL NUMBERS

RH 120 E - chapter 4.5 - serial numbers.doc - (00) – 02.03 Page 4.5 - 1

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

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

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4.5 Bottom roller4.5.1 General1. Bottom rollers have lifetime lubrication. They do

not require any maintenance until the wear lim-its have been reached.

2. The rollers are sealed with duo-cone seals (6).

Function and assembly of duo-cone seals - seechapter 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. The roller can be made fully operational byremoving and cleaning it, and then filling it withfresh oil.

5. Loose fastening bolts will immediately result in

leaks and further damage to the bottom rollers.

4.5.2 Components of the bottom rollerThe parts listed in table 1 refer to Fig.1, 2 and 3.

Components of the bottom roller


1 1 Roller body 2862 2 Support 33 each3 2 Bushing 1,9 each4 2 Disk 0,7 each5 2 Ring6 2 Duo-cone seal7 1 Plug8 2 Sealing ring9 ----10 ----11 1 Washer12 1 Hex. bolt M 16 x 6513 8 Hex. bolt M 30 x 190 see chapter 2.914 8 Washer61 0,2 kg Grease

Table 1

4.5 BOTTOM ROLLER

Page 4.5 - 2 RH 120 E - 2803247e - (00) – 11.99

Fig. 1 Bottom roller


7

8

78

15

4

3 2 5 6 1

2416690A.SKD

12

11

4.5 BOTTOM ROLLER

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13

Fig.3 Bottom roller - Installation

Y

13

1

14

Z

Z

2450928B .SKD

B

A-B

A

Y

4.5 BOTTOM ROLLER

Page 4.5 - 4 RH 120 E - 2803247e - (00) – 11.99

4.5.3 Bottom roller installationSequence of assembly for bottom roller installation

1. Position roller under the track frame and threatin mounting bolts (13) with washers (14).

2. Remove items 8, 9, 10, 11 on both bearings.

3. Press bearing with

auxiliary bolt Part-no. 2 157 689 (Fig. 4)

against connecting surface of the track frame.

4. ** ATTENTION ** Bearing has to lay at thewhole connecting surface of the track framewithout any axial tolerances.

5. Torque - tighten mounting bolts with torqueaccording to chapter 2.9 - ‘Tightening proce-dures’.

6. Fill in oil according to the service- and operat-ing instructions and plug bearing with items 7and 8.

Fill oil container to the marked level

Fig. 4 Auxiliary bolt Part-no. 2 157 689

4.5 BOTTOM ROLLER

RH 120 E - 3657707e.doc - (00) – 02.03 Page 4.5 - 1

4.5 Bottom roller4.5.1 General

• Bottom rollers have long term lubrication. Ifinstalled the rollers are connected to the un-dercarriage 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.

• The roller can be made fully operational byremoving and cleaning it, and then filling it withfresh oil.

• Loose fastening bolts will immediately result in


4.5.2 Components of the bottom rollerThe parts listed in table 1 refer to Fig.1, 2 and 3.

Components of the bottom roller


1 1 Roller body ∅ 360 mm 321

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 ----

10 2 O-Ring

11 2 Plug

12 ----

13 4 Hex. bolt M 30 x 220 Tightening torque Md = 2 250 Nm

14 4 Washer

20 1 Securing device for transport

30 0,2 kg Grease

Table 1

4.5 BOTTOM ROLLER

Page 4.5 - 2 RH 120 E - 3657707e.doc - (00) – 02.03


13 A


4.5 BOTTOM ROLLER

RH 120 E - 3657707e.doc - (00) – 02.03 Page 4.5 - 3

13

Fig.3 Bottom roller - Installation

Y

13

1

14

Z

Z

2450928B .SKD

B

A-B

A

Y

4.5 BOTTOM ROLLER

Page 4.5 - 4 RH 120 E - 3657707e.doc - (00) – 02.03

4.5.3 Bottom roller installationSequence of assembly for bottom roller installation

• Position roller under the track frame and threatin mounting bolts (13) with washers (14).

• Remove securing device (20, Fig. 4).

Because of the securing device fortransport the roller body and thesupports have been pre-loaded.Therefore it is important to press thesupports against the contact surfaceof the frame before The mountingbolts (13) are tightened. So the axialclearance of 1,0 to 2,0 mm isachieved.

The supports have to contact thewhole connecting surface of thetrack frame without any axial toler-ances.

Press bearings against connecting surface of thetrack frame.

• Tighten mounting bolts with torque accordingto chapter 2.9 - ‘Tightening procedures’.

• Fill in oil according to the service- and operat-ing instructions and plug bearing with items 7and 8.

• Fill oil container to the marked level

Fig. 4 securing device for transport

4.6 TOP ROLLER

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4.6 Top roller4.6.1 GeneralOnto each track frame 2 top rollers are installed.

1. Top rollers have lifetime lubrication. They donot require any maintenance until the wear lim-its have been reached.

2. The rollers are sealed with duo-cone seals (4).

Function and assembly of duo-cone seals - seechapter 4.11.

3. The majority of roller leaks is due to dirt thatenters into the duo-cone seals.

4. The roller can be made fully operational byremoving and cleaning it, and then filling it withfresh oil.

5. Loose fastening bolts will immediately result in


4.6.2 Components of the top rollerThe parts listed in table 1 refer to Fig.1, 2, 3.

Components of the top roller

Ref. no. Quantity Designation Further remarks Weight [kg]

1 1 Top roller body 109

2 2 Support 9,4 each

3 2 O-ring

4 2 Duo-cone seal

5 2 Bushing 4,6 each

6 1 Shaft 25

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 160Table 1

4.6 TOP ROLLER

Page 4.6 - 2 RH 120 E - 2803248e.doc - (00) – 11.99

Fig. 1 Top roller

Fig. 2 Top roller

4.6 TOP ROLLER

RH 120 E - 2803248e.doc - (00) – 11.99 Page 4.6 - 3

12

Fig. 3 Top roller - installation

4.6.3 Top roller installationSequence of assembly for top roller installation

• Position roller onto the track frame and threatin mounting bolts with spacers.

• Torque - tighten mounting bolts with torqueaccording to chapter 2.9 - ‘Tightening proce-dures’.

• Fill in lubricant according to the service- andoperating instructions and install sealing ring(9) and plug (10).

2450928C.SKD

1

12

11

4.6 TOP ROLLER

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4.7 SPROCKET

RH 120 E - 2803249e - (00) – 11.99 Page 4.7 - 1

4.7 SprocketThe sprocket is bolted to the travel gearbox.

• For Installation of the travel gearbox seechapter 7.2 ‘Travel gearbox’.


1 1 Travel motor cover2 41 Washer3 48 Washer4 48 Hex. bolt M 30 x 2 x 190 Tightening torque Md = 2 500 Nm5 1 Sprocket 1 4236 ----7 41 Hex. bolt M 30 x 2 x 240 Tightening torque Md = 2 500 Nm

8 2 Plug9 1 Plug10 2 Travel motor 72 each11 1 Travel gearbox 2 60012 4 Hex. bolt M 20 x 50 Tightening torque Md = 350 Nm13 4 Washer

Table 1

Fig. 1 Opening of track

A

4.7 SPROCKET

Page 4.7 - 2 RH 120 E - 2803249e - (00) – 11.99

4, 7

Fig. 2 Sprocket drive

Fig. 3 Travel gearbox and sprocket

3,7D

C

1

2450925B.SKD

3,4

E

F

5

11

4.7 SPROCKET

RH 120 E - 2803249e - (00) – 11.99 Page 4.7 - 3

Removal and installation of the sprocket can bedone while the travel gearbox is installed in thetrack frame.

The track has to be opened according to chapter4.3.

Avoid uncontrolled movement ofthe track by fixing it with help ofappropriate means, e.g. chainhoists or forklift before it isopened.

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 thesprocket from the gearbox.

Installation of the sprocket

• Mounting bolts

The threads and the heads of the mountingbolts have to be slightly oiled and must notcome into contact with the adhesive.

• Contact surface

Prior to installing the sprocket, all traces ofpaint and grease must be removed from thecontact surfaces between sprocket and travelgearbox with solvent Part-no. 216 405 (arrowsE and F, Fig. 2).Check the contact area of sprocket and gear-box carefully for mechanical damages.The contact surface (arrow F, Fig. 2) must becoated with mounting paste Part-no. 244 905.

• Threads

Clean all threads from paint, rust and greaseand blow out with compressed air. Check fordamage and tap threads again if required.

• Adhesive

When the sprocket has been prepared for in-stallation, apply adhesive Part-no. 1 991 417to one of the contact surfaces (arrow E, Fig.2).

Apply the adhesive with ca. 10 mm clearancefrom the threaded holes to ensure that no ad-hesive can be forced into the threaded holeswhen the gearbox is set down.Penetration of adhesive into a threaded holeleads to increased friction and thus to invali-dation of the starting power data.

• Sprocket

Pick up sprocket with lifting device.Align sprocket and gearbox, insert all mount-ing bolts and tighten hand-tight.

• Tightening of bolts

Start sprocket installation as soonas the adhesive has been applied.The adhesive starts hardeningwhen the metal surfaces have beenjoined without any air being admit-ted and is completed after approx.48 hours at an ambient tempera-ture of approx. 20°C.The hardening process is initiallystrongly delayed, so that the in-stallation time can be extended toa maximum of 8 hours.At temperatures below -10°C, acti-vator Part-no. 1 991 468 must besprayed onto the second joiningsurface - the surface with no adhe-sive.

4.7 SPROCKET

Page 4.7 - 4 RH 120 E - 2803249e - (00) – 11.99

After installing the sprocket screw in all boltsand

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) bymoving the excavator and close track.

After closing the track the ballvalve at the track tensioning cylin-der has to be opened and the pres-sure relief valve in the carbody hasto be adjusted (see chapter 4.10).

4.8 TRAVEL GEARBOX - REMOVAL & INSTALLATION

2461035e.doc - (00) - 01.97 Page 4.8 - 1

4.8 Travel gearbox -removal and installation

The removal and installation of the travel gearboxis described in

chapter 7.2

4.8 TRAVEL GEARBOX - REMOVAL & INSTALLATION

Page 4.8 - 2 2461035e.doc - (00) - 01.97

4.9 TRACK PAD

RH 120 E - 2803250e - (00) – 11.99 Page 4.9 - 1

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‘.

4.9 TRACK PAD

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4.10 HYDRAULIC TRACK TENSIONING SYSTEM

RH 120 E - 2803251e - (00) – 11.99 Page 4.10 - 1

4.10 Hydraulic track tensioning system4.10.1 GeneralTechnical 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 systemThe reference numbers are related to Fig. 1 and Fig. 2

Ref. no. Quantity Designation Further remarks Weight [kg]

1 1 Idler-unit 1 9532 2 Plug3 2 Sealing ring4 2 Bushing5 1 Shaft 1336 2 Thrust washer7 1 Pin8 2 Duo cone seal9 2 O-ring10 2 Sealing ring11 2 O-ring12 2 Sliding piece13 2 Locking pin14 2 Locking pin15 1 Spacer piece 22516 1 Tensioning cylinder 36317 4 Sleeve18 8 Hex. bolt M 24 x 160 Md = 670 Nm19 1 Accumulator20 1 Filling and testing port21 4 Hex. bolt M 8 x 20 Md = 21 Nm22 4 Spring washer23 1 Plug24 1 Ball valve

Table 1


Page 4.10 - 2 RH 120 E - 2803251e - (00) – 11.99

Fig. 1 Idler with track tensioning cylinder


RH 120 E - 2803251e - (00) – 11.99 Page 4.10 - 3

18, 21

Fig. 2 Idler with track tensioning system

2450

926A

.SKD

161924

19

21

151

1817

1618

24


Page 4.10 - 4 RH 120 E - 2803251e - (00) – 11.99

4.10.3 Releasing the track tensionBefore carrying out repair work the tracks haveto be slackened.

Procedure:

• Shut down the engines

• Open both pressure relief valves (3, Fig. 3);the track is slackening (each track is related toa pressure relief valve).

• Before opening the track the ball valve (10.Fig. 2) in the line to the track tensioning cylin-der must be closed to avoid the piston beingcompletely pushed out of the barrel when anengine is started.

• After completion of the repair close the pres-sure relief valves (turn in completely).

Fig. 3 Track tensioning system

Each pressure relief valve (3, Fig. 3) is adjusted to330 bar and sealed in this position.The seal must not be removed and the pressuresetting 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’

4.10.4 Checking the accumulatorsThe procedure how to check the accumulators isdescribed in chapter 8.6.4.8 ‘Track tensioningsystem’.

4.11 DUO-CONE SEALS

2440564e.doc - (00) - 11.96 Page 4.11 - 1

4.11 Duo-cone sealsDuo-cone seals (also referred to as steel-on-steelseals) are used as shaft seals. The arrangement ofthe seal is such that one steel ring, elasticallymounted in the fixed component, lies/runs axiallyagainst a second steel ring that is also elasticallymounted, but this time in the rotating component.

Duo-cone seals are used in the excavator's bottomrollers, support rollers and idlers.

Leakages in such components are usually due todamaged duo-cone seals. In case of leakages, theduo-cone seals are to be changed immediately.

Observe the following points when assemblingduo-cone seals:

1. The running surfaces ‘’A’’ of the steel rings (1,Fig. 1) must be completely free of scratchesand scores. Clean all traces of oil and dust fromrunning surfaces "A" and seating bevels ‘’B’’. Allsurfaces must be dry and free of rust, slag andscale.

Fig. 1 Duo-cone seals

2. Draw rubber seal (2) onto steel ring (1, Fig. 2).The rubber ring (2). is correctly positioned whenit sits twist-free parallel to the surface of thesteel ring (1)..


3. Place one complete half (1) and (2) of the duo-cone seal into/onto the rigid component and onecomplete half into/onto the rotating component(Fig. 3) - but without using any oil. Make surethat distance ‘’C’’ is equal all the way around theseal.


4. Before fitting the two machine components(rigid and rotating) together, carefully wipe thesurfaces ’’A’’ of the steel rings (1) to remove anyforeign bodies or even finger-prints. Then applya drop of thin oil between the running surfaces,but without allowing oil to get onto the otherparts.

Attention:

NEVER fit a new half of a duo-cone seal to aused half. When re-assembling used duoconeseals, make sure that pairs that were previouslyinstalled together are kept together.

4.11 DUO-CONE SEALS

Page 4.11 - 2 2440564e.doc - (00) - 11.96

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RH120E Undercarriage Technical Handbook

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