THE IDEAL PARTNER INTERTRACTOR AMERICA Operating and Maintenance Instructions for Track Vehicles and Running Gear Components Go Tettical dete ajecto range, Siast20005 Ait toie AMERICA Index 1. Safety and danger instructions 1.1. Tobe observed 1.2, Safety instructions 2. Operating and Service Instructions 2.1. General Maintenance Instructions: 2.2. Inspection intervals 2.3. Tightening torque tables 2.4. General instructions, 3. Drive, 1. Diive— Function and operation 2. Drive — Fitting and removal Front idler unit. 1, Front idler unit = Function and description 2. Front idler unit - Fitting and removal Carrier rollers/support rails 1. Carrier rollers/support rails — Function and operation 2. Carrier rollers/support rails — Fitting and removal Track rollers. 1, Track rollers — Function and operation, 2. Track rollers ~ Fitting and removal Crawler track and grouser shoe 1. Crawler track and grouser shoe - Function and description, 2. Crawler track and grouser shoes — Fitting and removal Other/Special components, 1. Track guide — Function and operation 2, Track guide — Fitting and removal 3, Covers evaee 10 3 13 19 26 26 43 52 52 54 55 57 58 61 83 83 84 ZaIie urely 1. Safety and danger instructions 1.1. To be observed 1.4.1 Warning signs Warning: Safety regulations and measures that protect the drive and other persons against injury and danger to life and limb, Caution: Particular instructions to prevent damage to the vehicle. Failure to observe these instructions ‘can lead to warranty becoming void, = Particular instructions for better handling during operating, control and setting procedures as well as maintenance work. TamIie urely 1.4.2 Foreword ‘These operating instructions are a part of the scope of delivery. They are to be kept close at hand and are to remain with the machine if being sold again All details, data and illustration contained in these operating instructions are subject to change as result of technical developments. All rights reserved. These operating instructions are not subject to any update service. Information on latest developments can be obtained from: Intertractor America 100 N. Lakeview Parkway Vernon Hills, IL. 60061 Tel, 847-484-0040 The illustrations in this manual are only diagrammatic and may differ from the actually installed components of the respective undercarriage. In addition, it is possible that there may also be other components on the undercarriage that are not described in this manual. Conversely, there may also be components described in this manual that are missing on the undercarriage. All components and their functions are subject to technical change. 1.4.3. Warranty Applicable conditions of warranty are stipulated in the confirmation of order. Warranty rights become void in the event of Damage as a result of malfunctions caused by incorrect use or incorrect operation. Repairs or alteralions carried out by persons who are neither trained nor authorized to do so + Damage being caused by accessories or spare parts being used for which no approval has been provided by Intertractor. ToraIie urely | ‘2 seyincne 1.2. Safety instructions 1.2.1 In general This undercarriage has been constructed to “state of the art” standards and is operationally Nowertholess, machines canbe the source of danger if they continue to be operated although a fault is suspected or has already occurred or it has been repaired incorrectly. Under these circumstances there is ‘+ Danger to life and limb ‘+ Danger to the machine and other facil fies and equipment etc. The machine must be shut down immediately if @ fault is suspected or has already occurred Which could endanger the safety of the operator, other persons on site or surrounding facilities and equipment etc. All components have been carefully matched to each other. Fault-free operation and a long service life are only possible if original spare parts are used. 1.2.2. Regulations for work safety Personnel Only property trained and authorized personnel with appropriate specialist knowledge are to be appointed with maintenance and repair work. amIie urely | ‘2 seyincne Appropriate measures must be taken before commencing any work on the undercarriage to ensure that the equipment cannot start up unintentionally or be started up inadvertently by others (e.g. blocks). All switching on and off procedures must be observed for this. Protective equipment and clothing is mandatory for all work. Wear protective helmets, shoes and gloves. Close fiting clothes help to avoid injuries. If assistants are required to help in carrying out work, responsibilities must be clarified beforehand so that there is no possibility of unclear competence occurring with regard to safety aspects. Tools and equipment Tools, lifting gear, fastening devices, jacks and other working equipment must be in a safe operational and working condition. Al lifting and fastening devices on the crawler undercarriage are only designed for the transportation of the undercarriage unless otherwise specified. Metal splinters may break off and cause injuries when driving equipment bolts in or out. For this reason, always wear safety goggles when driving bolts in or out. Equipment or components which are being fitted or removed or where their installation position is being changed must be secured against unintentional movement, slipping or falling over using suitable lifting gear of suspension/support devices. ‘Systems and units (i.e. tensioning units) must be depressurized in an appropriate manner before opening, Damaged hydraulic or mechanical pre-tensioned spring elements must be exchanged as a complete unit. Further information in this respect can be found in the respective component descriptions andior fitting and removal instructions. oorNTERTACTOR 2. Operating and Service Instructions 2.1. General Maintenance Instructions 24.4 Handling hydraulic substances and lubricants The relevant applicable safety regulations for the respective products must be observed when handling oil, grease or other chemical substances. Suitable safety measures must be taken to avoid scalding and burning when the machine has warmed up (ie, at operating temperature), as operating media are then at least the same temperature. Do not smoke if handling combustible fluids. Caution with fire and naked flames. Not only fuel but also other operating media often have a low flash point and ignite easily. Lubricants that are not being reused must be disposed of in an environmentally friendly way. 241.2. Conversions or changes to the undercarriage Unauthorized conversions or changes are not permitted for safety reasons. The rated pressure of connected pressure relief valves and pressure tanks must not be altered ‘Seals on units must not be removed. 2.4.3. Before starting up Before starting up: ‘+ Lubricate all lubrication points ‘* Check all oil levels and adjust if necessary ‘* Check function of all repaired components * Carry out visual inspection of all components TaIie urely AMERICA 2.4.4 Wear limits of undercarriage parts Wear of the undercarriage is caused by movements, loads contact between parts of the undercarriage and abrasive action of the ground. ance Instructions This wear is increased by other factors including: Track resting on hard uneven rock bed during operation One-sided undercarriage load during turning Driving long distances in reverse Driving over obstructions recklessly track which is not tensioned according to operating conditions Alarge degree of dirt on complete undercarriage Undercarriage components must be replaced by new parts if they are worn to 100 %. Otherwise, sudden machine failure is possible. Careful and regular measurements are necessary in order to establish the extent of wear and when replacements will be necessary. The parts involved and measuring parts must be cleaned thoroughly when carrying out measurements. If possible, carry out measurements at several points. The degree of wear is determined by the maximum vaiue, not the average value, Wear limits are shown on the wear tables. (Tables are not included with the manual, They can be ordered from Intertractor) oorare 22cm 2.2. Inspection intervals Table (OH: = Operating Hours) Component Tniewal _[Inspec- | Enent of maintenance work Description tion Track undereariage | aly visual [Extent of undereariage diriness | Chapter ‘General condition of the Track undercarriage components undercarriage Fastening elements of fame ‘sections and undercarriage fastenings. Tantiy | visual | Fastening elements of Fame sections and undercarriage fastenings ~ grouser shoe fastening (spot checks) Dave aly Visual [Seal of gear-motor unit and possible | Chapter hydraulic connections Drive "200-250 | eheck | Gearbox ol level on 300 = 2000 ‘Gearbax of change on at longest 4 monthly | cheek | Condon of and wear on sprocket Frontialer unt [dally Visual [General siate of spring and tension | Chapter system Front ialer unt weekly ‘Seal of fhe Font ler and the tensioning system Re-tensioning span of fe Wack {max. possible tensioning span reached) ‘heck [Condition of and wear on Font aler and siding blocks. Track rollers eal visual | Check for leakage Ghapier monthly | check | Condition of and wear on Wack aller | Track roller unit Carrier rales andor [dal visual [Check for leakage Chapter: wearing rails monthly [check [Consltion of and wear on carrier | Track roller unit roller rawr rack with [daly Visual | Check for leakage (only on oiler | Chapter ‘grouser shoes. grease lubricated tracks) Crawler track with “Track pre-tensioning ~ track saq_| grouser shoes Tmonihiy | check | Condition of and wear ontrack ink running surfaces, bushings (outer diameter), and stretching of track ‘Condition of and wear an the grouser shoes. Changes to intervals are possible depending on extent of use and operating conditions for the machine. TamTaare 2.3. Tightening torque tables These tables do not apply for fastening the base plate to the track. For standard bots For expansion bots Nm Nm so | a8 | 109 | 20 so | as | 9 | te ma 24298 wa a i822, us 5060-85100) Ms 23,33 48), Ms 85109140170) Ms 47,8580, Me 240,250) 350) Me "20 %40 200) 249) m0 430.490 890 839) mao 250230410) 800) ua 729, 85012001450) Miz 440/520, 740,880 wae 11501350, 19002300 Ma To, 840 200) 1400 a6 80.0. 210029503850) ms 4150) 135019002250 w8 245.0. 2000 40504850) M8 7550) 180.0 255.0 3050) M20 3450/4100 -$800 6000) M20 2250/2850, 3750, 4500 wae 450, 550078009300 Ma 3100) 38508200 620.0 ze 00.0. 7100, 7.0000 7.2000) Mat 380.0, 480.0 650.0) 780.0 Mar 990.0, 1.0500 1.8000. 1.8009) war ‘000° 7000/9900, 12000 a0 12000, 14800, 2.000" 2.4000 M30 8000/9500 1.8600, 1.5000 M36 2.4809 For standard bots with fine tread For expansion bolts with re thread Nm Nm 69 | a8 | 109 | 120 so | as | 9 | 129 Moe 250270380450 Mad 40, #7023020 oxi 25 440.820 730880) Moet 25 270330460) —_—850) Mix 25 0095013501600) Met 25 520, 61,0 8501050) MAaK1§ 750, 90,0 12501800) Mize 480,870. a00, 960) Maxi 5 250.1500 71007500) Maes 3109301350 780.0 Mtox1.5 19002250, 3150200 Mr6«i.5 4250 150.0 210.0 2850) Mex1.§ 2750, 325048005800 Mex 5 1000, 225031803800) Ma0xi 5 3850, 480064007700) 20K 5 255031504450, 530.0 Maax15 5200, 61008600. 1.0800 MaRS 3850) 430.0 61007300 iM zex2 50.0, 7800 1.1000 1.2009) Mae 4500, 5300, 7500, 9000] MarK2 970.0, 7.1500 1.6000 7.9800) Mane 700° 700.0. 11000, 13500] 3052 350.0, 1.6000 2.2500. 2.7000) M902 ‘960.0, £1500. 16000 +9000) For standara bots wih fine tread For UNE bolts with ne tread Nm Nm Mixt 350 950 anie20 1100-200 Maat 145.0 1600 1220 50-1450 Mian 220.0 250,0 area 200-2709 Mex 5 340.0 ‘3800 5616 s00 = 9700 a0 2.3600 2.4000 aaa 5760-8800 784 9150-40300 ri 1385.0 Ware