Service Manual Track components

Tension unit

Tension unit

A. Design

The tension unit (chain tensioner) is a part of the track and is used to absorb impacts, to which the chain and
the idler are exposed to during travel operation. In addition, the positioning of the idler and therefore the chain
tension are set via the tension unit.

Note!
The position numbers for the following illustrations are in the parts list, page 12.
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B. Removal and installation instructions

1. Remarks
Repairs may only be carried out by trained and authorized expert personnel.
Safety guidelines must be observed!
Prerequisites for expert repair are proper and complete basic tools as well as the required special tools.
Removal parts must always be checked for reuse and replaced, if necessary.
Tightening torques are noted in section 1.3.

2. Special tools
For the removal / installation of the tension unit, it is imperative that the specified special tools are used.

Description Id. No. M-Type Remarks Illustration

Installation tool Required for the
Tension unit removal /
installation of the
Mechanical device see section2.1 RL 44 tension unit –
(without hydraulic PR 734 F/N chain tensioner!
components) 1481-12368
PR 734 F/N
1482-13635
Hydraulic see section2.1 LR Series 4
components for RL 44
installation tool PR 734 F/N
1481-12368
Consisting of: PR 734 F/N
Hydraulic cylinder 1482-13635
Enerpac RC 506
Hydraulic hose
Enerpac HC- 7206
Pressure gauge
Enerpac GF- 50B
Intermediate section
Enerpac GA-2
Hand pump Enerpac
P80
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3. Removal of the tension unit

The track must be clean.
A seal kit must possibly be available.
Required special tools must be on hand.

Remove the cover on the track roller frame

Remove the hex head screws 21 on the cover 24 and remove the cover.
The fill nipple 20 becomes accessible.

Warning!
Danger of injury due to splashing grease!
When loosening the fill nipple, wear work gloves and avoid contact with spraying grease.

Position of the fill nipple of the tension unit

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Carefully release the fill nipple 20.

Grease emerges from the fill nipple and the chain tension is relieved.
Open and remove the chain (see Operating instructions).
Remove the idler with suitable aids (lifting tool).

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Push the pin in

Push the pin 8 in until the pin protrudes approx. 50mm from the bushing.

Removal of cover

Back out the hex head screws with washer 14.

Drive out the cover 11 with the aid of threaded extraction holes.

Fill nipple with twist guard LWT / Ausgabe / Edition / Edition / 01.2014

Remove the twist guard 19 and fill nipple 20.

Instead of the fill nipple 20, install a plug (see Special tools).

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Place a mark

On the bushing and the track frame, mark an X.

Installation of the assembly tool

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Assemble the assembly tool kit with the hydraulic components and place it on the track frame.

Note!
These two bores are used for the PR736, the PR 734 F/N 1481-12368 and the PR 734 F/N
1482-13635 .

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Adjust the assembly tool

Slide the intermediate section 31 on the pin 8 of the tension cylinder.

Through the welded on grooves on the inside on the intermediate section, the intermediate section is roughly
centered on the pin.
Position the assembly tool on the track frame in such a way that the receptacle 34 is pushed back on the track
frame.
Adjust the assembly tool with hex head screws 39 so that it is placed horizontally on the track frame and at the
same height as the intermediate section 31.

Clamp on the assembly tool

Clamp the assembly tool with counter brackets 38 and hex head screws with washers 36 on the track frame.
When installing the counter brackets, make sure that the lettering (PR736) is readable and not upside down.

Note!
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The lettering (PR736) is also valid for the PR 734 F/N 1481-12368 and the PR 734 F/N 1482-
13635

Build up pressure on the hydraulic cylinder 46 by actuating the hydraulic pump 50.
The piston of the hydraulic cylinder 46 extends.
Continue to build up pressure until the piston of the hydraulic cylinder 46 touches on the intermediate 31.
Center the intermediate section 31 on the piston of the hydraulic cylinder.
Check the position of the assembly tool on the track frame, otherwise remove the counter brackets 38 and
readjust the hex head screws 39 and reinstall the counter brackets 38.

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Danger!
Severe danger of injuries / crushing danger!
If the counter brackets 38 are not or incorrectly installed, then the assembly tool can release
from the track frame during the pressure build up.

Press in the tension unit

Danger!
Severe danger of injuries / crushing danger!
Due to pressure fluctuations, work on the track during the pressure build up is strictly
prohibited. It must be ensured that after the pressure build up, the drain valve X always
remains closed on the hydraulic pump 50.
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Actuate the hydraulic pump 50.

The tension unit 7 and spring 2 are pushed back.
Actuate the hydraulic pump until the distance between the track frame and the tension unit 7 is sufficient to
remove the three locks 13.
Remove the locks 13.
After removing the locks 13, slowly relieve the pressure on the hydraulic pump 50 by actuating the drain valve
X.
The intermediate section 31 and tension unit 7 are pushed out from the track frame due to the pretension of
the spring 2.
As soon as the spring 2 is completely relieved, remove the intermediate section 31 and assembly device 30.

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Removal of the tension unit

Under no circumstances pull the tension unit 7 out!

Note!
The tension unit 7 can only pushed out from the track frame from the rear via the spring 2, it
cannot be pulled out from the front.
When pulling it out, only the bushing 10 would release and the sleeve with all the glide
elements would remain in the track frame.
Push the spring 2 further out with a suitable tool at the opening to the grease fitting.
Then remove the tension unit 7 with a suitable tool.
If the spring 2 needs to be changed (for example if it is broken), then the spring must be pulled out from the
track frame with a suitable tool.

4. Installation of the tension unit

4.1. Preparations for installation of the tension unit

Before installation of the tension unit 7, observe the following points:
The bushing 10 and sleeve 9 must be secured with tension pin 23 to prevent them from twisting, otherwise
an exact positioning before installation is not possible.
To do so, push the bushing and sleeve with a screw driver apart and check if the tension pin is positioned
correctly.
(Bushing and sleeve can then no longer be turned toward each other). Otherwise, turn the bushing and
sleeve toward each other until the tension pin can be pushed into the intended bore (see Sectional view).
In addition, check if the pin 8 protrudes approx. 100 mm from the tension unit 7.
This ensures that the intermediate section 31 is centered at installation by the pin 8 and the assembly
device 30 is easier to install on the track.
The plug 41 must be installed on the sleeve 9 instead of the fill nipple 20.
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The tension unit 7 must be free of rust and lubricated with a suitable corrosion preventative.

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4.2. Installation
If the spring 2 was removed, push the spring into the track frame with a tool.
Center the tension unit 7 with a suitable tool on the spring 2. Then push the tension unit into the track
frame to the stop together with the spring.
This ensures that the tension unit 7 is centered in the track frame by the spring 2 and that the tension unit will
not become wedged in the track frame.

Position the left track / Position the right track

Note!
The tension unit 7 can no longer be positioned when pressed in.
For that reason, the tension unit must be exactly positioned before pressing it in otherwise the
fill nipple 20 and the twist guard 19 cannot be installed.
Position the tension unit via the positioning bores 51 as shown in fig. 429323.
The left track must be positioned via positioning bore 51 vertically to the center of the pin 8, the second
positioning bore 51 is offset by 80° to the right.
The right track must be positioned via positioning bore 51 vertically to the center of the pin 8, the second
positioning bore 51 is offset by 80° to the left.
The mark X which was marked at installation can be used for additional orientation. However, it can deviate
slightly due to the positioning at installation.

Note!
While pressing in the tension unit with the spring, it may twist and therefore change the
position. In this case, the pressure must be reduced again and the change in position must be
equalized.
Install the assembly took kit 30 with hydraulic components 45 (as described for removal) and install
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correctly on the track frame.

Note!
To ensure proper operation of the assembly device 30, the device must be centered on the
track frame at installation and adjusted horizontally to the height of the pin 8 with hex head
screws 39.

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Press the tension unit in

Danger!
Severe danger of injuries / crushing danger!
Due to pressure fluctuations, work on the track during the pressure build up is strictly
prohibited. It must be ensured that after the pressure build up, the drain valve X is always be
connected on the hydraulic pump 50.
Actuate the hydraulic pump 50.
The tension unit 7 and spring 2 are pushed back.
Actuate the hydraulic pump until the distance between the track frame and the tension unit 7 is sufficient to
install the three locks 13.
Place the locks 13 properly.
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After placing the locks 13, slowly relieve the pressure on the hydraulic pump 50 by actuating the drain
valve X.
As soon as the tension unit 7 and the spring 2 are pretensioned, remove the intermediate section and
assembly device.

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Vent the tension unit

Back out the plug on the fill nipple connection.

Push the pin 8 in the sleeve 9 until grease without air inclusions emerges on the grease fitting connection.
The tension cylinder is thereby vented.
Install the fill nipple 20 and twist guard 19.

Installation of cover

Install the cover 11 with hex head screws 14.

Install the idler and chain.
Adjust the chain tension to suit application (see Operating instructions).

Install the cover on the track roller frame

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Install the cover 24 with hex head screws.

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C. Sectional view of tension unit

1 Track frame 30 Assembly tool kit

31 Intermediate section
2 Spring Chain tensioner 32 Counter bracket
3 Idler 34 Receptacle (RL 44 / PR 736 /
4 Carrier roller PR 734 F/N 1481-12368 /
PR 734 F/N 1482-13635 )
7 Tension unit complete 35 Cylinder receptacle
8 Pin 36 Hex head screw
9 Sleeve 37 Washer
10 Bushing 38 Counter bracket
11 Cover 39 Hex head screw for height
adjustment
12 O- ring 40 Hex head screw with washer
13 Lock 41 Plug
14 Hex head screw
15 Washer 45 Hydraulic components
16 Radial seal ring 46 Hydraulic cylinder
17 Guide ring 47 Hydraulic hose
18 Grooved ring 48 Pressure gauge
49 Intermediate section Pressure gauge
19 Twist guard 50 Hydraulic pump
20 Fill nipple
21 Hex head screw 51 Positioning bore for
22 Washer tension unit
23 Tension pin
24 Cover X Marking for assembly
25 O- ring

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Sectional view Tension unit

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Tension unit

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