Service manual

SUBGROUP - INDEX

Section Group Type

Travel gearbox (with ball roller) 120.010.1 R 920 - R 924

Travel brakes 120.020.1 R 920 - R 924

Adjusting secondary P-R valves

for travel gear movements (motor type CMVE) 120.200.1 R 920 - R 924
LFR/en/Edition: 06/2016

120.000.1
 Service manual

LFR/en/Edition: 06/2016

120.000.2
 Service manual Travel gearbox (with ball roller)
Design

Travel gearbox (with ball roller)

1 Design

Fig. 1 Travel gearbox 6690 (left) or 6790 (right))

105 Sprocket wheel 6600 / 6700 Travel motor

6690 / 6790 Travel gearbox

The travel gear 6690 (or 6790) is driven by the travel motor 6600 (or 6700). It is bolted on the side
frame. The chain is driven by the sprocket wheel 105 which is driven by the travel gear.
The travel brakes are in the travel motor 6690. (see 080.130 CMVE travel motor)

2 Technical data

(See 020 Technical Data)

LFR/en/Edition: 04/2016

R 920 - R 924 120.010.1

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Travel gearbox (with ball roller) Service manual
Function

3 Function

Fig. 2 Section drawing

1 Connection housing 32 Planetary gear of planetary stage I

5 Planetary gear of planetary stage III 33 Snap ring
6 Snap ring 35 Driving shaft
10 Output housing with inner teeth 38 Roller cage
11 Ball roller 40 Cover
15 Sun gear of planetary stage III 41 Retaining disc
17 Distance ring 42 L-Ring
20 Planetary carrier of planetary stage II 45 O-ring
21 Retaining disc 46 Cylinder head screw
22 Planetary gear of planetary stage II 48 Plug
LFR/en/Edition: 04/2016

23 Snap ring 70 Slip ring seal

25 Sun gear of planetary stage II 96 Hex head screw
30 Planetary carrier of planetary stage I 6600 / 6700 Travel motor

The travel gear is composed of three planetary gears. The planetary carrier of the last gear is fixed.
For each stage the sun gear of stage N is fixed on the planetary carrier of the stage N-1.

120.010.2 R 920 - R 924

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 Service manual Travel gearbox (with ball roller)
Maintenance

In gear stage I, the driving shaft 35 transmits the power to the planetary gear 32, so it turns around
itself. As this planetary gear is interlinked with the output housing 10, it turns around the travel gear
axis. Thanks to the pivot between planetary gear 32 and the planetary carrier 30, the planetary
carrier 30 and the sun gear 25 begin to turn. That gives a ratio of transmission between the driving
shaft 35 and the sun gear 25.
In gear stage II, the sun gear 25 transmits the power to the planetary gear 22, so it turns around itself.
As this planetary gear is interlinked with the output housing 10, it turns around the travel gear axis.
Thanks to the pivot between planetary gear 22 and the planetary carrier 20, the planetary carrier 20
and the sun gear 15 begin to turn. That gives a ratio of transmission between the sun gear 25 and
the sun gear 15.
In gear stage III, the sun gear 15 transmits the power to the planetary gear 5. The planetary gear also
cogs in the output gear 10. As this planetary gear is connected to the connection housing 1, the output
housing 10 begins to turn. That gives a ratio of transmission between the sun gear 15 and the output
gear 10.
The total ratio of transmission of the travel gear is the ratio between the RPM of the driving shaft 35
and of the output housing 10.
The output housing 10 drives the sprocket wheel 105. The output torque of the hydraulic motor 6600
is transmitted to the driving shaft 35 via the inner teeth of the retaining disc 21. The ratio of
transmission is equal to the inverse of the complete transmission of the travel gear.
The rotating output housing 10 is seated on the stationary connection housing 1. The connection
housing 1 is fixed. Bearing rollers 11 are diagonally installed in double roller cages 38.
The slip ring seal 70 is mounted between the connection housing 1 and the output housing 10. It
sealed up the travel gear from the exterior.

4 Maintenance

(see Inspection and maintenance schedule, in 030 Maintenance)

5 Repair

Initial torque and tightening angle (pre-tighten crosswise 3 screws at least) FAT 355
Travel gear 98 mounting bolts 100 N.m
+ 90°
Sprocket wheel 99 mounting bolts 100 N.m
+ 80°

Tab. 1 Technical data

Note!
LFR/en/Edition: 04/2016

For the weight of the sprocket wheels and the travel gears: (See 020 Technical Data)

R 920 - R 924 120.010.3

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Travel gearbox (with ball roller) Service manual
Repair

Fig. 3 Repair

54 Oil draining plug 105 Sprocket wheel

98 Mounting bolts for travel gear 106 High pressure hose
99 Mounting bolts for sprocket wheel 107 Hose for control of motor displacement
103 Side frame 108 Leak oil hose
104 Chain 6600 Travel motor
6690 Travel gearbox

5.1 Removing
Park the machine on a level and firm ground.
Place the oil draining plug 54 at the bottom side of the gear.
Remove the oil draining plug 54.
Let the oil flow out into a suitable container.
LFR/en/Edition: 04/2016

Install the oil draining plug 54.

Slacken and remove the chain 104. (see 130.500 Chain complete)
Remove the guard plate of the hydraulic motor 6600.
Remove the mounting bolts 99 and remove the sprocket wheel 105.
Disconnect the high pressure hoses 106, the servo line 107 and the leak oil line 108 from the
hydraulic motor 6600.
Close off all connections.

120.010.4 R 920 - R 924

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 Service manual Travel gearbox (with ball roller)
Repair

Underpin the gear with an appropriate lifting accessory.

Remove the mounting bolts 98 and remove the complete gear.
Notice the position of the gear and put the gear down on a level floor.
Remove the travel motor: see 080.310 CMVE travel motor.

5.2 Repair
See the repair manual of the travel gearbox FAT with ball bearings.

5.3 Installing
Lift the gear with an appropriate lifting accessory.
Place the complete gear into its seat in the side frame. Take care of its right position.
Install the mounting bolts 98 and tighten them crosswise.
Connect the high pressure hoses 106, the servo line 107 and the leak oil line 108 on the travel
motor.
Place the sprocket wheel 105 onto the housing of the gear with an appropriate lifting accessory.
Install the mounting bolts 99 and tighten them crosswise.
Install the guard plate of the hydraulic motor 6600 to the side frame 103.
Install and tighten the chain 104. (see 130.500 Chain complete)
Place the oil draining plug 54 at the bottom side of the gear.
Fill in with recommended oil until the oil level has reached the filling holes.
LFR/en/Edition: 04/2016

R 920 - R 924 120.010.5

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Travel gearbox (with ball roller) Service manual
Repair

LFR/en/Edition: 04/2016

120.010.6 R 920 - R 924

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 Service manual Travel brakes
Design

Travel brakes

1 Design

The design of the brakes depends on the travel motor type:

– CMVE motor: The brakes are in the hydraulic travel motor. (see 080.130 CMVE travel motor)
LFR/en/Edition: 04/2016

R 920 - R 924 120.020.1

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Travel brakes Service manual
Design

LFR/en/Edition: 04/2016

120.020.2 R 920 - R 924

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 Service manual Adjusting secondary P-R valves for travel gear movements (motor type CMVE)
Blocking travel brakes

Adjusting secondary P-R valves

for travel gear movements (motor type CMVE)
To adjust the secondary pressure-relief (P-R) valves, block the travel brakes and then operate the
travel motors.

1 Blocking travel brakes

Br Cap 106 Hexagon socket set screw

Park the machine on a firm and level ground.

Release the pressure in the hydraulic tank by unscrewing the breather filter.
Remove covers of side frames.
Remove caps Br on both travel gears.
Screw a hexagon socket set screw no. 106 to the stop (see sub-chapter 010.050 Special tool for
maintenance and repairs).
LFR/en/Edition: 04/2016

R 920 - R 924 120.200.1

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Adjusting secondary P-R valves for travel gear movements (motor type CMVE) Service manual
Adjusting secondary pressure-relief valves

2 Adjusting secondary pressure-relief valves

M25 Measuring point / high pressure pump P1 5101 Primary pressure-relief valve P1
M26 Measuring point / high pressure pump P2

6604 Secondary pressure-relief valve / travel 6704 Secondary pressure-relief valve / travel
forward left forward right
6605 Secondary pressure-relief valve / travel 6705 Secondary pressure-relief valve / travel
backward left backward right

Remove protecting caps of measuring points M25 and M26 and connect pressure gauges 0-
600 bar.
Start diesel engine.
LFR/en/Edition: 04/2016

120.200.2 R 920 - R 924

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 Service manual Adjusting secondary P-R valves for travel gear movements (motor type CMVE)
Adjusting secondary pressure-relief valves

Fig. 1 Wizard window / Adjusting pressure-relief valves menu

B159 = Measuring point M25 B160 = Measuring point M26

Activate function with activation key.

Screw in primary pressure-relief valve 5101 until response pressure is greater than pressures set
at secondary pressure-relief valves.
Remove caps and locking devices from secondary pressure-relief valves.
Actuate left travel pedal to the stop.
Make sure that pressure M26 corresponds to required value of valve relief pressure (see
Adjustment checklist and adjustment procedure, chapter 030).
If measured value deviates from required pressure, loosen lock nut and screw (increase pressure)
or unscrew (decrease pressure) adjustment screw.
Tighten lock nut.
Actuate right travel pedal to the stop.
Make sure that pressure M25 corresponds to required value of valve relief pressure (see
Adjustment checklist and adjustment procedure, chapter 030).
If measured value deviates from required pressure, loosen lock nut and screw (increase pressure)
or unscrew (decrease pressure) adjustment screw.
LFR/en/Edition: 04/2016

Tighten lock nut.

Install caps and locking devices on all secondary pressure-relief valves.

2.1 Ending adjustment

Remove pressure gauges and screw on caps at measuring points M25 and M26.
Remove hexagon socket set screws 106.

R 920 - R 924 120.200.3

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Adjusting secondary P-R valves for travel gear movements (motor type CMVE) Service manual
Adjusting secondary pressure-relief valves

Screw caps Br.

Put on covers of side frames.

Note!
After adjusting the secondary pressure-relief valves:
Adjust primary pressure-relief valve 5101 (see Adjustment checklist and adjustment procedure,
chapter 030).

LFR/en/Edition: 04/2016

120.200.4 R 920 - R 924

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