SUB GROUP INDEX 12.01 Technical data R900 Litronic/ 101 —> 12.02 Technical data R902 Litronic/ 101 > 12.03 Technical data R912 Litronic/ 101 > R9z2LLitronic/ 101 > 12.04 Technical data .. see R932Litronic/ 101 —> 12.05 Technical data .. seve R942Litronic/ 101 —> 12.06 Wear of track components 12.08 Wear’ of track components D4 - D4D 12.09 Wear limits of track components B60 - 85 6 D6- E5. 12.10 Wear limits of track components D7 - B6 12.12 Removal and installation of track components .. R900-R 942 Litronic/ 101 —> 12.13 Removal and installation of track components R900 - R942 Litronic / 3001 > 12.15 Slipring seat 12.26 Idler .. R900- R942 Litronic/ 101 > 12.31 Tensionunit R900-R942LLitronic/ 101 —> 12.32 Tension unit 900-R942 Litronic/ 3001 —» 12.41 Track roller . R900 - R942 Litronic / 101 —> 12.46 Carrier roller R900 - R942 Litronic / 101 > Benennung/Desription/Denomination Twill) po0ola 42 LIEBHERR Te Uitronie Track Toren paride Datum/edition/bate 04,96 BlacuPage Feuille 12.Machine R 900 Litror Type 368 (STD) | 368 /596(HD-SL) Valid from Serial No. 101 3001 Chain Type Ds BeoL Number of Links 51 46 Distance between two pins mm 171.25 190 Pin diameter mm 33 37 Bushing diameter mm 508 59 Chain link Height of chain link mm 93 105 Track Pad Type D4 B60 Form 3 grousers 3 grousers Height of grousers mm 38 36 Ground pressure in N/cm2 with track pads 500 mm 46 5.0 600 mm, 39 42 750 mm, 34 34 ‘Track Pad Bolts Thread Size 5/8" M1Bx1.5 Tightening Torque (Nm) 350 500 Wrench Size (mm) 24 2 Track Roller Type Da B60 Number of rollers per chain 9 7 Carrier Roller Type Da B60 Number of rollers per chain 2 2 * These track components are for use in very hard conditions Benennung/Dexctiption/Dénomination LIEBHERR Datum/Eaition/Date 11.96 Technical Data Torques Wy R900 Type Litrenic ‘Ab/from/a partir de 101 / 3001 / 4001 Blatt/Page/Feuille 12.01.01Machine R902 Litronic Type 364 Valid from Serial No. 101 Chain Type D4(* B55) Number of Links 51(* 55) Track Pad Form 3 grousers Type ba Ground pressure in N/cm2 with ‘track pads 500 mm 48 600 mm 44 750 mm 33 1000 mm 28 Track Pad Bolts Thread Size 5/8" Tightening Torque (im) 350 (kpm) 355 Wrench Size (mm) 24 Track Roller Type Da Number of rollers per chain 9 Carrier Roller Type Da(*D4s) Number of rollers per chain 2 * These track components are for use in very hard conditions Benennung/Description/Dénomination Mode! Litronic LIEBHERR Technical Data Torques ‘Abifromva partir de Datum/Edition/Date 101 Blatt/Page/Feuile 12.02.01 12.98Machine R902 Litronic Type 582(STD) 364 (HD-SL) from Serial No. 3001 3001 Chait Type B60 B60 Number of Links 46 50 Distance between two pins mm 190 190 Pin diameter mm 38 38 Bushing diameter mm 60 60 Chain link Height of chain link mm 105 105 Track Pad Type 860 B60 Form 3 grousers 3 grousers Height of grousers mm 28 2B Ground pressure in Nrem? with track pads 500 mm 5a 47 600 mm 43 40 750 mm 35 33 ‘Track Pad Bolts Thread Size 20x 1.5 M20x1.5 Tightening Torque (Nm) 750 750 Wrench Size (mm) 2 27 Track Roller Type B60 B60 Number of rollers per chain 7 8 Carrier Roller Type B60 B60 Number of rollers per chain 2 2 * These track components are for use in very hard conditions Benennung/Description/Dénomination LIEBHERR 5 Technical Data Torques ‘Abifrom/a partir de 3001 Datum/Edition/Date Blatt/Page/Feullle 12.02.02 04.96Machine Type tc td stds 346 | 417 {aa | ate | 482 Valid from Serial No. 101} 2001 {2001 | 101 | 2001 Chain Type pap pap bap pap Déuptosn 104 Number of Links 55 35 31 3 Track Pad Form 3qrousers | 3grousers 3grousers | 3grousers Type ba Da ba ba Ground pressure in N/cm? with track pads 500mm 50 5.0 600 mm 43 43 750mm 34 34 36 36 1000 mem 265 2.65 28 28 Track Pad Bolts Thread Size 518" 58" 58" se" Tightening Torque (um) 350 350 350 350 (kpm) 355 35.5 355 355 Wrench Size (mm) 2 2 24 2 Track Roller Type ba pa D4 ba Number of rollers per chain " " 9 9 Carrier Roller Type D4 pba Da Da Number of rollers per chain 2 2 2 2 Benennung/Description/Dénomination Model LIEBHERR Litrenic Technical Data Torques ‘Abiteom/a partir de Datum/Edition/Date Blaturagerrourle ae 12.03.01R912 Litronic R922 Litronic Machine Hos HD-SL Type a6} 387 480 Valid from Serial No. 101 101 101 Chain Type 360(*D6C) 860 (*D6C) 860 Number of Links 47 (745) 52(*49) 52 Track Pad Form 3grousers 3 grousers 3 grousers Type B60 (*D6C) 860 (*D6C) 860 Ground pressure in Nlem? with track pads 500 mm 57 52 55 600mm 48 44 46 750 mm 39 36 38 Track Pad Bolts Thread Size 20x 1.5 (+3/4") | M20x1.5(43/4") | -M20x1.5 Tightening Torque (im) 750 (*600) 750 (*600) 750 (kpm) 76(*61) 76(*61) 76 Wrench Size (mm) 27(*30) 27 (#30) 27 Track Roller Type 06 D6 06 Number of rollers per chain 8 9 9 Carrier Roller Type a D6 D6 2 2 2 Number of rollers per chain 120301Machine R912 Litronic R922 Litronic ‘Type 483 (STD) 417 (HD-SL) 481 (HD-S) 480 (HD-SL) Valid from Serial No. 3001 3001 3001 3001 Chain Type B60 (* DEC) B60 (* D6C) B60 B60 Number of Links 46 (* 45) 50 (* 49) 4 50 Distance between two pins mm 190 (* 202,8) 190 (* 202,8) 190 190 Pin diameter mm 38 (* 44,5) 38 (* 44,5) 38 38 Bushing diameter mm 60 (* 66) 60 (* 66) 60 60 Chain link Height of chain link mm 105 (* 121,4) 105 (* 121,4) 105 105 ‘Track Pad Type 860 (* D6C) B60 (* D6C) B60 B60 Form 3 grousers 3 grousers 3 grousers 3 grousers Height of grousers mm 28 (* 39,5) 28 (* 39,5) 28 28 Ground pressure in N/cm2 with track pads 500mm 57 5,2 55 — 600 mm. 48 44 46 43 750 mm 39 3,6 38 35 Track Pad Bolts Thread Size 20% 1,5 (* 3/4 ")] M20x1,5(*3/4")| 20x15 M20x1,5 Tightening Torque (wm) | 750(* 600) 750 (* 600) 750 750 Wrench Size (mm) 27(* 30) 27(* 30) 27 7 Track Roller Type B60 860 860 B60 Number of rollers per chain 7 8 7 8 Carrier Roller Type B60 B60 B60 B60 Number of rollers per chain 2 2 2 2 * These track components are for use in very hard conditions Benennung/Description/Dénomination R912/R922 Mode! LIEBHERR ‘Type Litronic Technical Data ‘Abitromia parts de Datum/Edition/Date Torques 3001 vase BlattiPage/Fevile 12.03.02Machine R932 Litroni Type 1/365 HD-SL/381 EW/ 405, Valid from Serial No. 101 101 101 Chain Type B60 (*D6C) 8 60(*D6C) B60 Number of Links 52(*49) 52(*49) 52 Track Pad Form 3 grousers 3 grousers 3 grousers Type 8B 60 (*D6C) B60 (*D6C) 860 Ground pressure in Nie? with track pads 600 mm 60 61 750mm, 51 52 1000 mm 44 42 Track Pad Bolts Thread size 1M 20x.1.5(*3/4) 20x 1.5 (*3/4) 20x15 Tightening Torque (im) 750 (*600) 750 (*600) 750 (kom) 76(*61) 76(*61) 76 Wrench Size (mm) 27 (#30) 27(°30) 27 Track Roller Type BS BS 85 Number of rollers per chain 9 8 9 Cartier Roller Type ES ES ES Number of rollers per chain 2 2 2 Typ R932 Model BenennungiDescription/Dénomination LIEBHERR Technical Data Torques ‘Abyfromia part de 101 Datum/edionDate BiatuPagerFeuilie 12.04.01 11.92R932 Litronic Machine Type 572(STD) 571 (HD-SL) 590 (EW) Valid from Serial No. 3001 3001 3001 Chain Type 860 860 (* D6C) 860 Number of Links 52 52(* 49) 52 Distance between two pins mm 190 190(* 202,8) 190 Pin diameter mm 38 38 (* 44,5) 38 Bushing diameter mm 60 60 (* 66) 60 Chain link Height of chain link mm 105 105 (* 121.4) 105 Track Pad Type 860 B60 (* DEC) B60 Form 3 grousers 3 grousers 3 grousers Height of grousers mm 28 28 (* 39,5) 28 Ground pressure im N/em2 with track pads 500 mm 63 62 64 600 mm 54 53 56 750 mm 4a 43 46 Track Pad Bolts Thread size M20x1,5 M20x1,5 (* 3/4") M20x 1,5 Tightening Torque (nm) 750 750 (* 600) 750 Wrench Size (mm) 2 27 (* 30) 7 Track Roller Type 860 B60 B60 Number of rollers per chain 9 9 9 Carrier Roller Type 860 B60 860 Number of rollers per chain 2 2 2 LIEBHERR Datum/Edition/Date 02.97 * These track components are for use in very hard conditions Benennung/Description/Denomination Technical Data Torques Typ Mode Type R932 Literenic ‘Ab/from/a partir de 3001 Blatt/Page/Feville 12.04.02Machine R942 Litronic Type HD-SL/366 HD-S /382 Valid from Serial No. 101 101 hain Type D7 D7 Number of Links 52 52 Track Pad Form 3 grousers 3 grousers Type D7 D7 Ground pressure in N/cm2 with track pads 500 mm a ma 600 mm 60 60 750 mm 49 48 Track Pad Bolts Thread Size 31a" 31a" Tightening Torque (Nm) 600 600 (kpm) 61 61 Wrench Size (mm) 30 30 Track Roller Type B86 86 Number of rollers per chain " 8 Carrier Roller D7 Db? Type Number of rollers per chain LIEBHERR Datum/Eaitionibate 01.92 Benennung/Description/Dénomination Technical Data Torques 1,5 R942 Type Litronie ‘Abitromia parue de 101 RlarPagerFeulle 12.05.01Machine R942 Litronic Type 574(HD-SL) 573 (HD-S) Valid from Se 3001 3001 Chain Type D7 o7 Number of Links 51 51 Distance between two pins mm 202.8 202.8 Pin diameter mm 445 445 19 diameter mm 66,5 66,5 Height of chain link mm 117.3 117.3 Track Pad Type D7 07 Form 3 grousers 3 grousers Height of grousers mm 265 265 Ground pressure in N/cm? with track pads 500 mm 75 75 600 mm 63 63 750 mm 5A 5,1 ‘Track Pad Bolts Thread Size 34" 3/4" Tightening Torque (Nm) 600 600 Wrench Size (mm) 30 30 Track Roller Type 86 86 Number of rollers per chain 9 9 Cartier Roller Type &6 €6 Number of rollers per chain 2 2 ‘Benennung/Description/Dénomination Model . Type Litrenic LIEBHERR Technical Data Torques ‘Abifrom/a partir de 3001 Datumiedition/Date Blatt/Page/Feuile ones 12.05.02Wear on Track Components Wear on track components is caused by motion, load and contact. Improper operation ( such as jerky turns, lopsided load distribution, and running over obstacles) will accelerate normal wear and tear of track components. To prevent abnormal and premature wear, the following basic rules must be observed: 1. Under normal forward travel conditions, the travel gears must be in the rear of the machine. 2. When working parallel to the track chains with a backhoe attachment (when digging a trench), the travel gears should be in the rear and the idlers towards the attachment. Travel should then be backwards. 3. When working parallel to the track chain with a bucket, the travel gears should be in the front. 4, When laying pipes, the travel gears should be in the rear during travel. 5. When working with the bucket, or backhoe, make sure the machine is not lifted off the ground. ‘Worn travel components, such as links, track rollers, idlers, track pads) must be replaced as soon as the maximum wear limit has been reached (refer to sub group "Wear Limit"), Wear on track pins and bushings The chain is constructed in such a way, that the pin rotates inside the bushing as the excavator travels. However, the contact between the two parts is make only on a small area. The result is wear on only half the inside diameter of the bushing and half the outside diameter of the pin. As wear progresses, the pitch of the chain (distance between two adjacent pin centers) increases. The outside surfaces of the bushing also wear as a result of contact with the sprocket teeth, ‘The wear on bushings and pins can be reduced by turning the pins and bushings by 180°. The correct time to turn the pins and bushings is determined as follows: 1. Measure the distance from any point on one pin to the corresponding points on a pin at least 4 links away. Divide the measurements by 4, the result represents the wear per pin and bushing. Up to a maximum wear of 3 mm (.118"), the pins and bushings can be turned. Once the maximum wear limit of 5 mm (.197*) is reached, the pins and bushings must be replaced. 2. Measure the bushings. The maximum external wear limit is 3-3,5 mm (.118" to.137"). ‘Track components must be checked regularly and carefully to determine when a part needs to be replaced. lean parts thoroughly before taking any measurements. Measurements should also be made on several different points (sprocket/idler) or components (chain, links, and bushings). Use the maximum wear limit. To determine the wear, compare the actual measurement with the measurement of the new component and the wear limit, see chart in sub group “Wear Limi Example: Hn = Height - dimension of new component = 126mm. Hy = Maximum wear limit = 116mm H = Actuel measurement = 120mm 126-120 Degre of wear = = 60% 126-116 Benennung/Description/Dénomination LIEBHERR Wear Datum Edition 12.94 Date Fags == 12.06.01Chain links Measure the distance of the chain links between the chain link travel surface and the track pad with a depth gauge or tape. Measure pin and bushing wear from any point on one track pin to the corresponding point 4 links away, using a tape, The track chain must be tight. Measure the external bushing wear with a sliding cali- per at the point, which shows the greatest wear. 12.06.01Track pad Measure the track pad wear with a depth gauge or tape. CU Idler Measure the wear on the running surface of the idler with a depth gauge. Measure the wear on the running surface of the track roller, with a sliding caliper or outside caliper. 7 (ode! type’ Benennung/Description/Dénomination LIEBHERR Wear Depuis Datum Edition 12.94 DateCarrier roller Measure the wear on the running surface of the carrier roller with a sliding caliper or outside caliper. 12.06.02pa pap New | Weartimt [Maxwear | New | Weartimit | Mox Wear for Lit tor timit Reconditioning facondoning Sprocket zw nv aw zw Tooth new Tooth wear 224 ; minimum | upto Miimum | upto comm | tipot samm | spot tooth tooth Te hain link ao Mo ay wav in wy wav 2 86 952 2 6 ia Ho Pins tn uw Lv tn uv Ly ss os 20 cose | ose 708 Tun pins Tarn pint and and bushings bushings Bushings on ow paw Da ow paw oO soa “8 “6 se st 9 ones De SenennngiDesripton/Dénomination Typ Moe LIEBHERR Te Datumiédition/Date 01.92 Wear limits D4 -D4D ‘Abstrom/a partirde: BlatuPagerreuile 12.08.01Dap Da New | weartimt [Max wear | New | Wearlimit | Max Wear for Limit for Limit Reconditioning Reconditioning Track Pad Hn HW Hv Ho Hw Hav = 25 2 7 2 8 7 Idler bin ww tov in ay hav 8 2 a 18 2 25 How Track roller bn ot oa on ow av ws | sis us 155 sis 8 Carrier roller on ow ow bn ow ov 150 140 138 150 0 138 lbw ‘000 120801B60 D6 85 ES New | Max, Wear] New | Max Wear | New | Max.Wear] New | Max. Wear Limit eit Limit Limit Sprocket pv aw Bw aw Tooth new Tooth wear Z2v upto upto upto upto pot tipot tipof tipot tooth tooth tooth tooth fn | nav fot | aay tn | ay fn hav wos | 97 Pins wr | ow fin] ww uw | ww tn lw ye | ms Bushings Dn Dav Dn ov © me Dv Dn Benennung/Description/Denomination ‘Mode! Type LIEBHERR oo. Wear limits B60-D6-B5-E5 Abifrom/a partir de DatunvEaition/bate Blate/Page/Feuille 12.09.01 04,97B60 D6 Bs ES New | Max. Wear | New | Max.wear | New | Max Wear | New | Max Wear Limit Limit Limit iit Track Pad vin | tay | tin | way fom | aw Ho | av as | 2s Idler tin | tay | tin | wav | | ray Hn | av a ; 2 | 26 on | ow | on | pa | on | va pn | av wo | 17 | 160] 140 | 160 | 140 pw | on | ow | on | ow pn | paw wo} we fm} as8 wm | 138 on 12.09.01D7 psc New Max. Wear New Max. Wear Limit Limit Sprocket w wv Toothnew Tooth wear2v : upto up to tipof tip of » tooth tooth aoe Chain link Hn Hy Hn Hv "7 110 114 110 Ln Ww Ln lv 813 829 813 829 Bushings Dn Dv On ov 66.5 57 66 57 Dy ‘on Benennung/Description/Denomination Mode! Type LIEBHERR Wear | D7-B6-D6C its ‘Abitromva partir de Datum/Edition/Date Blatt/Page/Feulle 12.10.01 02.97D7 Be Dec New | Max Wear | new | Max.wear | New | Max. Wear Lit timit tit Track Pad Hn Hv | Hn Hv 26.5 12 39.5 14 Idler Hn Hv hin na 26 3 Track roller Dn bv re | 145 Carrier roller on Dv On 180 165 ov 121001For description for removal of track chain, see reverse page. 37 Idler assembly, complete 50 Allen head screw 38 Trackroller 51 Squarenut 39 Carrier roller 52 Allenhead screw 40 Track chain 54 Hexhead screw 41 Chainlink 56 Hexhead screw 42 Master pin 57 Hexhead nut 43 Spacer 59 Grease fitting 44 Bushing 61 Undercarriage 45 Trackpad 62 Side frame with gear carrier 46 Track pad 63 Track drive 47 Track pad 64 — Spring assembly, complete 48 Track pad 65 Hydr. grease cylinder 49 Flat track pad Benennung/Description/Dénomination typ Mode! R912 Litronic Type LIEBHERR Track Chain Removal and Installation ‘Abytromia partir de DatumrEditionDate 101 slatuPagerreuille 06.89 42.12.01|. To remove the complete idler and spring assembly 1.1 Remove chain 40, see page no. 12.12.02. 1.2. Pull the complete idler assembly 37 with spring assembly 64 from the side frame 62. 1.3. Separate the idler 37 and spring assembly 64. 1.4 See section 12.26 for idler removal and installation instructions See section 12.31 for spring removal and installation instructions To install the complete idler and spring assembly 2.1. Reassemble the idler 37 and spring assembly 64 2.2. Push the complete idler with spring assembly 37 into the side frame. 2.3. Reinstall the chain 40 , see page no. 12.12.02. To remove the track rollers 3.1. Remove chain 40, see page no. 12.12.02. See section 12.41 for track roller removal and installation. |. To install the track rollers 4.1. Mount track roller 38 onto side frame 62 and tighten screws 54, 4.2. See page no. 12.12.02 for description of installation for chain 40. To remove cartier rollers 5.1 Release track chain tension, see page no. 12.12.02. Insert a piece of wood between upper edge of side frame and chain to lift chain 40. 5.2 Remove screws 56 and press carrier rollers 39 from its mounting block. See section 12.46 for carrier roller removal and installation. . To install carrier rollers 6.1. Press carrier roller 39 into mounting block. 6.2. Remove the wood, align the carrier roller and torque screws 56. 63. Tension the track chain as outlined on page no 12.12.02.1. To remove the complete track chain 1.1. Park the machine on flat and solid ground. Run the track until the master pin 4 is close to the lower third of the sprocket (see fig. 1). Insert a wedge. 1.2. The master pin can be differentiated from the regular pin by its chamfered edge, see fig. 1, A/B. Note : Knurled master pins must be pressed (knocked) in from the outside of the chain toward the inside and pressed (knocked) out from the inside of the chain toward the outside. Grooved master pins can be pressed (knocked ) in and out from either side of the chain. 1.3 Carefully release the pressure on the grease fitting. Caution: Grease may squirt out! 1.4 Remove the master pin, see page 12.12.03 - reverse side. Remove the chain in travel direction If mecessary, the idler with spring assembly can now be removed from the side frame. Raise the machine and remove the track chain. 2. Toinstall the complete track chain 2.1. Position the machine on the track chain and insert a wedge 2.2. Pull the chain with a wire rope or with the attachment, or another machine over the idler and carrier rollers. Make sure the chain is installed in the correct travel direction and the track pads are positioned correctly, see fig. 1, C. 2.3 Insert spacer rings 5, align track chain ends and install master pin from the outside towards the inside, see page 12.12.03 2.4 Install fitting on grease cylinder and adjust chain tension Note : The chain tension is correct when the slack between the carrier roller and idler or sprocket is approximately 2 cm (0.787"). 3. To change damaged track pads Bent or loose track pads can cause damage to other track pads or the track chain. The track pads must be checked periodically, at least every 100 operating hours, for damage and tightness. Damaged pads must be replaced, 3.1. Remove track pad bolts and lift off the damaged track pads. 3.2. Clean the track chain mounting surface and install a new track pad. Install new track pad bolts and torque to specified value, see page 12.02.01 SerenungDesiptonDénommation te, LIEBHERR Type Track Chain Torrom parr de Datumeaivontote Removal, Repair, Installation BlatuPagerFeuille 06.89 12.12.02A B Grooved master pin Knurled master pin Cc Position of track links and pads Direction of track movement Forward travel directionDefective chain 1 1 = Chain link, complete : | 2 = Chain link, complete —— — nae torch cuts aster pin 1 5 = Spacer ring break | Remove the chain on torn chain link 1 and lay it on the A ground a Torch cut link, bushing and pin on the damaged chain 2 link segment. Remove the damaged parts. Disassembly 1 A Torch cut the bushing and grind the surface smooth (See sketch A) y Torch cut holes into the remains of the master pin and i knock the pin ends out (see sketch B). tobeground | point of chain support direction of vA during pin removal pin removal torch cut holes as shown 2 Repaired chain Install complete chain link with 2 spacer rings and aL master pin on the track chain (see reverse page). Install track chain, using master pin and 2 spacer rings. A Mount track pad. B direct A of pin installation 5 | —~3 ae Benennung!Description/Dénomination Track Chain Rep: Mode! Type LIEBHERR ‘Abitrom/a partirde Datumvedition/Date BlawPagerreuille 06.89 12.12.03To remove the master pin 1.1. Knock out the knurled master pin (see Fig. 1 - Sketch B) from the inside to the outside, using tool, see fig. 2. Grooved master pin (see Fig. 1 - Sketch A) can be pressed (knocked) out in any direction To install the master pin 1.1. Install spacer rings or lock rings and bushings into track chain ends and align chain ends Note : Using a sledge hammer when mounting the master pins, which are made from a special surface- hardened steel can be very dangerous due to material chipping off the pin. To avoid serious injuries, the master pins should only be mounted using a hydraulic press or proper pin installation tool as shown in fig. 2. 1.2. Start the master pin 4 on the outside of the chain, hold the punch guide on the chain link as shown below and use a hydraulic press to install the master pin (see Fig. 2)2. Idler assembly, complete 40° Track chain 54 Hex head screw 3 Hydr. grease tensioner 41° Chain link 56 Hex head screw 4 Cover 42. Master pin 59 Grease fitting 5 Cover 43. Spacer 60 Seal 6 Locking plate 44° Bushing 62 Side frame with gear carrier 7 Hex head screw pomp reck Pee, 63 Travel gear 38 Trackroller 50 Allen head screw 67 Tension spring 39° Carrier roller 51 Square nut 68 Spring plate 1, To remove and to install carrier rollers 1.1. Release tension of track chain 40, see § 4.2. Insert a piece of wood between upper edge of side frame and chain to lift chain 40. 1.2. Remove screws 56 and take away carrier rollers 39 from the side frame. See sub group 12.46 for carrier roller disassembly and assembly. 1.3 Lay carrier roller 39 on the threaded bores in the side frame and insert the screws 56. Remove the wood, align the carrier roller and torque screws. Tension the track chain as outlined in § 5.4. 2. To remove and to install the complete idler with grease tensioner Removal and installation of the tension spring 67 mounted inside the side frame behind the grease DEP tensioner 3 is not described in this subgroup. Should the tension spring be removed also, so i 12.32. § 1.1.2to 1.1.6, prior to remove the chait pretension must be released as noticed in subgroup §2.1 In the same way, during the reinstallation of the chain in § 2.6, the spring must be tensioned and then locked inside the side frame , as outlined in subgroup 12.32. § 1.2.1 to 1.2.8. Tye ‘Benennung/Descipton/Dénomination aenae Iedel_ See page no. 12. LIEBHERR Track components Removal and Installation one” 11.94 Be, 12.13.01 DateForward travel direction <_— \ a 2.1 Remove chain 40, see $4, 2.2. Pull the complete idler assembly 37 with grease tensioner 3 from the side frame 62. 2.3. Separate the idler 37 and the grease tensioner 3. 2.4 See sub group 12.26 for idler disassembly and assembly. See sub group 12.32 for grease tensioner disassembly and assembly. 2.5. Reassemble the idler 2 and grease tensioner 3. Push the complete idler with grease tensioner 3 into the side frame. 2.6 Reinstall the chain 40, see § 5. 3, To remove and to install the track rollers 3.1 Remove chain 40, see § 4. 3.2. Slightly raise the track chain, using the working attachment of the machine. Danger! Aa ‘Safely support the lifted side by inserting wooden blocks between track chain and bottom edge of the sideframe. 3.3 Loosen the screws 54 and remove the track roller 38. See sub group 12.41 for track roller disassembly and assembly. 3.4 Mount track roller 38 onto side frame 62 and tighten screws 54. 3.5. Lift the undercarriage using the attachment and carefully pull out the wooden blocks. 3.6 Reinstall the track chain, see §5. 4, Toremove the complete track chain Grooved Knurled 4.1 Park the machine on flat and solid ground. Run the track master pin master pin until the master pin 42 is close to the lower third of the Nw ~~ sprocket. Insert a wedge. 4.2 To release track tension, remove cover 4 from the side frame and carefully release some grease from the grease cylinder by loosening and turning the grease fitting counterclockwise, A ‘Warning : LAs) When adjusting the chain tension, keep your head clear of the access hole. The grease cylinder is under high pres- ‘sure and the chain will sag. Grease is under high pressure and might squirt out. Position of 4.3 The master pin can be differentiated from the regular pin track links and pads by its chamfered edge. JEP Note: Knurled master pins must be pressed (knocked) in from ‘the outside of the chain toward the inside and pressed (knocked) out from the inside of the chain toward the ‘outside. Grooved master pins can be pressed (knocked ) in and out from either side of the chain. 4.4 Remove the master pin, see § 9. Remove the chain in travel direction. Raise the machine and remove the track chain. Direction of track movement 12.13.015. To install the complete track chain 5.1. Position the machine on the track chain and insert a wedge. 5.2. Pull the chain with a wire rope or with the attachment, ‘or another machine over the idler and carrier rollers. Make sure the chain is installed in the correct travel direction and the track pads are positioned correctly. 5.3. Insert spacer rings 43, align track chain ends and install master pin 42 from the outside towards the inside, see § 8. 5.4 Install fitting 59 on grease cylinder 65 and adjust chain tension. To tighten a track = Remove the access cover 4 on the side frame of the undercarriage. - Attach a special fitting 2 to grease gun. Connect the grease gun to cylinder 3. ~Pump grease into cylinder 3 until the track chain is pro- perly tensioned. (On machines R900 up to R 942, the track chain tension is correct when the slack between both carrier roller is about 0.6" t0 0.8" (15 to 20mm). To check the chain slack : ~measure "X;" (fig. 2) , distance between running surface of carrier roller and top of sideframe. distance between chain link and top of measure "X2' sideframe. ~ calculate chain slack= "X; = X2". To change damaged track pads Bent or loose track pads can cause damage to other track pads or the track chain. The track pads must be checked periodically, at least every 100 operating hours, for damage and tightness. Damaged pads must be replaced. 6.1. Remove track pad bolts 50 and lift off the damaged track pads 45. 6.2. Clean the track chain mounting surface and install a new track pad. Install new track pad bolts 50 and torque (tightening sequence : 1, 2, 3, 4) to specified value, see “Technical Data - Torques"of track chain. Benennung/Description/Dénomination LIEBHERR Chain Datum Edition 11.94 Date Removal, Repair, Installation We, ae! Model See pageno. 12. from Depuis7, Repair of defective chi 1 Chain link, complete ee 2 Chain link, complete ” 3 Bushing 4 Master pin 5 6 Spacer ring End segment 7.4. Remove the chain on torn cha ground, Torch cut link, bushing and pin on the damaged chain link segment. Remove the damaged parts. ink and lay it on the 7.2 Torch cut the bushing A1 and grind the surface smooth. boi eee Torch cut holes into the remains of the master pin 2B and knock the pin ends out . point of chain support uring pin removal torch cut holes direction of ssthown Pinremoval me 7.3. Install two end segments 6 without bushing 3 and a 1 master pin 4 to chain link 2. 3 : {1 To press in the master pin, see §9. t i—] Insatall the track chain Fit the end segments 6 with two spacer rings 6 and close the chain using a master pin. Mount track pad, see § 6. Airetion instalation Benennung/Description/Dénomination LIEBHERR Track chain Repair8. To remove the master pin at 82 92 Knock out the knurled master pin (see § 4.3) from the inside to the outside, using a tool as shown picture bellow. Grooved master pin (see § 4.3) can be pressed (knocked) out in any direction. stall the master pin Install spacer rings or lock rings and bushings into track chain ends and align chain ends. Note : Using a sledge hammer when mounting the master pins, which are made from a special surface- hardened stee! can be very dangerous due to material chipping off the pin. To avoid serious injuries, the master pins should only be mounted using a hydraulic press or proper pin installation tool. Start the master pin 42 on the outside of the chain, hold the punch guide on the chain link as shown below and use a hydraulic press to install the master pin 42. 12.13.03Handling and installation instructions for slipring seals Slipring seals are precision components made out of chilled cast iron Therefore sharp knocks and blows should be avoided! Installation instructions 1, Do not remove slipring seals from protective packing until they are ready to be used. Protect the polished seal faces 1 from damage and dirt New slipring seals should only be installed per pair, as wraped. 2. The seal housings 2 (receiver parts) must be clean and free of burrs and machining residues. All edges in the housing bore must be smooth and chamfered. 3. For easier assembly, moisten the bore in the housing and the ‘o-ring 4 with a 1:1 mixture of water and spirit Install slipring seals with special installation tool 3 or using a thick string or a rope wound between o-ring 4 and seal ring 5 (fig. 2) The installation tool consists of two half shells that are closed around the seal ring. Pressure is applied evenly around the circumference of the elastomeric part 4 Seal face (sliding surface) Seal housing Installation tool O-ring (elastomer) Rope Seal ring ousens BenennungiDescristion’Dénomination LIEBHERR Slipring seal DatumiEaitonDate 01.92 ‘Abitromia partir de BlatwPagerFeuille 12.15.01Press the slipring seal into the housing. Take care that afterwards the seal face lies parallel with the housing surface. To verify the correct installation, measure the distance A at three points evenly positioned around the slipring circumference (see fig. 3) The o-rings must not sit wave-like in the housing bore or bulge partially looped out of the bore (fig. 4) Note: - Before assembly of both seal rings, wait for complete evaporation of water-spirit mixture. If necessary, blow out o-rings and seal housings with pressure air. Before assembling the slipring seals, apply a thin oil film to the seal faces 1, using a soaked chamois leather cloth. Take special care to do not apply oil to the elastomeric rings or to the housing bores. iasot1. Toremove the idler 1.1. Remove plug 2.7 and drain the oil into a suitable container. Knock out the roll pins 2.4, remove guides 2.1 and seals 2.5 from shaft 2.2. Pull the shaft from idler 2 1.2 Remove the lifetime seals 2.6 from guides 2.1 and idler wheel 2. Remove bushings 2.3 from idler wheel 2. Toinstall the idler 2.1 Press bushing 2.3 into the idler wheel 2. install lifetime seals 2.6 on idler wheel 2 and into guides 2.1 (see page. 777) Note : Lifetime seals come as a matched set and may not be interchanged! 2.2 Install O-ring 2.5 and guide 2.1 on shaft 2.2 and secure with roll pin 2.4. Coat the shaft with oil and slide through the idler whee! 2. install the remaining O-ring 2.5 and guide 2.1 on shaft 2.2. Secure with roll pin 2.4 3. Torefill the idler Oil level 3.1 Turn the idler until the oil filler hole is on top, add SAE 30 engine oil until the middle chamber is full 3.2 Carefully pressurize the middle chamber to press the oil into the side chambers, 3.3 Turn idler 2 until the filler hole is at a 45° angle, pointing upwards. Continue to add oil until oil runs out. 3.4 Install plug 2.7 and O-ring 2.8, using Loctite Benennung/Description/Oénomination Typ Model R912 Litronic Type LIEBHERR “Berco” Idler Abitrom partir de DatumeditionDate 101 BlatuPagerFeuille ee 12.26.011. Demontage 1.1 Todisassemble ten: sion unit Remove grease fitting 3.2 and pull piston 3.10 from cylinder 3.11, respec. spring tensioning bolt 4.2 for execution |. Pull seal 3.1 from piston 3.10. Remove wiper ring 3.3 from cylinder 3.11 1.2. Todisassemble spri ing tensioner For safety reasons, it is necessary to use a special holding tool and an hydraulic press to disassemble the spring tensioner. This disassembly should only be performed by the manufacturer of the spring tensioner. 2. Montage Install new seal 3.1, new wiper ring 3.3, complete piston 3.10 in cylinder 3.11 (respec. spring tensioning bolt 4.2) and install grease fitting 3.2 with new seal ring 3.4. ROIZLCS — 402/105 485/201 R912HD = 496/201 R9I2HD-S — 380/105 4481/2001 Model Dimension | Springpreload | max.pressure | Spring | gp ecution Type / Serial number aa» Pv Pmax. travel R900 368/101 R902LC 364/101 R9I2LC 346/101 4172001 R912 Std 416/ 101 345mm 14000 kp 25600 kp 45mm ' 482 /2001 RON2Std-S 476/101 483 /2001 ROIZEW 379/101 4484/2001 Ro12HD-st. 387/105 | 487mm 17000 kp 33000kp 60mm 0 R922HD-SL 480/101 R932HD-S 381/101 R932HD-SL 365/101 R932 HD-SL-W 405/101 ROMZHD-S 382/101 | 520mm 19000 kp 32600kp 61mm MW R9AZHD-SL 366/101 ROMZHD-S 382/258 | 553mm 22000 kp 34100kp 61mm uM R94ZHD-SL 366/258 Roa2V 493/101 | 570mm 25000 kp 36500kp 65mm nm LIEBHERR Datum/EditionDDate 01.93 ‘enennung/Description/Dénomination Tension Unit ie. See page 12. Model a5 Model Sub group ind Abitrom/a partirde BlatvPagerFeuile 12.31.01Execution | 2 Idlecomplet 3 Grease cylinder 3.1 Seal 3.2 Grease fitting 3.3. Wiperring 3.4. Sealring 3.10 Piston 4 Spring tensioner a4 42 44 45 46 47 Spring Spring tensioning bolt Hex head screw Roll pin Spring retainer plate Spring retainer plate Traverse 123101Execution II 2 Idlecomplet 4.1. Spring 3 Grease cylinder 4.2. Spring tensioning bolt 3.1. Seat 4.4 Hexhead screw 3.2. Grease fitting 45. Roll pin 3.3 Wiperring 4.6 Spring retainer plate 3.4 Sealring 47 Spring retainer plate 3.10 Piston 5 Traverse 4 Spring tensioner ‘Benennung/Description/Dénomination tye See page 12. “Sub group index LIEBHERR Tension unit ‘Abrtrom partir de DatumEawioniDate BlattPaneifeuille 2.31.02 10.90Execution Ill 2 Idlecomplet 4.1. Spring 3 Grease cylinder 4.2 Spring tensioning bolt 3.1. Seal 4.4 Hexhead screw 3.2 Grease fitting 45. Roll pin 3.3 Wiperring 4.6 Spring retainer plate 3.4 Seal ring 4.7. Spring retainer plate 3.10 Piston 5 Traverse 4 Spring tensioner 3.11 3.10 3.3 44 42 47 44 1231021, Removal and installation of the complete tension unit [X™ When removing only the idler assembly 2 with grease tensioner 3 (tension spring 67 is not removed), proceed as described in subgroup 12.13, §3. 1.1. Removal 1.1.1 Remove the cover 4 from the side frame of the undercarriage. 1.1.2. Remove the cover 5 from the side frame. 1.1.3 Fit the grease gun with the special adapter hose and connect it to the grease fitting 59 of the grease cylinder 3 1.1.4 Pump grease into the cylinder 3 (overtension the chain) until the spring plate 68 is pushed away from the locking plates 6. 1.1.5. Loosen the screws 7 and remove the locking plates 6. AA Never loosen the screws 7 as long as the spring plate 68 stays on the locking plates 6 1.1.6. Disconnect the grease gun from the fitting 59. 1.1.7. Release the track tension and remove the chain, refer to § 4 in subgroup 12.13. 1.1.8. Pull the idler wheel assembly 2 complete with the grease tensioner 3, then the spring plate 68 and the tension spring 67 out of the side frame. Benennung/Description/Dénomination 7 LIEBHERR Heel See page no. 12. Tension unit Datum Edition 11.94 Date1.2. Installation 1.24 1.2.2 1.23 1.24 1.25 1.2.6 1.27 1.28 Insert tension spring 67 into the side frame and push it onto the centering tube. Slide the spring plate 68 into the side frame so that the springs lays on the centering shoulder of the plate. Push the idler assembly 2 complete with the grease tensioner 3 inside the side frame 62. Install the chain and insert the master pin (see subgroup 12.13, §5). Pump grease into the cylinder 3 (overtension the chain) until the spring plate 68 passes beyond the openings 5 and the locking plates 6 can be installed. Install the locking plates and torque the screws 7. isconnect the grease gun from the fitting 58. Unscrew the grease fitting 59 and let grease escape from the grease cylinder to adjust the correct chain tension (see also § 5 in subgroup 12.13). 2. To disassemble tension unit Remove grease ing 59 and pull piston 3.10 from cylinder 3.11 Pull seal 3.1 from piston 3.10. Remove wiper ring 3.3 from cylinder 3.11. 3. To assemble tension unit Install new seal 3.1, new wiper ring 3.3, push complete piston 3.10 in cylinder 3.11 and install grease fitting 59 with new seal ring 60. 2 Idler assembly, complete 59 Grease fitting 3 Hydr. grease tensioner 60 Seal 3.1. Seal 62 Side frame with gear carrier 3.3. Wiperring 67 Tension spring 3.10. Piston 68 Spring plate 3.11. Housing 4 Cover 5 Cover 6 Locking plate 7 Hex head screw 12.32.014, Technical data Model o1 {reelenght Type / Serial number L, (mm) Pretensioned | Pretension tengheL, (mm) | force (kN) Spring travel Alm) R900 R902 +3001 R912 3001 100 537 481 169 75 58 R922 3001 100 537 481 169 ry 58 R932 3001 100 sv | ara 0 | 70 | se R942 3001 100 an zo | 6 | s Grease tensioner in welded execution Jenennung/Description: mination Tye. LIEBHERR | Sores eciPtondénominas Hose See page 12. Tension Unit Edition 04.96 Date Bat Fas, = 12.32.021. Todisassemble the track roller 1.1 Remove plug 5 and drain the oil into a suitable container. 1.2. Knock out roll pin 8 on both sides into track roller shaft. 10 and remove cover 7 from track roller shaft. Remove lifetime seals 9 from roller shell 1 and remove cover 7. 1.3 Remove seal 11 from the track roller shaft. Pull the track roller shaft 10 from the roller shell and remove roll pins8. Remove bushings 4 2. Toassemble the track roller . 2.1. Press bushings 4 into the roller shell. 2.2. Push the track roller shaft 10 into the roller shell and install O-rings 11 into the grooves on the track roller shaft. 2.3 Insert lifetime seals 9 into the roller shell and into cover 7. Install cover on track roller shaft 10 and secure with roll pins 8 2.4 Check the axial play and for easy movement. Apply about 6 bar (85 PSI) air pressure via the filler hole to check the roller for leaks 3. Torefill the track roller 3.1 Turn the idler until the oil filler hole is on top, add SAE 30 engine oil until the middle chamber is full 3.2 Carefully pressurize the middle chamber to press the oil into the side chambers. 3.3. Turn the track roller 1 until the filler hole is at a 45° angle, pointing upwards. Continue to add oil until oil runs out. Oil level 3.4. Install plug 5, using Loctite, Benennung/Descniption/Dénomination Meese See page 12. on Mode! si groupindex” Track Roller TAbtroma par de 101 Datumiediion/Date DiaturagerFeuille 10.90 12.41.01Roller shell 8 Bushing 9 Plug 10 O-ring " Cover Roll pin Lifetime seal Track roller shaft O-ring1. To disassemble the carrier roller 1.1. Remove plug 13 and drain the oil into a suitable container. 1.2. Release the snap ring 10 and pull off flange 9. Remove lifetime seals 8 from flange and roller shell 1, remove O-ring 11 1.3. Mount the complete carrier roller with cover 12 up in a vice. 1.4 Remove screws 16, cover 12 and O-ring Remove screws 4 and spacer 6 1.5. Pull the complete roller shell 1 from carrier roller shaft 3 . Pull the inner bearing race 7 from carrier roller shaft 3, Press outer bearing races 7 from roller shell 2. Toassemble the cartier roller 2.1 Press the outer bearing race 7 into roller shell 1. Press the inner bearing race 7 on carrier roller shaft 3. 2.2. Install roller shell on carrier roller shaft. Press the inner bearing race 7 on the carrier roller shaft. 2.3. Mount spacer 6 with screws 4 on carrier roller shaft 3. Insert cover 12 with O-ring 15 and tighten with screws 16. 2.4 Install lifetime seals 8 in roller shell 1 and in cover 9 Pull O-ring 11 on carrier roller shaft and press cover onto the shaft. Install snap ring 10. 2.5. Check the axial play and for easy movement. Apply about 6 bar (85 PSI) air pressure via the oil filler hole and check for leaks. 3. To refill the carrier roller 3.1 With the filler hole up, add SAE 30 oil until the upper edge of screw 4. Add oil until the proper level is reached, 3.2. Install plug 13, using Loctite and install with O-ring 14 in cover 12 BenennungiDescriptionDénomination Wye, See page 12. LIEBHERR : Type “Sv atovp nen Carrier Roller ‘Abtroma part de Datumiedor/Date 101 BlatPagerfeuile 10.90 12.46.01Roller shell Shaft Hex head screw Spacer Tapered rolter bearing Lifetime seal Cover Snap ring O-ring Cover Plug Oring O-ring Hex head screw