Service Manual Hydraulic Excavator Track Components SUB GROUP INDEX R900 B-R 944 12.51 Technical data . . 9008 / 6001 > 12.52 Technical data 5 se. R904/ 6001+ 12.53 Technical data R914-R924/ 6001 > 12.54 Technical data . +. R934 /5001 > 12.55 Technicaldata ..... coer . R944 / 5001 > e 12.56 Wear of track components cee R900 B-R924/ 6001 > R934-R944 / 5001 > 12.60 Wear limits of track components B60 - D6C R900 B-R924/ 6001 R934 /5001 > 12.61 Wear limits of track components D7 - D6HD - B6- . R944 /5001 > 12.62 Removal and installation of track components .... R900.B-R924/ 6001 > R934-R944 / 5001 > 12.65 Slipring seal : seen R900 B-R924/ 6001 > R934-R944 / 5001 > e 12.76 Idler... . cece cee cesses R900 B-R924/ 6001 —> R934- R944 / 5001 > 12.81 Tension unit . . - R900B-R924/ 6001 > R934-R944 / 5001 12.91 Track roller R900 B-R924/ 6001 > R934-R944 / 5001 > 12.96 Carrierroller B60 Berco R900B-R924/ 6001 > R934 / 5001 > 12.97 Carrierroller D7 Intertrac R944 / 5001 > K 900 6 -R 924 / 6001 > LIEBHERR 12.50.00 R934-R944/ 5001 > Issue: 12/2001Service Manual Hydraulic Excavator Track components e Technical Data- Tightening Torques Machine R908 Type 664 (STD) Valid from Serial No. 6001 Chain Type B6OL Number of links 46 Distance between two pins mm 190 Pin diameter mm 38 Bushing diameter mm 60 Chain link @ eigne of erain tink mm 105 Track Pad Type B60 Form 3 grousers Height of grousers mm 28 Ground pressure in Nicm? with track pads 500 mm 5,0 600 mm 42 750 mm 3.4 Track Pads Bolts Thread Size M18x 1.5 Tightening Torque (nm) 580 @ Wrench size (mm) 27 Track Roller Type B60 Number of rollers per chain 7 Carrier Roller Type B60 Number of rollers per chain 2 LIEBHERR 12.51.01 R900B / 6001 > Issue : 12/2000Service Manual Hydraulic Excavator Track components Technical Data- Tightening Torques Machine R904 Type 668 (STD) 669(HD-SL) Valid from Serial No. 6001 6001 Chain Type B60 L (* D6C) BEOL Number of links 50 (* 44) 46 Distance between two pins mm | — 190(* 202.8) 190 diameter mm 38 (* 44,5) 38 \ Bushing diameter mm 60 (* 66,7) 60 Chain link e@ Height of chain link mm 105(* 121,4) 105 Track Pad Type 860 (* DEC) B60 Form 3 grousers 3 grousers Height of grousers mm 28 (* 26,5) 28 Ground pressure in N/cm2 with track pads 500 mm 43 54 600 mm 42 4s 750 mm 35 37 Track Pads Bolts Thread Size Mi8x1,5(*3/4")} 18x 1,5, Tightening Torque (Nm) 580(* 650) 580 @ Wench size (mm) 27(7 30) 7 Track Roller Type B6OL BeoL Number of rollers per chain 8 7 Carrier Roller Type B6OL BeOL Number of rollers per chain 2 2 * The track components D6C are for use in very hard conditions LIEBHERR 12.52.01 R904 / 6001 > Issue : 12 / 2000Service Manual Hydraulic Excavator Track components e Technical Data- Tightening Torques Machine R918 R924 Type 641 (STD) 640 (HD-SL) 642(HD-S) | 645(HD-SL) Valid from Serial No. 6001 6001 6001 6001 Chain Type B60 (* DEC) B60 (* DSC) Dec B60 (* DSC) Number of links 46 (* 44) 50(* 47) 44 51(* 47) Distance between two pins mm | 190 (* 202,8) 190 (* 202.8) 202.8 190 (* 202.8) Pin diameter mm 38 (" 44,5) 38 (* 44,5) 44,5 38 (* 44,5) Bushing diameter mm 60 (* 66,7) 60 (* 66,7) 66,7 60 (* 66,7) Chain link @ rteight of chain tink mm | 105(*121.4) 105(* 121.4) 1214 105 (* 121,4) Track Pad Type B60 (* D6C) 860 (* DEC) Dec 860 (* DEC) Form 3 grousers 3 grousers 3 grousers 3 grousers Height of grousers mm 28 (* 26,5) 28 (* 26,5) 265 28 (* 26,5) Ground pressure in N/cm2 with track pads 500 mm 58 _ 59 600 mm 49 46 6.0 750 mm 42 38 Track Pads Bolts Thread Size Mex 1,5 (*3/4")] M18x 1,5 (* 3/4") aia" | taxa, (*3/4") Tightening Torque (Nm) | 580(* 650) 580 (* 650) 650 580 (* 650) @ wench size (mm) 27(* 30) 27(* 30) 30 277 30) Track Roller Type 860 860 B60 860 Number of rollers per chain 7 8 7 8 Cartier Roller Type 860 B60 B60 860 Number of rollers per chain 2 2 2 2 * The track components D6C are for use in very hard conditions R914-R924/ 6001 > LIEBHERR 12.53.01 Issue : 127 2000Service Manual Hydraulic Excavator Track components e Technical Data- Tightening Torques Machine R934 Type 648 (HD-SL) 647(HD-S) 649 (EW) Valid from Serial No. 5001 001 5001 Chain Type B60 (* DEC) B60 (* DEC) B60(* DEC) Number of links 52 52 52 Distance between two pins mm] — 190(* 202.8) 190 (* 202.8) 190(* 202.8) Pin diameter mm} 38 (* 44,5) 38 (* 44,5) 38(* 44,5) Bushing diameter mm| _60(* 66,7) 60 (* 66,7) 60 (* 66,7) Chain link @ srcight ot chain tink mm} 105 (*121,4) 105 (*121,4) 105 ("121,4) Track Pad Type B60 (* DSC) B60 (* D6C) B60 (* DGC) Form 3 grousers 3 grousers 3 grousers Height of grousers mm} 28(* 26,5) 28 (* 26,5) 28 (* 26,5) Ground pressure in N/cm2 with track pads 500 mm 66 66 66 600 mm 5,6 5,6 5.6 750 mm 45 45 45 Track Pads Bolts Thread Size M20x1,5 (3/4") | M20%1,5 (3/4") | M20% 1,5 (3/4") Tightening Torque (Nm)| 800 (* 650) 800 (* 650) 800 (* 650) @ wrench size (mm) 27(* 30) 27(* 30) 27(* 30) Track Roller Type B60 B60 B60 Number of rollers per chain 9 9 9 Carrier Roller Type 860 B60 B60 Number of rollers per chain 2 2 2 * The track components D6C are for use in very hard conditions R934/5001 > LIEBHERR 12.54.01 Issue : 12 / 2000Service Manual Hydraulic Excavator Track components e Technical Data- Tightening Torques Machine Road Type 651 (HD-SL) 650 (HD-S) Valid from Serial No. 5001 5001 Chain Type D7 & BHD D7 & BHD Number of links 51 51 Distance between two pins mm 2028 202,8 Pin diameter mm 445 445 Bushing diameter mm 66,5 665 Chain link e Height of chain link mm 117.3 117.3 Track Pad Type D7} D7 &BGHD D7 & B6HD Form 3 grousers 3 grousers Height of grousers mm 265 26,5 Ground pressure in N/cm2 with track pads 500 mm 78 78 600 mm 66 6.6 750 mm 5,4 54 Track Pads Bolts Thread Size 3/4 3/4" Tightening Torque (Nm) 650 650 @ Weeren size (mm) 30 30 Track Roller Type 86 86 Number of rollers per chain 9 9 Carrier Roller Type b7/s611653_ | D7/ 5611653 serial no. 5131 | — serial no. 5131 0715615338 | D7/5615338 serial no. 5132— | serial no. 5132 Number of rollers per chain 2 2 R944 /5001 > LIEBHERR 12.55.01 Issue : 12/ 2000‘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: 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 Limi 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 asmall 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. 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 new component and the wear limit, see chart in sub group "Wear Lim e DIEP Note :Clean parts thoroughly before taking any measurements. Measurements should also be ith the measurement of the Example: Hn = Height - dimension of new component = 126 mm Hv = Maximum wear limit = 116 mm. H = Actuel measurement = 120 mm. 126-120 Degre of wear = — = 60% 126-116 Benennung/Description/Dénomination e@ LIEBHERR From Bepuis Page 12.56.01 Fetile Wear Datum edition cation 99.98Chain links — Pin Bushing 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 caliper at the point, which shows the greatest wear. 12.56.02Service Manual Hydraulic Excavator Track Components e Wear of Track Components Track pad Measure the track pad wear with a depth gauge or tape. 4 e Idler Measure the wear on the running surface of the idler with a depth gauge. a 5 e Track roller Measure the wear on the running surface of the track roller with a sliding caliper or outside caliper. R 900 B--R 924 / 6001 > LIEBHERR 12.56.03 R934-R 944 / 5001 > Issue : 12 / 2000Service Manual Hydraulic Excavator Track Components Wear of Track Components e Carrier roller Measure the wear on the running surface of the carrier roller with a sliding caliper or outside caliper. Se CCC 12.56.04 LIEBHERR Issue: 12/2000Service Manual Hydraulic Excavator Track Components e Wear Limits B60 & D6C B60 bec New Max Wear New MaxWeat timit Time mm inch) mm ine) en eh) sm Ginch) Sproket ww Ww Toothnew Tooth wear upto up to Ss tipoftooth | ” tip of tooth a—— Chain Link Hn Hy Hn Hy 105 97 1214 110 Pins Ln Ww Ln Ww 762 73 813 829 Bushing Dn Dv Dn bv © 58,7 47 66 37 ov. Dn R900 B -R 924 / 6001 > LIEBHERR 12.60.01 R934 -R944/5001 > Issue : 12 / 2000Service Manual Hydraulic Excavator Wear Limits B60 & D6C Track Components 860 Dec New Max wear New Max Wear limi Umit mmm inch) mmm ined) | mm (ined sm inh Track pad Hn Hv Hn Hy 28 125 39,5 1” idler Hn Hv Hn Hy tin We 7 25 31 Track roller Dn bv Dn bv 154 11 Carrier roller Dn Dv Dn Dv ” 120 108 ov Senn nse ss NN NNN AASNNNSSNNNNANNSNNNNSNNNNNSNS 12.60.02 LIEBHERR Issue : 12/2000Service Manual Hydraulic Excavator Track Components e Wear Limits D7 & D6HD - B6 D7 &D6HD B6 New Max Wear New Max Weat Timi imi rm (neh) rm inch) mm (inch) sm Cinch) Sproket a Toothnew Tooth wear : _ 0 up to we tip of tooth —— Chain Link hin bw 17 110 Pins i ia 813 829 Bushing ~ bv 66,5 57 Dv be R944 / 5001 > LIEBHERR 12.61.01 Issue : 12 / 2000Service Manual Hydraulic Excavator Track Components Wear Limits D7 & D6HD - B6 D7 &D6HD BG New Max Wear New Max Wear lit limit Track pad mm (inch) ‘mm (inch) ‘mm (inch) ‘mm (inch) Hn Hv Hn Hv 26,5 2 Idler Hn Hy Hn Hv =~ Track roller Dn Dv Dn Dv 168 145 Carrier roller up toserial number 5131 Dn bv Dn Dv 120 104 Dn Dv Dn Dv 170 455 12.61.02 LIEBHERR Issue : 12 / 200038 Track roller 39° Carrier roller 40 Track chain 41 Chain link 42. Master pin Service Manual Hydraulic Excavator Track Components 1 Idler assembly, complete 43 spacer 3 Hyde. grease tensioner 44 Bushing a Cover 45. Trackpad 5 Cover 50 Allen head screw 51 Square nut Jat niin 54 Hex head screw 56 Hex head screw Grease fitting “eo 60. Seal 62 Side frame with gear carer 63 Travel gear 67 Tension spring 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. Laycarrier 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 UE™ tensioner 3 is not described in this subgroup. Should the tension spring be removed also, so its pretension must be released as noticed in subgroup 12.82. § 1.1.2 to 1.1.6, prior to remove the chain, § 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 12.82. § 1.2.1 to 1.2.8. 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 12.76 for idler disassembly and assembly. See sub group 12.82 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. R900 B-R924 / 6001 > LIEBHERR 12.62.01 R934-R944/ 5001 > Issue : 02 / 2002Service Manual Hydraulic Excavator Track Components eee a \ CN = 3. To remove and to install the track rollers 3.17, 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 12.91 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. 4, To remove the complete track chain 4.1 Park the machine on flat and solid ground. Run the track until the master pin 42 is close to the lower third of the sprocket. Insert a wedge. For safety reasons.never open and remove a track chain unless having previously totaly released the AA pretension of the chain tensioning unit. The removal ofthe track chain and of the grease tensioner 3 while pretension spring 67 is still mounted is allowed only if the grease tensioner unit and the chain are both immediately reinstalled, during the _ present Axefinalavec Axe final avec maintenance operation. chambrage moletage 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. When adjusting the chain tension, keep your head clear of the access hole. The grease cylinder is under high pressure and the chain will sag. il TI ll A Warning : . Grease is under high pressure and might squirt out. Position de la chenille 43. The master pin can be differentiated from the regular ‘et des maillons pin by its chamfered edge. Note : DIE 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. ‘Sens de montage dela chenille Raise the machine and remove the track chain 12.62.02 LIEBHERR Issue : 02 / 2002e LIEBHERR 5. 6. Datur dition 99.98 Date 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 § 9 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 properly tensioned. The track chain tension is correct when the slack between both carrier roller is about 0.6" to 0.8" (15 to 20 mm), To check the chain slack - measure "X;" (fig. 2) , distance between running surface of carrier roller and top of sideframe. = measure "X2", distance between chain link and top of sideframe, = calculate chain slack X1 7X2". 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. BenennungiDescription/Dénomination Chain Removal, Repair, Installation Moser See page no. 12 Bb From Bepuis@© repr otdetecivecsin i 1 Chain link, complete a tT] 2 Chain link, complete ti 3 Bushing + D 4 Master pin A) rch cuts 5 Spacerring break | | 6 End segment 7.1. Remove the chain on torn chain link and lay it on the =F ground. Torch cut link, bushing and pin on the damaged chain 2 link segment. Remove the damaged parts. i 1 7.2. Torch cut the bushing A1 and grind the surface <— | smooth. i Torch cut holes into the remains of the master pin 28 Lk and knock the pin ends out ; ‘tobe ground of chain support ing pin removal torch eut holes Bshove Sor direction of pin removal 7.3. Install two end segments 6 without bushing 3 and a master pin 4 to chain link 2 To pressin the master pin, see § 9 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. Benennung/Description/Dénomination e LIEBHERR a Track chain Bemus favo» 99.98 Repair fae. 12.62.05 Fedllle8.1 Knock out the knurled master pin (see § 4.3) from the inside to the outside, using a tool as shown picture bellow. 8.2 Grooved master pin (see § 4.3) can be pressed (knocked) out in any direction. 9. Toinstall the master pin 9.1 Install spacer rings or lock rings and bushings into track chain ends and align chain ends. DEP 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. 9.2. 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 17 6296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 witha 1:1 mixture of water and spirit. Install stipring 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) 4 Rope Seal ring aunwne Benennung/Description/Dénomination e LIEBHERR Slipring seal Datum Edition 99.98. Date 7 Moaet Type Be from Depuis Bat Fedile 12.65.01Press the slipring seal into the housing. e 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 circurnference (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 mix- ture. If necessary, blow out o-rings and seal housings with pressure air. e 4. 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. 12.65.02Service Manual Hydraulic Excavator Track components e@ Idler wheel 1. Todisassemble 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 slipring seals 2.6 from guides 2.1 and idler wheel 2. Remove bushings 2.3 from idler wheel. 2° Idler 2.1 Guide 2.2 Shaft 2.3 Bushing 24 Rollpin 2.5 O-ring 2.6. Slipring seal 27 Plug 2.8 O-ring 2. Toassemble the idler 2.1 Press bushing 2.3 into the idler wheel 2. Install slipring seals 2.6 on idler wheel 2 and into guides 2.1 Note : Slipring 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 wheel 2. Install the remaining o-ring 2.5 and guide 2.1 on shaft 2.2 Secure with roll pin 2.4 R900 B-R924 / 6001 > R934-R 944 / 5001 > LIEBHERR 12.76.01 Issue :12/ 2000Service Manual Hydraulic Excavator Track Components Idler wheel 3. To refill the idler Cillevel > — 450 3.1. Turn the idler until the oil filler hole is on top, add oil until the middle chamber is full 3.2. Carefully pressurize the middle chamber to press the oil into the side chambers. 3.3. If necessary, continue to add oil until prescribed quantity is reached. 3.4 Install plug 2.7 and o-ring 2.8, using Loctite Idler wheel Oil quantity Oil quali Type quantity quality Berco B60 500 cm? SAE 90 - APIGLS IntertracD7 | _500em3 ‘SAE 90- API GLS 2 Idler 25. O-ring © 2.1 Guide 26 Slipring seal 2.2 Shaft 27 Plug 2.3 Bushing 28 O-ring 24 Roll pin SSS 12.76.02 LIEBHERR Issue : 12 / 20001. To disassemble 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 slipring seals 2.6 from guides 2.1 and idler wheel 2. Remove bushings 2.3 from idler wheel. 2 Idler 2.1 Guide 22 Shaft 2.3. Bushing 24 Rollpin 25° O-ring 2.6. Slipring seal 27 Plug 28 O-ring 2. To assemble the idler 2.1. Press bushing 2.3 into the idler whee! 2. Install slipring seals 2.6 on idler whee! 2 and into guides 2.1 Note : Slipring 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 wheel 2. Install the remaining o-ring 2.5 and guide 2.1 on shaft 2.2. Secure with roll pin 2.4 Benennung/Description/Denomination @ wesHerr From Depuis Idler “Berco" Datum Edition 99.98. Date3. To refill the idler B41 3 33 3 = 24 22 23 24 Turn the idler until the oil filler hole ison top, add SAE 40 engine oil until the middle chamber is full Carefully pressurize the middle chamber to press +the oil into the side chambers Turn idler 2 until the filler hole is at a 45° angle, pointing upwards. Continue to add oil until oil runs out Install plug 2.7 and o-ring 28, using Loctite. Idler 25 O-ring Guide 2.6. Slipring seal Shaft 27 Plug Bushing 28 O-ring Roll pin Oil level 12.76.021, Removal and installation of the complete tension unit [XP when removing only the idler assembly 2 with grease tensioner 3 (tension spring 67 is not WW removed), proceed as described in subgroup 12.62, §3. Removal 4.1.1. Remove the cover 4 from the side frame of the undercarriage, 4.1.2. 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. 1.4.5 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. 4.1.7 Release the track tension and remove the chain, refer to § 4 in subgroup 12.62. 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. © crewHeErR | reer Deron raven Bee ‘ A Ab Datum Tension unit Bepuis Eatin 99,98 Bare ca 8 page = 12.81.0112 Installation 124 1.2.2 1.23 1.2.4 125 1.26 1.2.7 1.2.8 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 12.62, §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. Mount the locking plates so that the machined face (also marked with an arrow) shows in direction idler wheel Disconnect the grease gun from the fitting 59. Unscrew the grease fitting 59 and let grease escape from the grease cylinder to adjust the correct chain tension (see also § 5 in subgroup 12.62). 2. To disassemble tension unit Remove grease fitting 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 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. Idler assembly, complete 6 Locking plate Hydr. grease tensioner 7 Hex head screw Seal 59 Grease fitting Wiper ring 60 Seal Piston 62. Side frame with gear carrier Housing 67 Tension spring Cover 68 Spring plate Cover 12.21.024, Technical data Model @1 free lenght Pretensioned Pretension ‘Spring travel es e Type / Serial number (mm) | 1, (mm) | tenghtt,(mm) | force (kN) | AL(mm) | (mm) R900B 6001 100 442 372 140 56 49 R904 6001 100 442 372 140 56 49 wow eon pw | spe Ca R924 6001 481 169 75 58 Benennung/Description/Dénomination e LIEBHERR Tension Unit Datum Edition 99,98 Date 12.81.03Service Manual Hydraulic Excavator Track components e Track roller 1. To disassemble 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 pins 8. Remove bushings 4 2. To assemble 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 Oo 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. To refill the track roller 3.1. Turn the idler until the oil filler hole is on top, add oil, quality and quantity as per shedule below. Oil level 3.2 Carefully pressurize the middle chamber to press the oil into the side chambers, 3.3. Turn the track roller 1 until the prescribed quantity is reached, On B60 rollers the correct quantity is reached with the filler hole at a 45° angle, pointing upwards, 3.4 Install plug 5, using Loctite. et Type Oil quantity Oil quality Te Era Intertrac D7 600 cm3 1260 - Panolin Biotrac R900B -R924 / 6001 —» LIEBHERR 12.91.01 R934-R944/5001 > Issue : 12 / 2000Service Manual Hydraulic Excavator Track Components Track roller 1 Rollershel! 8 Rollpin 4 Bushing 9 Stipring seal 5 Plug 10 Track roller shaft 6 O-ring 11 O-ring 7 Cover 4 12.91.02 LIEBHERR Issue : 12/2000Service Manual Hydraulic Excavator Track components e Carrier roller B60 - Berco 1. To disassemble the carrier roller 1.1. Remove plug 3 and drain the oil into a suitable container. 1.2. Mount the complete carrier roller with end cover 8 up ina vice. Release the snap ring 10 and pull off flange 9, Remove lifetime seals 8 from flange and roller shell 1 1.3. Remove screws 11, cover 8 and o-ring 10 1.4 Remove screws 12 and disk 9 1.5. Pull the complete roller shell 1 from carrier roller shaft 3. Pull the lifetime seal 5 from roller shaft 1 and from end cover 7. Press outer bushings 4 from roller shell 1 The shaft 2 is pressed into the end cover 7 and cannot disassemble. 2. Toassemble the carrier roller @ —_21- Press the bushings 4 into roller shell 1. Install lifetime seals 5 in roller shell 1 and in cover 7 2.2. Install roller shell 1 on carrier roller shaft 2. 2.3. Mount disk 9 with screws 12 on carrier roller shaft 2. Insert cover 8 with o-ring 10 and tighten with screws 11 Tightening torque for hex head screws 11=59 Nm, Tightening torque for hex head screws 12 = 63 Nm Use Loctite no. 242 2.4 Check the axial play and for easy movement and check for leaks. 3. Torefill the carrier roller 3.1. With the filler hole up, add oil, quality and quantity as per shedule below. 3.2 Install plug 3, using Loctite and install in roller shell 1 @ f caricrroter [ot cuantiy nae Oil quality Berco B60 225 cme 202 cm? Agip Rota LSX 75W30 + 23 cm’ Agip Rocol ASO R 90-140HT R900 8-924 / 6001 > LIEBHERR 12.96.01 R934/5001 Issue : 12/2000Service Manual Hydraulic Excavator Track Components Carrier roller B60 - Berco r) Roller shell Shaft Plug Bushing Lifetime seal End cover, Cover Disk O-ring Hex head screw Hex head screw Oil Agip Rotra | | 12.96.02 LIEBHERR Issue : 12/2000Service Manual Hydraulic Excavator Track components A. Carrier roller D7 - Intertrac / 5615338 1. To disassemble the carrier roller 1.1. Remove the lower screw 11 and drain the oil into a suitable container. 1.2 Mount the complete carrier roller with end cover 8 up in a vice, 1.3. Remove screws 11, cover 8 and sealing ring 10. 1.4 Remove screws 12 and disk 9 1.5. Pull the complete roller body 1 from carrier roller shaft 2, Pull the slipring seal 5 from roller body 1 and from end part 7. DEP Pressing out the bushings 4 from roller body 1 is generally very uneasy The shaft 2is pressed into the end part 7 and cannot disassemble. @ ® reassemble the caseroter 2.1 To install the bushings 4 into roller body 1, cool them down in liquid nitrogen or use a press. Notice: The bushing 4b must be pushed in to the top, i. e, the collar of the bushing must be in contact with the roller body 1 The bushing 4a must be pushed in so to be even with the bottom of the slipring seal receptacle. 2.2 Install slipring seals 5 in roller body 1 and in end part 7. For installation procedure, refer to sub group 12.65 Install roller body 1 on carrier roller shaft 2 23° Mount disk 9 with screws 12 on carrier roller shaft 2 Insert cover 8 with sealing ring 10 and tighten with screws 11 (only install two screws). Tightening torque for hex head screws 11=80 Nm, Tightening torque for hex head screws 12=80 Nm Use Loctite no. 242 to install screws 11 and 12. 2.4 Check the axial play of the roller (easy movement) 3. Torefill the carrier roller 3.1 With the filler hole up, add 0,6 |. SAE 90 - API GL5 via the bore of a screw 11 3.2. Install the screw 11, using Loctite and tighten to prescribed torque. 4, To check the correct oil quantity in a roller This check can be performed only while removing the roller and draining the oil from the roller into a container. LIEBHERR 12.97.01 5132» R944 /5132 Issue : 12/2000Service Manual Hydraulic Excavator Carrier roller D7 - Intertrac / 5615338 10. 11/13 12. 4b 4a SN NNN AAAS SHAAN NNNSSSNNNNNNNNSNANNNNNN Issue : 12/2000 12.97.02 LIEBHERR Track Components Roller body Shaft Bushing Bushing Slipring seal End part Cover Disk Sealing ring Hex head screw Hex head screw Seal washer Oil SAE 90Service Manual Hydraulic Excavator Track components B. Carrier roller D7 - Intertrac / 5611653 Notice: This carrier roller is no more available. When ordering spare parts, this roller may be replaced by the roller D7 / 5615338, see page no. 12.97.01 1. To disassemble the carrier roller 1.1 Remove the lower screw 14 and drain the oil into a suitable container (cover 8 down), 1.2. Mount the complete carrier roller with end cover 8 up ina vice. 1.3 Release the snap ring 11, and pull off cover 8 and o-ring 10. 1.4 Remove screws 12 and disk 9 . 1.5. Pull the complete roller body 1 from carrier roller shaft 2. Pull the slipring seal 5 from roller body 1 and from end part 7. [IEP Pressing out the bushings 4 from roller body 1 is generally not possible. e The shaft 2 is pressed into the end part 7 and cannot disassemble. 2. Toassemble the carrier roller 2.1. To install the bushings 4 into roller body 1 2.2. Install slipring seals 5 in roller body 1 and in end part 7 For installation procedure, refer to sub group 12.65. Install roller body 1 on carrier roller shaft 2. 2.3 Mount disk 9 with screws 12 on carrier roller shaft 2 (tightening torque of screws 12= 80 Nm). Install the o-ring 10 to the cover 8. Install the cover in the carrier body and secure it with the snap ring 11 2.4 Check the axial play of the roller (easy movement) 3. To refill the carrier roller 3.1. With the filler hole up, add 0,2 |. SAE 90 via the bore of a screw 14. @ 32 Install the screw 14, using Loctite 4, To check the correct oil quantity in a roller This check can be performed only while removing the roller and draining the oil from the roller into a container. SSSNONNNNNNNNNN HHH HUHHSSNHHNIHIISNNNNNNNNNNNNNNNNNNNNSS NNN ESSA SHEENA R944 / 5001 > 5131 LIEBHERR 12.97.03 Issue: 12/2000Roller body 1 2 Shaft 4 Bushing 5 Slipring seal 7 Endpart 8 Cover 9 Disk 10 O-ring 11 Snap ring 12. Allen head screw 14 Oilfilling screw e * — OIISAE9O a 9 4 1 5 7 2 Z = IW [ yy ea Vy Y Wit LA S LA SG LIEBHERR Issue : 12/2000