Service Manual

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 Service Manual

Content
6 Frame and crawler device ....................................................................................... 1

61 Frame ................................................................................................................. 1

611 Profile ........................................................................................................... 1

62 Balance weight .................................................................................................. 1

63 Frame, bottom car body .................................................................................. 2

631 Idler .............................................................................................................. 3

632 Sprocket gear ............................................................................................... 8

633 Crawler ....................................................................................................... 10

634 Track roller ................................................................................................. 12

635 External spring parts; tensioning gear ....................................................... 13

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 Service Manual

6 Frame and crawler

device
61 Frame
611 Profile
Dismantlement of superstructure
Attention. Weight of superstructure: 1.5-2 tons,
excluding balance weight and excavating device.
1. Dismantle the excavating device.
2. Disconnect tightening bolts, sealing cover,
hydraulic oil tube, discharge tube and one servo
hydraulic oil tube of the central passage from the
Figure 6-1 central passage.
Attention. Tie up the tubes. Block each disconnected
tube and pipeline port.
3. Dismantle bolts used for installing external bearing
sleeve of pivoted loop (A).
4. Dismantle the cab, balance weight and protective
device. Tie the superstructure with a steel cable, and lift
it to a certain height with a crane to straighten the steel
cable.
5. Slightly lift the superstructure first, and then lift
and move it after confirming the surrounding is safe.
Figure 6-2
Installation of superstructure
1. Tie up the tubes connecting to the central passage
together, and place them vertically.
2. Add threaded glue to threaded hole of bolts and
rotary support.
3. Lift the superstructure and install it to the rotary
support.
Attention. Lower the superstructure and make the
rotary pinion and the rotary gear ring connect
together. Refer to the torque table for relevant
tightening. Make cross tightening of corresponding
bolts one by one.
4. Connect the tube, tightening bolts of the central
passage and sealing covers which are disconnected at
Figure 6-3 the time of dismantlement.

62 Balance weight
Removal of balance weight

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The balance weight is heavy. To lift the balance
weight, please use good identified cables with
enough load rate and length.
1. Place the machine on flat, solid and horizontal
ground without any barrier or disturbance.
2. Lower the working device to the ground
completely.
3. Ensure that the safety locking operating lever is
firmly placed in the locking position.
4. After fastening the lifting bolts, connect the lifting
steel cable or sling able to bear the balance weight to
Figure 6-4 the lifting point correctly.
5. Dismantle bolts connected with the overall.
6. Fully lifted the balance weight, making the stop pin
bear no load.
7. Place the dismantled balance weight on appropriate
rack.
Installation of balance weight
Slightly lift the balance weight, and continue the
installation after confirming that it is in safe and
horizontal position.
1. Place the machine on flat, solid and horizontal
ground without any barrier or disturbance. And place
the working device on the ground completely.
2. Ensure that the safety locking operating lever is
firmly placed in the locking position.
Figure 6-5 3. Connect the lifting steel cable or sling able to bear
the balance weight to the lifting point correctly, and lift
it to proper installation position.
4. Slowly lower the balance weight to installation
surface of rear upper structure. Align with the bolts
hole. Insert lock plate and gasket, and tighten the bolts.
Lower the balance weight to installation surface in the
rear of the superstructure.
Attention. Add thread glue to the screw thread.

63 Frame, bottom car body

Explanation of chassis/base plate
The chassis is composed of idler, track roller, sprocket
wheel, driving wheel, crawler and bottom structure.

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Figure 6-6
1 Crawler 2 Driving wheel 3 Sprocket wheel 4 Track roller 5 Idler 6 Bottom structure

631 Idler
Idler explanation

Figure 6-7 Idler

1-Idler 2-External support 3-Shaft 4-Shaft sleeve 5-Pin 6-Floating oil seal 7-Interior support
8-O-ring 9-plug 10-Support assembly 11-Spring 12-Oil cylinder assembly 13-Piston 14-Slotted nut
15-Cotter pin 16-U-shape seal ring 17-Scrapper seal 18-Gasket 19-Check valve assembly 20-Bolt
21-Spring washer

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Figure 6-8

Serial Inspection Remedial

Standard size Maintenance limit
No. item measure
External
1 diameter of 338 —
flange
External
diameter of
2 300 298.5
rippled
surface
Make
Depth of
2-1 19 26 fastening
thread
welding or
Width of
3 40 34 replacement
flange
Total width
4 of rippled 90 —
surface
Width of
5 rippled 25 31
surface
Allowable error Interval
Interval Standard
Standard Repair
between the size Crankshaft Hole Replace
6 size limit
shaft and liner
-0.010 +0.04
liner 40 1.4
-0.035 -0.01
Interval
between the +0.15 +0.25 Replace
7 44 —
idler and the +0.10 0 liner
liner
Table 6-2 Wear limit
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Measure rippled surface and flange wear
1. Clean the rippled (a) flange (b) surface of the idler.
2. Place a ruler on the flange (b) surface horizontally.
Use depth meter (e) to measure the depth (2-1) between
the flange (b) surface and the rippled surface (a).
3. Measure for 3 times, and take the average value.
Measure the right and the left alternatively. If necessary,
make maintenance or replacement.

Figure 6-9
Flange
1. Clean measuring surface of idler.
2. Use vernier caliper to measure the flange width
between (c) and (d).
3. Measure for 3 times, and take the average value.
Measure the right and the left alternatively. If necessary,
make maintenance or replacement.

Figure 6-10
Dismantlement of idler
1. Dismantle the bolts, and dismantle the spring sets.
2. Dismantle the bolts, and discharge the oil.
Attention. Discharge the engine oil to a container.

Figure 6-11
3. Put the pin clamp (d) on the pin (7), and beat the
clamp slightly with a hammer to knock out the pin.

Figure 6-12

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4. Put the idler (1) on the idler’s back-up block (f),
and put the shaft dismantling clamp(g) on shaft (2) and
use the clamp to knock the shaft out.

Figure 6-13
5. Put the idler (1) on the idler’s back-up block (f),
and put the liner dismantling clamp (e) and (h) on the
liner (4), and beat the clamp slightly to knock the liner
out.
6. Dismantle the floating seal ring (5) and the O-ring
(6) respectively from idler (1) and support (3).
7. Dismantle O-ring (9) from shaft (2).
8. Confirm that the sealing surface of the sealing
gasket (5) has no damage or rust.

Figure 6-14
9. Confirm that all wears of idler (1) are within the
allowable scope.
10. Confirm that all wears of shaft (2) or liner (4) are
with the allowable scope.

Figure 6-15
Assembly of idler
1. Put liner (4) on idler (1); use clamp (e) and (h), and
hold-down clamp (a) to install it well.

Figure 6-16

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2. Install O-ring (9) to shaft (2).
3. Smear a layer of lubricating grease on inner side of
support (3), install shaft (2) and insert the spring pin
(7). Under such condition, take care not to damage the
O-ring (9).
4. Insert the floating seal ring (5) and O-ring (6) into
the support and idler (1) respectively.

Figure 6-17
5. Install shaft (2) to idler (1). Smear a layer of engine
oil to the contact surface of the floating seal ring (5).
6. Install support (3) and its floating seal ring (5) and
O-ring (6)。

Figure 6-18
7. Use a hammer (k) to insert the pin (7).
8. Execute one pressure leakage test before filling the
oil.
Connect one pressure adjustment air pipe to the
oil-filling valve, and then immerse the components into
water completely.
When the pressure is 2 ~ 3 kgf/cm2, bubble cannot be
generated within 15 seconds.
Figure 6-19
9. Fill engine oil EO30-CD (j).
Attention. Engine oil volume: 50-70 cc
10. Install plug (8) and Teflon tape (L), and then
tighten completely.
11. Confirm that there is no oil leakage around the
sealing components (5, 6) and plug (8).
12. Assemble the idler components and crawler spring.
Figure 6-20 After the assembly, manually confirm that the idler
could rotate despite of resistance. (More than 10 times).
13. Terminal interval must be between 0.1 and 0.85
mm.

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Replace a front idler
1. Dismantle the crawler.
2. Use a ripping bar to push the idler assembly out of
the crawler frame.

Figure 6-21
3. Install a lifting bolt to the tension spring assembly
of the crawler.
4. Use a lifting equipment to dismantle the idler and
the tension spring assembly of the crawler.

Figure 6-22
5. Support it to a working table. Dismantle the bolts
connecting the idler and the tension spring assembly of
the crawler. Replace the idler unit and install the whole
assembly.

Figure 6-23
Attention. When installing the bolts, please use
thread fastening glue on the bolts thread.
6. Install crawler.

Figure 6-24

632 Sprocket gear

Wear measurement of chain wheel

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Figure 6-25

Remedial
Symbol Item Wear limit
measure
A Sprocket teeth profile wear limit 4
Width of chain Standard value 36±0.5 Replace
B
wheel Allowable value 33
Number of teeth 23 —

Measure sprocket teeth profile

1. Clean the sprocket teeth.
2. Align P1, P2 and P3 of wear measuring meter (1)
of sprocket teeth and wear line (3) of sprocket teeth.

3. Measure 2 times, and take the average value.

4. If the measured value (A) exceeds the wear limit,
the chain wheel shall be replaced.

Figure 6-26
1 Measuring meter of sprocket teeth wear
2 Side boundary of new sprocket teeth
3 Wear line of sprocket teeth
A Wear of tooth profile
Measure width of sprocket teeth
1. Clean the sprocket teeth.
2. Use vernier caliper (A) to measure width of the
sprocket teeth.
3. Measure 2 times, and take the average value.
4. If the measured value (B) exceeds the wear limit,
the chain wheel shall be replaced.

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Figure 6-27
Replace a chain wheel
1. Dismantle the crawler.
2. Lift the chain wheel (4), in the method of inserting
a block (3) between the crawler frame (2) and
connecting rod (1).
3. Dismantle screw (5) of the rotary chain wheel (4),
and dismantle the chain wheel (4) carefully.
4. Install a new chain wheel, and tighten the bolts in
several steps.
Tightening torque of connecting bolts：220 ±15 Nm
5. Install the crawler.

Figure 6-28
1 Crawler connection 2 Crawler frame 3
Block 4 Chain wheel 5 Bolts

633 Crawler
Adjust tightness of the crawler
When straining the rubber crawler,
1. As shown in the diagram, under the state of
suspension of crawler, adjust the A size (the interval
between the peripheral end of the central track roller
and surface of crawler fin) to 20～25mm.

链轮侧 Chain Wheel Side

惰轮侧 Idle Pulley Side
接缝部有∞标 The joint is
记。 marked with ∞
Figure 6-29
2. Insert the grease gun into the grease nipple to fill
grease.
After the adjustment, please rotate the crawler for 1-2
circles to confirm the tension of the crawler.

Figure 6-30
When loosening the crawler,

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Notices: since there is high pressure in the oil
cylinder, therefore, if the oil cylinder jet nozzle is
loosened excessively or quickly, the jet nozzle may
fly or high-pressure oil grease within the oil cylinder
will be sprayed, causing dangers. Therefore, do not
face close to the jet nozzle, and avoid the body from
front side of the jet nozzle, and then loosen the jet
nozzle slowly.
If cobblestone and other things are contained in the
chain wheel, firstly eliminate them and then conduct the
operation.
1 Insert the socket spanner into the root of the grease
fitting, and then slowly rotate 3-4 circles to loosen the
oil nozzle.
2. If there is grease flowing out of the thread, then
make it conduct non-load rotation under the suspension
state of the crawler, and then further loosen the jet
nozzle.
3. After the adjustment, use socket spanner and other
tools to tighten the hexagon bolt of the oil nozzle.
Important matters:
1. If ptotic amount of the crawler is 35 mm, please
adjust again.
2. In the 30th hour after use, please confirm tension of
the crawler and adjust again, and confirm the tension
every 50 hours in the following period, and conduct
essential adjustment.
3. If the crawler is excessively tightened, it will
accelerate wear of the rubber crawler.
If it is excessively loose, it will result in bad chain
wheel mesh, accelerate wear of rubber crawler, and
cause the rubber crawler to fall down.
4. After the operation, please clean the rubber crawler,
and do not lay the rubber crawler aside with soil on it.
5. If soil enters the rubber crawler or the crawler is
excessively tightened at the time of operation, please
use movable arm, bucket rod and bucket to make the
rubber crawler on single side suspend in the air in turn,
and make it rotate without load so as to eliminate the
soil.

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Replace a carrier roller:
Dismantlement
1. Place the machine in the maintenance position, a
flat surface having enough space to roll out the crawler.
2. Discharge the lubricating grease through tightening
the lubricating grease mouth on the oil cylinder, thus
tension of the crawler could be reduced. Put a piece of
cardboard below the lubricating grease mouth to receive
Figure 6-31 the discharged lubricating grease. After loosening the
crawler, please tighten the lubricating grease mouth.
Attention. Do not loosen the valve for more than
1circle. If it is loosened more than 2 circles, the valve
and lubricating grease are quite likely to be ejected
under great force.
3. Use a lifting device to lift the crawler away from
the top idler wheel. Add tension of the crawler, and
place a block between the crawler chain and the lower
structure. Lower the crawler to be above the block.

Figure 6-32
4. Dismantle the bolts of top idler wheel on bracket of
top idler wheel.

Figure 6-33
Installation
5. Replace old top idler wheel with new ones.
Dismantle the block, and align the connecting rod
center of the crawler with the top idler wheel.
Tighten the bracket bolts to stipulated torque: 113±10
Nm
Figure 6-34
Attention. Coat thread glue to the installation bolts.
6. Through the lubricating grease pumped into the
lubricating grease mouth on the tension oil cylinder, the
crawler may be loosened or tightened.
7. Make the tension distribute evenly in the method of
operate the crawling times in both directions.

Figure 6-35

634 Track roller

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Dismantlement of rack roller
1. Loosen the crawler tension, and lift the machine to
be about 300 mm high from the ground, as shown in the
diagram.
2. Place a wedge under the bottom idler wheel, and
then loosen installation bolts of four idler wheels.
3. Dismantle the bolts and pull out the bottom idler
wheel.

Figure 6-36
Installation of rack roller
1. Find out oil plug in front of the machine.
2. Coat thread glue to installation bolts of bottom
roller.
3. Calibrate the thread hole on the chassis and bottom
idler wheel (1), and fasten the bolts temporarily with a
small spanner.
Figure 6-37
Attention. If there is any abnormal condition, such
as sensing that the bolt resistance is excessively
large, dismantle the bolts and check the thread. Do
not use tightening spanner to fasten temporarily.
4. Use a torque at 267 ±25Nm

Figure 6-38

635 External spring parts; tensioning gear

Dismantlement of spring sets
1. Install the scrapper seal, support ring and U-shape
sealing ring into the oil cylinder (5) in turn.
2. Install shaft (1) in oil cylinder.
3. Place spring (6) in the oil cylinder (5) with shaft (1)
and piston installed.

Figure 6-39

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4. Fill the oil cylinder with lubricating grease, and
release the air from the oil cylinder.
5. Install guide seat and check valve.
Replace an assembly of crawler tension spring
crawler (tensioner)
1. Dismantle the crawler. Please refer to crawler chain
assembly.
2. Use a ripping bar to push the idler assembly out of
Figure 6-40 the crawler frame.
3. Install a lifting bolt to crawler tension spring
assembly.
4. Use a lifting equipment to dismantle the idler and
crawler tension spring assembly.
5. Support it on a working table. Dismantle the bolts
connecting the idler and the crawler tension spring unit,
and install the whole assembly.
Tightening torque of connecting bolts: 265 ±29Nm

Figure 6-41
Attention. When installing the connecting bolts,
please use thread fastening glue on the bolts thread.
Attention. Confirm that the protuberance of the
crawler’s tension spring piston end is in the crawler
frame hole.

Figure 6-42

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