anleitung hinowa fahrwerk englisch

TABLE OF CONTENTS

MANUFACTURER’S STATEMENT Page 32

INTRODUCTION Page 33

TRACKED UNDERCARRIAGE IDENTIFICATION DATA Page 34

TERMINOLOGY Page 35

SAFETY INFORMATION Page 36

PICTOGRAMS Page 37

SAFETY AND ACCIDENT PREVENTION

1. GENERAL PRECAUTIONS Page 38

1.1 Read these instructions with care Page 381.2 Unauthorized modifications Page 381.3 Safety valves Page 38

OPERATING PRECAUTIONS

2. INSTALLATION PRECAUTIONS Page 38

2.1 Remove paint before welding Page 382.2 Avoid welding near to pressurized pipelines Page 392.3 Avoid contact with high pressure fluids Page 392.4 Structural connection of the undercarriage Page 392.5 Hydraulic connections to the tracked undercarriage Page 402.6 Procedure for the first undercarriage’s starting Page 412.7 Installing tracked undercarriages with hydraulic widening Page 42

3. TECHNICAL DATA AND CONNECTION DIAGRAMS Page 43

OOOOPPPP EEEE RRRR AAAATTTT IIII NNNN GGGG AAAA NNNN DDDD MMMM AAAA IIII NNNN TTTT EEEE NNNN AAAA NNNN CCCC EEEE MMMM AAAA NNNN UUUU AAAA LLLL SERIES PT TRACKED UNDERCARRIAGES

Pagina 30

4. PRECAUTIONS TO ENACT WHEN STARTING TO USE THE UNDERCARRIAGE INSTALLED Page 44

4.1 Work with your machine in conditions of safety Page 44 4.2 Parking the machine Page 444.3 Working in streams Page 444.4 Use of rubber tracks Page 454.5 Rubber track tension Page 454.6 Steel track tension Page 464.7 Use of hydraulic widening Page 46

5. MAINTENANCE Page 47

5.1 Correct inspection and maintenance procedures Page 475.2 Maintenance of drive geared motors Page 48

5.2.1 Checking the oil level in the reduction unit Page 485.2.2 Replacement of oil in the reduction unit Page 485.2.3 Choice of type of reduction unit oil Page 485.2.4 Hydraulic circuit oil Page 49

5.3 Rubber track maintenance Page 495.3.1 Checking track tension Page 495.3.2 Track loosening/tightening procedures Page 505.3.3 Checking the rubber tracks Page 515.3.4 Replacement of rubber tracks Page 53

5.4 Steel track maintenance Page 555.4.1 Checking track tension Page 555.4.2 Checking pin and bush wear Page 55

5.5 Checking sprocket wear Page 565.6 Checking bolt tightness Page 575.7 Grease points Page 57

APPENDIX 1 Page 88

APPENDIX 2 Page150

Pagina 31


MANUFACTURER’S STATEMENT

The tracked undercarriage product is an incomplete part of a machineand cannot be used directly in a self-contained and independent man-ner because it is lacking the tool, implement or other instrument finali-zed for a specific application. It consequently does not fall within therange of application of Machine Directive Chap. I, Art. I and does notneed to comply with the provisions stipulated in Chap. I, Art. 5 andChap. II, Art. 8. Its destination, as indicated in attachment II, point B(see Chap.I, Art. 4, point 2), is to be incorporated in a machine or to beassembled with other machines in order to compose a machine wherethe Machine Directive is applied. Given the above,

The HINOWA S.p.A. CompanyVia Fontana - 37054 NOGARA (VR) - ITALYTel. 0442/539100 - Fax 0442/539075

STATES

that it is forbidden to put HINOWA series PT and series PT-ALLtracked undercarriages in service before the machine in which theyhave been incorporated has been stated to comply with the provisionsof MACHINE DIRECTIVE (EEC directive 98/37) and subsequent modi-fications.


Pagina 32

INTRODUCTION

• This manual is made to permit customers to properly employ Hinowa trackedundercarriages on the machines that they have designed and where they intendinstalling the undercarriages.

• Read this manual with care before making mechanical and hydraulic connectionsbetween the tracked undercarriage and your machine.

• Continuous improvements in Hinowa products may create illustrations in themanual that do not match exactly with the parts that are used.

• No matter where you live or work do not hesitate to contact our engineeringdepartment which is at your full disposal for all useful information and, in case, tofurnish you with any genuine spare parts you may require: these are the onlyspare parts that guarantee quality and perfect interchangeability.

• It is necessary, to correctly request spare parts, that every order be preceded bythe serial n° of the tracked undercarriage.

• The technical data and connection layouts illustrated in Chapter 3 refer to stan-dard versions and the main special versions of Hinowa tracked undercarriages.Consult with our engineering department regarding special versions not contem-plated in this manual.

Pagina 33


TRACKED UNDERCARRIAGE IDENTIFICATION DATA

The drawing shows the position of the serial n° on the tracked undercarriage.

CLASSIFICATION


Pagina 34

Matricola520202BH197

520202BH197

PT20 G L / ***

Type of undercarriage

G: rubber tracksA: steel tracks

C: short type undercarriage lengthL: long type undercarriage length

Undercarriage version

Example:

Example:

TERMINOLOGY

The following names for the various assembly components are given to make iteasier to understand safety warnings and operation and maintenance instructionsfor the tracked undercarriage.

1 Track2 Track-stretching wheel3 Track-stretching wheel support4 Spring5 Track-stretching cylinder6 Valve7 Truck8 Motor protection cover9 Cover10 Reduction gear drive11 Sprocket12 Roller13 Track guide

Pagina 35


111

2

3

4

5

6

7

8

9

10

12

13

SAFETY INFORMATION

To prevent accidents you must carefully read and comply with all the precautionsand warnings contained in this manual before starting to work and before perfor-ming any maintenance.

This is the safety warning signal. Pay attentionwhen you see this symbol on the tracked under-carriage or in this manual since there is potentialdanger for personal injury.Comply with recommended instructions and pre-cautions.

The words DANGER and WARNING are usedtogether with the safety warning symbol.The word DANGER indicates potential dangersituations that can quite probably cause severeinjury or death if the danger is not avoided andcan also cause serious damage to the undercar-riage.The word WARNING indicates potential dangersituations which, if they are not avoided, cancause minor harm or injury to the operator. Thisword can also be used only to indicate dangerswhich can cause damage to the tracked under-carriage.

This message is used in situations where failureto take due measures can shorten the workinglife of the tracked undercarriage.


Pagina 36

IMPORTANTE

PERICOLO

ATTENZIONE

DANGER

WARNING

IMPORTANT

PICTOGRAMS

CONSULT THE MANUAL

Read the contents of this manual with care before connecting the tracked undercar-riage to your machine or before performing maintenance.

DIRECTION OF MOVEMENT

Make sure that forward movement by the trackedundercarriage is always with the drive geared motorslocated in the rear part of the undercarriage.

DIRECTION OF ROTATION OF DRIVE GEARED MOTORS

The pictogram shows an example of direction of the reduction gear drive for theconnection of your machine to the hydraulic circuit. The rotation directions for eachmodel are indicated in the diagrams of this booklet (see chapt. 3).

Pagina 37


SAFETY AND ACCIDENT PREVENTION

1 GENERAL PRECAUTIONS

1.1 Read these instructions with care

Enact all possible safety regulations, precautions and instructions when installingand/or performing maintenance on the tracked undercarriage.

1.2 Unauthorized modifications

It is strictly forbidden to bring modifications to the tracked undercarriage whichcould compromise proper operation and safety. The Hinowa company is notresponsible for any injury or damage caused by unauthorized modifications.

1.3 Safety valves

It is strictly forbidden to modify or tamper with hydraulic geared motor control andsafety valves whenever these are present. The Hinowa company is not responsi-ble for damage to persons or property, to your machine or to tracked undercarriagecomponents when standard settings for hydraulic valves are tampered with.

OPERATING PRECAUTIONS

2 INSTALLATION PRECAUTIONS

2.1 Remove paint before welding

Whenever you weld your machine to the frame of thetracked undercarriage you must first remove the paint inthe welding zone. Heated paint in the welding zone, if itis not removed, can generate toxic fumes. Avoid poten-tially toxic fumes and dusts.Avoid inhaling dust if you sand or grind the paint to remo-ve it. Wear an approved breathing set.If you use solvents or similar substances for paint remo-


Pagina 38

PERICOLO

PERICOLO

DANGER

DANGER

PERICOLODANGER

val be sure to eliminate this substance with soap and water before welding the baresection.Remove solvent or paint removal containers from the welding zone. Wait at least15 minutes before starting to weld to make sure fumes disperse.Perform the entire job in a well-ventilated work zone.Dispose of paint and solvent in an environmentally-safe manner according to cur-rent local regulations.

2.2 Avoid welding near to pressurized pipelines

Never heat by welding near pressurized hydraulic pipeli-nes or other flammable materials. Excessive heatingnear to pressurized hydraulic pipelines can cut them andgenerate flammable spatter with consequent severeburns for yourself and for other nearby persons. Installheat-resistant screens if you cannot avoid welding nearto pressurized pipelines.

2.3 Avoid contact with high pressure fluids

Fluids which exit under high pressures can penetrate intothe skin and cause very severe injuries.Avoid this danger by eliminating pressures before con-necting hydraulic pipelines. Tighten all connections wellbefore pressurizing the circuit.When inspecting the system and looking for leaks use apiece of cardboard and protect the hands with glovesand the eyes with safety goggles. Consult a doctorimmediately if an accident happens. Fluid injected intothe skin must be surgically removed within a few hourssince otherwise it can cause serious diseases.

2.4 Structural connectin of the undercarriage

Weld the structures of the undercarriage such as cross-members and side framesas near as possible to the reinforcement points, as indicated in the picture. Do not weld outside the sketched area, in order to prevent structural failures of theside frames and/or of components such as rollers, wheels, reduction gear drives.

Pagina 39


NOTE: The undercarriages that are sup-plied without cross-members areassembled through a junctionreinforcement between the platefixing the reduction gear drive’s sup-port and the main structure. Suchreinforcement is ONLY little welded(see picture). Before using theundercarriage, weld this reinforce-ment by fixing it also to the machi-ne’s structure.

2.5 Hydraulic connections to the tracked undercarriage

Always make sure you connect the hydraulic components of the tracked undercar-riage to your machine’s system according to the diagrams given in this manual.Pay attention to the type of undercarriage you have purchased because series PTundercarriage connection circuits are not all the same since various types ofhydraulic geared motors are used.It is important to check, when connecting the hydraulic geared motors, what thegeared motor’s direction of rotation corresponds to forward movement by the machi-ne when the geared motors are positioned in the rear part of the undercarriage.Some versions of tracked undercarriages may be furnished without the drive controlvalve flanged to the geared motors. In this case it is your task to install the valve,complying with the diagrams indicated in this manual. If you choose to use in-linedrive control valves then the connection between hydraulic geared motors and val-


Pagina 40

ves must be made using pipelines of appropriate dimensions for the workinghydraulic pressure and the peak pressure.Adjustment of the drive control valves and the max. pressure valves that control thecircuit, must be according to the settings indicated in the technical data card.

We remind you that the function of the control valves that are flanged to themotor is to prevent pressure peaks due to the inertial force and to allow con-trolling the undercarriage when driving on a slope. The installer is responsi-ble for mounting under his machine a PT undercarriage which is not equip-ped with control valves.In addition to this, we remind you that a hydraulic motor not equipped withnegative brake always leaks, which can cause movements of the machine ifparked on a slope.

IMPORTANT

The standard Hinowa undercarriages are usually installed on open circuits(see attachments). For different applications (for example closed circuits)please contact the Hinowa engineers.For the hydraulic connections, in particular the drain connections, please refer towhat stated in the specific schemes for each model.

2.6 Procedure for the first undercarriage’s starting

Before putting the undercarriage into service, do what follows: 1) Oil fluxing: max. contamination allowed: absolute class NAS 9 1638 or 18/18 SO

DIS 44062) Operate the reduction gear drive idle for about 5 minutes (machine lifted) at low

load and in one direction, in order to ensure a good cleaning of the system and aperfect filling.

Pagina 41


UM

S01

024

PERICOLO

2.7 Installing tracked undercarriages with hydraulic widening

Be careful not to ruin the antifriction slide guides placed inside the central structureif you need to install your machine on a tracked undercarriage with hydraulic wide-ning. Perform the following operations before welding your structure to the centralframe of the tracked undercarriage:

1) support the central part of the trackedundercarriage with blocks that lift thetracks off the ground and permit you towork in safe and secure conditions;

2) remove the pins from the hydraulicwidening cylinder stems;

3) pull out the 2 longitudinal members ofthe tracked undercarriage that are nolonger connected to the central structu-re;


Pagina 42

ATTENZIONEWARNING

4) unscrew the sixteen screws from the4 protective covers (a) and removethe 4 slide guides (b) located insideeach cover.

At this point you can proceed to weld your machine onto the central frame of thetracked undercarriage. Be sure to make intermittent welds that do not deform thecentral structure of the undercarriage. Subsequently, to reassemble the undercar-riage, repeat procedures for removing the longitudinal members from the centralstructure in reverse order. Start by repositioning the slide guides inside the centralstructure. Close them with the 4 protective covers. Insert the 2 longitudinal mem-bers in the central structure and clamp everything together by inserting the pins ofthe widening cylinder stems into their seats on the longitudinal members.

3 TECHNICAL DATA AND CONNECTION DIAGRAMS

Be extremely careful to make sure you comply with thehydraulic connection diagram for the type of trackedundercarriage that you use, as indicated below.First discover, as indicated in the manual, the exact input positions (A and B) for oilto the geared motor, the drainage connection and the two speed drive control(when furnished). A and B inlets of drive geared motors equipped with negativebrakes and/or translation control valves must always be connected to open centersections of hydraulic distributors.The Hinowa company will not be responsible for damage to persons and/or pro-perty caused by failure to comply with this rule.For the max. performances of your undercarriage, please always refer to what sta-ted in the “technical data” section of the drawing attached to the order confirmationof the undercarriage you have purchased. In particular the maximum stated operating slope refers to maximum technicalperformance data expressed for the tracked undercarriage and may not coincidewith the actual slopes that can be climbed by your machine while still remaining in asituation of safety.

Pagina 43


PERICOLO

a

b

DANGER

4 PRECAUTIONS TO ENACT WHEN STARTING TO USE THE UNDERCARRIA-GE INSTALLED

4.1 Work with your machine in conditions of safety

Make sure that the work site terrain is strong enough tofirmly support your machine. When you work near anexcavation position the tracked undercarriage with itsdrive geared motors to the rear. Be careful not to tipover when working on frozen terrain. A rise in tempe-rature can soften the terrain and make it unstable.

4.2 Parking the machine

Park your machine on solid and flat terrain with enoughroom to permit inspection. If you cannot do this andmust park on a slope then insert safety wedges belowthe tracks.

4.3 Working in streams

If the bottom is level and the water flows slowly thenthe tracked undercarriage can work in water up to thetop surface of the track pads. Be very careful aboutthe type of bottom of the stream since if it is very softthe machine may slowly sink down.


Pagina 44

PERICOLODANGER

PERICOLODANGER

4.4 Use of rubber tracks

Avoid the following situations when working with an undercarriage with rubbertracks:1. Do not maneuver on hard, stony and uneven surfaces such as streambed rock,

gravel, etc.2. Don’t keep the rubber tracks lying in the direct sun light for more than 3 months

time. 3. Avoid improper steering maneuvers on asphalt and cement since these cause

excess pad wear. Avoid working on asphalt surfaces when their temperatureexceeds 60°C since this causes both excess pad wear and damage to theasphalt surface.

4. Maneuvers with a loose track on an irregular surface can cause the pad to deta-ch and/or damage to the rubber track.

5. Rubber tracks are designed only for use on soft terrain, not for hard and abrasivesurfaces such as sand, stone, minerals, etc. Use of rubber tracks on these sur-faces can cause premature wear and deformation.

6. Avoid contact between sharp concrete edges etc. and the rubber track.7. Fuels or synthetic oils must never come in contact with the rubber track. If this

does happen then they must immediately be cleaned.8. Avoid using rubber tracks in marine and seaside environments since saline air or

salt in general corrode adhesion between rubber and metal inner core.

4.5 Rubber track tension

When the tracked undercarriage is lifted the rubber track must deflect 10÷15 mm asindicated in the illustration. When tension decreases it must be re-tightened to pre-vent the machine from losing its tracks because they are too loose (see paragraph5.3.2).

Pagina 45


10 ÷ 15 mm

ATTENZIONEWARNING

4.6 Steel track tension

The chain tension must always be correct. This is correct when, in the top part ofthe track, the longest section of unsupported chain deflects about 20 mm.

The chain must be re-tightened when deflection exceeds this value (see paragraph5.3.2).

4.7 Use of hydraulic widening (only for tracked undercarriages with hydrau-lic widening)

Before widening or narrowing the tracks using thehydraulic widening mechanism first lift the machine offthe ground to prevent friction between tracks and ter-rain, caused by the weight of the machine, from cau-sing damage to the undercarriage structure.


Pagina 46

IMPORTANTEIMPORTANT

5. MAINTENANCE

5.1 Correct inspection and maintenance procedures

• Learn how to perform correct maintenance on the tracked undercarriage and howto perform the inspection procedures described in this manual.

• Always perform maintenance on a solid and level surface.• Never grease or lubricate or perform maintenance on the machine while it is in

motion.• Solidly support the undercarriage if it needs to be lifted up for maintenance.• Use great care when maintaining the hydraulic system since oil is very hot when

the machine has just finished working.• Circuits are under high pressures not only when working but also when work is •

Keep all components properly installed and in good condition.• Immediately repair all damage and replace worn or broken parts.• Remove any build-ups of grease, oil or debris.• Check for oil leaks and/or damaged hydraulic hoses.• Use recommended lubricants. Do not mix different brands of lubricants.• Use only original Hinowa spare parts.• Keep undercarriage widening cylinder and track-stretcher grease nipples clean.• Intervals for periodic maintenance are indicated for normal work conditions. If the

tracked undercarriage is used in severe work conditions then maintenance mustbe performed at shorter intervals.

• Dispose of lubricants in an ecologically safe way. Thoughtless disposal of lubri-cants can damage the environment. Become familiar with local anti-pollutionlaws and regulations before disposing of lubricants.

• Use suitable containers when draining lubricants. Do not use beverage or foodcontainers that might tempt someone to drink from them. Never pour lubricantson the ground or in a canal, pond or watercourse. Comply with current environ-mental protection regulations when disposing of lubricants.

Pagina 47


5.2 Maintenance of drive geared motors

5.2.1 Checking the oil level in the reduction unit

Every 100 hours check the oil level in the reductionunit gearbox. Usually on the external side of thereduction gear drive there are two plugs: A1 and Bor A2 and B, depending on the type of reductiongear drive, as indicated in the picture. Stop thereduction gear drive when the plug B is in theupper position. Remove the plugs A1 or A2 andcheck that the oil level is aligned with them. If thiswas not the case, re-fill from B using A1 and A2 asa level check.

5.2.2 Replacement of oil in the reduction unit

Replace the oil after the first 100 operating hoursand then at subsequent 1000 hour intervals.Proceed as follows to perform the replacement:- stop the reduction gear drive when the B plug is

in the lower position, as indicated in the picture;- remove both plugs, A1 and B or A2 and B and let

the oil come out completely;- then put the reduction gear drive as indicated in

5.2.1 and fill using the B plug and A1 or A2 as alevel check

Avoid using oils with different characteristics andbrands.

5.2.3 Choice of type of reduction unit oil

We recommend, for reduction units, using gear oils with E.P. additives and viscosityclass according to ISO VG 150 or SAE 80W/90.When temperature variation ranges are very high we recommend using syntheticoils with E.P. properties and minimum 165 viscosity index and viscosity class VG150 and VG 220.


Pagina 48

B

A2

A1

VG100 VG150 VG320 VG150-200

-20°C +5°C +5°C +40°C +30°C +50°C -30°C +65°CIV 95min IV 95min IV 95min IV 165min

ISO 3448

A1A2

B

IMPORTANTEIMPORTANT

In all cases select oils that are not subject to rapid aging at their operating tempera-tures. Continuous duty temperature must not exceed 90°C.

5.2.4 Hydraulic circuit oil

Use mineral oil with anti-wear additives such as HLP (DIN 51524) or HM (ISO6743/4) and viscosity according to ISO VG46. Recommended filtration must be 10m absolute or b10Ú75.

5.3 Rubber track maintenance

5.3.1 Checking track tension

Stop your machine on a flat and solid surface. Lift it in safe conditions and put sta-ble supports under the undercarriage frame to properly support it. Measure distan-ce A at the central roller of the undercarriage from the bottom of the roller to therigid inside surface of the rubber track. Track tension is normal if dimension A isbetween 10 and 15 mm.Adjust tension as described in the following paragraph if track tension does notcomply with these dimensions (loose or too tight).

Pagina 49


A

5.3.2 Track loosening/tightening procedures

1. Remove the screws and take off cover 3 to access the adjustment system.2. To loosen the track turn valve 1 counter-clockwise no more than 1 turn. One

turn of valve 1 is sufficient for loosening the track.3. If grease does not start to drain out then slowly rotate the track.4. When you have obtained correct track tension then turn valve 1 clockwise and

tighten it. Clean all traces of extruded grease.5. To stretch the track connect a grease gun to grease nipple 2 and add grease

until track tension falls within specified values.

The grease contained in the hydraulic track is pressurized. Never loosen greasevalve 1 for more than one turn. If the valve is loosened too much you risk expellinggrease under pressure and possible serious injury to the machine operator. Alsonever loosen grease nipple 2.Remove gravel or mud when they are jammed between the sprocket and the tracklink before loosening the track.

It is not normal for the track to remain too tight after turning valve 1 counter-clockwi-se or for it to remain loose after introducing grease into grease nipple 2. Never tryto remove the tracks or disassemble the track-stretching cylinder since pressure ofthe grease inside the track tension cylinder is extremely dangerous.


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PERICOLO

520202BH197

3

1

2

PERICOLO

DANGER

DANGER

5.3.3 Checking the rubber tracks

The structure of the rubber track is shown in fig. A. The steel cables and metal coreare embedded in the rubber. The carved profiles function to give stability on softterrain. They are made on the bottom part that rests on the ground. The wheel gui-des, located on the inside of the track, prevent the track from sliding off the guiderollers.

Causes of damage

A) Breakage of steel cables

Excess track tension can cause steel cables to break in the following conditions:- when stones or foreign matter accumulate between the track and the undercarria-

ge frame;- when the track slips off its guide system;- in case of great friction such as rapid changes in direction.

B) Wear and breakage of metal cores

Excess track tension can cause the metal cores to bend or break just like the steelcables as stated above. Other causes include:- improper contact between track and sprocket;- rotation of internal rollers;- operation on sandy terrain.

Pagina 51


Fig. A

CORDED'ACCIAIO

SCULTURA

LATO RUOTA

FORO RUOTADENTATA

ANIMA METALLICA

CARVEDPROFILE

STEELCABLES

SPROCKETHOLE

WHEEL SIDEMETAL CORE

C) Detachment of metal cores

The metal core functions as an adhesive forthe rubber, especially between the core itselfand the steel cables. Detachment can becaused by excess track tension or by cablebreakage for the following reasons:- metal cores have been rolled by a worn

sprocket as indicated in the figure. Whenthis type of wear or abrasion is encounte-red the sprocket must be replaced as soonas possible.

Rubber abrasion resulting on surfaces where guide rollers work incorrectly is illu-strated in photo 9 (see appendix 2).This type of breakage, like that indicated in paragraphs A-B-C, leads to total functio-nal inefficiency and the track must be replaced.

D) Fatigue cracks and abrasion

1. Cracks at the base of the carved profiles are caused by fatigue due to rubberbending caused by the sprocket or the track-stretching wheel as indicated inphoto 4 (see appendix).

2.Cracks and bends on the edge of the rubber are cau-sed by maneuvering the track on concrete edges andcurbs.

3. Cracks and abrasions in the rubber on the guide roller paths are caused by com-pression fatigue of the rubber due to the weight of the wheel combined with ope-ration on sandy terrain or repeated sudden changes in direction. These are illu-strated in photos 6-8-9 (see appendix).

4. Abrasion of the carved profile may be caused, in particular, by rotation on con-crete or gravel surfaces or hard surfaces (see photo 7 in the appendix 2).

Damage as indicated in paragraph D, points 1, 2 and 3, is not fatal for the track andthe track can continue to work even in the presence of gradual and progressivedamage.Continuation of the damage indicated at point 3 leads to exposure of the metalcores. If this exposure extends for more than half of the circumference of the trackthen it is time to replace the track, even though it can still be used.


Pagina 52

PARTI USURATE

CRACK

WORN PARTS

E) Cracks caused by external factors

Cracks on the outside surface of the track (the surface in contact with the terrain)are often due to contact with gravel, sharp stones, sharp materials such as sheetmetal, nails, glass. These cause cuts as illustrated in photo 10 (see appendix 2).This type of damage is inevitable given the very nature of rubber itself, although theentity depends on how the track is used.Cracks on the inside surface of the circumference and on the edge of the rubberare caused by contact between track and the undercarriage structure or with sharpconcrete edges. These are indicated in photos 12 and 13 (see appendix).Even though it does not look very good the track can still be subjected to severeworking conditions.

5.3.4 Replacement of rubber tracks

The grease contained in the hydraulic cylinder is underpressure. Never loosen grease valve 1 for more than 1turn. If the valve is loosened too much then pressurizedgrease may exit and cause severe injury to the machineoperator. Never loosen grease nipple 2. Remove gravel or mud when they are jammed betweenthe sprocket and the track link before loosening the track.

Removing the rubber track

1. Stop your machine on a solid and level surface. Lift it up and support it in safeconditions as described in paragraph 5.3.1.

2. Remove the screws and take off cover 3 that gives access to the adjustmentsystem.

Pagina 53


1

2

520202BH197

3

PERICOLODANGER

3. To loosen a track slowly unscrew valve 1 counter-clockwise for no more than 1turn. One turn of valve 1 is sufficient for loosening the track.

4. If grease does not start to drain out then slowly rotate the track.

5. Insert 3 steel tubes (4) inside the track inthe space between the rollers. Rotate thedriving gear in reverse (5) so that the steeltubes proceed with the track and arebetween the track tension wheel and thetrack tensioner. Exercise force (6)sideways to slide the track and and relea-se it from the track-stretching wheel.

Installing the rubber track

1. Make sure that you are always in safe conditions withthe machine lifted so to perform the operation fortrack installing.

2. Check that the grease contained in the hydraulic cylinder has been removed.

3. Mesh the track links in the sprocket andplace the other end of the track on thetrack-stretching wheel.

4. Rotate the driving gear in reverse (7) andpull the track soles inside the frame (8)

5. Position the track using a steel tube andturn the driving gear again.

6. Make sure track links mesh correctly inthe sprocket and in the track-stretchingwheel.

7. Adjust track tension (see paragraph 5.3.2 - Track loosening procedures).

8. Set the tracked undercarriage on the ground.


Pagina 54

PERICOLO

8

7

520202BH197

4

5

6

520202BH197

DANGER

5.4 Steel track maintenance

5.4.1 Checking track tension

Stop your machine on solid and level terrain. Check that there is a 15÷20 mmdeflection on the top part of the track in the longest section of unsupported track.

If track tension is not within the above-specified dimensions then follow the proce-dures described in paragraph 5.3.2 to tighten or loosen tension.

5.4.2 Checking pin and bush wear

This type of wear can prevail compared to wear of other chain parts when work isdone on terrain that is too abrasive. Replace these units when the length of 4 chainlinks exceeds the nominal value by more than 2%. Check the number on the track’sreference reported in the order confirmation of your undercarriage.

Pagina 55


5.5 Checking sprocket wear

Measuring wear on sprocket and driving gear teeth is one of the most difficult mea-surements to be done.In normal operating conditions, in fact, wear takes place so that no trace of preexi-sting tooth remains to furnish a clear reference for determining tooth wear. As aconsequence precise data cannot be furnished and it is always necessary, to makeany type of judgement, to refer to a new sprocket or wheel of the same type. As ageneral rule a sprocket should be replaced when wear reaches the illustrated limits.Since wear is never uniform you must always consider the point where wear isgreatest.Calculate, in order to determine the maximum admissible wear for each sprocket ordriving gear, that this maximum wear must not exceed 3% of the pitch of the chainthat meshes with the gear itself.


Pagina 56

5.6 Checking bolt tightness

Check the tightness of bolts and components which may become loose dependingon the tracked undercarriage’s type of use.Pay particular attention to frame components such as track-stretching wheels, drivegeared motors, driving gears and guide rollers. Make sure these are adequatelytightened according to the following table.

Threading diameter Pitch kgmmm. mm.

6 1 1,3 ± 0,158 1,25 3,2 ± 0,3

10 1,5 6,5 ± 0,612 1,75 11 ± 114 2 17,5 ± 216 2 27 ± 318 2,5 37 ± 420 2,5 53 ± 622 2,5 73 ± 824 3 92 ± 1027 3 135 ± 1530 3,5 184 ± 20

5.7 Grease points (only for tracked undercarriages with hydraulicwidening only)

Perform this maintenance procedure every 100 work hours, using lithium greasewith EP2 consistency.• Clean grease nipples before connecting them to the

grease gun.• Clean all grease that exits out after greasing.• Lubrication should be at more frequent intervals if the

tracked undercarriage is used in particularly severeoperating conditions.

The grease points for the tracked undercarriage widening cylinder pins are illustra-ted below.

Pagina 57


IMPORTANTEIMPORTANT

1

2

PT8

Pagina 92

1

RR

Impianto idraulico sottocarro cingolato PT8 con freno di stazionamento versione fissaHydraulic diagram of the PT8 with brake, fixed width version

Hydraulische Anlage Unterwagen PT8 mit Bremse fixe Breite

1

R R

Impianto idraulico sottocarro cingolato PT8 con freno di stazionamento versione allargabileHydraulic diagram of the PT8 with brake, variable width version

Hydraulische Anlage Unterwagen PT8 mit Bremse mit Spurverbreiterung

APPENDICE 1 - APPENDIX 1 - ANHANG 1

Pagina 93

Motoriduttore sottocarro serie PT8 senza freno

C1C2

1

1M

10x1

olio

n∞

2 a

90∞

tapp

i di c

aric

o e

scar

ico

fillin

g an

d dr

aini

ngn∞

2 pl

ugs

at 9

0∞ fo

r oil

A^N

d^N

3/8"

G 1

9 TP

I pro

f. 14

mm

B^N

d^N

3/8"

G 1

9 TP

I pro

f. 14

mm

usur

a tip

o H

LP (

DIN

515

26)

o H

M (

ISO

674

3/4)

olio

idra

ulic

o a

base

min

eral

e co

n ad

ditiv

i ant

iO

lio p

er c

ircui

to id

raul

ico:

wea

r ty

pe H

LP (

DIN

515

26)

or H

M (

ISO

674

3/4)

min

eral

hyd

raul

ic o

il w

ith a

dditi

ve a

gain

stO

il fo

r hy

drau

lic tr

ansm

issi

on:

R

A B

or S

AE

80W

/90

or M

IL-L

-210

5C o

r AP

I GL

5.U

se o

il w

ith E

.P. c

hara

cter

istc

s ac

cord

ing

follo

win

g no

rmes

: IS

O V

G 1

50op

pure

SA

E 8

0W/9

0, c

orris

pond

ente

a M

IL-L

-210

5C o

ppur

e A

PI G

L 5.

Usa

re o

lio c

on c

arat

teris

tiche

E.P

. ave

nte

le s

egue

nti s

peci

fiche

: IS

O V

G 1

50

=

=

AB

Oil q

uanti

tyQu

antita

' olio

ridutt

ore

0,5

ltQ

uest

o di

segn

o Ë

di p

ropr

iet�

del

la H

INO

WA

S.r.

l. e

non

puÚ

ess

ere

ripro

dotto

nË

tras

mes

so a

terz

i sen

za a

utor

izza

zion

e

SC

ALA

DE

NO

MIN

AZI

ON

E

PO

S

MA

T.V

alor

i ang

olar

i +/-

1∞

Dim

ensi

one

linea

re js

13

Foro

H13

Alb

ero

h13

TOLL

ER

AN

ZE G

EN

ER

ALI

R=0

.5

Rag

gi n

on q

uota

ti

1*45∞

Sm

ussi

non

quo

tati

NO

TA B

EN

E

MODIFICHE

Via

Fon

tana

370

54 N

OG

AR

A (V

R)

TEL.

(044

2)53

9100

-539

106

FAX

.(044

2)53

9075

PE

SO

DA

TA

DA

TA

PG

R.

Q.T

A

UTE

.

123

TRA

TTA

ME

NTO

PG

R.

DA

TAU

TE.

DA

TA

CO

DIC

E

Sottocarri Serie PT8 con freno

Pagina 94

1

R

A B

R

A B

Impianto idraulico sottocarro cingolato PT8 con freno di stazionamento versione allargabile

A

Impianto idraulico sottocarro cingolato PT8 con freno di stazionamento versione fissa

1

BA

R

B

R

Pagina 95

Motoriduttore sottocarro serie PT8 con freno

C1C2

1

1M

10x1

olio

n∞

2 a

90∞

tapp

i di c

aric

o e

scar

ico

fillin

g an

d dr

aini

ngn∞

2 pl

ugs

at 9

0∞ fo

r oil

A^N

d^N

3/8"

G 1

9 TP

I pro

f. 14

mm

B^N

d^N

3/8"

G 1

9 TP

I pro

f. 14

mm

=

=

R

A BPr

essio

ne m

inima

aper

tura

Min.

relea

se pr

essu

re

DATI

TECN

ICI F

RENO

- BRA

KE TE

CHNI

CAL D

ATA

Copp

ia fre

nante

Brak

ing to

rque

AB

Usa

re o

lio c

on c

arat

teris

tiche

E.P

. ave

nte

le s

egue

nti s

peci

fiche

: IS

O V

G 1

50op

pure

SA

E 8

0W/9

0, c

orris

pond

ente

a M

IL-L

-210

5C o

ppur

e A

PI G

L 5.

Use

oil

with

E.P

. cha

ract

eris

tcs

acco

rdin

g fo

llow

ing

norm

es: I

SO

VG

150

or S

AE

80W

/90

or M

IL-L

-210

5C o

r AP

I GL

5.

min

eral

hyd

raul

ic o

il w

ith a

dditi

ve a

gain

stw

ear

type

HLP

(D

IN 5

1526

) or

HM

(IS

O 6

743/

4)

olio

idra

ulic

o a

base

min

eral

e co

n ad

ditiv

i ant

ius

ura

tipo

HLP

(D

IN 5

1526

) o

HM

(IS

O 6

743/

4)

Oil

for

hydr

aulic

tran

smis

sion

:

Olio

per

circ

uito

idra

ulic

o:

20 d

aNm

|5%

28 b

ar 0,5

ltQu

antita

' olio

Oil q

uanti

tyQ

uest

o di

segn

o Ë

di p

ropr

iet�

del

la H

INO

WA

S.r.

l. e

non

puÚ

ess

ere

ripro

dotto

nË

tras

mes

so a

terz

i sen

za a

utor

izza

zion

e

SC

ALA

DE

NO

MIN

AZI

ON

E

PO

S

MA

T.V

alor

i ang

olar

i +/-

1∞

Dim

ensi

one

linea

re js

13

Foro

H13

Alb

ero

h13

TOLL

ER

AN

ZE G

EN

ER

ALI

R=0

.5

Rag

gi n

on q

uota

ti

1*45∞

Sm

ussi

non

quo

tati

NO

TA B

EN

E

MODIFICHE

Via

Fon

tana

370

54 N

OG

AR

A (V

R)

TEL.

(044

2)53

9100

-539

106

FAX

.(044

2)53

9075

PE

SO

DA

TA

DA

TA

PG

R.

Q.T

A

UTE

.

123

TRA

TTA

ME

NTO

PG

R.

DA

TAU

TE.

DA

TA

CO

DIC

E

TRA

SM

ITA

L 70

0C1H

+MG

65 C

F

APPENDICE - APPENDIX - ANHANG 2

Pagina 150

FOTO - PHOTO N. 1

CORDE D'ACCIAIO CHESONO STATE TAGLIATE

STEEL CORDS WHICHHAVE BEEN CUT

ZERRISSENEDRAHTSEILE

FOTO - PHOTO N. 2

ABRASIONE E ROTTURADELLE ANIME IN ACCIAIO

ABRASION AND BREAKAGE OF COREMETALS

ABNÜTZUNG UNDVERSCHLEISSDER METALLKERNE

FOTO - PHOTO N. 3

SEPARAZIONE DELL'ANIMA IN ACCIAIO

SEPARATION OFCORE METAL

ABLÖSUNG DERMETALLKERNE

Pagina 151

FOTO - PHOTO N. 4

ROTTURA DELLA BASESCULTURA CAUSATA DALLOSFORZO DI PIEGAMENTO(CURVATURA) DELLA GOMMA

CRACK ON LUG FOOTCAUSED BY BENDINGFATIGUE OF THE RUBBER

DEFEKTE PROFILE ALSFOLGE EXTREMERRICHTUNGSÄNDERUNGENMIT REIBWIDERSTAND

FOTO - PHOTO N. 5

ROTTURA SULLA PARTEESTERNA DELLA GOMMASOTTO IL BORDO DELLAANIMA IN ACCIAIO

CRACK ON OUTER SIDERUBBER UNDER THEEDGE OF CORE METAL

DEFEKTE AN DERAUSSENSEITEÜBER DEM METALLKERN

FOTO - PHOTO N. 6

ROTTURA SULLA PARTEINTERNA DELLA GOMMA SULLATO DELL'ANIMA IN ACCIAIO

CRACK ON INNER SIDERUBBER ON SIDE OFCORE METAL

DEFEKT AN DER INNENSEITEBEI DEN METALLKERNEN

Pagina 152

FOTO - PHOTO N. 7

ABRASIONE DELLE SCULTURE

ABRASION OF LUGS

ABNÜTZUNG DES PROFILS

FOTO - PHOTO N. 8

ABRASIONE DELLA GOMMADOVUTA ALLE RUOTE GUIDA(STADIO INIZIALE)

ABRASION OF RUBBERRUN OVER BY GUIDEWHEELS(BEGINNING STAGE)

ABNÜTZUNG DES GUMMIS UND DERFÜHRUNGSNOCKEN(ANFANGSSTADION)

FOTO - POTO N. 9

ABRASIONE DELLA GOMMADOVUTA ALLE RUOTE GUIDA(STADIO FINALE)

ABRASION OF RUBBER RUNOVER BY GUIDE WHEELS(TERMINAL STAGE)

ABNÜTZUNG DES GUMMISUND DERFÜHRUNGSNOCKEN(ENDSTADION)

Pagina 153

FOTO - PHOTO N. 10

TAGLIO DI MATERIALETAGLIENTE SULLA PARTEESTERNA DELLA GOMMA

CUT ON OUTER SIDE RUBBER FROM A SHARPMATERIAL

SCHNITTSCHÄDEN AMRAUPENPROFILVERURSACHT DURCHSCHARFE GEGENSTÄNDE

FOTO - PHOTO N. 11

ROTTURA E ABRASIONESULLA PARTE ESTERNADELLA GOMMA CAUSATADA RIGIDE CONDIZIONIDEL TERRENO

CRACK AND ABRASIONON OUTER SIDE RUBBERCAUSED BY SEVEREGROUND CONDITIONS

VERLETZTES PROFIL ALSFOLGE VON HARTEM U. SCHNITTIGEM MATERIALZ. B. ABBRUCH

FOTO - PHOTO N. 12

TAGLIO AL BORDO SULLAPARTE INTERNA DELLAGOMMA DOVUTO MATERIALITAGLIENTI O A SPIGOLI RIGIDI

EDGE CUT ON INNER SIDERUBBER BY SHARP MATE-RIALS OR CONCRETE RIDGES

SCHNITTSCHÄDEN AN DERAUSSENSEITE VERURSACHTDURCH SCHARFKANTIGE,UNVERPUTZTEBETONMAUERN

Pagina 154

FOTO - PHOTO N. 13

ROTTURA DELLA PARTEINTERNA DELLA GOMMACAUSATA DAL CONTATTOCON IL TELAIO DELSOTTOCARRO

CRACK ON INNER SIDEOF RUBBER CAUSED BYCONTACT WITH FRAMEOF UNDERCARRIAGE

SCHÄDEN AM RAUPEN-INNERN VERURSACHTDURCH ANSTOSSEN AMFAHRWERK

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