OPERATING INSTRUCTIONS 6015 / RH40E Inspection and servicing

Track tensioner Design

The tracks are tensioned with the help of the hydraulic pressure created during travelling. Fig. 3-90:and Fig. 3-91: show parts of the tracks and the tensioner:

Function

The tensioning system is under permanent pressure of ca. 100 bar / 1450 psi which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the engine has been started. Retensioning is not required.

For cleaning and servicing work, the tracks can be slackened.

To do so:

 stop the engine

 open both pressure limiting valves (6, Fig. 3-91:) to slacken the tracks.

 After the work, screw down the pressure limiting valves (6) to the limit stop.

Pos. Function

4 Pressure accumulator

5 Pressure cylinder

6 Pressure limiting valve

9 Mini- measuring port

10 Support roller

11 Drive sprocket

12 Track roller

13 Crawler track

14 Idler

Techncal data

Track tensioning pressure Approx. 100 bar / 1450 psi

Pressure limiting valve 250 bar / 3626 psi

Gas pressure in pressure accumulator (nitrogen filling pressure) 80 bar / 1160 psi

The pressure-limiting valves (6) are preset to a pressure of 250 bar / 3626 psi and sealed in this position. The lead seal must not be removed and the pressure setting of 250 bar / 3626 psi must not be changed.

The track tensioners are maintenance-free.

Pressure-accumulator inspection regulations

The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Extract from the German regulations

The accumulator vessel must not be subjected to welding, soldering or any other mechanical work. Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Extract from the German acceptance regulations

Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations]. Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Checking the gas charging pressure in the pressure accumulator

After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year

The above-mentioned pressure tests are required to ensure the functioning of the track tensioner. They are no substitute for the inspections as required by the "Pressure Vessel Regulations".

Group Inspections prior to commissioning Regular at the factory at the place of use inspections III p ≥ l bar p·x l ≥ 200 and p x l ≤ 1000

Preliminary inspection by an expert Prototype and pressure test certified by the manufacturer (type approval) or the expert

Acceptance inspection by an expert Test programme to be drawn up by end user based upon experience with the type of operation and fluid.