Service Training MALAGA

Challenger 35 & 45

X. UNDERCARRIAGE
1. Components 2. Belts and Spacers 3. Testing & Adjusting
Sara MAY 1997

CHALLENGER 35 & 45
CHAPTER : Undercarriage

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IDLER

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FRONT IDLER ASSEMBLY

SWING LINK

HUB

CHAPTER : Undercarriage

SETSCREW TAB

LEVER PIN BEARING ASSEMBLY

CHALLENGER 35 & 45

PIN LOCKNUT CAP

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MID-ROLLERS SEAL GROUP

UNDERCARRIAGE

MID-ROLLER ASSEMBLY
CHAPTER : Undercarriage

CHALLENGER 35 & 45

CAP

BEARING ASSEMBLIES

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HUB DUO-CONE SEAL SPHERICAL BEARING HUB DRIVER

REAR DRIVER ASSEMBLY

REACTION ARM

CHAPTER : Undercarriage

CHALLENGER 35 & 45

REAR AXLE HOUSING

CHALLENGER 35 & 45
CHAPTER : Undercarriage

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CHALLENGER 35 & 45
CHAPTER : Undercarriage

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CHALLENGER 35 & 45
CHAPTER : Undercarriage

GAUGE AND BELT COMBINATIONS

Desired Gauge Spacing 1524 mm (60 in.) 1575 mm (62 in.) 1626 mm (64 in.) 1676 mm (66 in.) 1727 mm (68 in.) 1828 mm (72 in.) 1930 mm (76 in.) 2032 mm (80 in.) 2235 mm (88 in.) Spacer Length (each) No Spacers 25.4 mm (1 in.) 50.8 mm (2 in.) 76.2 mm (3 in.) 101.6 mm (4 in.) 150.6 mm (6 in.) 203.2 mm (8 in.) 254 mm (10 in.) 355.6 mm (14 in.) Available Belt Widths 406, 457 mm (16, 18 in.) 406, 457, 508 mm (16, 18, 20 in.) 406, 457, 508 mm (16, 18, 20 in.) 406, 457, 508 mm (16, 18, 20 in.) 406, 457, 508. 635 mm (16, 18, 20, 25 in.) 406, 457, 508. 635 mm (16, 18, 20, 25 in.) 406, 457, 508. 635, 813 mm (16, 18, 20, 25, 32 in.) 406, 457, 508. 635, 813 mm (16, 18, 20, 25, 32 in.) 406, 457, 508. 635, 813 mm (16, 18, 20, 25, 32 in.)

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CHALLENGER 35 & 45
CHAPTER : Undercarriage

ADJUSTMENTS
Undercarriage Adjustments and Procedures
Adjustments and procedures to the undercarriage include: Procedure to detension and tension the track Procedure to check nitrogen charge (when adjusting track tension) - SM 29/July/96 Procedure to raise and lower the tractor Adjustment procedures to align the belts - SM 18/March/96 Procedure to remove the undercarriage (change tractor gauge) - SI, SEHS9982 (8/96) - Appendix Procedure to Detension and Tension the Track Detensioning 1. Connect one end of the charging hose assembly to the left "+" implement coupler port of the No. 3 or No. 4 implement control valve and the other end to the quick disconnect fitting on the manifold assembly. If the charging hose assembly cannot be connected to the quick disconnect, see the topic titled "Release of Residual Pressure." To check the current charge pressure, first close the valve on the charging hose. Open the charging valve (requires a 13 mm wrench) on the manifold assembly and read the gauge. The charging valve is the valve under the guard. The charge pressure should be 19000 kPa (2750 psi). 2. Place the No. 3 or No. 4 implement control lever (depending how the tractor is equipped) for the port selected in the FLOAT position. 3. Open the charging valve (if not already open) and the charging hose valve to release the tension charge pressure into the implement hydraulic system. 4. As the tension charge pressure is released, the front idlers will pivot rearward and the belt will sag. Push the idlers rearward to finish retracting the ram. 5. Close the charging valve and remove the charging hose assembly. Page: X-8

CHALLENGER 35 & 45
CHAPTER : Undercarriage

ADJUSTMENTS
Maintenance Recharge Tensioning (Unopened System) 1. Verify that the charging valve is closed. 2. Connect one end of the charging hose assembly to the left "+" implement coupler port of the No. 3 or No. 4 implement control valve and the other end to the quick disconnect fitting on the manifold assembly. If the charging hose assembly cannot be connected to the quick disconnect, see the topic titled "Release of Residual Pressure." 3. Start the engine and run at low idle. Place and hold the No. 3 or No. 4 implement control lever (depending how the tractor is equipped) in the RAISE position. 4. With the charging valve open 1/4 to 1 full turn maximum, wait a minimum of 50 seconds for the hydraulic ram to fully charge. 5. Close the charging hose valve first. Continue holding the implement control lever in the RAISE position. Read the gauge to verify the tension charge pressure. The charge pressure should be 19000 kPa (2750 psi). 6. If the charge pressure is correct, close the charging valve and open the charging hose valve. 7. Shut off the engine and place the implement control lever in the FLOAT position. Remove the charging hose assembly.

Release of Residual Pressure

If difficulty is encountered when connecting the charging hose to the quick disconnect fitting, the resistance may be due to hydraulic pressure behind the quick disconnect nipple. The pressure can be safely relieved by using the following procedure: 1. Verify that the charging valve (3) is closed. 2. Using an 11/16 in. wrench, loosen the quick disconnect fitting (1) 1/2 to 3/4 of a turn. DO NOT loosen beyond 3/4 of a turn. A few drops of oil may leak out at the base along as the pressure is relieved. If a significant amount of oil leaks or sprays out, tighten the coupler immediately. The hand valve may be malfunctioning and the hydraulic ram can only be safely detensioned through the use of the bleeder screw.

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CHALLENGER 35 & 45
CHAPTER : Undercarriage

ADJUSTMENTS
Check nitrogen Charge in Accumulator when Adjusting Track Tension Check the dry nitrogen gas charge in the accumulator each time the tract tensioner group is adjusted. Use the same tooling used to adjust the track (not the nitrogen charging group). Use the following procedure for adjustment.

1. Charge the tensioner group to a minimum of 17 200 kPa (2500 psi) using 1U9058 Hose Group, then close the gate valve. Stop the engine and place the control lever in the FLOAT position. 2. Open the gate valve enough to slowly relieve the tensioner pressure. The gauge pressure should steadily decrease from 17 200 kpa (2500 psi) until a rapid drop in pressure occurs. Record the pressure at which the rapid drop occurred and the resulting pressure immediately after the rapid pressure drop. Close the gate valve. The pressure at which the rapid drop occurs is the approximate dry nitrogen precharge of the accumulator. The rapid pressure drop should occur between 10 000 and 12 000 kPa (1450 and 1750 psi) and drop rapidly at the maximum of 1400 kPa (200 psi). If the range of the rapid pressure drop exceeds 1400 kPa (200 psi), the pressure was bled too quickly. An inaccurate pressure reading result. Recharge and re-bleed the tensioner group to obtain a better reading. The slower the bleed rate, the more accurate the pressure measurement will be. 4. If the rapid pressure drop occurs below 10 000 Kpa (1450 psi) or does not occur at all, the accumulator requires service or replacement.

NOTE :

Do not operate the machine with an accumulator that has an inadequate nitrogen charge. The accumulator functions as a spring for the undercarriage to recoil.

Machine operation with and inadequate nitrogen charge could result in undercarriage damage and/or steering difficulty.

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CHALLENGER 35 & 45
CHAPTER : Undercarriage

ADJUSTMENTS
Procedure to Raise and Lower the Tractor 1. Raise the front of the tractor by placing a jack under the center of the hardbar. Lift the tractor until approximately 102 mm (4 in.) of clearance exists between the belt treadbars and the ground. Place stands under the flat support surfaces provided on each of the frame rails. Lower the jack until the flats rest on the stands. Remove the jack. 2. Raise the rear of the tractor by placing a jack under the center of the swinging hardbar, directly behind the front pivot bracket. Lift the tractor until approximately 102 mm (4 in.) of clearance exists between the belt treadbars and the floor. Place stands under each side of the drawbar cage. Lower the jack until the cage rests on the stands. Remove the jack. 3. Check the stability of the support system by trying to manually shake the tractor. Do not continue with any procedure until satisfied that the tractor is secure.

NOTE:

Reverse the procedure to lower the tractor. If the belts must be removed, approximately 204 mm (8 in.) of clearance will be needed.

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CHALLENGER 35 & 45
CHAPTER : Undercarriage

ADJUSTMENTS
New Track Alignment Procedure This Procedure replaces the current procedure found in the Operation & Maintenance Manual. Procedure #1

Alignment Check 1. Travel on a smooth and level surface for 61-91 m (200-300 ft) at a speed less than 8 km?h (5 mph) without turning the steering wheel. Allow the tractor to coast to a stop. 2. Apply the parking brake. Stop the engine. Block the front and rear of the track. 3. Measure the clearance between the inside edges of the front midwheel and the sides of the guide-blocks. If these distances agree withing 2 mm (.080 in), the track is aligned correctly. Otherwise, use the following procedure to adjust the alignment.

Adjust Track Alignment

1. To cause the guide-blocks to ride closer to the outside midwheels, first loosen outside locknut and turn screw counterclockwise 1/4 turn. Loosen the opposite side locknut and tighten the corresponding set screw to a torque of 5510 Nm (407 lb ft). 2. To cause the guide-blocks to ride closer to the inside midwheel, loosen the inside locknut and turn the setscrew counterclockwise 1/4 turn. Loosen the opposite side locknut and tighten the corresponding set screw to a torque of 5510 Nm (407 lb ft). NOTE : Do not adjust the setscrews more than 1/4 turn at a time. 3. Repeat the Checking Track Alignment procedures. If needed, repeat Steps 1 and 2 above until guide-blocks are properly centered. 4. Tighten both locknuts to a torque of 13615 Nm (10011 lb ft).Hold the setscrews when tightening the locknuts to prevent overtightening the set screws.

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CHALLENGER 35 & 45
CHAPTER : Undercarriage

ADJUSTMENTS
Procedure #2 1. After belt/track tension has been applied drive the machine on a level paved road with as little steering as possible for approximately 15 to 18 minutes. 2. Stop the machine. Immediately record the maximum temperature of the inboard and outboard idler (inner) side walls. If the temperature difference between the inboard and outboard idler is 22 deg. C (40 deg. F) or more, proceed to step 3. If the temperature difference between the inboard and outboard idler is less than 22 deg. C (40 deg. F) belt/track is in alignment.

Alignment Check

Adjust Track Alignment 1. If the outer idler is the hottest, then loosen locknuts and back inside setscrew out (counterclockwise) 1/4 turn. Turn outside screw in (clockwise) 1/4 turn. If the inner idler is the hottest then loosen locknuts and back outside setscrew out (counterclockwise) 1/4 turn. Turn inside setscrew in (clockwise) 1/4 turn. 2. Tighten both setscrews to a torque of 5510 Nm (407 lb ft). Tighten locknuts to a torque of 13615 Nm (10011 lb ft).

NOTE : Do not adjust the setscrews more than 1/4 turn at a time.

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CHALLENGER 35 & 45
CHAPTER : Undercarriage

ADJUSTMENTS

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CHALLENGER 35 & 45
CHAPTER : Undercarriage

ADJUSTMENTS

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