HYUNDAI-R450/R485 Forged Idler Wheel Group/Heavy-Duty construction machinery undercarriage parts/source undercarriages factory DPW Machinery Parts offere directly
Product Specifications
Hyundai-R485 Forged Front Idler Assembly: Technical Specifications & Design
Engineered for Heavy-Duty Earthmoving & Mining Applications
1. Core Function & Mechanical Role
Primary Role: Front-track guide wheel maintaining chain alignment, tension control, and load distribution for Hyundai’s 50-ton R485 excavator.
Critical Load Handling: Designed to absorb dynamic shocks (e.g., rock impacts, drop loads) and static loads up to ≥25,000 kg per track.
Tension Adjustment: Interfaces with Hyundai’s hydraulic track tensioner for real-time chain slack management.
2. Forged Construction Advantages
| Feature | Benefit |
|---|---|
| Material | SAE 4140/4340 Alloy Steel (Ultra-High Carbon) |
| Process | Hot-Forged + Tempered (HRC 45-50) |
| Density | Near-zero porosity → 30% higher impact resistance vs. casting |
| Fatigue Strength | Aligned grain structure → 2X lifespan in abrasive environments (e.g., mines) |
| Weight Capacity | Rated for R485’s max operating weight: 50,200 kg |
3. Assembly Components & Engineering
| Component | Specification |
|---|---|
| Idler Wheel | Forged core; CNC-machined flanges (height: 70-80mm); hardened surface (500 HB) |
| Shaft | Induction-hardened (55-60 HRC); diameter: 90-100mm |
| Bearings | Oversized Tapered Rollers (Timken/KOYO); dynamic load rating: ≥150,000 N |
| Sealing System | Triple-defense: Labyrinth + lip seals + grease-purge cavity (IP69K-rated) |
| Mounting Housings | Bolt-on design with reinforced gussets; compatible with R485 track frame interface |
| Lubrication | Dual grease zerks (high-pressure EP2 grease channels) |
4. R485-Specific Design Features
Track Compatibility: Matches 216mm pitch x 600mm shoe width tracks.
Flange Geometry: Taller flanges (vs. R305-7) to contain wider/heavier track chains.
Enhanced Seals: Rock-guard extensions + tungsten-reinforced lip seals for quarry/mine debris.
Tensioning Interface: Optimized for Hyundai’s high-force hydraulic tensioner (adjustment range: 0-150mm).
Corrosion Resistance: Phosphate coating + baked-on paint (salt-spray tested >500 hrs).
5. Performance Metrics
| Parameter | Value |
|---|---|
| Service Life | 8,000–12,000 hrs (severe duty) |
| Max Radial Load | 35,000 kg (static) / 28,000 kg (dynamic) |
| Operating Temp | -40°C to +120°C |
| Weight | 180–230 kg (assembly) |
| Maintenance Interval | Grease purge: every 50 hrs |
6. Target Applications
Primary Machine: Hyundai R485C-9/R485LCR-9 Excavators
Industries: Mining, quarry blasting, dam construction, heavy demolition
Harsh Conditions:
Rock-filled terrain (abrasion resistance)
High-impact loading (e.g., hammering, rock dropping)
Continuous swamp/mud immersion
7. Failure Prevention & Maintenance
Critical Inspection Points:
Flange wear (>15% thickness loss = replace)
Bearing play (vertical movement >3mm = rebuild)
Seal leakage (grease contamination = immediate purge)
Lubrication Protocol:
Use Hyundai HMG Grease EP2 or equivalent NLGI #2 lithium-complex grease.
Purge until clean grease emerges from seal cavity (≈300-400g).
Track Tension: Maintain 20-30mm sag (mid-span measurement).
8. Why Forged > Cast for R485 Class?
Fatigue Resistance: Handles R485’s breakout force (≥290 kN) without micro-cracking.
Cost of Ownership: Forged idlers last 1.8–2.5X longer than cast equivalents in mining.
Collateral Damage Prevention: Prevents chain derailment → protects rollers/sprockets (savings: $15,000+).
9. Genuine Hyundai OEM vs. Aftermarket
| Factor | Genuine Hyundai | Aftermarket Risk |
|---|---|---|
| Dimensional Accuracy | ±0.1mm tolerance (CNC-matched) | Tolerance stacking → misalignment |
| Material Integrity | Batch-tested alloy certification | Unknown origin → premature fracture |
| Sealing Performance | Validated in Hyundai test cycles | 68% higher failure rate in mud |
| Warranty Coverage | 2 years / 5,000 hrs (undercarriage) | Voided machine warranty |
10. Technical Specifications Summary
Shaft Diameter: 95mm
Bore Size: 100mm (tapered)
Bearing Type: 4-row tapered roller (e.g., KOYO 32238)
Bolt Pattern: 8x M24 bolts (grade 10.9)
Track Contact Width: 580mm
Hydraulic Tension Pressure: 150-200 bar
