Product Specifications

KOMATSU PC100/PC120/PC138 Forged Track Idler Assembly: In-Depth Technical Overview by HAN GONG/DPW PARTS

Abstract

This technical document provides a comprehensive, professional, and detailed overview of the forged track idler assemblies (part numbers: 2033000131, 2033000133, 2033000210, KM2795) designed for Komatsu PC100, PC120, and PC138 hydraulic excavators. As a professional forged track guide wheel manufacturing factory, HAN GONG/DPW PARTS employs advanced forging technology, precision engineering, and stringent quality control to produce durable, high-performance undercarriage components that meet or exceed OEM specifications. This content is structured to serve as a definitive resource for industry professionals, distributors, and end-users seeking reliable technical information.

1. Product Introduction & Application Scope

1.1 Forged Track Idler Assembly Function

The track idler (also known as the track guide wheel or front idler) is a critical component within the crawler undercarriage system. It serves multiple essential functions:

• Guide and Align: Precisely guides the track chain, maintaining proper alignment and preventing derailment.

• Tension Maintenance: Works in conjunction with the tensioning system to maintain optimal track tension, reducing wear and improving efficiency.

• Load Distribution: Helps distribute the machine's weight and dynamic operational loads across the track frame.

• Impact Absorption: Absorbs initial shocks and impacts from ground irregularities before they are transmitted to the final drive and mainframe.

1.2 Komatsu Model Compatibility

• KOMATSU PC100-6, PC100LC-6 Excavators

• KOMATSU PC120-6, PC120LC-6, PC120-7, PC120LC-7 Excavators

• KOMATSU PC138US-10, PC138USLC-10, and related PC138 Series Excavators

1.3 Part Number Cross-Reference

2. Advanced Manufacturing: The Forging Advantage

HAN GONG/DPW PARTS specializes in precision hot forging for track idler production, a superior process compared to casting or welding.

2.1 Forging Process Breakdown

1. Material Selection: High-carbon, high-alloy steel (e.g., 50Mn, 60Si2Mn) is selected for superior toughness and wear resistance.

2. Hot Forging: Steel billets are heated to a precise plastic state and formed under immense pressure in closed dies. This refines the grain structure, creating a continuous grain flow that follows the contour of the idler.

3. Machining: Forged blanks undergo CNC turning, drilling, and boring to achieve exact dimensions, flange profiles, and sealing surface finishes.

4. Heat Treatment: A controlled quench-and-temper process establishes a deep, uniform hardness (typically 55-60 HRC on the rim) while retaining a tough, shock-resistant core.

5. Surface Finishing: Precision grinding of the wear surface and flange sides ensures smooth operation and extended life.

6. Assembly: The forged wheel is integrated with high-quality seals (e.g., labyrinth, multi-lip), premium tapered roller bearings, and a robust shaft to form a complete, greasable assembly.

2.2 Benefits of Forged Idlers

• Enhanced Strength & Durability: Forged grain flow eliminates porosity and inclusions common in castings, resulting in higher impact and fatigue strength.

• Superior Wear Life: The dense, homogeneous microstructure provides exceptional resistance to abrasion and flange wear.

• Increased Reliability: Reduced risk of catastrophic failure (cracking or breaking) under high-stress conditions.

• Optimal Weight-to-Strength Ratio: Forging allows for strategic material placement, ensuring strength without unnecessary weight.

3. Technical Specifications & Design Features

3.1 Material & Metallurgy

• Wheel Material: Premium forged alloy steel.

• Hardness Profile: Hardened wearing surface (55-60 HRC) with a tough, ductile core (30-40 HRC).

• Shaft & Bearing: High-tensile strength steel shaft paired with ISO-classified tapered roller bearings for radial and axial load capacity.

3.2 Sealing System

• Multi-Stage Sealing: Utilizes a combination of nitrile rubber radial lip seals and metal face seals to create a robust barrier against contaminants (mud, sand, water) and retain lubricant.

• Grease Purge Function: The sealing design often allows for grease purging, enabling the expulsion of ingested contaminants during routine maintenance.

3.3 Dimensional Integrity

• Flange Geometry: Precisely contoured flanges prevent track pin interference and promote smooth track link engagement.

• Bore & Shaft Tolerance: Maintains strict IT6/IT7 tolerance grades to ensure perfect fit with the track frame and secure bearing press-fit.

4. HAN GONG/DPW PARTS Factory Capabilities

As a dedicated professional forged track guide wheel manufacturing factory, we integrate vertical production with rigorous quality assurance:

• In-House Forging Facility: Complete control over the forging process from die design to final form.

• CNC Machining Centers: Automated, high-precision machining for consistent quality.

• Metallurgical Lab: Spectrometer analysis, hardness testing, and microstructural examination to verify material properties.

• Quality Management System: ISO 9001-certified processes govern every stage, from raw material inspection to final assembly and packaging.

• Performance Testing: Simulated load and rotation tests to validate sealing integrity and bearing performance.

5. Why Choose HAN GONG/DPW PARTS Forged Idlers?

• OEM Interchangeability: Engineered to match original Komatsu dimensions, bolt patterns, and performance specifications.

• Extended Service Life: Forging technology directly translates to longer intervals between undercarriage overhauls, reducing downtime and cost-per-hour.

• Total Cost Savings: Despite a potentially higher initial investment than inferior cast parts, the extended wear life and reliability offer a significantly lower total cost of ownership.

• Global Support: Available through the DPW PARTS distribution network, backed by technical support and warranty.