![SERVICE MANUAL
EXCAVATOR
JS115, JS115 [T2/3],
JS130, JS130 [T2/3], JS145
EN - 9813/7050 - ISSUE 1 - 04/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2017 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales](https://image.slidesharecdn.com/jcbjs130excavatorservicerepairmanualsnfrom2373080to2375080-200513155544/85/Jcb-js130-excavator-service-repair-manual-sn-from-2373080-to-2375080-1-320.jpg)
Jcb js130 excavator service repair manual sn from 2373080 to 2375080
- 1. SERVICE MANUAL EXCAVATOR JS115, JS115 [T2/3], JS130, JS130 [T2/3], JS145 EN - 9813/7050 - ISSUE 1 - 04/2018 This manual contains original instructions, verified by the manufacturer (or their authorized representative). Copyright 2017 © JCB SERVICE All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. www.jcb.com Foreword The Operator's Manual You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand. Treat the Operator's Manual as part of the machine. Keep it clean and in good condition. Replace the Operator's Manual immediately if it is lost, damaged or becomes unreadable. Contents 01 - Machine 03 - Attachments, Couplings and Load Handling 06 - Body and Framework 09 - Operator Station 12 - Heating, Ventilating and Air- Conditioning (HVAC) 15 - Engine 18 - Fuel and Exhaust System 21 - Cooling System 27 - Driveline 30 - Hydraulic System 33 - Electrical System 72 - Fasteners and Fixings 75 - Consumable Products 78 - After Sales
- 2. 27 - Driveline 36 - Track 00 - General 27 - 11 9813/7050-1 27 - 11 00 - General Introduction .................................................... 27-11 Component Identification ............................... 27-12 Check (Condition) .......................................... 27-13 Introduction The left and right track assemblies are installed on the machine undercarriage. Each track consists of a chain and a series of bolt on shoe plates. The gearbox sprocket is engaged with the chain and transmits the drive from the track motor gearbox to the chain. The chain runs on several bottom rollers mounted on the undercarriage. The rollers carry the weight of the machine. Top rollers keep the chain clear of the undercarriage. The number of top and bottom rollers is dependent on the machine variant. A track guide prevents the chain being forced sideways off the bottom rollers. The chain runs on an idler wheel at the opposite end of the carriage. The idler wheel bracket mounting can slide forwards and backwards in the undercarriage. This allows the chain to be tensioned using a grease cylinder. A spring loaded recoil unit acts as a shock absorber. This allows the idler wheel to move in the carriage if the track is subjected to shock loads, when travelling over rough ground for example. Figure 329. Typical track installation E D B A C F G A Top roller B Shoe plate C Idler wheel D Undercarriage E Bottom roller F Gearbox sprocket G Track motor gearbox
- 3. 27 - Driveline 36 - Track 00 - General 27 - 12 9813/7050-1 27 - 12 Component Identification Figure 330. Typical track installation F M E D G K J H C A B L A Top roller B Shoe plate C Idler wheel D Undercarriage E Bottom roller F Gearbox sprocket G Track motor gearbox H Idler wheel bracket mounting J Recoil unit K Grease cylinder L Track guide (if installed) M Chain
- 4. 27 - Driveline 36 - Track 00 - General 27 - 13 9813/7050-1 27 - 13 Check (Condition) The track assembly is subjected to high forces and operates in a harsh environment. To enable the maximum service life, check the condition of the assembly at regular intervals as follows. 1. Clean off mud and debris from the track and undercarriage. 2. Check that the track tension is correct. Refer to: PIL 27-36-03. 3. Check the gearbox sprocket teeth for excessive wear. 3.1. Make sure the fixing bolts are installed and tightened to the correct torque. 4. Check the steel track chain for defective pins, bushes and links. 4.1. Measure the wear status. Refer to: PIL 27-36-03. 5. Check that the shoe plates are not excessively worn or distorted. 5.1. Make sure the fixing bolts are installed and tightened to the correct torque. 6. Check the condition of the top and bottom rollers. 6.1. Check that the wearing diameters are within the wear limits. 6.2. Check that the fixing bolts are installed and tightened to the correct torque. 6.3. Check that there are no oil leaks. 6.4. Check that the rollers rotate with the chain. 7. Check the condition of the track guide (if installed). 7.1. Check that it is free from distortion and excessive wear. 7.2. Check that the fixing bolts are installed and tightened to the correct torque. 8. Check the condition of the idler wheel. 8.1. Make sure that the idler wheel rotates with the chain. 8.2. Check the wearing diameter for excessive wear. 8.3. Check that there no oil leaks. 8.4. Check that the axle mounting bracket fixing bolts are installed and tightened to the correct torque. 9. Check the condition of the tensioner / recoil unit. 9.1. Make sure the recoil spring is free from packed material such as soil, clay and sand. 9.2. Make sure the recoil spring is not broken. 9.3. Check that the grease cylinder seals and check valve maintain the pressure in the grease cylinder. If the track components show signs of premature wear or failure, investigate the operating conditions. 1. Make sure the machine is being operated as intended, especially with the track motors at the rear when travelling or excavating. 2. Make sure that the applicable maintenance schedule is being followed. Refer to: PIL 78-24. 3. Make sure that the correct shoe plates are installed for the operating environment. 4. Make sure that packed material is being removed from the undercarriage when necessary. Excessive packing of materials such as soil, clay and sand causes premature wear of the track and undercarriage components. 5. If the machine is stored in a harsh environment, such as wet freezing conditions, make sure the operator follows the correct procedures. Refer to: PIL 27-36-03.
- 5. 27 - Driveline 36 - Track 03 - Steel Track 27 - 14 9813/7050-1 27 - 14 03 - Steel Track Introduction .................................................... 27-14 Technical Data ............................................... 27-15 Component Identification ............................... 27-17 Check (Condition) .......................................... 27-18 Adjust ............................................................ 27-25 Remove and Install ....................................... 27-26 Store and Recommission .............................. 27-28 Introduction The steel track consists of track links which are connected using pins and bushes to form a chain. The ends of the chain are connected by means of a removable master pin. This enables removal and installation of the track. The master pin has a tapered recess in the centre of its diameter to enable identification. The steel track is a wear item. When it is at the end of its service life it must be replaced. It is possible to extend the service life of the pins and bushes by dismantling the chain and assembling with the pins and bushes rotated to present new wear surfaces, this is known as 'turning'. The time involved may make this uneconomical, it may be more cost effective to replace the chain assembly with a new one. Figure 331. A A Steel track chain
- 6. 27 - Driveline 36 - Track 03 - Steel Track 27 - 15 9813/7050-1 27 - 15 Technical Data Track Tension Measure the track tension and compare the measurement with the data in the table. Adjust the tension if necessary. Refer to: PIL 27-36-03. Figure 332. A A Measurement - track tension Table 133. Minimum Maximum 30 mm 25 mm Pin and Bush Wear Guide (Track Pitch) Measure the track pitch and compare the measurement with the data in the table. Follow the correct procedure. Figure 333. A A Dimension A Table 134. 110 - 145 se- ries 160 - 235 se- ries Pitch (new con- dition) 171.05 mm 190 mm Wear % Dimension A mm Dimension A mm 0 686.8 761.0 10 688.0 762.3 20 689.2 763.6 30 690.4 764.9 40 691.6 766.2 50 692.6 767.5 60 694.0 768.8 70 695.2 770.1 80 696.4 771.4 90 697.6 772.7 100 698.8 774.0 110 701.6 776.5 120 704.2 779.5 Bush Wear Guide Measure the minimum bush diameter and compare the measurement with the data in the table. Follow the correct procedure.
- 7. 27 - Driveline 36 - Track 03 - Steel Track 27 - 16 9813/7050-1 27 - 16 Figure 334. A A Dimension A Table 135. 115, 130 series 130HD - 235 series Diameter (new condition) 50.8 mm 58.7 mm Wear % Diameter A - Normal / High impact mm (1) Diameter A - Normal / High impact mm (1) 10 50.5 / 50.6 58.4 / 58.4 20 50.4 / 50.5 58.0 / 58.1 30 50.0 / 50.2 57.6 / 57.9 40 49.7 / 50.0 57.1 / 57.4 50 49.2 / 49.6 56.8 / 57.1 60 48.8 / 49.4 56.4 / 56.9 70 48.5 / 49.1 56.0 / 56.6 80 47.7 / 48.6 55.6 / 56.5 90 46.6 / 48.0 54.9 / 56.3 100 45.6 / 47.4 54.1 / 55.9 110 44.8 / 46.7 53.2 / 55.2 120 43.8 / 46.1 54.8 / 52.5 (1) Wear allowance depends on the operating ground conditions. When operating on hard ground components are subject to high impact loads, allowable wear is reduced to avoid component failure. Track Link Wear Guide Measure the link height and compare the measurement with the data in the table. Follow the correct procedure. Figure 335. A A Dimension A Table 136. 110 - 145 se- ries 160 - 235 se- ries Wear % Dimension A mm Dimension A mm 0 96.0 106.0 10 95.4 105.3 20 94.9 104.6 30 94.3 103.9 40 93.7 103.2 50 93.3 102.5 60 92.6 101.9 70 92.1 101.1 80 91.4 100.2 90 90.8 99.5 100 90.0 98.8 110 89.3 97.8 120 88.6 97.0
- 8. 27 - Driveline 36 - Track 03 - Steel Track 27 - 17 9813/7050-1 27 - 17 Component Identification The illustration shows a chain link with a normal pin, bush and sealing washers. The single master pin, master bush and spacer assembly is also shown. Figure 336. Typical track link assembly G F D C J AB E H H E D C A B A E G F F E A Spacers (master bush) B Master bush C Master pin D Pin E Links (right) F Seal washers G Bush H Links (left) J Tapered recess
- 9. 27 - Driveline 36 - Track 03 - Steel Track 27 - 18 9813/7050-1 27 - 18 Check (Condition) Measuring the Normal Wear Status To check the normal wear status of the steel track chain proceed as follows. 1. Make the machine safe. Refer to: PIL 01-03. 2. Clean the tracks and undercarriage. It will not be possible to get accurate wear measurements if there is an accumulation of dirt and debris on the components. Refer to: PIL 01-33. Link Rail Surface Wear Status As the link rail surface wears the distance between the rail and the underside of the shoe plate reduces. Figure 337. A A Link rail surface wear area Measure the distance as follows. 1. Use a suitable depth gauge to make the measurements as shown. Figure 338. D A B C A Shoe plate underside B Track pin C Track link - rail wear face D Depth gauge 1.1. Position the gauge on the outside of the links in-line with the ends of the track pins. 1.2. Make sure the gauge is flat against the rail surface and perpendicular to the underside of the shoe plate 1.3. Take measurements to the specified degree of accuracy. Length/Dimension/Distance: 0.25 mm 2. Compare the measurements with the track link wear guide given in Technical Data (PIL 27-36-03). 2.1. Use the data to obtain the wear percentage value. Track Pitch (Internal Wear Status) As the internal mating faces of the track pins and bushes wear, the pitch distance of the track chain links increases. Measure the distance as follows. 1. Use an old track pin or suitable bar to stretch the chain as shown. 1.1. Place the pin on the gearbox sprocket and slowly operate the track motor so that the chain is tensioned. Do not operate the track motor past the position shown. Get the help of an assistant. 2. Use a suitable tape measure calibrated in the increments specified and measure the distance over four chain links. Length/Dimension/Distance: 0.5 mm
- 10. 27 - Driveline 36 - Track 03 - Steel Track 27 - 19 9813/7050-1 27 - 19 Figure 339. A B C A Tape measure B Track pin C Old track pin 2.1. Measure from one side of a track pin to the same side of the 5th pin away (four chain links). 2.2. Make sure the master pin is at least three links away form the section being measured. 2.3. Do not place the end of the tape measure at the first pin. Start the measurement at a convenient increment along the tape. 3. Repeat the process for at least two different sections of the track. 4. Divide the results by four to obtain the chain link pitch. 5. Compare the measurements with the pin and bush wear guide given in Technical Data (PIL 27-36-03). 5.1. Use the data to obtain the wear percentage value. Bush External Wear Status As the external mating face of the bushes engage with the gearbox sprocket the bush surface wears. Measure the wear as follows. Figure 340. B A A Bush B Caliper 1. Use a suitable caliper to measure the smallest diameter of the bushes. Avoid false readings as follows. 1.1. Make sure the bush diameter surface is clean. Figure 341. Debris on bush 1.2. Keep the caliper perpendicular to the axis of the bush. Figure 342. Caliper at wrong angle 1.3. Make sure the caliper is passed completely over the bush.
- 11. 27 - Driveline 36 - Track 03 - Steel Track 27 - 20 9813/7050-1 27 - 20 Figure 343. Caliper not passed over the bush 1.4. Do not force the caliper over the bush diameter, the caliper can spread and then spring back. The reading will be less than the bush diameter. Figure 344. Caliper forced over the bush 1.5. Make sure to measure the smallest diameter on the bush. Inspect it carefully, there may be more than one worn area. Figure 345. Caliper not mea- suring smallest diameter 1.6. Practise using the caliper on a bush removed from a track. Make sure you can get repeatable results to the necessary accuracy. Length/Dimension/Distance: 0.25 mm 2. Compare the measurements with the bush wear guide given in Technical Data (PIL 27-36-03) 2.1. Use the data to obtain the wear percentage value. General Wear Assessment In addition to checking the steel track components for normal wear a general assessment of their overall condition should be carried out. This can help identify operational issues and if the use of repair procedures to extend the service life of the chain are applicable. Repair procedures may not suitable if components are worn beyond their service limit, or show excessive defects not caused by normal wear for example. In addition, the condition of the other undercarriage components must be assessed before repairing or replacing the track chain. Track Link Condition Assessment Check the track links for the following. Scalloping The rail surface is worn with uneven scallops typically caused by over tensioning or snaking track. Can be repaired in most cases. Check the track chain tension. Figure 346. A A B A Wear - due to reduced contact area with idler wheel B Wear - due to reduced contact area with bottom rollers Side Wear The side of the rail is worn excessively. Typically caused by over tensioned or snaking track, frequent traversing the side of steep slopes, frequent turning or over sized shoe plates. Repair not recommended. Check the track chain tension. Check the shoe plate width is compatible with the operating environment.
- 12. 27 - Driveline 36 - Track 03 - Steel Track 27 - 21 9813/7050-1 27 - 21 Figure 347. A A Wear Gouging The side of the track link shows gouging from contact with the gearbox sprocket teeth. Typically caused by snaking track, frequent traversing the side of steep slopes, frequent turning or over sized shoe plates. Check the alignment of the track and gearbox sprocket. Check the shoe plate width is compatible with the operating environment. Repair not recommended. Figure 348. A A Gouging Pin Boss Wear The top of the track link pin bosses are worn from contact with the bottom rollers. This can be caused by excessive bottom roller wear or the track link rail surface worn more than 100 %. If the track pin retention is still effective repair the track link rail. Check the wear status of the track links and bottom rollers. Replace the bottom rollers if applicable. Figure 349. A A Wear Counterbore Elongation The bush locating counterbores in the track links are elongated. Typically caused by elongated pitch due to internal wear on the pins and bushes. Check the track pitch (internal Wear) status. Replace or turn the pins and bushes as applicable. If the bush retention is effective the links can be used. Figure 350. A A Counterbore elongation Face Wear The track links are worn at their rotating faces. Typically caused by operating in highly abrasive material, frequent traversing on the side of steep slopes, frequent turning or over sized shoe plates. Check the shoe plate width is compatible with the operating environment. Repair not recommended. Figure 351. A A Wear
- 13. 27 - Driveline 36 - Track 03 - Steel Track 27 - 22 9813/7050-1 27 - 22 Pin Boss End Wear The ends of the pin bosses in the track links are worn due to contact with the track guides (if installed). Typically caused by bent track guides or incorrect chain tension. Check the condition of the track guides, replace as applicable. Check the track chain tension. Figure 352. A A Wear Chipping or Flaking The track link rail faces are chipped or flaking due to impact with the bottom rollers. This is normal especially on heavy machines. Check the shoe plate width is compatible with the operating environment. Check the track chain tension. Figure 353. A A Chipping / flaking Cracks The track link has cracks due to bending during high impact force with the bottom rollers. Check the shoe plate width is compatible with the operating environment. Check the track chain tension. Repair is not possible, cracking can cause the track chain to separate. Figure 354. A A A A A A Cracks Pin and Bush Bore Enlargement The track link has enlarged location bores for the pin or bush. Typically caused by the use of incorrect tooling when removing / installing the pins and bushes. In addition high bending forces can cause the pins and bushes to slide in the bores, causing wear. Check the shoe plate width is compatible with the operating environment. Check the track chain tension. Check the tooling before removing / installing pins and bushes. Pin and bush retention is not effective, do not use the affected track links. Track Bush Condition Assessment Check the track bushes for the following. Reverse Side Drive Wear When the machine operates in reverse travel direction the bush wears at its mating face with the gearbox sprocket between 30 –65 ° from vertical as shown. Excessive wear can cause cracks in the bush. Measure the bush external wear status. Check the track chain tension. When turning the bushes for extended service life, the reverse side drive wear will be closer to the forward drive side of the bush. Bushes worn close to 100 % or more, are less suitable for turning.
- 14. 27 - Driveline 36 - Track 03 - Steel Track 27 - 23 9813/7050-1 27 - 23 Figure 355. 30 65 Forward Side Drive Wear When the machine operates in forward travel direction the bush wears at its mating face with the gearbox sprocket between 30 –60 ° from vertical as shown. Excessive wear can cause cracks in the bush. Internal wear in the same position can cause the bush to wear completely through. Measure the bush external wear status. Measure the track pitch. Check the track chain tension. Figure 356. 30 60 End Wear The ends of the bushes are worn. Typically caused by abrasive material between the bush and the seals or high side loading from frequent traversing the side of steep slopes. Check the shoe plate width is compatible with the operating environment. When turning the bushes for extended service life, lubrication sealing may be defective. Figure 357. A A Wear End Cracks The ends of the bushes have cracks. Typically cased by impact with the counterbore due to internal wear or track snaking. Repair not recommended. Figure 358. A A A A Cracks Counterbore Wear The bush is worn at the ends of the outer diameter on its reverse drive side. This is caused by internal wear. As the pitch increases the bushes wear against the track links on the reverse drive side. Check the track pitch. When turning the bushes for extended service life, lubrication sealing may be defective.
- 15. 27 - Driveline 36 - Track 03 - Steel Track 27 - 24 9813/7050-1 27 - 24 Figure 359. A A A Wear Wall Cracks The bush has cracks in its wall due to impact with the gearbox sprocket. Caused by excessive wear, incorrect chain tension or over sized shoe plates. Check the shoe plate width is compatible with the operating environment. Check the track chain tension. Repair is not recommended. Figure 360. A A Cracks Track Pin Condition Assessment Check the track pins for the following. Diameter Wear The pins are worn on one side of the outside diameter due to contact with abrasive material or bush. Caused by sealing failure, excessive packing of abrasive material in the track, extended high speed travel, incorrect track tension, or over sized shoe plates. Check the shoe plate width is compatible with the operating environment. Check the track chain tension. Check the track pitch. Pins can be turned for an extended service life. Figure 361. FDS A A Wear FDS Forward direction side End Wear One, or both ends of the pins are worn due to contact with track guides. Caused by track snaking, bent track guards, worn rollers or frequent traversing on the side of steep slopes. Check the track chain tension. Check the condition of the track guides. Check the condition of the top and bottom rollers. When turning pins for extended service life remove the sharp edges on the end of the pins. Sharp edges can remove material from the track link pin bosses during assembly. This will reduce pin retention. Figure 362. FDS RDS A A Wear FDS Forward direction side RDS Reverse direction side Loose Pins Pin not retained in the track link pin bosses. Caused by excessive impact or bending forces, cracked track links or incorrect pin installation procedures. Check the condition of the track links. Check the shoe plate width is compatible with the operating environment. Check the shoe plate retaining bolts are present and tightened to the correct torque value. Track link repair is not recommended.
- 16. 27 - Driveline 36 - Track 03 - Steel Track 27 - 25 9813/7050-1 27 - 25 Figure 363. Broken Pin The track pin is broken. Caused by operating the track components past their wear limit, incorrect track tension, excessive loading due to material packing or trapped between the bush and gearbox sprocket. Replace all the affected components. A broken track pin can cause severe damage to other components. Check the shoe plate width is compatible with the operating environment. Check the track chain tension. Check the track pitch. Figure 364. A A Break Adjust Notice: Always make sure that the track tension measurement is not less than specified or severe strain to the track will result. WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out. If you over-loosen too much grease could spurt out or the valve cover fly out and cause serious injury. Track Tension 1. Stop the machine on solid, level ground 2. Move the machine backwards and forwards several times, find the slack point, then move the machine forwards and stop it on level ground. 3. Stop the engine. 4. Check the track tension. 4.1. Place a long, stiff and straight piece of steel or wood on top of the tracks touching above the front idler and the top roller. Figure 365. A A Track tension - measurement 5. Make sure the track tension is within the specified limits. Refer to: PIL 27-36-00. 6. If necessary, adjust the track tension. 6.1. To adjust the track tension, inject or release grease from the check valve.
- 17. 27 - Driveline 36 - Track 03 - Steel Track 27 - 26 9813/7050-1 27 - 26 Figure 366. 6.2. Inject grease to increase the tension. 6.3. Release grease to decrease the tension. 6.4. When you open the check valve, always stand to one side and loosen it a slowly until the grease starts to release. 6.5. Do not loosen the check valve too much, grease can spurt out or the cover of the check valve can come off and cause serious injury. 7. Never attempt to disassemble the check valve or try to remove the grease point from the check valve. 8. If there is a clearance between the idler wheel shaft and the track frame, use pressure to apply the grease. 9. If there is no clearance after the application of grease the grease cylinder or recoil assembly may be faulty. 10. Do not tension the tracks too much, this will cause the track rail to wear the drive rollers and sprocket. 11. Always make sure you adjust the track tension to the specified limits. Incorrect tension can cause wear to the drive sprocket and the track rail. 12. Repeat the procedure for the other track. Remove and Install WARNING When opening the check valve always stand to one side and loosen a little at a time until grease starts to come out. If you over-loosen too much grease could spurt out or the valve cover fly out and cause serious injury. WARNING Stand clear and to one side of the track while you remove the master pin. When the master pin is removed the track could fall forward and injure you. Remove 1. Make the machine safe. Refer to: PIL 01-03. 2. Move the track link until the master pin is over the idler wheel in the position shown, place a wooden block under the track shoe. Refer to Figure 367. Figure 367. 2.1. The master pin is identified by a tapered recess in the centre of its diameter. 3. Slacken the check valve to bleed out the grease. Figure 368. 4. Disconnect the track link by removing the master pin as follows. 4.1. Remove bolts and lift off the track shoe plates adjacent to the master pin.
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- 19. 27 - Driveline 36 - Track 03 - Steel Track 27 - 27 9813/7050-1 27 - 27 Figure 369. 4.2. Position a suitable hydraulic press so that its ram aligns with the master pin. Figure 370. 4.3. Insert the spacer bar between the master pin and the hydraulic ram. 4.4. Slowly operate the press hydraulic ram and press out the master pin. 5. Operate the track drive motor to remove the track. 6. Lift the lower frame clear of the track. Figure 371. 6.1. Support the lower frame with wooden blocks. 6.2. Using suitable equipment pull the track clear of the machine. Install 1. Clean off old grease, mud and debris from the master pin, master bush and spacers. 1.1. Check the components for signs of excessive wear. If necessary replace them with new components. 2. Position the lower frame on the track. 3. Move the track link. Figure 372. 4. If necessary clean the spacer housings in the chain links. Insert the spacers and clamp into position. Figure 373. 5. Using a plastic hammer, tap the upper link down to align holes. 5.1. As the links overlap, the spacers will be held in position. Remove the clamps. 6. Insert the pointed guide pin from the inner face and tap through its full length.
- 20. 27 - Driveline 36 - Track 03 - Steel Track 27 - 28 9813/7050-1 27 - 28 Figure 374. 7. Position a suitable hydraulic press so that its ram aligns with the guide pin. 8. Put some grease on the center diameter of the master pin. 9. Insert the master pin into its locating hole. 10. Slowly operate the hydraulic press ram to press the master pin into position. Figure 375. 11. Install the track shoe plates. Refer to: PIL 27-36-04. 12. Adjust the track tension. Refer to: PIL 27-36-03. Store and Recommission During storage, or non continuous work periods in wet environmental conditions, the track link joints can seize. Figure 376. When the machine is used, wear occurs between the pin and bush in the track link. This results in the gap between the pin and bushes increasing. Figure 377. C B E F B Traction C Gap increase E Pitch elongation F Wear The metal particles worn from the pin and bush can accumulate in the bush leading to seizure of the link joint. To help prevent seizure make sure to complete the following steps. 1. Operate the machine (making sure that the machine travels on its tracks) at least once per week to keep the link joints flexible. 2. Do the undercarriage basic maintenance before you stop the machine (washing and mud cleaning).
- 21. 27 - Driveline 36 - Track 03 - Steel Track 27 - 29 9813/7050-1 27 - 29 3. Avoid allowing the machine to stand for long periods in a wet environment (such as in wet soil or water). 4. Do a regular check of the track tension to avoid excessive joint wear (excessive track tension affects joint internal wear). Refer to: PIL 27-36-03.