G.

Frame and track devices

1. Frame
1.1 General
Disassembling of superstructure

Warning!
The superstructure is heavy. Before continuing
disassembling or mounting the superstructure,
pay attention to the safety of the standing point
and areas around the crane.
Caution: Weight of the superstructure: 4-7 tons
(excluding the counterweight and digging devices)

1 Disassemble the digging devices.

2 Disconnect the slewing connector fastening
screw, seal cover, hydraulic oil hoses,
discharge hoses and one service hydraulic oil
hose of the slewing connector.
Caution: Bundle up all hoses and block each
opening of all disconnected hoses and pipes.
3 Remove the screw (A) on the outer bearing
sleeve of the mounting slewing ring.
Fig. 1 Mounted slewing ring.
4 Disassemble the driver’s cab, counterweight
A Screw and protection devices. Fasten the
B Confirmed match alignment mark superstructure with a steel cable and lift it to a
certain level by one crane before straightening
the cable.

5 Slightly lift the superstructure. Lift and move it

after confirming the surrounding is safe.

Fig. 2 Lifting of the Superstructure

Mounting of the superstructure

1 Bundle up the hoses connected with the
slewing connectors and place them vertically.
2 Coat the thread holes on screws and slewing
rings with “Threebond Glue Thread kk1215”
(Loctite#515).
3 Lift the superstructure and mount it onto the
slewing ring.
Caution: Lower the superstructure to engage
the slewing pinion with its gear rings.
Fig. 3 Mounting of the superstructure
217
 Caution: Please refer to the torque table for
tightening.
Caution: Tighten crosswise the
corresponding screws one by one.
4 Remount the hose, slewing connector
fastening screw and seal cover disconnected
during disassembling.

1.2 Counterweight
Additional counterweight and digging device
To keep steady, an additional counterweight
should be applied when special digging devices,
such as scrap-handling tongs and log loader, are
mounted onto the excavator.
In this case, please check the specification of the
digging device and carefully compare the Table for
Lifting Capacity of Excavator’s Load in the
Operation and Maintenance Manual.
For any doubt, please contact your local distributor
for suggestions.
The additional counterweight may be mounted in
accordance with special digging devices. However,
we are not liable for the excavator malfunction or
the crack of digging devices in purpose of such
purpose.

Disassembling of the counterweight,

Warning!
The counterweights are heavy. Please
disassemble them with special care. And use
the approved cables in good condition and
with sufficient loading rate and length to lift the
counterweight.
1 Keep the machine on an even, solid and
horizontal ground. No obstacles or
disturbance are permitted.
2 Descend the operating device till fully onto the
ground.
3 Make sure the safe locking control lever is
firmly located at the locking position.

Fig. 4 Counterweight 4 Disassemble two plugs from the top of the

counterweight.
5 As shown in the diagram, before connecting to
the hoisting cables or sling wires, properly fix
the lifting bolt (C), which is able to bear the
counterweight, to the lifting point (A).
6 Disassemble four bolts (B).
7 Lift the counterweight fully to remove all loads
from the stop pin.

218
 8 Place the disassembled counterweight onto a
proper rack.

Installation of the counterweight

Warning!
Slightly lift the counterweight, and continue the
installation after having confirmed it is in safe
and horizontal position.
1 Connect the shackles from lifting cables or
sling wires to the counterweight (C), and lift it
to the intended position.
2 Align the screw holes. Insert locking plates
and gaskets before fastening the screws.
Ÿ Lower the counterweight to the
assembling surface at the back of the
superstructure.
Table 1 Tightening Torque, Unit: kgf·m
Item Tightening Torque
Mounted screw (4) 135±5
Caution: Coat the thread of the screw with Loctite
Glue #601.

1.3 Frame of the undercarriage

Description of the body
understructure/chassis,
The chassis is composed of the leading wheels,
springs, supporting wheels, carrier rollers, sprocket
gears, track link, lower frame and track protection
devices.

Fig. 5 Structure of the Chassis

1 Truck frame 3 Carrier roller 5 Spring set 7 Supporting wheel
2 Leading wheel 4 Track link 6 Track protection devices 8 Sprocket gears

219
 Tightening torque of the chassis

Fig 6 Tightening torque

LG6150
A 7 ± 0.25 kgf·m
B 52 ± 5 kgf·m
C 27 ± 3 kgf·m
D 42 ± 4 kgf·m
E, F, G, H 27 ± 3 kgf·m

220
 2. Traveling mechanism
Track traveling mechanism
Select track shoes
Select applicable track shoes to meet the ground
surface conditions.
Track shoes selection method
Select track shoes according to the listed purpose
in the table below.
Types B and C are wide track shoes, so their
purposes are limited. Before choosing a track shoe
with suitable width and taking it in application,
please check the purpose limitation and carefully
consider the application conditions. If necessary,
please instruct the user for use.
As to the width of the track shoe, select the
possibly narrowest one within the permitted range
of buoyance and surface pressure. If the
unnecessarily wide track shoe is applied, it will add
heavy load onto the track shoe and possibly cause
the bending track shoes, connection cracks, pin
fractures, loose track shoe screws or other
problems.

Table 2 Category of Track Shoes

Specification Category Purpose Precautions Descriptions

500mm A Rocky Drive at a low speed when
track shoe surface, processing on the uneven
normal surfaces with such obstacles
600mm soil as big rocks or fallen trees.
track shoe
700mm B Soft Only drive at high speed on
track shoe ground the even surfaces. Drive at the
half speed if the obstacles are
750mm unavoidable to pass over.
track shoe Caution: Inapplicable on the
coarse surfaces where big
obstacles such as big rocks or
fallen trunks exist.
800mm C Very soft Only applicable on the ground
track shoe ground that type A and B track shoes
are not allowed. Only drive at
900mm high speed on the even
track shoe surfaces. Drive at the half
speed if the obstacles are
unavoidable to pass over.
Caution: Inapplicable on the
coarse surfaces where big
obstacles such as big rocks or
fallen trunks exist.

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 2.1 Front idler, including the front fork
Descriptions of the leading wheel

Fig. 7 Structure of the leading wheel

1 Leading wheel 6 O-ring
2 Shaft 7 Pin
3 Support 8 Plug
4 Bushing 9 O-ring (shaft)
5 Packing

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 Measurement of the leading wheel wear

Fig. 8 Measurement of the Leading Wheel Wear

Table 3. Wear Limit, Unit: mm

No. Check Item Standard Dimensions Service Limit Remedy

Measures
1 Outer diameter of the 540 - Reinforce
flange welding or
replace it
2 Outer diameter of the 495 483
patterned surface
3 Flange width 68 60
4 Total width of the 140 –
patterned surface
5 patterned surface 36 40
width
6 Clearance between Standard Allowable error Clearance Replace the
the shaft and bushing dimensions bushing
Crankshaft Hole Standard Service
dimensions limit
60 0 +0.35 0.3 1.5
–0.03 +0.30 ~0.38
7 Clearance between 78 +0.132 +0.064 0.038 – Replace the
the leading wheel and +0.102 0 ~ 0.132 bushing
bushing

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 Measurement of the patterned surface and
flange wear
Patterned surface
1 Clean the patterned surface (a) and surface of
the flange (b) of the leading wheel.
2 Horizontally place one dipstick on the surface
of the flange (b).
Use the depthometer (e) to measure the depth
between the surface of the flange (b) and the
patterned surface (a) (2-1).
3 Measure it for three times and take the
Fig. 9 Measurement of the Patterned Surface average value.
Wear
4 Alternatively measure the left and right sides.
If necessary, repair it or replace it.

Flange

1 Clean the measuring surface of the leading

wheel.
2 Use the vernier caliper (f) to measure the
depth of the flange between (c) and (d).
3 Measure it for three times and take the
average value.
4 Alternatively measure the left and right sides.
If necessary, repair it or replace it.

Fig.10 Measurement of the Flange Wear

224
 Disassembling and assembling tools of the
leading wheel

Table 4. Tools

Symbol Tools Remark

a Pressing tool 20t
b Lubricating grease gun
c Torque spanner 60 kgf·m
d Pin jig

e Socket assembler and remover jig

f Supporting jig of the leading wheel

g Shaft extrusion jig

h Socket assembler and remover jig

j Engine oil SAE 10W-30

k Hammer
L PTFE tape 1

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 Disassembling of the leading wheel
Caution! Numbers in parenthesis after the part
name refer to numbers in the figure.

1 Remove screws and spring set.

2 Remove the pin (8) and drain out oil.
Caution! Drain the lubricating oil into one
container (p)

Fig. 11 Removal of the Spring Set

3 Place the pin jig (d) on the pin (7); slightly

knock the jig with one hammer to push out the
pin.

Fig. 12 Removal of the Pin

4 Place the leading wheel (1) on the supporting

block (f) of the leading wheel; place the shaft
removing jig (g) on the shaft (2) and use the
pressing tool to push out the shaft.

Fig. 13 Pushing with One Pressing Tool

5 Place the leading wheel (1) supporting rack (f)

of the leading wheel; place the bushing
removing jigs (e) and (h) on the bushing (4);
after that, slightly knock the jig to push out the
bushing.
6 Respectively remove the seal ring (5) and
O-ring (6) of the leading wheel (1) and support
(3).
7 Remove the O-ring (9) of the shaft (2).
Fig. 14 Removal of the Bushing
8 Confirm that the seal surface of the packing
(5) has no damages or rust.

226
 9 Confirm that all wears of the leading wheel (1)
are in the allowable range.
10 Confirm that all wears of the shaft (2) and
bushing (4) are in the allowable range.

Fig. 15 Position to be Checked

Assembling of the leading wheel

Caution! Assemble it in the reverse order with the

removal.
1 Place the bushing (4) on the leading wheel
(1); use jig (e) and (h) and pressing tool (a) for
installation.

Fig. 16 Assembling of the Bushing

2 Install the O-ring (9) onto the shaft (2).

3 Coat the inside of the support (3) with one
layer of lubricating grease; afterwards, install
the shaft (2) and insert the spring pin (7). In
such case, please be cautious not to damage
the O-ring (9).
4 Respectively insert the seal ring (5) and O-ring
(6) into the support and leading wheel (1).

Fig. 17 Assembling of the O-ring

5 Install the shaft (2) onto the leading wheel (1).

Coat the contact surface of the seal ring (5)
with one layer of engine oil.
6 Install the support (3) and its seal ring (5) and
O-ring (6).

Fig. 18 Assembling of the Shaft

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Fig. 19 Assembling of the Spring Pin
Fig. 20 Assembling of the Leading Wheel and
Track Spring
• Coat the screw A with
277thread-locking agent
• Tightening torque: 27 ± 3 kgf·m
7 Insert the pin (7) with the hammer (k).
8 Prior to oil filling, perform one pressure
leakage test.
- Connect one air pipe for pressure
regulation with the oil filling throttle; after
that, complete immerse the component
into water.
- When the pressure is 2 ~ 3 kgf/cm2, air
bubbles shall not occur within 15s.
9 Fill engine oil (j).
Caution! Engine oil amount: 260 cc
10 Install the plug (8) and PTFE tape (L) and
completely tighten them.
11 Confirm that areas around the packings (5, 6)
and plug (8) have no oil leakage.
12 Assemble the leading wheel components and
track spring. Afterwards, manually confirm that
the leading wheel can rotate even though
resistance exists. (More than 10 times).
13 The terminal clearance shall be between 0.1
and 0.85 mm.
Caution! Coat the screw A with Loctite Glue #
277.
• Prior to oil filling, perform one pressure
Loctite leakage test firstly.
– Connect one air pipe for pressure
regulation with the oil filling throttle; after
that, complete immerse the component
into water.
– When the pressure is 2 ~ 3 kgf/cm2, air
bubbles will occur within 15s.
• The axial clearance shall be between 0.1 and
0.6 mm.
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 Replace one leading wheel

Tool
14290046 track axis pin pressing tool

Warning!
The work covers the heavy part processing; if
attention is not focused, serious damages will
be caused.
1 Remove the track. Please refer to the removal
of the track chain assembly in P237.
2 Use one pry bar to push the leading wheel
assembly out from the track rack.

Fig. 21 Front Leading Wheel

3 Install one lifting eye bolt onto the tension

spring assembly of the track.

Fig. 22 Installation of the Lifting Eye Bolt

4 Use one lifting equipment to remove the

leading wheel and track tension spring
assembly.

Fig. 23 Removal of the Leading Wheel and Track

Tension Spring Assembly

229
 5 Support it on one working table. Remove
screws connecting with the leading wheel and
track tension spring assembly. Replace the
leading wheel unit and install the whole
assembly.
- Tightening torque of connecting screws:
265 ±29 Nm
Caution! When installing the connecting
screw, coat the screw thread with Loctite liquid
#277.
Caution! Confirm that the bulge of the piston
end of the track tension spring is located in the
Fig. 24 Removal of the Connecting Screw track frame hole.
6 Install the track. Please refer to the installation
of the track chain assembly in P238.

2.2 Sprocket wheel tooth

Measurement of the sprocket wheel wear

Fig. 25 Sprocket Wheel

Table 5. Wear Limit, Unit: mm

Symbol Item Wear Limit Remedy Measures

A Wear limit of the sprocket wheel tooth profile 6 Replace it
B Width of the sprocket Standard value 58 ±2
wheel
Allowable value 50
Tooth number 21 EA -

230
 Measurement of the sprocket wheel tooth
profile
1 Clean the sprocket wheel tooth.
2 Align with the P1, P2, and P3 of the sprocket
wheel tooth wear measuring appliance (1) and
the wear line (3) of the sprocket wheel tooth.
- Part number of the measuring gauge for
the sprocket wheel tooth wear: 14516699
3 Measure it for twice and take the average
value.
4 If the measuring value (A) exceeds the wear
limit, replace the sprocket wheel.

Fig. 26 Measurement of the Sprocket Wheel Tooth

Wear
1 Measuring appliance for the sprocket wheel
tooth wear
2 Side line of the new sprocket wheel tooth
3 Wear line of the sprocket wheel tooth
A Tooth profile wear

Measurement of the sprocket wheel tooth

width
1 Clean the sprocket wheel tooth.
2 Use the vernier caliper (A) to measure the
sprocket wheel tooth width.
3 Measure it for twice and take the average
value.
4 If the measuring value (B) exceeds the wear
limit, replace the sprocket wheel tooth.

Fig. 27 Measurement of the Sprocket Wheel Wear

A Vernier caliper
B Tooth width wear

231
 Removal of the sprocket wheel tooth
1 Remove the track.
2 Place one wood block (W) on the track and
place the chassis onto the wood block to
depart the sprocket wheel tooth from the track.

3 Use one socket spanner to remove the

mounting screw (C) of the sprocket wheel
tooth.

Fig. 28 Removal of the Sprocket Wheel

Installation of the sprocket wheel tooth

Install it in the reverse order with the removal.

1 Install the sprocket wheel tooth onto the track

gearbox.
2 Coat the sprocket wheel screw (C) with Loctite
Glue # 277, and tighten it with the appointed
torque.
• Tightening torque: 27 ±3 kgf·m

Fig. 29 Tightening Screws

2.3 Steel track

Adjustment of the track tension

1 Rotate the superstructure to one side; make

downward operation with the boom to lift the
track.

Fig. 30 Lifting of the Track

232
 2 Slowly rotate the track forwards and
backwards for several times. Stop the track
during backward movement.

Fig. 31 Measurement of the Track Sagging

3 Measure the track sagging between the

central track plates of the track rack and
mounting surface of the track drum.

Warning!
The adjusting cylinder of the track contains
high-pressure lubricating grease. Don’t remove the
grease nozzle or bolt and valve component to
release the lubricating grease.
4 If it is intended to reduce the track tension, use
one oil-filling gun with the max. pressure of
690 bar to fill the multi-purpose lubricating
Fig. 32 Adjustment of the Track Tension grease into the adjusting oil cylinder from the
lubricating grease mouthpiece (B). If it is
A Tightening torque: 7 ± 0.25 kgf·m intended to increase the track tension, loosen
the valve component (A) for one circle to drain
out the lubricating grease of the adjusting oil
cylinder of the track from the bar hole (C).
Screw down the valve component after the
track sagging is well adjusted.
Caution! If pistons in the oil cylinder of the
track adjuster don’t act, replace the valve
assembly and repair or replace the oil
cylinder.
5 Adjust the track tension according to soil
conditions of the working place. See following
table for details.
Table 6. Track Tension Adjustment Based on
Soil Conditions, Unit: mm

Item Distance (A)

Common soil 250 ~ 260
Rocky ground 240 ~ 250
Soft ground (marsh, clay, 260 ~ 280
and loam)

233
 Descriptions of the track chain
Track chain

Fig. 33 Structure of the Track Chain

1 Connection (left) 5 Common pin 9 Common seal 13 Track shoe screw
2 Connection (right) 6 King pin 10 Separator 14 Nut
3 Main connection (left) 7 Common bushing 11 Pin
4 Main cconnection (right) 8 End locking bushing 12 Track shoe

234
 Wear limit of the track chain

Fig. 34 Dimensions of the Track Chain

235
Table 7. Wear Limit, Unit: mm

No. Check Item Standard Dimensions Service Limit Remedy

Measures
1 Connection space 171.75 175.75 Rotate or
replace the
2 Outer diameter of 53.75 48.75
pin and
the bushing
bushing
3 Track shoe height 25 15 Weld the
flange or
replace it
4 Connection height 94.5 88 Replace it
5 Clearance between Standard Specified Clearance Replace it with
the connection and dimensions tolerance a larger
bushing bushing
Shaft Hoe Standard Service
dimensions limit
53.75 +0.05 -0.176 -0.126 0.1
- 0.05 -0.25 ~ -0.3
6 Clearance between 36.55 +0.05 -0.2 0.15 0.15 Replace it
the connection and 0 -0.15 ~ -0.23 with a larger
pin pin
7 Clearance between 36.35 +0.02 + 0.05 + 0.02 - -
the connection and - 0.02 0 ~ +0.07
king pin
8 Clearance between - - - 5 Rotate or
the pin and bushing replace the
pin and
bushing
9 Clearance between 1.2 (one side) 5 (both sides)
connections
10 Tightening torque of 42 ± 4 kgf·m Tighten it
the track shoe
screw

236
 Measurement of the track wear
Measurement of the wear of the connecting
space of the track
1 Place the pin (3) onto the part connecting with
the sprocket wheel tooth and the track rack;
afterwards, slowly start the machine and move
it backwards to tension the track connection.
- Tool: Axis pin (Φ 40 × 160 mm)
2 Measure dimensions of four connections (1)
from the three connections away from the king
pin (2).
- Tool: Tape measuring tool
3 Measure it for twice and take the average
value.
Alternatively measure both left and right sides.
- Tool: Tape measuring tool
4 If the measuring value exceeds the wear limit,
repair or replace the track connection.

Fig. 35 Measurement of the Wear of the Track Connection Space

1 Dimensions of four connections
2 King pin
3 Pin
4 Frame

237
 Measurement of the outer diameter wear of the
bushing
1 Make measurement along D1 and D2
directions, and determine the smaller value of
two dimensions (D1 and D2).
- Tool: Vernier caliper
2 Measure it for twice and take the average
value.
Alternatively measure both left and right sides.
- Tool: Vernier caliper
3 If the measuring value exceeds the wear limit,
repair or replace the bushing.

Fig. 36 Measurement of the Outer Diameter Wear of Bushing

1 Pin
2 Bushing
3 Track shoe
4 Vernier caliper
5 Main connection

238
 Measurement of the connection height wear
1 Clean and connection.
2 Use the vernier caliper (3) to measure the
height (4) of the connection (2).
Caution! Measure the height of the
connection (2) at its center,
3 Make measurement along D1 and D2
directions, and determine the smaller value of
two dimensions (D1 and D2).
4 Measure it for twice and take the average
value. Alternatively measure both left and right
sides.
5 If the measuring value exceeds the wear limit,
repair or replace the track connection.

Fig. 37 Measurement of the Connection Height

Wear

1 Bottom plate 2 Connection 3 Vernier caliper 4 Connection height

239
 Measurement of the track shoe height wear
1 Clean the track shoe.
2 Use the depthometer (3) to measure the
height (4) of the track shoe (2).
3 Measure it for twice and take the average
value.
Alternatively measure both left and right sides.
4 If the measuring value exceeds the wear limit,
repair or replace the track shoe (2).

Fig. 38 Measurement of the Track Shoe Height

Wear
1 Connection
2 Bottom plate
3 Depthometer
4 Track shoe height

240
 Measurement of the clearance between
connection wears
Caution! Make measurement along the direction
of the leading wheel (5) or sprocket wheel tooth
(6).
1 Make cleaning and connection.
2 Use the thickness gauge (1) to measure the
clearance (4) between the interior connection
(2) and exterior connection (3).
3 Measure it for twice and take the average
value.
Alternatively measure both left and right sides.
4 If the measuring value exceeds the wear limit,
repair or replace the connection.

Fig. 39 Measurement of the Wear Between Connections

1 Thickness gauge
2 Interior connection
3 Exterior connection
4 Clearance between connections
5 Leading wheel
6 Sprocket wheel tooth

241
 Removal of the track chain
Tool

1 Every track is installed by one king pin. Move

the machine to make the king pin be located in
the position pointed by the arrow.

Fig. 40 Position of the King Pin

2 Loosen the track tension regulation valve;

drain out the lubricating grease from the
cylinder to loosen the track tension.

Fig. 41

Warning!
The tension spring oil cylinder is filled with
high-pressure grease. Please be careful when
adjusting the track tension or loosening the
track. And, faces, hands, and bodies shall be
away from the nozzle and valve.
• Don’t loosen the valve for 1 circle.
• If the loosening circle number is larger than 2,
the valve and lubricating grease will depart.
3 Remove the track shoe screw, track shoe, and
pin from the main connecting pieces of the
track.

242
 Warning!
Don’t’ be close to the leading wheel, for the
track component may fall and injure your feet.
4 Use the hydraulic pressing tool (1) to remove
the king pin (2). (Remove the pin after
removing the track shoe around the king pin.)

Fig. 42 Removal of the King Pin

5 Repeat above steps and disassemble the

track in another side.
6 Slowly start the machine backwards to lower
the track. Drive the machine onto another
track or thickened steel plate.

Fig. 43 Slowly Starting the Machine

Installation of the track chain

Tool
1 When one assistant slowly starts the machine,
insert one stick to the king pin hole at the end
of the track; help align the track with the
sprocket wheel tooth.
Caution! Please pay attention to the
assembling direction of the track chain.

Fig. 44 Inserting One Stick into the King Pin Hole

A Leading wheel side
B Sprocket wheel side
C Track chain

243
 2 When aligning the king pin (A) hole of the
track connection, use the wood blocks (B) and
(C) to support the track.

Fig. 45 Track Support

Assembling the king pin

Fig. 46 Assembling of the King Pin and Spacer Piece

3 Install the spacer piece (1) into the hole (3) of

the main connection (2). Pay attention to the
direction of the spacer piece.
4 Connect the track main connection (2) with the
common connection (5); align the pin hole (4)
of the main connection (2) with the hole of the
main bushing (6) installed onto the common
connection (5) with the pressing tool.

Fig. 47

244
 5 Use one hammer to insert the king pin (7) into
the aligned holes (4, 6).

Fig. 48 Insertion of the King Pin

A Hydraulic pressing tool
B Locking device

6 Push one small pin (9) into the small hole (8)
of the king pin (7) end and bend it for 30°.
Assemble the removed track shoe.
Tightening torque: 42± 4 kgf.m
Caution! Prior to assembling the track shoe screw,
please confirm that paint and oil stain on the
assembling surface of the track shoe screws are
cleared.

Fig. 49 Pin Bending

1 Track connection
2 After installing the axis pin, bend it (above
30°).

245
 2.4 Slide rail of the carrier roller
Descriptions of the top roller

Fig. 50 Structure of the Carrier Roller

1 Contact roller shell 9 Snap ring
2 Crankshaft 10 Lock washer
3 Cover 11 Plug
4 Bushing 12 Screw
5 Bushing 13 Shaft collar
6 Plate
7 Packing
8 O-ring

Measurement of the carrier roller wear

Fig. 51

246
Table 8. Wear Limit, Unit: mm

No. Check Item Standard Dimensions Service Limit Remedy

Measures
1 Outer diameter 165 – Reinforce
of the flange welding or
replace it
2 Outer diameter 140 130
of the patterned
surface
3 Flange width 71.5 –
4 Clearance Standard Allowable error Clearance Replace the
between the dimensions bushing
Crankshaft Hole Standard Service
shaft and
dimensions limit
bearing
40 –0.030 +0.35 0.33 ~ –
–0.090 +0.30 0.44
5 Clearance 46 +0.150 +0.030 -0.09 – Replace the
between the +0.120 0 ~ 0.15 bushing
contact roller
and bushing
6 Mounting screw 52 ± 5 kgf.m
torque

Measurement of the outer diameter wear of the

top contact roller patterned surface
1 Clean the top contact roller.
2 Use the outer diameter caliper (1) to
measure the outer diameter (2) of the top
contact roller patterned surface.
3 Read the vernier caliper value.
4 Alternatively measure both left and right sides.
If the measuring value exceeds the wear limit,
repair or replace the top contact roller.

Fig. 52 Measurement of the Outer Diameter Wear of the Top Contact Roller Patterned Surface
1 Outer diameter caliper (200mm)
2 Outer diameter of the top contact roller patterned surface
3 Vernier caliper(200mm)

247
 Measurement of the top c contact roller flange
width wear
1 Clean the top contact roller.
2 Use the vernier caliper (2) to measure the
flange width (1) of the top contact roller flange.

3 Alternatively measure both left and right sides.

If the measuring value exceeds the wear limit,
repair or replace the top contact roller.

Fig. 53 Measurement of the Top Contact Roller

Flange Width Wear
1 Width of the top contact roller flange
2 Vernier caliper(200mm)

248
 Disassembling and assembling tools of the top
roller

Table 9. Tool, Unit: mm

Symbol Tool Remark
a Screw screwdriver
b Pliers
c Pliers
d pressing tool 20t (44000 pounds)
e Spanner
f Supporting mould of the
carrier roller

A: 85
B: 100
C: 105
h Disassembling and
assembling moulds of the
bushing

A : 35
B : 41.5
i Torque spanner 3 ~ 10 kgf·m
j Hammer Elastic hammer
k Loctite # 277
l General spanner 6 mm
n Engine oil SAE 10W-30
p PTFE tape 1
r Snap ring pliers

Disassembling of the top roller

1 Remove the plug (11) and drain out oil.

2 Use one snap ring to remove the snap ring (9)
of the drum shell (1).
3 Remove the cover (3) and pull out the O-ring
(8). Upon assembling, replace one new
O-ring.
4 Straighten the lock washer (10) and remove
the mounting screw (12).
Fig. 54 Disassembling of the Top Roller

249
 5 Simultaneously remove the shaft and shaft
collars (2, 13) of the drum shell (1).
6 Remove the seal (7) from components of the
roller housing (1), shaft and shaft collars (2,
13).

Fig. 55 Removal of the Shaft and Shaft Collar

7 Place the drum shell (1) cover onto the

supporting block (f) downwards.
8 Place the socket assembler and remover jig
(h) onto the bushings (4, 5), and push them
out with the pressing tool (d).
• Confirm that the packing seal surface is
not damaged or rusty.
• Confirm that the contact roller wear is in
the allowable range.
• Confirm that the wear of the shaft and
bushing is in the allowable range.
Fig. 56 Removal of the Bushing
• Confirm that the interference between the
bushing and contact roller is in the
allowable range.

Assembling of the top contact roller

Caution! Completely clean the parts prior to
assembling.
Assemble parts in the reverse order with the
disassembly.

1 Place the cover (3) of the contact roller

housing (1) onto the working table
downwards, and calibrate the bushing (4) and
frame hole. Place the socket assembler and
remover jig (h) onto the bushing (4) and install
it with the pressing tool (d). Assemble the
bushing (5) with the same method.
2 Vertically install the shaft component and
shaft collar onto the bench vice.
3 Install the packing (7) onto the seal slot of the
shaft and shaft collar components (2, 13).
4 Install the packing (7) onto the seal slot of the
Fig. 57 Installation of the Bushing
roller housing (1).
5 Clean the seal ring and contact surface and
coat them with a thin layer of engine oil.
Install the roller housing (1) onto the shaft
and shaft collar assemblies (2, 13); the seal
(7) shall not slide out.

250
 6 Place the plate (6) onto the shaft (2) in the
roller housing; align with the screw hole, and
install the locking plate (10). Tighten the
assembling screw (12) with the appointed
torque, and bend the locking plate (10) as
well.
7 Install the O-ring (8) onto the cover (3).
8 insert the cover (3) into the contact roller
housing (1). In such case, pay attention not to
damage the O-ring (8). Afterwards, use one
snap ring pliers to install the snap ring (9).

Fig. 58 Installation of the Roller Housing

9 Prior to oil filling, perform one pressure

leakage test firstly.
- Connect one air pipe for pressure
regulation with the oil filling throttle; after
that, complete immerse the component
into water.
- When the pressure is 2 ~ 3 kgf/cm2, air
bubbles will not occur within 15s.
10 Fill engine oil (SAE 10W–30, 50 cc). Use the
PTFE tape (p) to install the plug (11), and
tighten it with the general spanner.
11 Manually confirm that the top roller (1) can be
smoothly rotated by hand.
Confirm that areas around the packing (7) and
cover (3) have no leakages.
Caution! The axial clearance shall be
between 0.14 and 0.85 mm.
Fig. 59 Application of the Engine Oil

251
 Replacement of one top roller
Removal

Warning!
The work covers the heavy part processing; if
attention is not focused, serious damages will
be caused.

1 Place the machine at the repair position F,

and ensure that the space is enough to extend
the track. Please refer to P45 for details of the
repair position.
2 Drain out the lubricating grease from the
lubricating grease mouthpiece (1) on the
tension oil cylinder to reduce the track tension.
Place one piece of hard board under the
lubricating grease mouthpiece to receive the
drained lubricating grease. After loosening the
track, please tighten the lubricating grease
mouthpiece.
Fig. 60 Track Tension Lubricating Grease
Caution! The valve shall not be loosened for
Mouthpiece
more than 1 circle. If being loosened for more
than 2 circles, the valve and lubricating grease
may be sprayed under large force.

3 Use the lifting device to lift the track away from

the top contact roller. Increase the track
tension, and place the wood block between
the track chain and undercarriage. Lower the
track till it reaches the wood block.

Fig. 61 Lifting of the Track

4 Remove screws of the top contact roller on the

top contact roller bracket.

Fig. 62 Removal of the Carrier Roller

252
 Installation

5 Replace the old top contact roller with a new

one. Remove the wood block. Align the track
linkage center with the top contact roller.
- Tighten the bracket screw (A) with the
specified torque of 510 ±49 Nm
Caution! Coat the mounting screw with
Loctite 277 thread-locking agent.
6 Pump in the lubricating grease with the
lubricating grease mouthpiece on the tension
oil cylinder, and tension the track as well.
7 Evenly distribute the tension by means of
Fig. 63 Installation of the Top Contact Roller operating track forwards and backwards for
several times in two directions.

8 Measure tension and sagging of the track

shoe from track shoe top to the chassis
bottom. And, measure the place with the max.
sagging.
Table 10. Track Tension Adjustment Based on
Soil Conditions, Unit: mm

Working Conditions Clearance (A), Unit:

mm
Common soil 260 ~ 280
Rocky ground 240 ~ 260
Fig. 64 Measurement of the Track Sagging
Soft ground (marsh, 280 ~ 300
clay, and loam)

253
 2.5 Bottom roller
Descriptions of the track roller

Fig. 65 Structure of the Track Roller

1 Drum shell 6 O-ring
2 Shaft 7 Plug
3 Shaft collar (support) 8 Pin
4 Bushing 9 O-ring
5 Seal ring

254
 Wear limit of the track roller

Fig. 66 Dimensions of the Track Roller

Table 11. Wear Limit, Unit: mm

No. Check Item Standard Dimensions Service Limit Remedy

Measures
1 Outer diameter of the 185 – Reinforce
flange welding or
replace it
2 Outer diameter of the 150 140
patterned surface
3 Flange width 24 13.5
4 Clearance between Standard Allowable error Clearance Replace the
the shaft and bushing dimensions bushing
Shaft Hole Standard Service
dimensions limit
60 0 +0.31 +0.26 1.5
–0.019 +0.26 ~0.329
5 Clearance between 68 +0.110 +0.030 -0.045 - Replace the
the contact roller and +0.075 0 ~ -0.110 bushing
bushing
6 Mounting screw 27 ± 3 kgf·m
torque

255
 Measurement of the diameter wear of the contact roller
patterned surface
1 Clean the track roller.
2 Use the outer diameter caliper (1) to measure the outer
diameter (2) of the track roller patterned surface.
3 Read the vernier caliper value.
4 Alternatively measure both left and right sides.
If the measuring value exceeds the wear limit, repair or
replace thetrack roller.

Fig. 67 Measurement of the Outer Diameter Wear

of the Track Roller Patterned Surface
1 Outer diameter caliper (200mm)
2 Outer diameter of the track roller
patterned surface
3 Vernier caliper (200mm)

Measurement of the contact roller flange width

wear
1 Clean the track roller.
2 Use the vernier caliper (2) to measure the
track roller flange width (1).

3 Alternatively measure both left and right sides.

If the measuring value exceeds the wear limit,
repair or replace the track roller.

Fig. 68 Measurement of the Track Roller Flange

Width Wear
1 Track roller flange width
2 Vernier caliper (150mm)

256
 Removal of the track roller

1 Loosen the track tension and lift the machine

till the distance between it and the ground is
about 300 mm, as shown in the figure.
2 Place one wooden wedge under the track
roller, and loosen four mounting screws of the
contact roller.

Fig. 69 Lifting of the Machine

3 Remove the screw and pull out the track roller.

Fig. 70 Removal of the Screw

Installation of the track roller

1 Find the front oil plug of the machine.

2 Coat the mounting screw thread of the bottom
drum with Loctite #277.
3 Calibrate the chassis and the screw hole of
the bottom contact roller (1); temporarily
tighten the screw with one small spanner.
Caution! If any abnormity occurs, including
too large screw resistance, remove the screw
and check the thread. It is not allowed to
Fig. 71 Position of the oil plug tighten the spanner for temporary fastening.
1 Track roller
A Front surface

4 Use one torque spanner to tighten the screw

with the specified torque.

Fig. 72 Installation of the Screw

257
 Disassembling and assembling tool of the
track roller

Table 12. Tool (Unit: mm)

Symbol Tools Remark
a Hammer
b Pressing tool 20t
c Pin jig

d Bottom roller supporting jig

e Assembling and
disassembling mould of the
shaft

f Bushing extrusion mould

h Molybdenum lubricating
grease
i PTFE tape 1
j Engine oil SAE 10W-30
k General spanner 6 mm

258
 Disassembling of the carrier roller

1 Remove the plug (7) and drain out lubricant.

Caution! Prepare one container to collect the
lubricant from the contact roller (1).
2 Take out the pin (8) from the shaft collar (3)
with the jig (c).

Fig. 73 Removal of the Spring Pin

3 Place the bottom contact roller shell (1) onto

the supporting jig (d). Place the shaft extrusion
jig (e) onto the shaft (2) and use the pressing
tool (b) to push the shaft out.

Fig. 74 Removal of the Shaft

4 Remove the packing (5) and O-ring (6) of the

shaft collar (3).

Fig. 75 Removal of the O-ring

5 Remove the packing (5) and O-ring (6) of the

contact roller housing (1).

Fig. 76 Removal of the O-ring

259

Fig. 77 Removal of the Bushing
Fig. 78 Removal of the O-ring
Fig. 79 Installation of the Pressing Tool for
Assembling the Bushing
260
6 Place the contact roller (1) onto the supporting
block (d), and place the socket assembler and
remover jig (f) onto the bushing (4). And, use
one hammer (a) and shaft extrusion grinding
tool (e) to push the bushing out.
7 Remove the O-ring (9) of the shaft (2).
8 Confirm that the ring seal surface has no
damages or rust.
9 Confirm that the wear of the contact roller is in
the allowable range.
10 Confirm that the wear of the shaft and bushing
is in the allowable range.
11 Confirm that the interference between the
bushing and contact roller is in the allowable
range.
12 Confirm that the clearance between the
bushing and shaft collar (side clearance of the
contact roller) is in the allowable range.
Assembling of the carrier roller
Caution! Completely clean the parts prior to
assembling.
Caution! Assemble it in the reverse order with the
removal.
1 Coat the bushing (4) with a thin layer of
molybdenum grease. Place the bushing
assembling and disassembling jig (f) onto
the bushing, and press the bushing as well.
 2 Install the new O-ring (9) at both sides of the
shaft.
3 Coat the inside of the shaft collar (3) with a
thin layer of lubricating grease and insert the
shaft (2). Here, pay attention not to damage
the O-ring (9).
Fig. 80 Assembling of the O-ring

4 Install the O-ring (6) and seal ring (5) onto the
shaft collar on the shaft; use one hammer to
knock the pin (8) into holes of the shaft collar
(3) and shaft (2).
5 Install the O-ring (6) and seal ring (5) onto the
contact roller shell (1). Assemble the shaft (2)
onto the contact roller shell (1) till the seal ring
on the shaft collar contacts with the seal ring
on the contact roller shell (1). Coat the contact
surface of the seal ring (5) with a thin layer of
lubricant.
Fig. 81 Assembling of the Pin

Fig. 82 Assembling of the Shaft onto the Contact

Roller Shell

6 Overturn the drum to make the installed seal

ring face downwards.
Caution! Pay attention not to fall the seal ring.
7 Install the seal ring (5) and O-ring (6) onto the
opposite shaft collar (3) and contact roller
shell. Coat the inside of the shaft collar (1)
with one thin layer of lubricating grease; install
it onto the shaft (2) till contacting with the
corresponding seal ring (5). Afterwards, coat
the contact surface of the seal ring with a thin
layer of engine oil.
8 Completely press the shaft collar (3).

Fig. 83 Assembling of the Shaft Collar

261
 9 When installing the shaft collar (3) and shaft
(2), keep the levelness of the contact roller.
Calibrate holes on the shaft collar (3) and
shaft (2), and use one hammer to install the
pin (8).
10 Prior to lubricant filling, perform one pressure
leakage test firstly.
- Connect one air pipe for pressure
regulation with the oil filling throttle; after
that, complete immerse the component
Fig. 84 Assembling of the Pin into water.
- When the pressure is 2 ~ 3 kgf/cm2, air
bubbles will not occur within 15s.
11 Fill the lubricant (j) through the plug hole of the
shaft collar (3). After filling, use PTFE tape
mounting plug (7), and tighten it with the
general spanner (k).

Table 13. Lubricant Amount

Type Item Specification Lubricant Type

LG6150 Oil amount 300 cc ISO VG 220

12 Confirm that areas around the packing (5) and

plug (7) have no lubricant leakages.
13 Manually confirm that the track roller (1) can
stably rotate for more than 10 circles (feeling
some resistance).

Table 14. Axial Clearance Between A to B mm.

Type Specification (A ~ B)
LG6150 0.16 ~ 0.74

262
 2.6 Tension device of the spring kit
Descriptions of the spring set

Fig. 85 Structure of the spring set

1 Cylinder body 7 Plate 13 Screw
2 Piston 8 Lubricating grease valve 14 Bar
3 Spring 9 Gasket
4 Locking device 10 Backup ring
5 Yoke iron 11 Dustproof ring
6 Nut 12 Grease gun nozzle

Disassembling of the spring set

Warning!
As the spring set bears a huge force, please be
cautious upon disassembling.
1 Remove the screw, plate (7), and lubricating
grease valve (8) from the piston (3) in turn.

263
Fig. 86 Removal of the Lubricating Grease Valve
and Plate

2 Remove the piston (2), dustproof ring (11),

bracket ring (10), and gasket (9) from the oil
cylinder (1) in turn.

Fig. 87 Removal of the Piston, Seal, Bracket Ring,

and Liner

Warning!
Use the special safety tool. When compressing or
loosening the spring with the pressing tool, the
spring shall not slide out.
3 Prepare one press machine with the energy
larger than 25t.
4 Use the press machine (D) to slowly compress
the spring (3). Remove the nut (6).
5 When releasing the force applied on the
spring (3), remove the yoke (5) and spring (3).

264
Fig. 88 Removal of the Screw and Lock Washer
A Screw bar C Metal plate
B Nut D Pressing tool

6 Remove the locking screw (13) and linkage

(14).

Fig. 89 Removal of the Screw and Linkage

7 Confirm that the cylinder inside and piston

outside have no damages or rust.
8 Replace the gasket and packing.

265
 Assembling of the spring se

Warning!
The spring shall not slide out upon installation.
Use the special safety tool. When compressing
or loosening the spring with the pressing tool,
the spring shall not slide out.
1 Install the moveable bar (14) onto the oil
cylinder (1). Align the screw hole of the
moveable bar (14) with the oil cylinder (1);
tighten the locking screw (13) as well.

Fig. 90 Installation of the Screw and Linkage

2 Place the spring (3) and yoke (5) into the oil
cylinder (1) with the bar (14) and piston (2);
slowly compress the spring (3) till the bar
thread is exposed. Install the nut (6) and
linkage (14) in turn.

Table 14. Installation Length and Load of the

Spring

Specification
Installation length, mm 405
Installation load, kg 8560 ± 685

266
Fig. 91 Installation of the Nut, Yoke, and Spring
A Screw bar C Plate
B Nut D Pressing tool

3 Install the liner (9), bracket ring (10), and

dustproof ring (11) onto the oil cylinder (1).

Fig. 92 Installation of the Piston, Seal, Bracket

Ring, and Liner

4 Fill the oil cylinder body (1) with the

lubricating grease and push in the (2).
Release air out form the oil cylinder.
5 Install the lubricating grease valve (8) to the
piston (2).
• Tightening torque (lubricating grease
valve): 7 ± 0.25 kgf·m

267
Fig. 93 Installation of the Lubricating Grease Valve

268