008-003-KUC-Guia para Medicion de Carrileria

SELA 1208-09
PROCEDURE MANUAL
EDITION 15
September 2014
FOREWORD
Previous KUC Procedure Manual “Edition 14” was updated with following change
1. Various tables of following were reviewed and updated by adding new models
1) Ultrasonic Measuring Point
2) Track Roller Sequence
3) Shoe Bolt Tightening Torque
4) Track Press Tooling Dimension Table
5) Track Selection
6) Shoe Application
2. Following information which has been provided by UC Flash News etc were added
1) Idea of “Simple Wear Check Gauge” for Track and Rollers
2) New Ultrasonic Tool (KOMEHC-09DL1: Arranged by KAC)
3) Caution of using KUC Program on Office 2007 and Office 2010
4) Caution at installation of “Dual Bushing Track”
● Dual Bushing Track needs “Exclusive Teeth”
● “T/Roller sequence Change” for Dual Bushing Track installation
5) Caution at C/Roller installation

6) NLubrication Oil Table for Idler, T/Roller & C/Roller
7) Shoe Jumping
8) Brittle Fracture of Shoe Bolt
9) Precaution for long traveling
3. Others
1) Brand name of “Lubrication Oil for Extreme Cold Spec.” was changed
Hoping the updated KUC Procedure Manual “Edition 15” will support on your sales promotion
activities for Komatsu Genuine Undercarriage
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CONTENTS
I. General Information.......................................................................................................................................... 6
1. Wear Measurement & Total Potential Hour................................................................................................. 6
1-1. Track Measuring Tool ......................................................................................................................... 6
1) KUC Measurement Kit ................................................................................................................... 6
2) Ultrasonic Tool ............................................................................................................................. 13
2)-1. New Ultrasonic Tool............................................................................................................... 16
3) Measurement Kit by KSA ............................................................................................................. 17
4) Simple Wear Check Gauge ................................................................................................... 20
1-2. Measuring Technique........................................................................................................................ 24
1) Link Height ................................................................................................................................... 24
2) Bushing O.D. ................................................................................................................................ 25
3) Link Pitch ..................................................................................................................................... 26
4) Shoe Grouser ............................................................................................................................... 31
5) Idler .............................................................................................................................................. 32
6) Track Roller .................................................................................................................................. 32
7) Carrier Roller ................................................................................................................................ 33
8) Sprocket Teeth ............................................................................................................................. 35
9) Other Check Point ........................................................................................................................ 38
10) Ultrasonic Measuring Point Table ................................................................................................ 39
1-3. Calculation of Hour Left..................................................................................................................... 41
1) Basic Idea .................................................................................................................................... 41
2) 3-Ways for Calculating of Hours Left ........................................................................................... 43
1-4. Study on Point of Sales ..................................................................................................................... 50
2. Undercarriage Component ........................................................................................................................ 51
2-1. Structure & Function ......................................................................................................................... 51
1) Overview ...................................................................................................................................... 51
2) Shoe Assy .................................................................................................................................... 52
(1) General .................................................................................................................................. 52
a) Grease Sealed vs S.A.L.T. (Sealed and Lubricated Track) .............................................. 52
b) Master Pin vs Master Link ................................................................................................ 52
c) HD Link & AR Link ............................................................................................................ 53
d) Wedge Ring Type UC ....................................................................................................... 55
e) Rotary Bushing Track (PLUS) ... [Optional Track] ............................................................ 56
f) Dual Bushing Track ... [Optional Track] ............................................................................ 57
g) Q & A on Rotary Bushing, PLUS and Dual Bushing Track ............................................... 63
(2) Link ........................................................................................................................................ 71
(3) Bushing .................................................................................................................................. 72
(4) Pin .......................................................................................................................................... 72
(5) Seal ........................................................................................................................................ 73
(6) Shoe....................................................................................................................................... 75
3) Rollers .......................................................................................................................................... 75
(1) Idler ........................................................................................................................................ 75
a) Track Adjuster & Recoil Spring ......................................................................................... 75
(2) Track Roller............................................................................................................................ 76
a) X-Bogie vs K-Bogie ........................................................................................................... 78
b) T/Roller Sequence ............................................................................................................ 78
(3) Carrier Roller.......................................................................................................................... 84
4) Sprocket ....................................................................................................................................... 86
5) Material Difference of UC parts among STD, Cold and Extreme Cold Specification ................... 87
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2-2. Wear Limit ......................................................................................................................................... 88
1) General View ............................................................................................................................... 88
(1) Rebuilt vs Run to Destruction ................................................................................................ 88
(2) Normal Limit vs Impact Limit .................................................................................................. 88
2) Concept on Wear Limit for each UC Parts ................................................................................... 89
2-3. Wear & Problem ................................................................................................................................ 91
2-3-1. General check point of job-site, machine and undercarriage at field ........................................... 91
2-3-2. Each Component ....................................................................................................................... 112
1) Link ............................................................................................................................................ 112
2) Bushing ...................................................................................................................................... 118
3) Pin .............................................................................................................................................. 121
4) Shoe ........................................................................................................................................... 122
5) Idler ............................................................................................................................................ 124
6) Track Roller ................................................................................................................................ 126
7) Carrier Roller .............................................................................................................................. 128
8) Sprocket Teeth ........................................................................................................................... 130
3. Variables that Affect Undercarriage Parts ............................................................................................... 133
3-1. Controllable Variables ..................................................................................................................... 133
1) Track Adjustment ....................................................................................................................... 133
2) Shoe ........................................................................................................................................... 134
(1) Shoe Width/Shoe Type ........................................................................................................ 134
(2) Factors Affecting Machine Production ................................................................................. 135
(3) Undercarriage System Wear & Structural Life Factor .......................................................... 136
(4) Sealed and Lubricated Track Joint Life................................................................................ 137
(5) Shoes for Special Conditions ............................................................................................... 137
3) Track Guards ............................................................................................................................. 137
4) Alignment ................................................................................................................................... 137
(1) Track Frame......................................................................................................................... 137
(2) Front Idler............................................................................................................................. 139
(3) Sprocket ............................................................................................................................... 139
5) Others ........................................................................................................................................ 140
(1) Cleaning ............................................................................................................................... 140
(2) Routine Inspection ............................................................................................................... 140
(3) Keeping Good Records........................................................................................................ 140
3-2. Partially Controllable Variables ....................................................................................................... 141
1) Use Slowest Operating Speed ................................................................................................... 141
2) Minimize Reverse Travel ........................................................................................................... 141
3) Avoid Spinning the Tracks ......................................................................................................... 141
4) Avoid Favoring One Side ........................................................................................................... 141
5) Frequent Turning in the Same Direction .................................................................................... 141
6) Alternatives ................................................................................................................................ 141
7) Traveling Across a Lateral Slope ............................................................................................... 142
8) Side-Hill Cutting ......................................................................................................................... 142
9) Others ........................................................................................................................................ 142
3-3. Uncontrollable Variables ................................................................................................................. 143
1) Soil & Underfoot Condition ......................................................................................................... 143
2) Terrain Condition ....................................................................................................................... 147
3) Job Application ........................................................................................................................... 147
3-4. Reference........................................................................................................................................ 149
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4. Maintenance and Adjustment .................................................................................................................. 150
4-1. Proper Way of Track Installation on Machine ................................................................................. 150
4-2. Track Adjustment ............................................................................................................................ 155
4-3. Idler Guide Adjustment.................................................................................................................... 155
4-4. Track Roller Rotation ...................................................................................................................... 155
4-5. Field Action against Oil Leakage..................................................................................................... 157
4-6. Requirement of the Shoe Bolts Tightening ..................................................................................... 160
5. Reference ................................................................................................................................................ 164
5-1. Rebuilding ....................................................................................................................................... 164
5-2. Necessary Dimension Table for Track Press Tool/Jig .................................................................... 164
5-3. Lub. Oil Table (Oil type & Volume) for Idler, T/Roller and C/Roller ................................................. 167
5-4. Wear Mechanism ............................................................................................................................ 171
1) Sprocket Teeth & Bushing O.D. ................................................................................................. 171
2) Chain Tightness ......................................................................................................................... 176
3) Pin/Bushing Internal Wear ......................................................................................................... 177
5-5. Operator’s Comfort & Vibration ....................................................................................................... 179
5-6. Distinguishing from the Non-Genuine Parts .................................................................................... 180
1) General View ............................................................................................................................. 180
2) Way for Distinguishing from the Non-Genuine Part ................................................................... 180
II. Undercarriage Management......................................................................................................................... 182

1. General.................................................................................................................................................... 182
2. Countermeasure for R & M Cost Reduction ............................................................................................ 183
2-1. Precautions when Turning Pin & Bushing ....................................................................................... 183
1) Bushing O.D. wear ..................................................................................................................... 183
2) Link Tread Surface Wear ........................................................................................................... 183
3) Pin Wear .................................................................................................................................... 183
4) Reusing Seal .............................................................................................................................. 183
5) Rollers Wear .............................................................................................................................. 184
6) Sprocket Wear ........................................................................................................................... 184
2-2. Contribution to R & M Cost Reduction for K-Bogie and Wedge Ring ............................................. 185
1) Features of K-Bogie and Wedge Ring UC ................................................................................. 185
2) Merit for R & M Cost Reduction ................................................................................................. 185
2-3. Contribution to R&M Cost Reduction on PLUS (Rotary bushing track) .......................................... 185
1) Features of PLUS (Rotary bushing track) .................................................................................. 185
2) Advantage for R & M Cost Reduction ........................................................................................ 185
2-4. Case Study of Pin and Bushing Turning ......................................................................................... 186
III. Selection Guide ............................................................................................................................................ 189

1. Track Selection........................................................................................................................................ 189
2. Shoe Selection ........................................................................................................................................ 191
1) Types of Shoe ............................................................................................................................ 194
2) Applicable Shoe on Each Model ................................................................................................ 196
3) Practical Idea for Shoe Width Selection on D475A .................................................................... 202
3. Track Roller Guard Selection .................................................................................................................. 207
4. Hints for Field Action ............................................................................................................................... 208
1) Wear Criteria on the Soft Ground .............................................................................................. 208
2) Soil Packing ............................................................................................................................... 208
3) Skid Guard ................................................................................................................................. 208
4) Tri Link Track for Oil Field Application ....................................................................................... 209
5) Shoe Jumping ............................................................................................................................ 210
6) Brittle Fracture of Shoe Bolt ....................................................................................................... 211
7) Precaution for long traveling ...................................................................................................... 211
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I. General Information
1. Wear Measurement & Total Potential Hour
1-1. Track Measuring Tool
The following instruments and tools are required to make inspections and measurements.
1) KUC Measurement Kit

Parts Number
791-502-1005
Other Tools:
To remove mud, the following auxiliary tools are also
required:
a. 1-m Pinch bar
b. Scoop
Inspection & Measurement Tool List

Remark
Index
Part No. Instrument Inspection &
No. Purpose
Measurement
1 790-301-1410 Steel Measure D
2 791-502-1011 Muti-scale A, C, F, H, I, J, K, L, M
3 791-502-1021 Adapter I
4 791-502-1030 Adapter I
5 791-502-1061 Outer Calipers G
6 791-502-1071 Thickness Gauge E
7 791-502-1080 Scale A,L
8 791-502-1090 Scale A,L
9 791-502-1210 Test hammer B
10 791-502-1220 Pin D,E
11 791-502-1230 Wire Brush For removing mud
12 791-502-1240 Pinch Bar For removing mud
13 791-502-1260 Binder For filing sheets
14 791-502-1291 Case For carrying measuring instruments
Remark Inspection
Inspection & Measurement
Index Parts Name
A Shoe Grouser Height
B Loose Shoe Bolt
C Link Link Height
D Link Pitch
E Gap on Link Face
F Outer Diameter of Bushing
G Carrier Roller Outer Diameter of Roller
H Flange Width
I Track Roller Outer Diameter of Roller
J Flange Width
K Front Idler Tread Depth
L Tread Width
M Tread Radius
N Sprocket Tooth Width
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(1) How to Use a Multi-scale
1. Names of parts of a multi-scale and adaptor.
Depth reference plane 1st vernier
2nd vernier
Regular scale
O.D. measuring Stopper

reference plane
Jaw
Depth contacting face
Track roller measuring adaptor
2. How to read the multi-scale.

(1) Regular scale and 1st vernier
The scale can be read to an accuracy of 1/20 mm. Learn how to read the multi-scale by the follow-
ing example.
40 50 60
Regular scale
1st vernier
0 2 4 6 8 10
Fig. 1
1 Read the “0” position of the 1st vernier on the regular scale. In Fig. 1, the “0” position is located
between the 41-mm and 42-mm scale divisions.
2 Find out where the scale of the 1st vernier coincides with that of the regular scale. In Fig. 1, the
scale of the 1st vernier concides with a division between the 4- and 6- divisions of the regular
scale. Then, it can be seen that a division between the 41-mm and 42-mm divisions is 0.5.
3 Consequently, the measured value is 41 + 0.5 = 41.5 mm.
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50 60 70 80
Regular scale
1st vernier
0 2 4 6 8 10
Fig. 2
1 The “0” division of the 1st vernier is located between the 55-mm and 56-mm divisions on the reg-
ular scale.
2 The scale of the 1st vernier coincides with the 6.5-division of the regular scale. That is, the regu-
lar scale reading is 0.65 mm.
3 Consequently, the measured value is 55.65 mm.
When the multi-scale is used as a depth gauge to measure the depth, the scale can be read in the
same manner as described above.
(2) 1st and 2nd verniers

[How to use the multi-scale to measure the track roller O.D.]
1 First measure the link tread height by at-
taching the depth contacting face to the Shoe
link and fix the 1st vernier with a stopper.

Link
Lock the 1st vernier
Stopper Multi-scale
2 Then, set an adaptor on the bolt used for

Multi-scale
lubricating track roller with oil and align the
tip of the 2nd vernier with the adaptor. Adaptor
Track-roller
Shoe
3 Readings of the 1st and 2nd vernier in this case form a value of the track roller O.D.
NOTE: The 1st and 2nd verniers give a twofold reading. That is, the actual track roller outside
diameter can be read directly.
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The scale of the 2nd vernier can give a reading with a 1/5 mm-accuracy.
See the following example
0 1 2 mm
2nd vernier
1st
vernier
250 60 70 80
Fig. 3
1 Find out where the “0” position of the 2nd vernier is on the 1st vernier. In Fig. 3, the “0” position is
located between the 254-mm and 256-mm scale divisions.
2 Then, find where the scale of the 2nd vernier coincides with that of the 1st vernier. In Fig. 3, both
vernier scales coincide with each other in a division of 1.6. Thus, it can be seen that the division
of 1.6 mm is between the 254-mm and 256-mm divisions of the 1st vernier.
3 Consequently, the track roller O.D. is 254 + 1.6 = 255.6 mm.
0 1 2 mm
2nd vernier
1st vernier
200 10 20 30
Fig. 4
1 The “0” division of the 2nd vernier is located between the 206-mm and 208-mm divisions of the
1st vernier.
2 Both vernier scales coincide with each other in the 0.4-division of the 2nd vernier.
3 Consequently, the measured value is 206.4 mm.
3. Precautions for use of the multi-scale.

(1) Measurement of the link height
The link height should be measured at the mid-point of the link. Keep the multi-scale upright to the
shoe with the depth contacting face pressed onto the shoe. Next, slide the 1st vernier until it comes
into contact with the link, then, read the 1st vernier. Do not make a measurement on a bent shoe. If
the right angularity cannot be insured, the measurement will not be correct.
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(2) Measurement of the track roller O.D.
As shown above, locate the center of the track roller to be measured at the mid-point of the link
wherever practicable and measure the O.D. Force the depth contacting face onto the shoe tightly
with the multi-scale kept upright to the shoe. Then, slide the 2nd vernier along the 1st vernier fixed
with a stopper until the 2nd vernier is aligned with the adapter. At this time, check the shoe for bend-
ing. Do not measure a bent shoe. The measurement should be carried out at the mid-point of link,
because the link wears out as shown below and different measured values are obtained at various
points of measurement on the link.
Park the machine on a mound so that the track rollers come into close contact with links and then
make the measurement. If they are not in a close contact with each other, errors will likely occur in
the measured values.
Remarks: Multi scale is not supplied anymore due to supplier problem
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(2) Sprocket Wear Gauge
● Wear gauge ● Wear gauge with holder assembly
Purpose: To check abrasion on the face

of sprocket teeth.
Sprocket wear gauge
Holder Assembly
The above type gauges have been developed for

some models.
Refer to SERVICE TOOL GUIDE for details.
The wear gauge used to be available as SERVICE Tool for old models.
But it is not available anymore for new models.
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● Current system
Sprocket Wear Gauge is not supplied as service tool for new model
1. Komatsu provides a sketch of sprocket profile in Shop Manual for each model.
2. You take a photocopy on transparency film (for OHP) by enlarging into actual size.
(A scale factor indicated in a sketch)
3. Use the transparency film as sprocket weargauge
(See a sample sketch below)
Align here on the center of bolt
* The above drawing is reduced to 35%. Enlarge it to 287% to return it to the full scale and make it copy
on an OHP sheet.
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2) Ultrasonic Tool
The ultrasonic measurement tool enables to shorten
the measurement time for bushing, track rollers, etc.
(1) Part Number

799-A50-1000
(Komatsu America supplies)
(2) Feature
1) Removing extra dirt is not necessary.
For measuring, just remove as much dirt as about
20 mm the diameter of the measuring probe.
Wear after turned of track bushing
2) The tool enables you to easily measure wear of the
turned track bushing.
The external shape of the turned track bushing is
warped, and you cannot measure its wear correctly
with calipers, etc.
The ultrasonic measurement tool measures the
thickness (A size) of the bushing directly and
calculates the wear amount, while calipers cannot
correctly measure the wear amount after turned
due to the influence of the wear amount (B size)
Wear before turn of track bushing
before turn of track bushing.
3) The tool enables you to easily measure the tread

of a track roller.
When you try to measure it with traditional
calipers, the calipers hit the guard, etc. and that
prevents you from measuring it. But the ultrasonic
measurement tool enables you to measure it
simply by bringing the probe to it.
(3) Cautions in Measuring with The Ultrasonic Measurement Tool

In measuring idler tread (the inside surface is not finished) and link height, measured values vary with
the position to which the probe is placed. So, you have to measure them carefully.
- 13 -
(4) How to Use
4.1 Preparatory work
1) Connection of probe
Connect a probe to the tool.
2) Zero point adjustment
Turn the tool ON and apply the couplant to the
probe.
Place the probe on the test disk on top of the tool.
When Prb0 is displayed, the adjustment is
satisfactory.
3) Inputting data of the machine to be measured

s 4URNONTHEPOWEROFTHETOOLPRESSTHE&),%
button, and select CREATE.
s 3 E L E C T + / - ! 4 3 5 T E M P L A T E A N D I N P U T
model name, serial number, service meter,
measurement date, and track type.
s 5SINGTHE5PAND$OWNARROWSTOSCROLLTHROUGH
alphabet/numbers and the Left & Right arrows
to change character position, ENTER the
information as prompted.
4.2 Measuring each Component (see note). Follow

prompts for each measurement.
1) Measuring link bushing thickness
Put couplant on end of probe.
Place the probe on the link bushing and measure
the thickness of the bushing.
2) Measuring link height
Place the probe on the link and measure the
height of the link.
3) Measuring shoe grouser height
Place the probe on the shoe grouser and measure
the height of the grouser.
4) Measuring idler tread
Place the probe on the idler tread and measure
the thickness of the tread.
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5) Measuring carrier roller tread
Place the probe on the carrier roller tread and
measure the thickness of the tread.
6) Measuring track roller tread
Place the probe on the track roller tread and
measure the thickness of the tread.
Note: Refer to “Ultrasonic Measuring Point Table”

on KUC procedure manual for where to take
ultrasonic measurements.
Warning: Ultrasonic Measurements are based on the velocity of sound through various materials.
Before taking any undercarriage measurements, verify that the velocity is set to 5900
meters/sec.
Additional couplant is available: Part Number 799-A50-1130 4 oz. bottle.
(5) Others
Since link pitch cannot be measured with the ultrasonic measurement tool, the manual measurement
from the scale can be entered into the ultrasonic measurement tool.
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2)-1. New Ultrasonic Tool (Arranged and supplied by KAC)
KAC arranged to supply New Ultrasonic Tool under corroboration with new supplier.
New Ultrasonic Tool is e-CARE friendly of course as same as previous one. And one of feature is that
USB cable which is used for data transfer from Ultrasonic Tool to PC becomes standard accessory
(It was not available on previous kit).
Detail is as follows.
Subject: KOMATSU ULTRASONIC UNDERCARRIAGE TOOL

Part Number—KOMEHC-09DL1
In Komatsu’s continuing effort to provide a
practical technical approach for everyday busi-
ness problems, we are proud to offer the new
Ultrasonic Measuring Tool for the ultrasonic
test and evaluation of undercarriage wear.
The ultrasonic tool measures and records

worn part dimensions. Not only does the ultra-
sonic tool improve many aspects of the meas-
uring process but also electronically collects
and stores the data required to calculate the
remaining wear life and provide detailed re-
ports. The tool comes with a USB cable that
connects to your laptop or pc and downloads
the information to your personal computer for
evaluation in the Komatsu eCare Program.
Measuring and evaluating undercarriage wear

is a proven tactic used by Komatsu distributors
to successfully market replacement undercar-
riage parts. The Ultrasonic Measuring Tool has
a multitude of key advantages in supporting
these efforts:
• Decreases the amount of time required to

prepare a part for measurement
• Provides consistent accuracy even when used by different inspectors
• Records the measurement as it is taken, providing a reliable data recording operation
• Measure bushings after a turn • Will store the data for over two hundred machine inspections
• Accepts manual measurements • Downloads data directly to your personal computer for calculation of re-
maining wear life and other detailed reports in the Komatsu e-Care program
• Accurately measures in inches or millimeters to two decimal places
• Can be used to measure the thickness of other parts such as fuel tanks and cutting edges up to twenty inch-
es in thickness
x Provides a professional, high tech impression
A copy of the Ultrasonic Tool Manual, if it’s not included in your kit, can be located on the Extranet in the Un-
dercarriage page under the Parts tab.
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3) Measurement Kit by KSA
This measurement tool kit is a manual measuring tool, but it has unique tools in it.
Fog example ...
i Small depth gauge for measuring idler tread
ii Small caliper for measuring Bushing O.D.
(1) Part Number

Fig. 1
CK40-25
(Komatsu South Africa supplies)
(2) Components
This tool is composed of three layers, and there are two kinds of outside calipers on the upper layer
as shown in Fig. 1, there are three kinds of scales, two kinds of depth gauges and one kind of outside
caliper on the middle layer as shown in Fig. 2, and there are one kind of vernier caliper and brushes on
the lower layer as shown in Fig. 3.
Fig. 2 Fig. 3
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Component parts:
No. PART NUMBER DESCRIPTION Q'ty SIZE
1 P40-25 CASE 1 400 x 250 x 100 mm
2 PDG-34 DEPTH GAUGE ALUMINIUM 1 340 mm
3 PDG-12 DEPTH GAUGE ALUMINIUM 1 120 mm
4 POC10-1 OUTSIDE CALIPER 1 100 mm
7 PV200-1 VERNIER CALIPER 1 200 mm
8 PST300-1 TAPE MEASURE 1 3 Meter
9 PSR300-1 STEEL RULE 1 300 mm
10 PSR100-1 STEEL RULE 1 100 mm
11 PWB-1 WIRE BRUSH 1
12 PS50-1 SCRAPER 1 50 mm
Note: You can order components individually.
(3) Feature
1) Three kinds of calipers are available suitably for parts Shape for easy measurement
to be measured. and caliper with screw
2) The calipers are fitted with screw and enables you
to measure accurately because it prevent positions
from changing at the measuring time. In addition, the
caliper tips are shaped, enabling to measure easily.
3) The depth gauges enable you to measure link

heights and grouser heights accurately.
Depth gauge
(4) How to Use

4.1 Measurement of wear of idler tread
1) Use the depth gauges to measure wear.
2) Read the scales to determine the depths measured
with the depth gauges.
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4.2 Measurement of Link Height
1) Use the depth gauges to measure link height.
2) Read the scales to determine the depths measured
with the depth gauges.
4.3 Outer Shape of Bushing

Use the outside calipers to measure outside shape.
4.4 Measurement of Grouser Height

Use the depth gauges to measure grouser height.
4.5 Measurement of Carrier Roller Tread

Use the vernier caliper to measure carrier roller tread.
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4.6 Measurement of Track Roller Tread
Use the vernier caliper to measure tread diameter.
4.7 Measurement of Link Pitch

Use the scales to measure link pitch.
4) Simple Wear Check Gauge

Simple Wear Check Gauge is very handy tool to check whether undercarriage wear reaches to “wear
limit” already or not.
1. Features and usage of gauges

1) There are “Track gauge” and “Roller gauge”
● Track gauge: Check wear of Bushing O.D., Link height and Shoe grouser
⇒ Bushing O.D. wear is checked by radial wear only as simple method
● Roller gauge: Check tread wear of Idler, T/Roller and C/Roller
2) Gauges are arranged to check whether wear reaches to “wear limit (100% wear) or not
● So Gauge dimension is designed based on 100% wear from STD surface (no wear)
Track Gauge Roller Gauge
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3) Judge whether wear reaches to “wear limit” or not by touching gauge on wear portion and check if
there is clearance between gauge and STD surface.
● If there is a clearance, still not reaches to wear limit (100% wear)
● If gauge touches to STD surface, wear is over wear limit (100% wear)
Sample of
C/Roller
Gauge is not touched to C/Roller flange (STD surface) yet Gauge touches to C/Roller flange (STD surface)
⇒ Tread wear still not reaches to wear limit ⇒ Tread wear is over wear limi
2. Available model for gauges (Gauge drawings are ready)

1) H/E: PC200-7/8, PC300-7/8 and PC400-7/8
2) Bull: D37-23, D39-23, D51-22, D61-22/23, D65-12/15/16 and D155A-5/6
Simple Wear Check Gauge is very handy tool for your parts marketing activity. We believe it’s very
effective to use on following cases.
1. Want to check undercarriage wear condition in short and limited time.

● Can not take long time (stop machine) to measure UC wear by wear measuring tool
● Checking time for one machine is very limited as customer has many machines
2. Want to grasp UC condition just briefly by simple way. Because it’s no need to measure UC wear at
each visiting time as UC life is very long.
● Like as Excavator case
3. Want to show and explain UC wear condition to customer visually.

● It becomes easier to convince customer of replacing UC parts by showing wear condition by gauge
(if it’s over wear limit)

4. Want to use it as initial UC checking tool for newly joined PSSR (not full trained yet).
REMARKS
1. Needless to say, we can not check “wear life %” of UC parts by the Simple Wear Check
Gauge. Then we can not estimate “Point of sales” timing accordingly.
2. We believe that individual marketing approach based on visiting, measuring wear and
estimating “Point of sales” is more important for large size machine. It’s a different activity from
simple wear check gauge approach.
3. So there is no plan to make simple wear check gauge for large size machine.
4. Even Simple Wear Check Gauges which are currently available, please utilize them as
supplementary tool to traditional wear measuring activity.
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Link height wear check
Gauge touches link tread surface

but not on bottom of shoe plate
yet. This means link height still not
reaches to 100% wear.
Bushing O.D. wear check
It’s better see from upper side to

check if gauge touches to
bottom of shoe plate or not
Gauge touches to bushing
but not to bottom of shoe
plate yet. This means
bushing wear still not
reaches to 100% wear.
Shoe grouser wear check
Gauge touches to tip of

grouser but not to base of
shoe plate yet. This means
shoe grouser still not
reaches 100% wear
- 22 -
Idler wear check
Gauge touches to Idler tread (both)
Gauge not reaches to top of Idler
This means Idler

tread still not reaches
100% wear
C/Roller wear check
Gauge touches to C/R tread (both)
Gauge not reaches to top of flange
This means C/Roller

100% wear
T/Roller wear check
Gauge touches to T/R tread (both)
Gauge not reaches to top of flange
This means T/Roller

100% wear
- 23 -
1-2. Measuring Technique
The Komatsu undercarriage measurement tool kit allows you to quickly and accurately measure all
undercarriage components.
As a professional alternative, Komatsu ultrasonic measurement tool is available. This tool measures part
thickness by sending high frequency sound waves through the component to be measured.
1) Link Height
Track links may be measured by either the multi-scale or ultrasonic measurement tool.
(1) By Manual Tool

The multi-scale measures link height from the track shoe to the track
tread. The ultrasonic measurement tool measures the distance from the
link tread surface to the bushing bore.
Obtain an average value by measuring more than 3 places on both right

and left sides.
Check for cracked links.
Cracks can be overlooked when the link is filled with mud.
(Clean with a wire brush)
Measure the tread at the place of the greatest wear.
Some rock, swamp, triple-grouser shoes have steps on the link-shoe
contacting surfaces. These steps must not be added to the link height.
(2) By Ultrasonic
The reference value represents the length of the bushing press fitting part.
The minimum length shall be ready by moving the probe on the center
line of the bushing press fitting part and the read value shall be regarded
as a measured one.
- 24 -
Special Instruction
Caution on Wear Measurement of Link Height by Ultrasonic
Please remind followings when you measure link height wear by Ultrasonic.
1) Measure the length from link tread to bushing press fitting part (That length is provided as wear criteria
for ultrasonic measurement), not pin press fitting part.
2) Read minimum length by moving the prove around the vertical center line of the bushing press fitting part
The attached photos and materials are for your reference to explain the above.
Read minimum length by

moving the prove
“Correct measurement” “Incorrect measurement”

Measuring bushing press fitting part Measuring pin press fitting part
2) Bushing O.D.
The track link bushing is the most important component to measure in
the undercarriage. The bushing may be measured by the multi-scale, by
ultrasonic measurement tool or by the outside caliper. The multi-scale
measures the diameter of the bushing. The ultrasonic measurement tool
measures the bushing wall thickness. The outside caliper measures the
diameter of the bushing.
By the multi-scale
By the ultrasonic
measurement tool
By the outside caliper
- 25 -
3) Link Pitch
Grease Sealed Track
Measurements shall always be made by first applying tension to the track
by engagement of pin with sprocket.
Steel Pin
Regular pin for tentioning
Master pin
Measurement B
Measurement A
Measure the lengths of 4 links, at a point more than 2 links from the
master pin.
(Measurement A)...... for master pin
(Measurement B)...... for regulation pin
Check for excessive wear on the boss of the link.
Ask how many times the pin-bushing were replaced by new ones.
Sealed and Lubricated Track
#1 #2 #3 #4
Measurement Technique
Sealed Track internal wear is measured by determining the pitch extended length over four adjacent
sections with a tape measure calibrated in 0.02" (0.5 mm) increments.
The track and tape must be stretched tight and straight to obtain an accurate measurement. The
calibrated side of the tape should be located along an imaginary line which connects the pin centers. The
reading should be made from one side of a pin to the same side of the fifth pin away (which includes 4
track sections).
The hook on the 0" (0 mm) end of the tape should not be used and the mark at an even increment of
inches or centimeter should be placed at the 5th pin leaving the end of the tape free to measure the
fractional part of the total length (see diagram above.) This measurement should be taken at least 3
sections away from one-piece type master link joints and should be repeated at least twice over different
sections of the track on both sides of the machine. This measurement can be used directly to find percent
worn in the charts.
- 26 -
Hint for Checking of Link Pitch Extension
Link pitch extension is one of checking items on UC wear measurement.
In case of “Grease Sealed Track” which is installed on excavator, it is recommended to measure it at each time
because of following reasons.
1) On “Grease Sealed Track”, grease which was filled between pin and bushing is easily disappear at
early stage due to simple sealing mechanism.
2) Then metal to metal contact leads to extend link pitch gradually.
3) Link pitch extension sometimes becomes criteria for track (link assy) replacement.
4) So measuring link pitch extension is important on “Grease Sealed Track”.
In case of “SALT” which is installed on bulldozer however, it is recommended to check if there is lubricating oil
by “Hot Pin Check” prior to measure link pitch extension because of following reasons.
1) Even on “SALT”, link pitch extends if lubricating oil is leaked from seal. On the contrary no link pitch
extension is anticipated as long as there is lubricating oil.
2) F5 seal which is used on Komatsu genuine SALT has high reliability against oil leakage. So, as
general speaking, it’s no need to worry about oil leakage up to 4,000H in normal condition.
3) Then it is recommended to check if there is lubricating oil by “Hot Pin Check” prior to measure link
pitch extension as simple and easy checking.
- 27 -
“Hot Pin Check” means to check heat of bushing. Practical way and action after checking is shown in next page.
1. Check heat of bushing by touching your bare hand or by “Heat gun”
1) Operate the machine for 30 min. at least before checking

2) Check heat immediately after machine stopped
3) Touch bushings as many as possible
4) Touch pin end (side face) if you can not approach bushing due to mud packing etc
2. If you can touch bushing continuously with your hand, we can judge there is still lubricating oil. So you can
skip measuring link pitch extension.
3. Hot pin which you can not touch bushing continuously or heat gun shows more than 50 degree C indi-
cates loss of lubricating oil and link pitch extension due to metal to metal contact.
● Lubricating oil for final drive is always stirred during movement and you can not touch final drive case
continuously due to high temperature. So image of “Hot” means final drive case temperature.
Final Drive case
- 28 -
4. If you found some hot pin, please follow instruction below.
1. Please refer to Shop Manual on how to replace one set of link

2. But replacing one set of link in field is not easy job.
3. So, as a general guideline, it’s better to continue working if no. of hot pin is
less than 10%.
4. If hot pin increases more than 10%, it’s better to remove link assy from the
machine and repair it at track repair shop.
Reference: Alternative way for measuring link pitch extension
You must stretch the track for measuring link pitch extension.
Usually you do it by reversing the machine after putting a round bar on sprocket as shown below chart
Put round bar on sprocket

Reverse the machine
- 29 -
If you don’t have a round bar with you, please stretch the track with following method and measure link pitch
extension as alternative.
1) Raise the track off the ground

● Excavator: Raise one side of track off the ground by using work equipment
● Bulldozer: Raise whole machine off the ground by using blade and ripper
Remark 1: Check if ground is hard enough before raising
2) Rotate the track 2 – 3 times in the air so all track sag comes lower side of track
3) Measure link pitch extension on upper side of track
Remark 2: Be careful as machine is dangerous position
Sample of Excavator
Sample of Bulldozer
- 30 -
4) Shoe Grouser
Grouser wear is the only measurable wear on the track shoe. Track shoe may be measured by the multi-
scale, by the straight scales or by the ultrasonic measurement tool.
The scales measure the height from the shoe plate to the tip of the grouser.
The ultrasonic measurement tool measures the distance from the tip of the grouser to the bottom of the
shoe plate.
(1) Grouser height by the multi-scale

Grouser height may be measured by the multi-scale, convex rule or steel scale.
Remove all mud stuck on the shoe.
Obtain an average by measuring 2 or 3 places on both right and left sides.
Measure swamp shoe at about 100 mm from either end of the shoe.
Grouser type shoe Swamp shoe
(2) Grouser height by the ultrasonic measurement tool

Grouser height may be measured by the ultrasonic measurement tool.
Measure the grouser height at the points 1/4 of the shoe width distant from the shoe ends.
Grouser type shoe Swamp shoe
- 31 -
5) Idler
(1) By manual
Idler tread wear may be measured by the multi-scale, by the depth
gauge or by the straight scales. The both scales measure the height
from the idler center flange to tread surface.
multi-scale
straight scales depth gauge
(2) By ultrasonic
Measure the tread thickness at the center of the
tread width. (Type-A)
Measure the tread thickness at the flange-side end
of the tread width, both on the inner side tread and
outer side tread, to adopt the thinner reading as the
measurement value. (Type-B)
Type A Type B
6) Track Roller
By the outside calipers
(1) By manual
Track roller wear is the most difficult to measure in the undercarriage.
Track roller guard or other conditions prevent measurement of all
rollers. Track roller tread wear may be measured by using the outside
calipers, the multi-scale or the ultrasonic measurement tool.
The outside calipers measure tread diameter and give a direct reading.
The multi-scale measures height from the track shoe to the center of
the track roller circle. The calculated result gives an indirect reading.
By the multiscale
The ultrasonic measurement tool measures the distance from the tread
surface to the inside diameter of the roller.
(2) By ultrasonic
Tread thickness may be measured by the ultrasonic tool.
Measure the tread thickness at a point slightly shifting toward the
By the ultrasonic measurement tool
center of the part from the center of the tread width.
(Common with single flange and double flange types)
- 32 -
7) Carrier Roller
(1) By manual
Carrier roller tread wear may be measured by the outside calipers. The
outside calipers measures tread diameter and gives a direct reading.
(2) By ultrasonic
Tread thickness may be measured by the ultrasonic tool.
Type A, B
Measure the tread thickness at a point near the outer
end of the tread on the opposite side of the support,
avoiding the bolt hole.
Type A Type B
Type C, G
Measure the tread thickness at the point slightly
outward from the center of the tread on the opposite side of the support.
When the measuring point deviates too far out, the tread thickness
becomes thinner than the normal section and compare the measurement
Type C Type G value with the reference value to make sure measurement is being made
at the right position.
Type D, E, F
Measure the tread thickness at a point near the
outer end on the tread on the opposite side of the
support.
Type D Type E Type F See Measuring point table.
- 33 -
Special Instruction
Caution on Wear Measurement of C/Roller by Ultrasonic
Please remind followings when you measure C/Roller tread wear by Ultrasonic.
1) Always refer to the “Ultrasonic Measuring Point Table” in KUC Procedure Manual as measuring point
differs depend on the shape of C/Roller
2) Generally speaking, measure the tread thickness at a point near outer end of the tread on the opposite
side (far side) of C/Roller support (That area’s thickness is provided as a wear criteria for ultrasonic
measurement)
3) Avoid measuring at cover bolt area
The attached photos and materials are for your reference to understand the above.
Support Correct measurement

1. Opposite side of support
2. Near outer end of tread
3. Avoiding cover bolt
Cover Bolt
Incorrect measurement Incorrect measurement

“Near side of support” “Measuring at cover bolt area”
- 34 -
8) Sprocket Teeth
Sprocket wear may be measured by the sprocket wear gauge or ultrasonic
measurement tool.
(1) By manual
The gauge determines the sprocket tooth percent worn.
When applying the wear gauge, fit the upper and lower portions at the
standard line, and cover the two sprocket teeth with the gauge so that the
quantity of the right and left teeth becomes equal.
Where a sprocket is not of a segment type, the standard line cannot
clearly be determined. Therefore, the amount of wear should be estimated
from the viewpoint of balance of the entire profile.
(2) By ultrasonic
Type A Type B Type C
Sprocket hub
mounting side
See Measuring point table.
Special Instruction
UC Wear Measurement on PLUS
Wear measuring method on PLUS is same as conventional track as basic. There however are some
reminding points on measurement because of its structure difference as below.
1. Feature of PLUS and reminding points at wear measurement

1) PLUS has “Rotary Bushing”
Rotary Bushing
Additional machining for oil

reserve at bushing inside
- 35 -
(1) Bushing rotates so bushing O.D. surface wears evenly
● There are no “Forward drive wear”, “Reverse drive wear” and “Radial wear” anymore which is
common on conventional track .
You can measure bushing O.D. at any direction on both ultrasonic and manual
measurement
(2) There is additional machining for oil reserve at inside of bushing
The additional machining is counted on wear criteria of bushing O.D. for ultrasonic
measurement
2) PLUS has “Parallel link”
Wear criteria of link

Outer Link Inner Link height for Ultrasonic
measurement
Small Bushing
(1) There are 2 kinds of link; Outer link and Inner link
● Pin is press fitted on outer link
● Small bushing is press fitted on inner link
Wear criteria of link height for ultrasonic measurement is provided as length between
link tread surface and outer surface of small bushing which is press fitted in inner link,
as shown the above
- 36 -
2. Reference photo on wear measurement by ultrasonic
1) Bushing O.D.
● Wear criteria of link height for

Ultrasonic measurement
● Small Bushing
2) Link Height
● Measure under vertical center

line of bushing
● Read minimum value by
moving the prove
“Correct measurement” “Incorrect measurement”

Measuring bushing press fitting part Measuring pin press fitting part
- 37 -
9) Other Check Point
(1) Hot Pin Check for SALT (Sealed and Lubricated Track)
Check the pins temperature by thermometer or hand quickly after
stop the machine which operates over 30 minutes.
1. HOT: Pretty hot. It can’t touch continuously.
(More than 50°C)
2. WARM: Like tepid water, but it is hotter than Link.
(About 35°C)
3. Cold: A normal temperature which is same as Link.
(About 25°C)
s 7ARMANDHOTPININDICATESLOSSOFLUBRICATIONOIL
(2) Gap of Link Face
Gap of linked faces may be measured by the thickness gauge.

Carefully check gaps, particularly on a machine operated at high speed,
carry all and scraper-towing tractor.
Measure the gap between the outer and inner link after scraping off the
dirt.
Measure with the track tightened.
(3) Roller Flange Wear

1. Carrier roller
Carrier roller flange wear may be measured by the multi-scale.
The multi-scale measures the thickness of the flange.
2. Front idler
Idler flange wear may be measured by the multi-scale or by the
ultrasonic measurement tool. The multi-scale measures the tread width.
Tread width by the multi-scale

Tread width may be measured by the multi-scale.
Measure from the end of roundness.
(4) Shoe Bolt Loose

Shoe bolt loose may be measured by tapping with the test hammer.
A shoe bolt may be loose even though there is no mud stuck on it.
(A visual check should be made.)
- 38 -
10) Ultrasonic Measuring Point Table
Bulldozer
Ultrasonic Measuring Point Ultrasonic Measuring Point

Model Model
C/R Idler Sprocket C/R Idler Sprocket
7 A 21
A
8 E 21
D21 A A A
7A ESS 2,2A
P
8 15
21 A EX 15E0
EX A A D85 C B B
22 C 15R
D31
21 A P 21
PX A A
22 C 15
21 A PX 15E0
EX
22 15R
A A
C 2
EX & Exi 23
PLUS A 5
D37
21 A 6
PX D155 C B B
22 5
A A
C AX 6
PX & Pxi 23
PLUS 7
21 2
EX A
22 5
D275 C B B
EX & Exi 23 5
AX
PLUS 5E0
D39 B A A
21 D355 A 5 C B B
PX
22 3
PX & Pxi 23 3
PLUS 5
E 6 5E0
D41 B A A D375 A C B B
P 6 5R
EX & Exi 22
PLUS 6
D51 B A B
PX & Pxi 22 6R
PLUS 3
12 3
EX
15 D475 A 3 C B B
EX & Exi 23 5
PLUS 5E0
D61 C A B
12 D575 A 3 C B B
PX
15
PX & Pxi 23
PLUS
12
15
PLUS
EX
16
PLUS
17
PLUS
12
15
PLUS
D65 C B B
PX
16
PLUS
17
PLUS
15
PLUS
WX 16
PLUS
17
PLUS
D68 ESS 12 C B B
D70 LE 12 C B B
- 39 -
Hydraulic excavator
Ultrasonic Measuring Point Ultrasonic Measuring Point

Model Model
C/R Idler Sprocket C/R Idler Sprocket
PC60 7 F A C 6
6 7
US
8 7E0
PC78 F A C
6 8
UU
8 8R
PC88 MR 8 F A C 10
PC400 C B C
6 6
PC120 E A C
8 7
2 7E0
LC
US 8 8
PC128 10 E A C 8R
2 10
UU
8 6
2 7
8 7E0
US
8T 8
PC138 10 E A C 8R
2 10
PC450 C B C
USLC 8 6
10 7
6 A 7E0
LC
7 8
8 8R
B
8E0 Hybrid 10
10 10
PC200 C C PC490 C B C
6 A LC 10
7 6
LC 8 7
B
8E0 Hybrid 8
10 8E0
PC2䠍0i 10 C B C 8R
PC210LCi 10 C B C PC600 C B C
6
1 Hybrid 7
HB205 C B C
2 Hybrid LC 8
1 Hybrid 8E0
HB215 LC C B C
2 Hybrid 8R
6 A 6
7 7
8 B 8
10 8E0
PC220 C C PC650 C B C
6 A 6
7 7
LC LC
8 B 8
10 8E0
3 PC700 LC 8E0 G B C
US 8 6
10 7
PC228 C B C
3 6
USLC 8 PC750 LC G B C
7
10 6
6 SE
7
7 6
7E0 7
8 8
10 8E0
PC300 C B C
6 8R
7 PC800 8 G B C
LC 7E0 LC 8E0
8 8R
10 8
6 SE 8E0
7 8R
7E0 8
8 8E0
10 8R
PC350 C B C PC850 G B C
6 8
7 SE 8E0
LC 7E0 8R
8 6
10 PC1100 LC 6 G B C
1 Hybrid SE 6
HB335 C B C
LC 1 Hybrid 7
1 Hybrid 8
HB365 C B C
LC 1 Hybrid 8R
PC1250 7 G B C
LC
8
7
SE
8
PC1800 6 C B C
PC2000 8 C B C
- 40 -
1-3. Calculation of Hour Left
1) Basic Idea
(1) The purpose of UC wear measurement is as follows.
To calculate the remaining service life (hours) based on the dimension.
To estimate the replacement timing of UC parts based on the remaining service life.
(2) As for all of UC parts, the wear portion is heat-treated, and the surface has the higher hardness. But
as the portion is inner, the hardness is lower.
(3) The wear progression is influenced by the hardness, and the hardness is higher, the wear is less.
Hour
A
Total life
More than 50% B

The time per
of a total life 1 mm worn
Wear limit
Depth of worn out

1 2 3 4 5 6 mm
A 50% point of a allowance

of wear limit
(4) For example, as for the bushing outer-diameter, the relation between the wear progression and the
hardness is explained as follows.
A surface is the hardest in the area of allowance of worn out. At the surface area it takes longer
time to be worn 1 mm of depth. And the wear progresses slowly at the beginning.
But when the wear progresses to the deeper portion, the hardness is lowered. Therefore, the wear
progresses faster.
is the hours of the life potential. It is called Total Life. To be 50% of the wear allowance (3 mm),
it takes more hours than 50% of the wear life. (Point )
→ A wear does not go on in the relation with hours in propotion.
- 41 -
(5) As above-explained, because the relation between the wear amount and the service life is not linear,
the total life cannot be calculated by the simple comparative calculation due to the wear ratio between
the present service meter and the dimension.
(6) Komatsu guesses by the experience that the relation between the wear amount and the life becomes
the curve of the quadratic function Y = aXk. The shape of curve (the k value of Y-aXk) is varied by the
relation between the heat-treatment depth and the wear limit (the tolerance margin of 100% Wear)
of the UC part. (Usually, Wear Limit of UC part is designed that it is bigger than the heat-treatment
depth.)
(7) Based on the above relation, after the wear dimension measurement of the UC part, the life is
calculated by the measured value, at this time, Komatsu prepares the following three methods.
* The method that “Percent Worn Chart” and “Hours Left Chart” are used.
* The method that “Wear Life %” is calculated by using “KUC Program (Software)”, and based on
this, “Total Potential Hour” is calculated.
* The method that “Wear Life %” is calculated by using “Wear Life % Table, and based on this, “Total
Potential Hour” is calculated.
(8) The concept of the life calculation is the above , but currently, Percent Worn Chart is not prepared.
Accordingly, use or . Basically, use KUC Program. But when the personal computer is not
prepared, or when the approximate life is desired after the undercarriage wear is measured at the
jobsite, the method Wear Life % Table is convenient. For each detail, refer to the following item.
- 42 -
2) 3-Ways for Calculating of Hours Left
(1) Percent Worn Chart & Hours Left Chart
s 4HIS IS THE WAY THAT WHILE CHECKING THE TABLE THE
calculation is done manually. D375A-2 #16001 - #16999
s 4HEWAYISASFOLLOWS IDLER Tread Step Tread Radius Thickness
195-30-53110 Type B
Conditions: Multi-scale Idler wear gauge Ultrasonic

1. Service meter reading: 1600 hours. mm Inches % Worn mm Inches mm Inches
22.5 0.89 0 457.5 18.01 30.0 1.18
2. Wear value of idler tread step: 31.3 mm 23.8
25.0
0.94
0.98
10
20
456.3
455.0
17.96
17.91
28.8
27.5
1.13
1.08
26.3 1.03 30 453.8 17.88 28.3 1.03
Step 1. Using the PERCENT WORN CHART on the right, 27.5 1.08 40 452.5 17.81 25.0 0.98
28.8 1.13 50 451.3 17.77 23.8 0.94
convert the wear value of the idler step to a percentage. 30.0
30.6
1.18
1.21
60
65
450.0
449.4
17.72
17.69
22.5
21.9
0.89
0.86
31.3 1.23 70 448.8 17.67 21.3 0.84
* Wear rate = 70% Measure 31.9 1.25 75 448.1 17.64 20.6 0.81
32.5 1.28 80 447.5 17.62 20.0 0.79
Wear value
Step 2. Using the HOURS LEFT CHART below, draw a line up 33.1
33.8
1.30
1.33
85
90
446.9
446.3
17.59
17.57
19.4
18.8
0.76
0.74
34.4 1.35 95 445.6 17.54 18.1 0.71
from 1600 hours (Service meter reading) on the horizontal 35.0 1.38 100 445.0 17.52 17.5 0.69
35.6 1.40 105 444.4 17.50 16.9 0.66
axis, and find point A where it intersects the horizontal 36.3
36.9
1.43
1.45
110
115
443.8
443.1
17.47
17.45
16.3
15.6
0.64
0.62
37.5 1.48 120 442.5 17.42 15.0 0.59
line drawn from 70% (wear rate) on the vertical axis. 37.5 1.48 120 442.5 17.42 15.0 0.59
38.8 1.53 130 441.3 17.37 13.8 0.54
Step 3. Draw a curve parallel to the nearest curve to point A 40.0
41.3
1.57
1.62
140
150
440.0
438.8
17.32
17.27
12.5
11.3
0.49
0.44
up to the right and find point B where it intersects the

Note: 1. A l w a y s u s e t h e P E R C E N T W O R N
horizontal line from the 100% wear rate.
CHART that is applicable for the model
Step 4. Draw a perpendicular line from point B down to and Serial No.
intersect the horizontal axis (operating hours) at point C. 2. Obtain the wear rate from the measured
This point C (2100 hours) indicates the service limit for wear value using the PERCENT WORN
repair and rebuilding. CHART, or calculate it with the following
Step 5. Subtract the present service meter reading (1600 hours) formula.
from the reading at point C (2100 hours) to obtain the Standard value - measured wear value
Wear rate =
estimated hours left until repair and rebuilding (D). Standard value ñ repair limit
* D = 2100 - 1600 = 500 hours
Wear rate
(%) (Graph for y = axk, k = 1.3)
130
B
100 Repair limit
70 A
50
C
0
1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
1600 Operating hours (H)
s(OWEVER SINCE THE +5# 0ROGRAM HAS BEEN INTRODUCEDh0ERCENT7ORN #HARTv IS
NOTMAINTAINED4HEREFOREASFORTHENEWMODELSBOTHh0ERCENT7ORN#HARTvAND
“Hours Left Chart” are not prepared.
- 43 -
(2) KUC Program Software is Used.
s 4HISMETHODISALTERNATIVEFORTHEMETHODTHAT4OTAL0OTENTIAL(OURISOBTAINEDBYUSINGTHEBOTHh0ERCENT
Worn Chart” and “Hours Left Chart”.
s !FTER SETTING THE OPERATION AND THE USAGE CONDITIONS OF THE UNDERCARRIAGE IN 0ROGRAM WHEN THE
measured dimension is input, “Wear Life %” (The current rate of the use life when Total Potential Hour
is 100%.) is automatically calculated by Program.
s !FTER THAT BASED ON THE CALCULATED h7EAR ,IFE v h4OTAL 0OTENTIAL (OURv AND h2EMAINING ,IFE 4OTAL
Potential Hour - Current SMR) are manually calculated.
s h4OTAL0OTENTIAL(OURvISTHEHOURTHATTHE5#PARTREACHESFROMh.EWvTOh7EAR,IMITvANDIS
calculated by the following formula.
Total Potential Hour = Current SMR / Wear Life %
FEATURE OF THE PROGRAM

The program
#ANBEPROCESSEDBYONLYCLICKINGITSMENUBAR
(ASALLSTANDARDVALUEANDWEARCRITERIA
- Automatically calculate wear life percent with formula “y=aXkv
- Automatically calculate second wear life after bushing turn basing on the first
measurement.
#REATECOLOREDREPORTRAPIDLY
- Create wear percent graphs automatically
for not only standard measurement but also ultrasonic measurement.
- 44 -
SUMMARY OF THE PROGRAM
Program Main Menu

There are four (4) functions which are
1. Create New Inspection Report
2. Edit Library
6IEWOF,IBRARY3TANDARDVALUE
machine database
4. Chart (graph) and Summary report
Create New Report-1

Base information and measurement data are only
required for Input!
Register the customer name and machine
information so that it will be loaded on the
Inspection report automatically.
/NCETHEBASEINFORMATIONAREREGISTEREDONLY
input measured value is required.
Create New Report-2

Input measured value in the report form so wear
life percent are automatically calculated.
And it can be displayed in three (3) different
COLORSWHICHARE
"LACKUNDER
Pink (over 80% to 99%) and
Red (over 100%)
Edit Library
Any mistake of data input can be corrected by
using the edit function.
The inspection report need to be corrected can
BESEARCHEDBYCLICKINGONLYMENUBUTTONANDIT
is required to input correct data and save.
- 45 -
View function
!LLSAVEDINSPECTIONREPORTSTANDARDVALUEAT
wear and wear criteria at 100% wear and database
which are Customer and machine information can
be referred simply.
Create wear trend graph

It can be done by only clicking sheet button for
specifying area and undercarriage component to
create graph.
The graph can be modified as required under
Excel program.
Summary report for fleet machines

It is quite useful to let customer grasp each
machines wear condition.
Summary report for models

It is quite useful to understand wear condition
per model to schedule proper undercarriage parts
stock in advance.
Printing Reports
)NSPECTIONREPORT3UMMARYREPORTFORmEET
customer and Summary report for models are
able to print by clicking menu button only as
same as graph creation.
- 46 -
s 0RECAUTIONSWHENUSING+5#0ROGRAM
s By using this Program, both Manual measurement value (the measurement value by Caliper, etc)
and Ultrasonic measurement value can be processed. But both exclusive displays should be started,
and it is careful that both measurement values cannot be processed by the same display.
s As for K-bogie which are adopted on D275A-5, D375A-5 and D475A-5, Wear Criteria are different in
S/F and D/F of T/Roller. But in the current KUC Program, only Wear Criteria of S/F can be indicated.
When Wear Life % of D/F is required, this is calculated by using “Wear Life % Table”.
s Until now, Program and the updated Wear Criteria are designed so that they are downloaded from
WebCARE, but it is careful that after January in 2005, the system is changed so that they are
downloaded from Global Extranet.
Caution : KUC program on “Office 2007” and “Office 2010”.
When you use KUC Program on Microsoft “Office 2007” and “Office 2010”, you need to set “Add ins” tab
newly for indicating “Menu bar for KUC program”.
s0LEASESEEBELOWPROCEDURE
No menu bar for KUC Program so you can’t use it
1. If you see “Security Warning” at opening “KUC

Program” on Office 2007, click “Options”
2. If you don’t see “Security warning”, go to page 6
1. Select “Enable this content”
2. Then click “OK”
22 33
Become full screen
1. Click R.H. of mouse

2. Then click “Close full screen
44 55
- 47 -
Last tab is “View”
Now you have new tab “Add-ins”
“Security Warning” was disappeared
Click “Menu”
66 77
The menu bar has the same function as before
When you click “Add-ins” tab, menu bar for

“KUC Program” appears
88 99
Now you can use KUC Program same as before
10
10
- 48 -
(3) Wear Life % Table
This Table is the table that “Wear Life %” can be directly read from the measurement value by using KUC
Program. The sample is as follows.
s "ECAUSE THE READ VALUE IS h7EAR ,IFE v SAME AS +5# 0ROGRAM h4OTAL 0OTENTIAL (OURv CAN BE
calculated by the following formula.
Total Potential Hour = Current SMR/Wear Life %
s h7EAR ,IFE 4ABLEv WAS RESPECTIVELY DELIVERED BY 5# 3ALES 0ROMOTION -ATERIAL h5#&.
(Bulldozer)” and “UCFN05-001 (Excavator)”.
s 7HENTHEIRTABLESAREPRINTEDOUTTHEYCANBECONVENIENTLYUSEDATTHElELD4HEREFOREUSETHEM
- 49 -
1-4. Study on Point of Sales
1) As already described, the purpose for the measurement of UC part wear dimension is as follows.
(1) Based on the measurement value, the remaining hour of UC part is calculated.
(2) By matching to the replacement time or the maintenance time, the part is timely prepared and offered
to the customer for receiving the part order.
2) For calculating Remaining Hour, “Total Potential Hour” is calculated by three previously-described
methods. But the following precautions are required.
(1) When the Wear Life %, which was obtained by KUC Program and Wear Life % Table, is less than
30%, the value of Total Potential Hour, which was calculated by depending on it, is not accurate.
Accordingly, it is better to use as the reference for assuming the next measurement time.
(2) When “Wear Life %” is about 50%, the assumption is accurate.
(3) In the case that the rough life of undercarriage is obtained by the experience at the jobsite, the
following is recommendable. When Wear Life % is about 50%, shortly at the middle point, the wear
of undercarriage is measured, and Total Life is assumed. After that, when Wear Life % is assumed at
approx. 90%, the wear is measured again, and the replacement time is specified.
3) As previously described, Total Potential Hour, which is obtained by KUC Program or Wear Life % Table is
the hour reaching to 100% Wear Limit. Accordingly, depending on the use method of “Use by rebuilding”
or “Run to destruction”, actual Total Potential Hour, shortly how long the part is used, is required to change
as follows. Usually, the use is depending on the customer favorite, budget, etc. Therefore, by preparing
various options, explain and negotiate with customers.
(1) Using by rebuilding: Calculated Total Potential Hour is used as it is.
(2) Run to destruction: Total Potential Hour x 1.3 is used.
4) Accordingly, the concept of Remaining Hour is changed as follows.

(1) When the UC part is used by rebuilding.
Remaining Hour = Calculated Total Potential Hour - Current SMR
(2) When the UC part is used by “Run to destruction”.
Remaining Hour = Calculated Total Potential Hour x 1.3 - Current SMR
5) From the calculated Remaining Hour, Point of Sales is assumed by the following procedures.
(1) By the Hour Meter, which the machine worked from Delivery Date to the present measurement time,
the monthly mean operation hours is obtained.
(2) The Remaining Hour is divided by the monthly mean operation hours, and the period, which reaches
the UC part replacement or the maintenance from the wear measurement.
(3) This period is applied to the calendar, and the time is specified. This time is the Point of Sales.
6) When the Point of Sales is identified, the next preparation is progressed elaborately and the sure order
receiving is endeavored.
(1) The Quotation for the customer is prepared and produced.
(2) The stock of the required parts is ensured and the order of the Non-Stock parts is prepared.
(3) The next visit to the customer is arranged.
- 50 -
2. Undercarriage Component
2-1. Structure & Function
1) Overview
The tracks which bear and spread the weight of the machine on the ground convert the driving power
transmitted from the sprockets into tractional force. The track group includes a pair of right and left track
frames, where front idlers (1), carrier rollers (2) and track rollers (3) are mounted. The track looped around
each track frame is driven by the sprocket (5) and its rolling is guided by the front idler, carrier roller and
track rollers. The track roller guard (6) attached on the bottom surface of each track frame prevents the
track from slipping off due to intrusion stones.
5
2 6
1
3
2
(1) Track links
The hardness of the track link tread and side-surface improves durability and
increases strength against impact load. Dust seals are equipped to prevent sand
and soil from entering the gap between track links and bushing. Lubricated track
link assemblies are also available.
(2) Rollers
Track rollers
Track rollers are arranged under each track frame, they distribute the
machine weight evenly onto the tracks on
which the track rollers rotate.
Carrier rollers
Carrier rollers are arranged above each
track frame, and act to support the upper
half of the track loop in the proper rolling condition, preventing the track from
dangling by its own weight.
(3) Track shoes

Various track shoes are available to meet any working condition. The
grouser hardness strengthens the track shoes against wear and impact
load. Excellent ground penetration guarantees a large drawbar pull.
(4) Idlers
The front idler mounted at the front-end of each
track frame. The idler maintains smooth rolling
of the track.
- 51 -
(5) Sprocket teeth
The sprocket teeth are hardened through a unique heat treatment method for
added strength. Deep hardening enhances durability and increases strength
against impact load.
(6) Recoil spring

Keep the track tension properly.
2) Shoe Assy
(1) General
a) Grease Sealed vs S.A.L.T. (Sealed and Lubricated Track)
Well, let us see what type of stress is delivered on a track by the nature of job specification, A bulldozer
is required to have more traction force than dozer-shovels or hydraulic excavators that work with bucket.
There are two types of track links. One is oil sealed and lubricated type and the other is grease sealed
type. In both types, the clearance between bushing and pin is lubricated. But Oil sealed type last much
longer than Grease sealed type.
Sealed and lubricated type track Grease sealed type track

Oil type: GO80W90
b) Master Pin vs Master Link

Master Link Type
Master Link Type is whereby the link is divided into sections and
secured by bolts. You can easily remove and install the track shoe by
the bolts.
Master link
Regular link
Bolts for installing

master link
Example of master link
- 52 -
Master Pin Type
Master Pin Type shares the same link shape with portions of other links but the shape is different from
that of the pin and bushing. You need to pull the pin for replacement.
Master bushing is shorter

than regular one to allow easy
extraction from the links.
Difference between master pin, master bushing and

regular pin, regular bushing.
Master pin
Pin
Example of master pin, Link
master bushing Master pin has the same diameter as regular pin. The
Regular pin end of the regular pin are flat but the surfaces of the
master pin are chamfered for easy identification.
Bushing
Master bushing has the same diameter and tightening
limit as the regular bushing but is slightly shorter. This
Regular bushing
Example of regular pin, is for easier replacement purpose.
regular bushing
c) HD Link & AR Link

There are HD track link and AR track link on D39-21 ~ D65-15. If you use proper tack link on your
machine to meet job-site condition, you can extend UC life and reduce operation cost.
Here is a detailed explanation on both tack link.
HD track Link
The Heavy Duty (HD) track link is reinforced versions of the STD track link to have more durability and
life. Generally speaking HD track link has a bigger diameter of pin and bushing and higher link height
than STD track link.
The outlook is different between HD track link (or HD base AR link) and STD track link as shown below.
Example: D41-6 case

HD Link adopt longer pin press fit area, larger
bushing and higher link height so that more
durable than STD Link.
Link height: 106 Link height: 98
The HD track link is available on D41-6 and D65-12. On after miner changed machine (see below). The
HD track link has been applied from factory. But even before miner changed machine, you can install
the HD track link with some modification. (Please refer to P&S News “BB99001” and “BT01015”)
D41-6 m/c machine: S/N B30001 and up
D65-12 m/c machine: S/N 65001 and up
NOTE: On D61-12, the idea of HD track link has been applied on STD track link since the beginning
- 53 -
Because of the advantage of HD track link against STD track link, we recommend that you use the HD
track link on harsh load works sites such as rocky ground work sites and forestry work sites.
AR Track Link (Optional parts)

Abrasion Resistant (AR) track link has a special heat treatment bushing (Through hard, See below in
detail) to achieve longer wear life of bushing than normal bushing on STD and HD track link. The AR
track link exhibits advantage in sandy soil work sites where normally the bushing wears very rapidly.
Cautions
1) The AR track link is abrasion resistant track link for usage on lighter load work sites and it is not all
mighty track link.
2) Since the bushing hardness of AR track link is high in deep by special heat treatment, the bushing
may break if AR track link is used on other work sites than sandy soil condition. It is recommended
to use STD or HD track link on other works sites.
3) Do not use AR track link on the rocky terrain like as river bed. Reduce the speed when getting over
an obstacle even on the sand soil.
AR link is available on following models as an optional parts

D39-21 D65-12 (STD-AR and HD-AR)
D41-6 (STD-AR and HD-AR) D65-15
D61-12, D61-15, D51-22
“Hardness distribution of bushing for AR track link”
Hardness
Soft Hard
Outer surface
AR
(Through hard)
STD
Inner surface
AR bushing is through hard so that hardness
and wear limit could be increased.
AR
STD
Wear limit
“Wear progress on bushing”
Because of the hardness distribution change on
bushing for AR track link as shown the above, Worn
long wear life could be achieved. value
AR track link has 1.5 times wear life to STD track

Busing
link. 1.5 times
Hours
- 54 -
d) Wedge Ring Type UC
1) Wedge ring is installed at the end of pin. It

partially take charge of holding pin so that pin
press fitting force can be reduced. Link
2) Shape of link side face and guard has been Wedge ring
changed as shown below. In old track, the pin
end contacts with the guard. But in new track,
upper portion of link contact with guard prior to the
pin contacts with guard. So there is no wear at pin Pin
end.
3) Because of changing link side shape, total width of
link tread and T/Roller tread got widen as shown
below.
This change will help to extend wear life.
4) Wedge ring type UC has been adopted on
D275A-5, D375A-5 and D475A-5.
Wedge ring
Link
Wedge ring Pin
- 55 -
e) Rotary Bushing Track (PLUS) ... [Optional Track]
The outline of Rotary bushing track (PLUS: Parallel Link Undercarriage System) as below.
1. Structure
Difference from traditional parts and feature.
(1) Track shoe ass’y

- Rotary bushing system improves wear life and eliminate pin and bushing turn work.
s 4RACKBUSHINGSAREPRESSEDINTOTRACKLINKSINSTANDARDTRACK
s 4HEWEAROFBUSHINGISCAUSEDBYSLIDINGMOTIONTOSPROCKETTEETHDURINGFORWARDREVERSE
drive rotation of sprocket.
s "UT BUSHING OF 0,53 TRACK DO NOT SLIDE ON SPROCKET TEETH DUE TO THE ROTATING BUSHING
structure.
s )TIMPROVESWEARLIFE
- High link improves wear life.
- Parallel link system makes it easy to replace link in the field.
Parallel link type
Standard undercarriage
PLUS undercarriage
(2) Sprocket teeth

- Rotary bushing system reduces teeth wear life.
- New grooved Shape assures little damage to track seal in rotary bushing portion.
(3) Track roller guard

- New guard shape drastically reduces New guard
pin end face wear. (Contact to Link side)
New
Current
Traditional guard
(Contact to pin end face)
- 56 -
2. Feature and advantage of rotary bushing track
1) Reduce operating cost
(1) Improve Wear life.
Rotary bushing system improve wear life of bushing and sprocket.
High Link (Increase wear amount) improve the total track life (About 2-times than traditional
track life).
(2) Eliminate pin and bushing turn.

PLUS eliminate pin and bushing turn, so no cost for it and no machine down.
(3) Benefit of R&M cost

In conbination of the above (1) and (2), PLUS can reduce R&M cost drastically
2) PLUS can be used in varying soil condition same as traditional undercarriage.
Low
High Impact
General condition
Abressive Varying Condition
PLUS can be used
Low Impact
Abressive Condition
High
Low Impact High
(Sand) (Dirt) (Rock)
f) Dual Bushing Track... [Optional Track]
1. Whole outlook of Dual Bushing Track
Link shape of Dual Bushing Track

is “off set type” and it’s the same
as conventional track as shown left
photo. So outlook of track is the
same as conventional track.
- 57 -
2. Structure of Pin/Bushing area
Dual Bushing Track
Seal Link Conventional Track
Pin
Inner Bushing (Fix) Collar
Outer Bushing (Rotates)
Rotating
Bushing
(Outer Bush.)
+
Fixed
Bushing
(Inner Bush.)
=
Pin Dual
Bushing
Collar
1) Pin is press fitted into link

2) Collar (White) is press fitted into link, then “Inner Bushing (Blue)” is press fitted into the collar
3) “Outer Bushing (Green)” is free and rotates around “Inner Bushing (Blue)”
4) There is sealed and oil lubricated between pin and “Inner Bushing”, and between “Inner Bushing”
and “Outer Bushing”
5) Collar (White), “Outer Bushing (Green)” and “Inner Bushing (Blue)” are supplied as sub-assembly
from factory (as equivalent as bushing of conventional track).
- 58 -
Bushing Assy for Dual Bushing Bushing for conventional track
Collar (Inner Bushing is Outer Bushing

press fitted inside)
3. Function of Inner Bushing (Structure of One Link)
Dual Bushing Track Current Track
Bushing Link Pin
1) “Inner Bushing” is press fitted into link together with collar. So, as basic, one link of Dual Bushing
Track forms similar rigid structure as current track.
4. Mechanism of Dual Bushing Track

1) “Outer Bushing” is free and rotates
● Majority of bushing O.D. wear is caused by relative (sliding) motion with sprocket teeth
● On Dual Bushing Track, “Outer Bushing” is free and rotates so no more sliding motion is
produced
● Then wear which is caused by sliding motion is not produced anymore on bushing O.D. and
sprocket
2) Sealed and lubricated between “Outer Bushing” I.D. and “Inner Bushing” O.D.
● Outer Bushing is free and rotates around “Inner Bushing”.
● The space between 2-bushings is sealed and lubricated. So no wear is produced
3) Sealed and lubricated between “Inner Bushing” I.D. and Pin O.D.
● “Inner Bushing” is press fitted into link so it moves (rotates) around pin by link motion.
● Space between Pin and “Inner Bushing” is sealed and lubricated as same as current track. So
no wear is produced
- 59 -
Below picture shows advantage of Dual Bushing Track in the sliding motion with sprocket in
comparison with current track
5. Suitable/Targeted Application for Dual Bushing Track

1) Current link assembly life is less than 6,000H (including TPB)
2) Current Bushing O.D. life is less than 50% of link height wear life
3) SiO2 + Al2O3 contents are more than 90% (very abrasive job-site)
4) Job site where reversing speed is used R2 in majority
● This implies job site is not so rocky area
Reminder : Dual Bushing Track needs Exclusive Teeth.
Bushing O.D. of Dual Bushing Track is larger than the one of Conventional Track (See below table).
Bushing O.D. (mm)
Reference
Dual Bushing Track Conventional Track
D275A-5 98 90 AT07130
D375A-5 108 98.5 AT11108
D475A-5 126 116 AT10177
So it’s absolutely necessary to install Dual Bushing Track together with Exclusive Teeth for Dual without exception.
If you install Dual Bushing Track together with Conventional Teeth wrongly, bushing may have
cracks in early stage due to improper meshing between bushing and teeth.
- 60 -
Remarks : T/Roller Sequence change for Dual Bushing Track Installation.
When you install Dual Bushing Track on large bulldozer, please change T/Roller into S/F type at all
position (Please do not use D/F T/Roller for Dual Bushing track).
The reason and purpose are as follows.

1. There are inner and outer flange on D/F T/Roller as shown the above
2. If wear progressed on Link height and T/Roller tread, the tip of inner flange may interfere with track
bushing and cause for machine vibration
3. In case of Dual Bushing Track, this interference occurs earlier than Conventional Track because of
larger size of Bushing O.D. and slow progress of bushing wear
4. In such a case it’s hard to achieve a long life advantage of Dual Bushing Track (Of course, situation
will be varied depend on wear balance between track and T/Rollers)
5. So in order to avoid such risk, it’s better to change T/Rollers into all S/F type
In case of D/F T/Roller In case of S/F T/Roller
Remarks
1. When Dual Bushing Track is installed at factory on machine, we put S/F T/Rollers in all position at
same time.
2. When Dual Bushing Track is installed in field, our recommendation policy on T/Roller is as follows.
1) If customer replaces T/Roller at same time, please install S/F T/Rollers in all position.
2) If customer doesn’t replace T/Roller at same time, please change them into all S/F at next replacement timing.
● But please make customer understand that there is afore mentioned risk if Dual Bushing Track
works with D/F T/Rollers.
Special attention for D375A-5E0, D375A-6 and D475A-5E0 (8-T/Roller machine)
Please follow below instruction when you change T/Roller into all S/F type on D375A-5E0, D375A-6 and
D475A-5E0 (8-T/Rollers machine; D375A-5R, 8-T/Roller is the same but almost no machine in market)
1. In case of D375A-5E0, D375A-6 and D475A-5E0, S/F T/Roller is at No. 1 & No. 8, and D/F is on No.
2 – No. 7 (as shown in below chart). These No.2 – No.7 T/Roller should be changed into S/F
T/Roller Sequence
Model REMARK
No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8
A 5 K-BOGIE
D275 5 S D D D D D S K-BOGIE
AX
5E0 K-BOGIE
5 S D S D S D S K-BOGIE
5E0 S D D D D D D S K-BOGIE
S D S D S D S K-BOGIE, 7-T/Roller
D375 A 5R
S D D D D D D S K-BOGIE, 8-T/Roller
6 S D D D D D D S K-BOGIE
6R S D S D S D S K-BOGIE
5 S D D D D D S K-BOGIE
D475 A
- 61 -
2. But S/F T/Roller which should be installed on No.2 – No. 7 is not the same as No. 1/No.8. It should
be S/F T/Roller which is used on D375A-5, D475A-5 (7-T/Roller machine)
Reason and purpose are as follows

1. Because of different size of tread O.D.
1) Tread O.D. of S/F T/Roller on “8-T/Roller machine” is larger than the D/F T/Roller.
2) Tread O.D. of D/F T/Roller on “8-T/Roller machine” is the same as the one of S/F T/Roller on “7-T/
Roller machine”.
3) In case of changing T/Roller sequence into S/F from D/F, same tread O.D. is preferable with
consideration of wear balance.
4) So S/F T/Roller which is used on “7-T/Roller machine” should be installed.
2. Because of difference length of T/Roller shaft

1) T/Roller shaft length of S/F T/Roller on “8-T/Roller machine” is longer than the one on “7-T/Roller
machine” (Though shaft O.D. at mounting is the same).
2) T/Roller shaft length of S/F T/Roller on “7-T/Roller machine” is the same as the one of D/F T/
Roller on “8-T/Roller machine”.
3) Then S/F T/Roller which is used on “7-T/Roller machine” should be installed so that shaft end is
not outside of mounting bracket.
Image for Changing T/Roller at Installation of Dual Bushing Track (Sample Case of D375A-5E0)
D375A-5
This machine has 7 rollers and sequence is S D S D S D S with 270mm diameters.
1 2 3 4 5 6 7
270 270 270 270 270 270 270
195-30- -01412 -01422 -01412 -01422 -01412 -01422 -01412

S/F(270) D/F(270) S/F(270) D/F(270) S/F(270) D/F(270) S/F(270)
D375A-5E0
This machine has 8 rollers with S D D D D D D S sequence and the 1st and the last (8th) roller is S/F with bigger diameter
1 2 3 4 5 6 7 8
280 270 270 270 270 270 270 280
195-30- -01491 -01422 -01422 -01422 -01422 -01422 -01422 -01491

S/F(280) D/F(270) D/F(270) D/F(270) D/F(270) D/F(270) D/F(270) S/F(280)
D375A-5E0 DUAL : Change into all S/F T/Roller
1 2 3 4 5 6 7 8
280 270 270 270 270 270 270 280
195-30- -01491 -01412 -01412 -01412 -01412 -01412 -01412 -01491

S/F(280) S/F(270) S/F(270) S/F(270) S/F(270) S/F(270) S/F(270) S/F(280)
- 62 -
g) Q & A on Rotary Bushing, PLUS and Dual Bushing Track
1. What is “Rotary Bushing”?

● It’s a bushing which is not press-fitted into link so that the bushing itself can rotate freely around
pin. So it is called “Rotary Bushing”.
● Compared with this, the bushing of conventional track is press-fitted into link so that the bushing
itself can not rotate freely around pin.
Bushing is not press fitted into link Bushing is press fitted into link
Rotary Bushing Track Conventional Track
2. Why is bushing not press-fitted into link?

● Because it makes bushing free from link motion so that bushing O.D. life is extended drastically.
3. How does “Rotary Bushing” make to extend bushing O.D. life?

● Let’s think in conventional track first to understand wear mechanism easily. When link bends/
winds at sprocket portion, bushing also moves together with link (as bushing is press-fitted) under
contacting with sprocket. This creates sliding motion between bushing O.D. and sprocket and
causes wear on both surface.
● But In “Rotary Bushing” track, there is no more sliding motion between bushing and sprocket as
bushing is free from link motion.
● Then bushing O.D. wear is reduced drastically and life is extended.
● Please refer to UCTS07-001, -002 and -003 for details of Bushing O.D. wear mechanism.
- 63 -
4. What is PLUS?
● PLUS is abbreviation of Parallel Link Undercarriage System. (Note: It is not “Trade Mark”)
● Rotary Bushing Track which was developed for small/medium size bulldozer adopted parallel link.
So we named it PLUS. Compared with this, we call “Off-set Link” for link of conventional track.
Parallel Link
Off-set Link
Rotary Bushing Track Conventional Track
5. Why was parallel link adopted on Rotary Bushing Track?

● Because it keeps rigidity of track.
● I mean, if you see one link in conventional track, pin and bushing are both press-fitted into off-
set link of both side (L.H. and R.H.) and forms strong trapezoidal shape. Then continuing strong
trapezoidal shape makes a track.
Forms strong trapezoidal shape Link

ConventionalrTrack
● However if we make Rotary Bushing Track with off-set link, we can not keep rigidity. Because
bushing should be free on Rotary Bushing Track so that we can not make strong trapezoidal
shape as only pin is press fitted into link.
Weak point due to no press

fitted bushing (In case of Off-set link)
● So parallel link was adopted on Rotary Bushing Track in order to compensate such weakness of
off-set link.
● In other word, there are Outer Link and Inner Link on parallel link. Pin is press fitted into both end
of Outer Link and forms strong square shape.
Both pin ends are press

fitted into outer link
- 64 -
6. If there is a rigidity on PLUS, It can be used on any kind of application?
● PLUS can be used in any application under same condition with conventional track
7. Is there any other merit on adoption of parallel link?

● Yes, repairing track in field such as replacing one link is easier than conventional track.
● In case of conventional track, complicated job is required to replace one link as bushing is
protruded into inside of off set link. This is a big job in field.
● On parallel link system, however, disassembling job of track is easier by removing one outer link first.
Removed outer link
Field repair of PLUS
● Please refer to Shop Manual of each model for details.
8. Total no. of links should be even number always by parallel link. What do you do for odd number track?
● Good question. As you pointed out, if we use only parallel link, it always becomes even number
track.
● So we prepared “Off-set link” as well for PLUS and used for odd number track.
● D65 EX-15 has 39 links on one side track so we use off-set link for PLUS.
Off-set link is used on D65EX-15
9. How much can we expect to extend UC life on PLUS?

● We can expect much longer life on Bushing O.D. wear and Sprocket wear.
● So after introducing PLUS, link height wear is critical and becomes criteria for link assy life. (In
most of the case on conventional track, bushing O.D. wear is faster than link height wear and it
becomes criteria for link assy life)
● Link height and wear amount were increased on PLUS so that link life itself was improved from
conventional track (It is expected 1.4 times better life than conventional link)
- 65 -
● We made user test of PLUS with several machines before introducing it in the market. According
to the test result, link assy life shows about 2 times better than conventional track in average. We
believe that improving link life on PLUS contribute to this favorable result.
● As you know well, undercarriage wear is varied depend on machine operation and ground/soil
condition so “2-times better life than conventional track” is not guaranteed on all cases.
● As an example, if link height wear is faster than bushing O.D. wear and becomes criteria for link
assy life, even introducing PLUS can be helped to extend only 1.4 times better life as improvement
of link height life. Please be careful.
● On the contrary, if bushing O.D. wear is much faster than link height wear, introducing PLUS helps
a lot to extend link assy life (more than 2 times).
10. Can we expect to extend Sprocket wear life?

● Yes, it is.
● There is no more sliding motion between bushing and sprocket so that sprocket life also extends
drastically.
11. Is there any other merit on PLUS?

● Yes, turning pin and bushing (TPB) is not necessary anymore. It means customer can save a lot
of down time caused by TPB job.
● It is a big merit for the customer who usually does TPB on his undercarriage.
12. Is bushing O.D. of PLUS bigger than conventional track?

● No, bushing O.D. of PLUS is the same as conventional track bushing (on all D51, D61 and D65)
- 66 -
13. If bushing O.D. is the same as conventional track, I can use same segment teeth which are used
for conventional track on PLUS too?
● No, please use segment teeth which prepared for PLUS.
● There are grooves on side face of PLUS segment teeth. The grooves help to push out mud and
dirt which is packed bottom of sprocket teeth and prevent PLUS seal from damaging caused by
mud packing.
PLUS segment teeth has a groove

on side face
● If you use conventional segment teeth for PLUS, you might have premature oil leaking from PLUS
seal caused by mud packing.
14. On which models is PLUS available?

● It is available on D51-22, D61-15 and D65-15, -16, -17 currently.
● It will be available on D39, Tier 4 machine in future.
15. From when is PLUS available?

● It’s from 2008
16. Is PLUS STD or Option?

● It’s Option. As basic, PLUS is factory installation.
● However PLUS is installed on all machines for KAC and KEISA (as regional STD).
17. Is it possible to convert into PLUS from conventional track in field?

● Yes, it’s possible. But many UC items, except idler, are necessary to replace at the same time.
● Some rework on track frame is required also in order to avoid from interfering with T/Roller Flange.
● Please refer to P&S News BT08010 (D65-15), BB08004 (D61-15) and BB08003 (D51-22) for details.
18. Is it possible to identify whether PLUS or conventional track in field?

● Yes, it’s possible by checking link. In case of parallel link, it is PLUS.
● Shoe bolt is installed in parallel. So you can identify PLUS on this point as well. (Conventional
track uses off-set link so that shoe bolt is not in parallel)
- 67 -
19. Does CAT have any Rotary Bushing Track?
● Yes, they have. CAT named it SystemOne.
20. What is SystemOne? What is a different from PLUS?

● SystemOne is a new undercarriage system to improve all UC life. CAT reviewed all undercarriage
components when they developed Rotary Bushing Track.
● SystemOne adopted parallel link as same as PLUS.
● However SystemOne adopted cartridge type rotary bushing assy. This is a biggest different point
from PLUS.
CAT SystemOne
21. On which models is SystemOne available?

● Currently it’s available on D3, D4, D5, D6 and D8.
22. What is Dual Bushing Track?

● It is Rotary Bushing Track which is developed for D275A-5.
● There is double bushing (Inner and Outer) structure so we called it Dual Bushing Track.
● Inner bushing is press fitted into link but outer bushing is free and rotates around pin.
Outer bushing
Inner bushing
Off-set link
Reference: Dual Bushing Track is introduced by following P&S News

D275A: AT07130
D375A: AT11108
D475A: AT10117
- 68 -
23. Why did you adopt double bushing structure for Rotary Bushing on D275A-5?
● Because it’s necessary to keep rigidity of track under off-set link structure.
● In other word, Dual Bushing Track uses off-set link as same as conventional track, not parallel link.
As explained previously, in case of off-set link, both pin and bushing should be press fitted into link
in order to keep rigidity of track.
● So double bushing structure was adopted. Track keeps some rigidity by press fitting inner bushing
into link.
Inner bushing is press

fitted into off-set link
24. Why didn’t you adopt parallel link for Rotary Bushing Track on D275A-5? Why do you use off-set
link as it is on D275A-5?
● Because it contributes for minimizing lead time and cost for development.
● Development of D275A-5 Dual Bushing was originally initiated by a complaint from customer in
Florida, USA. His complaint was “Short track life of D275A-5” and asked to improve.
● After surveyed job site and operation, we confirmed that bushing O.D. life and sprocket life was
very short (about 600H) but link height wear life was OK (more than 3000H).
● This means extending bushing O.D. life and sprocket was a key for improvement. It’s no need to
touch anything on link.
● So we started to develop Rotary Bushing track together with current off-set link. As a result, we
adopted Dual Bushing structure.
● If we tried to develop Rotary Bushing Track for D275A-5 with parallel link, it would take long lead
time and huge cost for developing as starting from zero.
25. If there is a rigidity on Dual Bushing Track, we can use it at any application as same as PLUS?
● No, it’s not applicable for any kind of application.
● Even bushing O.D. is increased than conventional track, there are inner and outer bushings. And
each bushing thickness is thinner than conventional bushing. So if Dual Bushing Track works in
rocky terrain, there is some risk to have a crack on bushing.
● Then we recommend that Dual Bushing Track should be used in sandy terrain only.
● We believe this is reasonable as most job site which we receive complaint of short bushing O.D.
life is sandy terrain.
26. Is off-set link for Dual Bushing Track same as the link for conventional track?
● Forged shape and heat treatment are exactly the same as conventional track. This means link
height and wear amount are also same.
● But link P/N is different from conventional track as pin O.D. etc are different.
- 69 -
27. Is it lubricated between Inner Bushing and Outer Bushing?
● Yes, it is.
● Both between pin and Inner Bushing, and Inner Bushing and Outer Bushing are lubricated on Dual
Bushing Track. So there is no internal wear theoretically.
28. How much can we expect life extension by introducing Dual Bushing Track?
● Link height wear becomes criteria for Dual Bushing Track life.
● As an actual result in Florida, track life was extended to around 3000H (Link height wear was
criteria) by introducing Dual Bushing Track against only 1300H (including TPB) which was
previously experienced on conventional track (Bushing O.D. wear was criteria).
LIFE/HOUR
0 1000 2000 3000 4000 5000
Link Pitch
Link Height 3500

3500 Dual
Current
Bushing
700
Sprocket
Teeth 700
● As explained before, link is the same as conventional track, no improvement for extending the life.
So estimated link height life which is calculated based on current conventional link height wear
becomes total life of Dual Bushing Track.
29. Is Dual Bushing Track optional parts?

● Yes, it’s an optional parts.
● But if you ask Dual Bushing Track as factory installation, you should apply it by “Special Order
Request Format”.
● Usually you purchase it through parts supply channel and install it in field. P/N for Dual Bushing
Track is available on CSS-Net and registered on P-Wins already.
30. Do we need to replace any other parts when we install Dual Bushing Track?
● Yes, sprocket teeth is necessary to be replaced together (Bushing O.D. of Dual Bushing Track is
larger than normal track).
● Other parts such as Idler, T/Roller, C/Roller all remain the same as conventional one.
31. On which application can we recommend to use Dual Bushing Track?

● Current link assembly life is shorter than 6,000H (include Bushing turn)
● Current Bushing O.D. wear life is shorter than 50% of Link wear life.
● SiO2 + Al2O3 contents are more than 90% (stort wear Iife site)
● Major reverse speed is R2
- 70 -
32. Is it possible to identify whether conventional track or Dual Bushing Track in field?
● Yes, it’s possible. Please check sprocket.
● Segment teeth for Dual Bushing Track has a groove on its side face as same as PLUS sprocket.
There is no groove on conventional segment teeth. So you can identify it on this point.
7hr
Groove on teeth
Dec.8-06
33. Is Dual Bushing Track available only for D275A-5?

● No. It’s available for D375A-5, -6 and D475A-5 as well.
34. Do you have any plan to develop PLUS on large size bulldozer?
● As explained before, developing PLUS will take more time and cost than developing Dual Bushing
Track.
● So we don’t have such a plan now but it may change in future depend on market situation.
35. Do you plan to have both PLUS and Dual Bushing Track on one model?
● No, we don’t have such a plan
36. Does CAT also have Dual Bushing Track?

● Up until now, we don’t have such information yet. If you’ve heard or seen it, please let us know it.
● Dual Bushing Track is a unique and only available at Komatsu.
(2) Link
Track link has complicated style. Required characteristics are long wear life, durability against crack and
chipping-off of tread.
Tread of track link

(Rail top)
Track link
Track link pin
Track link
bushing
A view of a track link
Link tread wears by sand and other abrasives, and receives cyclic stress from track roller. That is why the
link is built with tenacious materials not to crack nor wear in a short time. Pin is pressed into one side of
link and bushing is pressed into the other side. Fitting part of link with either pin or bushing is contrived
not to come off by strong stress, for instance a part of link where bushing is pressed into is designed as
thick as possible not to crack.
- 71 -
(3) Bushing
Sprocket
The essential qualities of a bushing are fatigue tolerance and wear
resistance. As the surface of both inner and outer diameter of the
bushing are subjected to friction and wear through regular use,
the bushing is quenched to increase its durability. In addition, a
high fatigue strength is designed to enable the bushing to endure
constant impact from the sprocket.
Bushing
- The exterior surface of the busing is engaged with the sprocket and is subjected to hammering. Soil
particles which got in between the sprocket and the busing accelerates wear process.
- Interaction between the interior surface of the busing and the pin also creates wear process. The oil
sealed type track link can help to prevent this process. If the tension of link assembly is too tight, the
inner wear will be faster.
The exterior surface of the busing wears down more prominently than the inner surface. For Komatsu
products, both surfaces are quenched and made tenacious for a long use.
Machine weight
(4) Pin
The essential qualities of a pin are endurance to constant A
B
stress and wear resistance.
The pin is always subjected to pull strength (A) from track
links. It is an important part that joints the links together. In B
addition, with the presence of track roller and link, it is also
subjected to bending force (B) from the machine weight.
Hence, the pin is designed to have a high strength against
fatigue.
A
There are 2 types of pins, one being the normal ones (regular
pins) and the other being used for replacement of track link
(master pins).
For oil sealed type track link For grease sealed type track link
Regular pin Regular pin Master pin
- 72 -
(5) Seal
The life span of the oil lubricated type track link lies in the seal. If the seal is torn or broken, oil leaks and
fine sand will enter inside of the bushing and cause wearing of the bushing and pin. Pitch of the track
link assembly will also be elongated.
As sand particles often come in contact around the area of the seal, both the seal and the seal surface of
the bushing tend to wear out faster than the general seals.
As the seal wears out, the sealing tension also reduces causing the interior of the bushing and pin to
wear out faster due to internal oil leaks and intrusion of the sand particles. Seals designed by Komatsu
are such that its sealing performance remains as good as new even though wear continues at the
sealing portion.
Sealing portion
Seal (load ring) Seal (seal ring) Link
Bushing
Pin
Seal used in oil sealed type track link
Seal for SALT type track link

The oil sealed track link seal consists of a seal ring that seals off sand and internal lubricating oil and a
load ring which produces a pressing force against the seal. The load ring is designed to maintain the
sealing performance with its elasticity as it is compressed and embedded into the link.
F type W type
Seal (load ring)
being compressed
Seal (seal ring)
- 73 -
Seal for grease sealed type track link
As the seal ring in the grease sealed type track link seal is squashed and embedded, it also has a similar
function as the load ring in the oil sealed type track link.
W type V type
Seal (seal ring)
There are other

different types of
seal
Function of seal
The track parts are always subjected to the effects of soil or
Entry of soil
water, but in addition to this, the bending and sliding motion
Entry of soil
creates a condition where it is always easy for soil to enter
between the pin and bushing (link connection).
To prevent the entry of soil and water, and to prevent leakage of
the oil sealed inside the track, a special seal is used for sealed
& lubricated track.
The structure of this seal is similar to that of floating seals used

in idlers and rollers of the undercarriage. It consists of a part
which seals oil in and keeps dirt and sand out, and a load ring
which imposes a thrust to the said part. The load ring is set in
place in a crushed condition. Its resilience pushes the sealing
Load ring
portion in the direction of thrust, exerting the proper surface
pressure on the sliding surface with the bushing.
The thrust is also given in the radial direction of the link
counterbore, preventing oil from leaking from the bores. The Sealing
spacer is set inside the seal to protect it from overload and keep part
the deflection of the seal at a proper level while the machine is
traveling.
Radial direction
Free conditions of a seal

Load ring
Direction of thrust
Sealing part
Oil
Spacer
Installation condition of a seal Structure of floating seal
- 74 -
(6) Shoe
Structure and characteristic
Track shoe is fixed on the track link by 4 bolts and 4 nuts
in general. Shoe has a varieties which width and type of
grouser are different. Track shoe consists of plate part where
machine weight is supported and grouser which transfer the
traction to the ground. During a operation, shoe receives a
complex stress of bend, shock and friction from the ground.
Therefore track shoe is designed to have been hardened
through and tenacious not to bend, crack or wear soon.
If the shoe bolt is loosen or came off, track shoe and link
will get damaged. Therefore it is required to inspect a shoe
bolt periodically to avoid a undercarriage trouble.
3) Rollers
The following figures show how the idler, track roller and carrier roller work when a bulldozer is dozing. Let
us call them “Rollers” for the three items in the explanation below.
Some common phenomenons for the rollers are:

1. Abrasions occur on the surfaces of the rollers and the tread of track links.
2. Flanges of rollers prevent track links from falling out. Abrasions occur also on flanges of rollers due
to constant contact with the track link assembly.
2
1 1
1 2 1
2
Carrier roller Track
roller
Idler
(1) Idler
a) Track Adjuster & Recoil Spring
Idler is installed at the front of the track frame and is used to guide the track link assembly. Inner parts
consisting of bushings and shaft, are lubricated with oil.
Idler is equipped with track link tension adjustment mechanism and cushion mechanism.
- 75 -
Track shoe Assy
Rubber cushion Grease chamber

Spring
Idler
cross section Idler equipped with rubber cushion minimizes stress and
of an idler when vibration around the track shoe Assy enhancing operators
viewed from A
comfort.
Hardened and wear
resistance portion An example of track tension adjustment mechanism
and a rubber cushion.
Flange
As the tread and flange are

prone to wear, these portions are
hardened to extend the life.
Oil type: TO30 (D21 ~ D65, PC78 ~ PC600)
GO85W140 (D85 ~ D575, PC800 ~ PC2000)
(2) Track Roller

There are single flange type and double flange type rollers which are
installed to a track frame. The rollers roll on the track link assembly under
heavy load of machine weight. Track rollers are installed, not to warp the
link, but to bear the machine weight and distribute evenly over the track
shoes. Bushing and roller shaft are lubricated by oil. Track rollers installed
near idler and sprocket are single flange rollers. The order of installation
Single flange type track roller
of single or double flange rollers are decided depends upon machine size.
S D S D S D S Double flange type track roller
Example for D155A model A crawler type vehicle works on a rough ground. Therefore,
S: Single flange type track roller single and double flange rollers are positioned to release a
D: Double flange type track roller lateral trust while the vehicle is working.
- 76 -
Flange of track roller improves straight drivability
The flange of the track roller guides the track link assy to prevent it from moving in a zigzag manner. The
hardness of the flange has to be improved for abrasion resistant because the flange rubs against the
side of the track links.
Hardened and wear resistant portion
Flange
Single flange Double flange

type track roller type track roller
Structure of track roller

As shown below, oil is filled to minimize friction between the bushing and the shaft.
As the inner parts of a roller are lubricated with
Bushing
oil, floating seal is used to prevent oil leak.
Since the sealed area may be filled with mud or
sand, erosion takes place. Therefore, this area
is designed so that sand or foreign objects do
not easily enter the floating seal area.
Floating seal Oil type: TO30 (D21 ~ D37, PC120 ~ PC400)

GO85W140 (D39 ~ D475, PC78,
Oil chamber
PC600 ~ PC2000)
This area is designed
so that sand or foreign
objects do not enter.
Roller
Moreover, when the track shoe rides on stones,
track rollers will be subjected to impulsive loads.
Under such a condition, the floating seal is used to absorb distortion of sealing surface and prevent oil
leak.
Floating seal
Oil chamber
Oil stain at this portion is

an evidence of oil leakage
from floating seal
- 77 -
a) X-Bogie vs K-Bogie
Advanced Resilient Equalized Undercarriage (REU)
1) X-bogie
The Komatsu X-bogie resilient equalized undercarriage
(REU) performs independent see-saw movements.
Tremendous traction can be achieved even on uneven
ground, because the shoe always follows the contour of
the ground.
A rubber shock absorber is mounted on the X-bogie and decreases vibration and shock. The X-bogie
and rubber cushion provide different absorption characteristics, depending on the ground surface.
When the machine travels on flat ground, the REU functions as a conventional rigid undercarriage.
When the machine travels on uneven ground, the REU maximizes the suspension effect. The Komatsu
REU system improves traction, component durability, and operator comfort.
Conventional Undercarriage
There is minimal shoe slippage with the conventional low drive type undercarriage. The shoe slip limit
has been substantially raised due to long tracks and large ground contact area. The large traction force
thus obtained, in combination with high engine power, results in superb drawbar pull. With the low
center of gravity, dynamic stability is excellent.
Flexibility
Flexibly grasps ground surface due to Komatsu's unique track roller design for better ground contact.
Independent X-bogies and rubber pads (cushions) are incorporated into the track rollers.
Powerful Drawbar Pull for All Kinds of Terrain

The X-bogie and rubber pad provide different suspension characteristics depending on the ground
surface. On flat ground, REU functions as a conventional rigid undercarriage. On uneven terrain, the
REU maximizes the suspension effect the shoes always follow the contour of the ground, ensuring a
greater actual ground contact for greatly-improved drawbar pull.
On flat ground
Functions as a conventional Ensures almost the same traction force

rigid undercarriage. as a conventional rigid undercarriage.
- 78 -
On uneven ground
Seesaw movement is performed Compared with a rigid type, the actual

corresponding to ground surface. ground contact area increases and powerful
drawbar pull is ensured because the track
shoes follow the contour of the ground. Large
deformation of the rubber pads contributes to
greater suspension effect.
Comfortable Ride on Uneven Ground Minimum Shock in Riding Over Obstacles
Conventional
rigid type
Fall height A
REU
Obstacle height B
Flat ground Rough terrain travel

travel
On uneven ground, the rubber pad
provides four times the suspension effect. A
B
When riding over obstacles, the height of

the machine fall is low.
- 79 -
On flat ground
Bogie center
Bogie center
Bogie stroke
On uneven ground
Bogie center
Rollers follow the track link due to

the long stroke of K-Bogie.
b) T/Roller Sequence
No.1 No.2 No.3 No.4 No.5 No.6 No.7
- 80 -
Track Roller Sequence
S : Single flange
Bulldozer
D : Double flange
T/Roller Sequence
Model
No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8 REMARK
7
A
8
D21 S S S S S
7A
P
8
S
21 S
EX D
S
D31 22 S S D/F is option
D S
21 S S
PX D
22
21 S S
EX S S S S D/F is option
22 D D
EX & Exi 23 S D S S D S
PLUS
D37
21 S S
PX S S S S D/F is option
22 D D
PX & Pxi 23 S D S S D S
PLUS
21 S S
EX S S S S D/F is option
22 D D
EX & Exi 23 S D S S D S
PLUS
D39
21 S S
PX S S S S D/F is option
22 D D
PX & Pxi 23 S D S S D S
PLUS
E 6 S D S
D41 S D S
P 6 D S D S
EX & Exi 22
PLUS
D51 S D S D S D S
PX & Pxi 22
PLUS
12 S D S S D S
EX
15 S D S S D S S
PLUS
EX & Exi 23 S D S S D S S
PLUS
D61
12 S S D S S D S S
PX
15 S S D S S D S S
PLUS
PX & Pxi 23 S S D S S D S S
PLUS
12 S S D S D S S
S S D S D S S
15
PLUS D D D D D D S
EX
16 S S D S D S S
PLUS
17 S S D S D S S
PLUS
12 S S D S S D S S
15 S S D S S D S S
PLUS
PX
D65 16 S S D S S D S S
PLUS
17 S S D S S D S S
PLUS
S S D S D S S
S S D S S D S S PAT
15
PLUS D D D D D D S
PLUS S D D D D D D S PAT
WX
16 S S D S D S S
PLUS
17 S S D S D S S
PLUS
(to be continued)
- 81 -
S : Single flange
D : Double flange
T/Roller Sequence
Model
D68 ESS 12 S D S D S D S
D70 LE 12 S S D S D S S
A 21 S D S S S D S
E 21 S D S S S D S
ESS 2,2A S S D S S D S S
15
EX 15E0 S D S S S D S
D85
15R
P 21 D S D S S S D S
15
PX 15E0 S S D S S S D S
15R
2 D D D S D D S RIGID
A 5 D S S D D S X-BOGIE
6 S D D D D D S RIGID
D155 5 D S S D D S X-BOGIE
S D S D S D S K-BOGIE
AX 6
S D D D D D S RIGID
2 S D D S S D D S X-BOGIE
A
5 K-BOGIE
D275
AX
5E0 K-BOGIE
D355 A 5 D D D S D D S
S D D S D S X-BOGIE, 6-T/Rollers
3
S D S D S D S X-BOGIE, 7-T/Rollers
D375 A
S D S D S D S K-BOGIE, 7-T/Rollers
5R
S D D D D D D S K-BOGIE, 8-T/Rollers
6 S D D D D D D S K-BOGIE
6R S D S D S D S K-BOGIE
S D S D S D S X-BOGIE(SD)
3
S D D D D D S K-BOGIE
D475 A
D575 A 3 D S D S D S D S X-BOGIE
- 82 -
Hydraulic excavator S : Single flange
D : Double flange
T/Roller Sequence (Availability of D/F)

Model
6
7 S S S
S S S S D/F is Option
7E0 D D D
S S S
8 S S S S D/F is Option
D D D
S S S
PC350 D D D
6
7
7E0
LC S S S S
D D D D
S S S S
D D D D
1 Hybrid
HB335
LC 1 Hybrid
S S S
1 Hybrid S S S S D/F is Option
D D D
HB365
S S S S
LC 1 Hybrid S S S S D/F is Option
D D D D
6
7 S S S
7E0 D D D
8 S S S
8R D D D
10
PC450 6
7 S S S S
7E0 D D D D
LC 8 S S S S
8R D D D D
S S S S
D D D D
S S S
PC700 LC 8E0 S S S S S D/F is Option
D D D
6
S S S
7 S S S S S D/F is Option
D D D
6
PC750 LC
7
6
SE S S S
D D D
6
S S S
D D D
8
S S S
8E0 S S S S S D/F is Option
D D D
PC800 8R
8
LC 8E0
8R
8
SE 8E0
8R
8
S S S
8E0 S S S S S D/F is Option
D D D
PC850 8R
8
S S S
SE 8E0 S S S S S D/F is Option
D D D
8R
- 83 -
(3) Carrier Roller
There are mainly two types of carrier rollers, flange type and flat type. The flange type roller is used for
medium and large size Bulldozers, and Dozer shovels.
The flat type roller is used for small size Hydraulic Excavators.
Since the carrier rollers support only the shoe assembly, the structure is less complicated compared to the
track rollers. However, the accumulation of sand and soil around the carrier rollers will also cause erosion.
Lubricating oil
Be careful when operating a machine at a high speed. This
will cause the track links to hit the carrier rollers strongly and
as a result, it will shorten the life of both items.
The bearing and the shaft in the carrier roller are lubricated
with oil.
Oil type: TO30 (D21 ~ D37, PC120 ~ PC600)

GO85W140 (D39 ~ D575, PC800 ~ PC2000)
Seal
Flange type
There are center flange type and single flange type.
The center flange type is used for Hydraulic Excavators,

small size Bulldozers and Dozer shovels.
Center flange type
The single flange type is used mainly for medium and large
size Bulldozer, and Dozer shovel.
Single flange type
Flat type
The flat type is used for small size Hydraulic Excavators.
- 84 -
Reminder : Caution at C/Roller Installation.
There is a clearance between retainer of C/Roller and support in order to adjust alignment on bulldozer.
The clearance is varied depend on model and it is explained in each Shop Manual.
● Please refer to attached chart for designed clearance (on drawing) for each model
However, sometime it’s difficult to get proper alignment even you install C/Roller according to the set
clearance due to looseness of support mounting bolt holes and unbalanced clearance (R.H. & L.H.) of
Idler support. (If you find unbalanced clearance of idler support, please correct it first)
So please understand that clearance is just a reference and install C/Roller after checking of
alignment with following procedure (Same guidance as explained in Field Assembly Guide).
1. Put C/Roller shaft into support hole with set clearance

2. Tighten the shaft squeezing bolt temporary
3. Move the machine on flat ground about 10m by F1 and R1 repeatedly about 3 to 4 times
4. Confirm there is no strong contact between C/Roller flange and Link inside surface
5. Tighten the shaft squeezing bolt with proper torque after confirmation of no strong contact
If machine works under C/Roller misalignment condition, C/Roller tread wears unevenly as shown below
photos. So please be careful.
Designed clearance between C/Roller retainer and support
Model D31/D37 D39 D51 D61 D65 D85 D155 D275 D375 D475 D575
Structure
Clearance
Clearance 3 4.5 4.4 3 3 2 1.2 4.3 1.75 4.3 4

(mm)
- 85 -
4) Sprocket
Structure and characteristic
The sprocket engages with bushing of tack link, and drives the vehicle.
Abrasion occurs to various parts around the sprocket while it is running.
Knowing the place to be worn is not difficult if we understand how
power is transferred from sprocket to track link assembly.
Relationships between sprocket and link (bushing and pin)

On a new machine, the link pitch (center distance between link pins) is equal to the sprocket pitch (distance
between two teeth along the pitch line of sprocket). In many hours of operation, the sprocket pitch will be
shortened slightly by the worn tooth surface, whereas the link pitch will be extended by the worn pin O.D.
and bushing I.D. In the lapse of time, both pitches will be more unmatched to each other. If the sprocket
is used continuously under such a condition, the bushing O.D. and sprocket tooth surface will have to the
abnormal wear, shortening the sprocket life.
P.C.D. (Sprocket Sprocket pitch

pitch circle
diameter)
Link pitch
The sprocket pitch is the center distance between teeth beyond one tooth and every two teeth; the
sprocket meshes with a bushing. If a sprocket has an even number of teeth, the same teeth come into
mesh with the same bushing at all times. Therefore, the sprocket has normally an odd number of teeth to
make different teeth mesh with different bushings every rotation, insuring the even wear of sprocket tooth
surface and bushings.
- 86 -
5) Material Difference of UC parts among STD, Cold and Extreme Cold Specification
For “Cold Spec. (up to -30 degree C)” and “Extreme Cold Spec. (up to -50 degree C)”, different kind of oil
from “STD Spec.” is used for undercarriage parts in order to prevent oil from freezing due to low temperature.
Addition to that, O-rings which are used for floating seal etc is different material from “STD Spec.” in order
to keep elasticity even at low temperature.
So if STD Spec. UC parts work under out of temperature range (very cold climate), sometime it causes
for trouble such as oil leakage etc due to improper specification.
In order to clear all the differences on each undercarriage component among “STD Spec.”, ”Cold Spec.”
and “Extreme Cold Spec”, we made a chart as attached for your reference.
Please understand it and take care on appropriate Spec. especially if your machine works at very cold
climate.n
Material Difference of UC Commodity depend on Specification (Temp. range)
Specification
STD Spec. (-20 C) Cold Spec. (-30 C) Extreme Cold Spec. (-50 C)
Seal Load Ring <Same as STD Spec. Material B
Material A
(Different material from STD Spec.)
Track (SALT) Designated Brand (Remarks 2) Designated Brand (Remarks 1)
Oil (For Lubrication) GO80W90 - Yuni Lube “MB-11-X” (Nihon Lub. Co.) - Mobile Gear “SHC220” (Mobile Co.)
or
- Adeka Carpole “HT-65” (Asahi Denka Co.)
Seal Ring STD Same as Extreme Cold Spec. A Add Nylon Coarting on seal ring (Remarks 3)
Floating
Seal Same as Extreme Cold Spec. A Material B
O-Ring Material A (Different material from STD Spec.)
Rollers Same as Extreme Cold Spec. A Material B
(Idler) O-Ring (Fixed Position) Material A
(T/Roller) Small B/D ; TO30 Same as Extreme Cold Spec. A Designated Brand (Remarks 2)
(C/Roller) Middle & Large B/D ; GO85W140 - Yuni Lube “MB-11-X” (Nihon Lub. Co.)
Oil
Small & Middle PS ; TO30
Large PS ; GO85W140 - Adeka Carpole “HT-65” (Asahi Denka Co.)
Same as Extreme Cold Spec. A Steel after “Thermal refining”
Shaft (For C/Roller) Steel w/o “Thernal refining”
Remarks 1 and 2: “Designated Brand Oil” can be purchased from Komatsu as follows
P/N Oil Brand Qty

195-32-61990 Mobilube1 SHC75W-90 18 Ltr X 1
150-09-19270 Yuni Lube “MB-11-X” 18 Ltr X 6
Remarks 3: Detail and Purpose of “Nylon coating on Seal Ring”
Nylon coating on red line zone of seal ring
- Mud and water penetrates into red line zone during working
- Those will be frozen at night time
- When machine moves in that condition, Nylon coating helps for frozen mud to slip on
seal ring (rotating side) and prevents O-ring from damaging
- 87 -
2-2. Wear Limit
1) General View
For the wear portion of all UC parts, the allowable wear margin (100% Wear Limit) is specified. The
allowable wear limit is specified by considering the required conditions on the UC parts performance
and the strength (especially when rebuilding), and by considering the interference with the other parts
at wear. (For details, refer to Chapter 2.) Accordingly, depend on how UC parts are used (rebuilt or run
destruction), handling of Wear Limit is different.
In addition, Bushing and Pin of Link engage with Sprocket, and directly receive the bigger load from the
ground at the lower portion of Final Drive. The strength of received load depends on the condition of
machine operation and the ground condition. Accordingly, in order to keep the strength corresponding to
the load condition, based on the ground condition, as for Bushing O.D. and Pitch elongation, the Wear Limit
is classified as two types of Impact and Normal. Therefore, in order to do Management, it is necessary
that the ground condition is ensured on the jobsite, and the suitable allowable value is selected
(1) Rebuilt vs Run to Destruction

When “Rebuilt” is done
s 7HEN REBUILDING BY TURNING "USHING BUILD UP BY WELDING 2OLLER TREAD SURFACE ETC IT IS NECESSARY TO
do it at the time when the wear is within Wear Limit. Especially, as for Bushing, when it is turned after
exceeding Wear Limit, it is very probable that Bushing has already been cracked. Therefore, it is
careful that this causes the early Oil Leakage after turning.
When use “Run to Destruction”

s 7HENTHE5#PARTSAREUSEDTOTHEVERYENDANDABANDONEDWITHOUTTURNING"USHINGETCITISUSUAL
that the UC parts are continued to use as it is after exceeding Wear Limit. But when exceeding Wear
Limit, the structural problems such as the interference with other parts, cracks, breakage, etc occur.
Generally, the replacement time is the time when the vibration occurs by the interference, and the part
is broken.
(2) Normal Limit vs Impact Limit

Normal Limit
s 4HISIS7EAR,IMITATTHETIMEWHENTHEMACHINEISOPERATEDATTHESANDYLANDWITHOUTROCKSETCAND
at the jobsite where the shock is not given to each portion of the undercarriage.
Impact Limit
s 4HISIS7EAR,IMITATTHETIMEWHENTHEMACHINEISOPERATEDATTHEROCKYLANDANDATTHEJOBSITEWHERE
the shock is given to each portion of the undercarriage.
Komatsu’s Concept when the criteria of Impact and Normal are specified. (Remarks)
s /NLY"ULLDOZERHASBOTHCRITERIAOF.ORMALAND)MPACT!SFOR(%ITISBASICALLYNOTOPERATEDATTHE
rocky land, and its travel is less. Therefore, the criteria is one.
s )NADDITION"USHING/$ANDTHE0ITCHELONGATIONHAVEBOTHCRITERIAOF.ORMALAND)MPACTANDEXCEPT
them, other UC parts have one criteria.
s !SFOR'REASE3EALED4RACKOF"ULLDOZERBOTH"USHING/$AND0ITCHELONGATIONHAVETHECRITERIAOF
Normal and Impact. In the case of Impact, by considering the crack occurrence of Bushing and the pin
breakage due to the impact load, Wear Limit is smaller.
- 88 -
s !SFOR3!,4OF"ULLDOZER"USHING/$HASTHECRITERIAOF.ORMALAND)MPACT!SFOR3!,4BECAUSE
there is no pitch elongation, Pitch elongation has only one criteria. In addition, as for Bushing O.D.,
because there is no pitch elongation, shortly there is no internal wear, Wear Limit is bigger than that of
Grease Sealed Track.
2) Concept on Wear Limit for each UC Parts

(1) Track Link (Tread Wear)
s 7EAR,IMITISSPECIlEDBYCONSIDERINGTHEREBUILDING4HEREFOREWHENTHEWEARISWITHIN7EAR,IMIT
after rebuilding by weld-overlaying the tread surface, the strength can be maintained.
s 7EAR ,IMIT IS SPECIlED BY CONSIDERING THE INTERFERENCE WITH OTHER PARTS 4HEREFORE WHEN THE WEAR
exceeds Wear Limit, the interference of following portions may occur.
- Pin Boss portion and T/Roller Outer Flange
- Bushing and T/Roller Inner Flange
- Bushing and C/Roller Flange
- Bushing and Idler Flange
s &ROMTHEVIEWPOINTOF,IFEGENERALLYONTHEWEARBALANCEWITHOTHERPARTSDUETOTHESOILTHEFOLLOWING
items are considered.
s 4WOTIMESLIFEOF"USHING/$"USHINGISTURNABLE
(2) Bushing (O.D. Wear)

s 4HISISSPECIlEDBYCONSIDERINGTHETURNINGUSE4HEREFOREWHENTHEWEARISWITHIN7EAR,IMITEVEN
the load is applied, the crack does not occur. Accordingly, it is important that Bushing turning is done
within Wear Limit.
(3) Pin & Bushing (Inner Wear, Pitch Elongation)

s 4HISISSPECIlEDBYCONSIDERINGTHETURNINGUSE4HEREFOREWHENTHEWEARISWITHIN7EAR,IMITEVEN
the load is applied, the crack and the breakage do not occur on Pin and Bushing. Accordingly, when
Bushing is turned, Pin can be also used.
s 4HISISSPECIlEDBYCONSIDERING4RACK3AGADJUSTMENT4HEREFOREWHENTHE0ITCHELONGATIONOCCURSIFTHE
wear is within Wear Limit, Track Sag can be absorbed within the range of Idler forward adjustment amount.
(4) Idler (Tread Surface Wear)

s 7EAR ,IMIT IS SPECIlED BY CONSIDERING THE REBUILDING 4HEREFORE WHEN THE
wear is within Wear Limit, after building up by welding the tread surface, the
strength can be maintained.
s 7EAR ,IMIT IS SPECIFIED BY CONSIDERING THE INTERFERENCE WITH OTHER PARTS
Therefore, when the wear exceeds Wear Limit, the interference between
Bushing of Link Ass’y and Flange portion may occur.
- 89 -
(5) Track Roller
s 7 E A R , I M I T I S S P E C I F I E D B Y C O N S I D E R I N G T H E
rebuilding. Therefore, when the wear is within Wear
Limit, after building up by welding the tread surface,
the strength can be maintained.
s 7 E A R , I M I T I S S P E C I F I E D B Y C O N S I D E R I N G T H E
interference with other parts. Therefore, when the
wear exceeds Wear Limit, the following interference
may occur.
- Outer Flange and Link Pin Boss portion
- Inner Flange and Link Bushing portion
(6) Carrier Roller

s 7EAR ,IMIT IS SPECIFIED BY CONSIDERING THE REBUILDING
Therefore, when the wear is within Wear Limit, after building
up by welding the tread surface, the strength can be
maintained.
s 7EAR ,IMIT IS SPECIlED BY CONSIDERING THE INTERFERENCE WITH
other parts. Therefore, when the wear exceeds Wear Limit,
the interference between Bushing of Link Ass’y and Flange
portion may occur.
(7) Shoe (Grouser Height Wear)

s 7EAR,IMITISSPECIlEDBYCONSIDERINGTHEREBUILDING4HEREFOREWHENTHEWEARISWITHIN7EAR,IMIT
the enough strength is maintained, and the bend does not occur. Accordingly, the rebuilding is possible
by the lug-weld.
s &ROMTHEVIEWPOINTOFPERFORMANCEWHENTHEGROUSERWEARISWITHIN7EAR,IMITTHEPERFORMANCEIS
specified so that the traction force is obtained on the general soil.
(8) Sprocket Teeth

* When the wear is within Wear Limit, if the load is applied, the crack and the breakage do not occur.
- 90 -
2-3. Wear & Problem
2-3-1. General check point of job-site, machine and undercarriage at field
Check Sheet for Job-site, Machine and Undercarriage
ᯏ⒳ ภᯏ 䍙䍎䍩䍼䍛䍰䍎䍞⺞ᩏᐕ᦬ᣣ
Model Serial No. S.M.R Insp. Date
䍳䍎䍙䍼ฬ
User Name
৻⥸੐㗄
General
Ⓙ௛࿾䊶࿖
Job-site Location/Country
䍡䍼䍆䍎䍵ฬ
Distributor Name
䍕䍊䍩䍼䍻⒳㘃
Machine Spec.
ゞਔ䈱䉴䊕䉾䉪
Operator Cabin ROPS Cabin, ROPS, Cabin, Others 䋨䇭䇭䇭䇭䇭䇭䇭䋩

೨ᣇ 䉮䊷䊦䊑䊧䊷䊄䇮䊐䊦䊷㪬䇮䉶䊚䊷㪬䇮䉴䊃䉼䊦䇮䊧䊷䉨
䍏䍞䍍䍟䍰䍻䍢 Front Coal Brade, Full-U Brade, Semi-U Brade, Straight Tilt Brade, Rake Brade, Others
Attachment ᓟᣇ 䉳䊞䉟䉝䊮䊃䊥䉾䊌䊷䇮䊙䊦䉼䉲䊞䊮䉪䊥䉾䊌䊷䇮䉦䉡䊮䉺䊷䉡䉢䉟䊃䇮䉡䉞䊮䉼
Rear Giant Ripper, Multi Sahnk Ripper, Counter weight, Towing Winch
䍚䍋䍎᏷ 䊤䉫ઃ䈔᦭ή
Shoe Width Lug welded?
䍚䍋䍎䍞䍐䍪䍽䉲䊮䉫䊦䉫䊨䊷䉰䊷䋨ᮡḰ䇮㪟㪛䉺䉟䊒䋩䇮䊃䊥䊒䊦䉫䊨䊷䉰䊷䇮Ḩ࿾䉲䊠䊷䇮䈠䈱ઁ
Undercarriage Spec. & Maintenance
Shoe Type Single Grouser (STD or HD Type), Triple Grouser, Swamp, Others
⿷࿁䉍䈱䉴䊕䉾䉪䊶䊜䊮䊁䊅䊮䉴
ጁᏪ䍰䍎䍔
ጁᏪ Track Maker Komatsu Original, Berco, ITM (Sorefa, I-Track etc), KUT, ITR Others ( )
Track ጁᏪ䍛䍫䍽䍍䍖䉥䉟䊦ኽ౉䇮䉫䊥䊷䉴ኽ౉ 䊙䉴䉺䊷䊥䊮䉪䇮䊙䉴䉺䊷䊏䊮
Track Spec SALT, Grease Sealed Master Link, Master Pin
ጁᏪᒛ䉍 ㆡᱜ ⷐ⺞ᢛ
Track Tention Proper Need to adjustment
ጁᏪⵝ⌕ᣇะ ㆡᱜ ㅒⵝ⌕䋨 ஥䇮ਔ஥䋩
Track Installation Proper way Opposite way 䋨One side, Both side)
෻ォ᦭ή
Bushing Turned? * Check by touching bushing upperside by your hand
䊨䊷䊤䉧䊷䊄 ᦭, Yes Full Guard, Center Guard, Other ( )
T/R Guard ή, No
⿷࿁䉍ㇱຠ䈱៊்
Any damage on UC Parts?
Sand, Soil, Rock (Take Picture)
⍾⾰࿯䋨エ⎬䋩䊶☼⾰࿯䋨エ⎬䋩䊶⍾䊶⍾೑䊶⍾䉏䈐䊶₹⍹䊶ォ⍹䊶⎬ጤ
Ground Condition
࿾ᒻ䊶࿯⾰䈱⁁ᴫ
࿯⾰エጤ䊶⎈⍹䊶᦭ᯏ࿯䊶⍹὇䊶㋶⍹䊶䉼䉾䊒䊶㔐䊶ಓ࿯䊶䉯䊚㘃䊶䈠䈱ઁ
Soil Condition 䃁ጤ䈱⒳㘃䋨䇭䇭䇭䇭䇭㩷㩷䋩㩷㪢㫀㫅㪻㩷㫆㪽㩷㪩㫆㪺㫂㩷㩿㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㪀
䃁ઍ⴫⊛䈭࿯⾰䉕䉰䊮䊒䊥䊮䉫䈜䉎䈖䈫䇯㪫㪸㫂㪼㩷㪪㫆㫀㫃㩷㪪㪸㫄㫇㫃㪼㪃㩷㫀㪽㩷㫅㪼㪺㪼㫊㫊㪸㫉㫐
䇭䇭䋨䉰䊮䊒䊥䊮䉫䈱ᄢ䈐䈘䈲䇮䉯䊦䊐䊗䊷䊦ᄢ䇯䋩
ੇḨ ੇ䈇䈩䈇䉎䊶᥉ㅢ䊶Ḩ䈦䈩䈇䉎
Wet or Dry Dry, Normal, Wet
࿾ᒻ ᐔမ࿾䊶௑ᢳ࿾䋨䇭䇭䇭䇭䋩ᐲ䇭䇭䇭䇭䇭䈏䋨ᄙ䈇䊶ዋ䈭䈇䋩
Flat or Slope Flat, Slope
⎈⍹䊶ቛㅧ䊶䊙䉟䊆䊮䉫䋨⍹὇䊶㋕䊶㌃䊶䈜䈝䊶䊥䊮䋩
Quarry, Land Development, Mining (Coal, Iron, Copper, Tin, Phosphorous, Others )
૞ᬺ䋨Ꮏ੐䋩 ᑪ⸳䋨䉻䊛䊶ᴡᎹ䊶㆏〝䊶䈠䈱ઁ䋩
Job Application Construction (Dam, River, Road, Others )
ㅧ᧚䍃䈠䈱ઁ䋨䉯䊚ಣℂ䊶䊉䊨ಣℂ䋩
Logging䍃Others (Waste Disposal, Scoria Disposal, )
Working Condition
૞ᬺ䊶Ⓙേ᧦ઙ
䍪䍼䍷䍢䍼䍎䍙䍼䋺㪙㫌㫃㫃㪻㫆㫑㪼㫉 ᴤ࿶䍚䍌䍫䍼䍷䋺㪜㫏㪺㪸㫍㪸㫋㫆㫉
ជ೥᛼࿯䊶䊤䊮䊄䉪䊥䉝䊥䊮䉫䊶䉴䊃䊥䉾䊏䊮䉫䋨⴫࿯䋩 Ⓧㄟ䉂䍃ជ೥䍃ហ䈐⪭䈚䍃⎕⎈
૞ᬺౝኈ Dozing, Land Clearing, Overburben Stripping Loading, Digging, Scraping
Job Condition 䊥䉪䊤䊜䊷䉲䊢䊮䊶䊧䈼䊥䊮䉫䊶䉰䉟䊄䉦䉾䊁䉞䊮䉫 Braker, Skidding
Reclamation, Leveling, Side Cutting Others
䊥䉾䊏䊮䉫䊶䉴䉪䊧䊷䊌䊶䈠䈱ઁ
Ripping, Scraper, Others ( )
૞ᬺᤨ㑆䇭䇭䇭䇭䇭䇭䇭䇭䇭H/Day
Working Hour 䇭䇭䇭䇭䇭䇭䇭䇭䇭Days/Week, 䇭䇭䇭䇭䇭䇭Days/Month
Average H/year
ゞਔ䈱૶↪ᦼ㑆䊶ᤨ㑆
Life/Usage
Machine Usage䋨Year, Hours) Year, Hours (Till scrap)

䊤䉟䊐
UCᐔဋ䊤䉟䊐 Shoe/Link Assy䇭䇭䇭䇭䇭䇭䇭䇭䇭H䇭䋨Replaced at H䇮೨࿁੤឵ᤨ䈱SMR䇭䇭䇭䇭䇭䇭䇭䇭䋩

Av. UC Life Others
䈠䈱ઁ᳇䈨䈇䈢䈖䈫
Remarks
- 91 -
Guidance for checking (with sample photo etc)
䍳䍎䍙䍼ฬ
User Name
৻⥸੐㗄
General
Ⓙ௛࿾䊶࿖
䍡䍼䍆䍎䍵ฬ
Distributor Name
Machine Spec.

ጁᏪ䍰䍎䍔
ጁᏪᒛ䉍Canopyㆡᱜ ⷐ⺞ᢛ ROPS Canopy
෻ォ᦭ή
T/R Guard ή, No
ROPS Cabin
Cabin
- 92 -
䍳䍎䍙䍼ฬ
User Name
৻⥸੐㗄
General
Ⓙ௛࿾䊶࿖
䍡䍼䍆䍎䍵ฬ
Distributor Name
Machine Spec.

ጁᏪ䍰䍎䍔
෻ォ᦭ή
T/R Guard ή, No
- 93 -
䍳䍎䍙䍼ฬ
User Name
৻⥸੐㗄
General
Ⓙ௛࿾䊶࿖
䍡䍼䍆䍎䍵ฬ
Distributor Name
Machine Spec.

ndercarriage Spec. & Maintenance
ጁᏪ䍰䍎䍔
෻ォ᦭ή
Single-shank Ripper
The ripper is used for site preparation prior to
digging work, when it becomes necessary to remove rocks,
pavement for other obstacles. Also effective
for pulling out tree stumps.
- 94 -
Attachment ᓟᣇ 䉳䊞䉟䉝䊮䊃䊥䉾䇮䊙䊦䉼䉲䊞䊮䉪䊥䉾䇮䉦䉡䊮䉺䉡䉟䊃䇮䉡䉞䊮䉼
Ma
ゞ
Undercarriage Spec. & Maintenance 䍚䍋䍎䍞䍐䍪䍽䉲䊮䉫䊦䉫䊨䊷䉰䊷䋨ᮡḰ䇮㪟㪛䉺䉟䊒䋩䇮䊃䊥䊒䊦䉫䊨䊷䉰䊷䇮Ḩ࿾䉲䊠䊷䇮䈠䈱ઁ
ጁᏪ䍰䍎䍔
෻ォ᦭ή
T/R Guard ή, No
Shoe Application "Type & Width (mm)"

Classification Classification Classification
Model
Single Heavy Single Heavy Single Heavy Single Heavy
Swamp
Grouser Duty Grouser Duty Grouser Duty Grouser Duty
A 21 560 560 610 610 660 660
E 21 560 560 610 610 660 660
ESS 2,2A 510 560 610
15 560 560 610 610 660 660
EX 15E0 560 560 610 610 660 660
D85
15R 560 560 610 610 660 660
P 21 910 910
15 910 910
PX 15E0 910 910
15R 910 910
2 560 560 610 610 660 660 710
A 5 560 560 610 610 660 660 710
6 560 560 610 610 660 660 710
D155
5 560 560 610 610 660 660 710
AX 6 560 560 610 610 660 660 710
7 560 560 610 610 660 660 710
2 610 710 760
A
5 610 710 760
D275
5 610 710 760
AX
5E0 610 710 760
D355 A 5 610 710 760
㪧㫃㪼㪸㫊㪼㩷㫉㪼㪽㪼㫉㩷㫋㫆㩷㫇㪸㪾㪼㩷㪈㪏㪇㩷㪄㩷㪈㪏㪎㩷㪽㫆㫉㩷㪻㪼㫋㪸㫀㫃㫊
Please refer to page 197 - 201 for details
- 95 -
ゞਔ䈱䉴䊕
Machine S
ጁᏪ䍰䍎䍔
෻ォ᦭ή
T/R Guard ή, No
Check if lug welded on shoe grouser?
New Worn condition
Lug welded grouser
- 96 -
䍏䍞䍍䍟䍰䍻䍢
ゞਔ䈱
, , , g , ,
Mach
ጁᏪ䍰䍎䍔
෻ォ᦭ή
T/R Guard ή, No
Shoe
Shoe with hole Triple grouser shoe Swamp shoe
Single grouser shoe Shoe without hole
There are many kinds of shoe and variety of shoe width available
1. Proper shoe selection Is very important for better machine performance and
longer undercarriage life
2. Golden rule of shoe selection is “Select narrower shoe possible with adequate
flotation”
- 97 -
ゞਔ䈱䉴
Machin
ጁᏪ䍰䍎䍔
෻ォ᦭ή
T/R Guard ή, No
Komatsu
Berco
Sorefa
- 98 -
䍏䍞䍍䍟䍰䍻䍢
ゞਔ䈱
Front Coal Brade, Full-U Brade, Semi-U Brade, Straight Tilt Brade, Rake Brade, Others
Machi
ጁᏪ䍰䍎䍔
෻ォ᦭ή
T/R Guard ή, No
Link Assy There are 2 kinds of track available in Komatsu

1. Grease Sealed Track
2. SALT (Oil lubricated)
Vertical Hole of Pin
Bushing Pin
Grease Sealed Track
(Please don’t call DRY anymore) SALT (Sealed And Lubricated Track)
SALT is better than Grease Sealed Track to get longer undercarriage life
Link Assy: Joint

1. There are 2-kinds of joint system on link assy; Master Link & Master Pin
2. Combination of track kind and joint is as follows
• SALT + Master Link
• Grease Track + Master Pin
Master Link Master Pin
SALT (Sealed and Lubricated Track䋩 Grease Sealed Track

㵰Bull Dozer 㵰 “Bull Dozer
“Excavator㵱
Komatsu BERCO ITM Please be careful on Plug for SALT Pin

Komatsu genuine SALT pin has a plug on both end
Pin
Berco, ITM and other UC maker has a plug only one side
Plug hole on
Plug hole on
one side So please check both side of pin when you check
both side
track spec (SALT or Grease) on non-genuine UC
- 99 -
೨ᣇ 䉮䊦䊑䊧䊄䇮䊐䊦㪬䇮䉶䊚㪬䇮䉴䊃䉼䊦䇮䊧䉨
ゞਔ䈱䉴
Machine
ጁᏪ䍰䍎䍔
෻ォ᦭ή
T/R Guard ή, No
Check track tension
Too loose Too tight
Proper tension
- 100 -
p , , ,
ゞਔ䈱䉴䊕
Machine S
ጁᏪ䍰䍎䍔
෻ォ᦭ή
T/R Guard ή, No
Track Shoe Assy

Pin must be forward on
one link
View A
View A
Shoe bolt position,

when you see
shoe plate from
rear of final drive
Shoe Grouser Position
There is a proper way of Shoe Assy installation as shown the above.

1. You can install it in opposite way. But, in such a case, bushing & sprocket
wears very fast.
2. If you see wrong installation of Shoe assy in field, please correct it as UC
Pro !
Remarks
1) Above shows on conventional track
2) Please refer to page 145, 146 for PLUS
- 101 -
ゞਔ䈱䉴䊕
Machine S
ጁᏪ䍰䍎䍔
෻ォ᦭ή
T/R Guard ή, No
Check if bushing turned already
After TPB, worn side of bushing comes shoe plate side䋨You can confirm it by touching䋩
You can check it by observing bushing through clearance of shoe (Photo shows before TPB䋩
- 102 -
p
ゞਔ䈱䉴䊕
Machine S
ጁᏪ䍰䍎䍔
෻ォ᦭ή
T/R Guard ή, No
RollerGuard
Roller Guard
- 103 -
ROPS Cabin, ROPS, Cabin, Others 䋨䇭䇭䇭䇭䇭䇭䇭䋩
Machine Sp
Operator Cabin
ゞਔ䈱䉴䊕
ጁᏪ䍰䍎䍔
෻ォ᦭ή
T/R Guard ή, No
Check undercarriage condition if any damage
Pin came out Shoe bolt loose Link tread chipping
Shoe plate crack, bend T/Roller mounting bolt missing T/Roller oil leak
- 104 -
Ground Condition
ㅧ᧚ 䈠䈱ઁ䋨䉯䊚ಣℂ 䊉䊨ಣℂ䋩
Rocky job site
Sandy job site
- 105 -
Ground Condition ⍾⾰࿯䋨エ⎬䋩䊶☼⾰࿯䋨エ⎬䋩䊶⍾䊶⍾೑䊶⍾䉏䈐䊶₹⍹䊶ォ⍹䊶⎬ጤ
Working Condition

Dry condition
Reclamation, Leveling, Side Cutting
Very wet condition
Others
Working Hour Days/Week Days/Month
Medium (Normal) condition
- 106 -
Ground Condition
Working Condition

Flat condition Reclamation, Leveling, Side Cutting Others
Working Hour Days/Week Days/Month
Slope
- 107 -
࿾ᒻ䊶
Groun
Working Condition

Average H/year
Coal Mining Granite Mining
White Sand Mining
Stone quarry
Dam Construction
Road Construction Logging
- 108 -
࿾ᒻ䊶
Groun
Working Condition

Average H/year
Land clearing Top soil removal
Dozing (Bulldozer) Ripping (Bulldozer)
Excavating & Loading (Excavator) Lifting (Excavator)
Breaker (Excavator)
- 109 -
Guidance of Taking Photos for Undercarriage Report
- 110 -
1. Before taking individual photo of undercarriage, please grasp
overall situation on job-site, ground condition and operating
condition etc
• “Whole to Part”
2. Even there is a problem on undercarriage, please take photos not
only problem portion but also surrounding part / area as well
• In order to compare, it’s important to take photo on non-trouble
part of same item
- 111 -
2-3-2. Each Component
1) Link
(1) Wear Pattern
a) Wear of Link Tread
CAUSES: Wear is caused by contact with track rollers which support
tractor weight.
This is normal wear.
Abnormal progress of wear will be caused by grinding effect of hard
gravely particles or quartz sand intruded between link tread and roller
tread.
EFFECT: Link height will be decreased, causing interference of roller

flange to pin boss.
Excessive progress of wear will make reconditioning difficult.
REMEDY: When link tread wear has reached the repair limit,
recommend replacement of link otherwise hard facing build-up welding.
b) Uneven Wear of Link Tread

CAUSES 1: Wear due to difference of surface pressure
As width of link tread is small at link joints, portion “A” which is
subjected to higher surface pressure of track roller than portion “B” will
wear faster.
B C
CAUSES 2: Wear due to contact with front idler

When track link runs around the front idler, only the middle portion “C”
of link comes into contact with idler and, therefore, uneven wear will
progress over a long period of operation.
EFFECT: The deeper the worn step, the more difficult even padding
will be. Generally the uneven wear appears at the beginning of
operation and continue to grow in the period. Then the wear do not
progress.
This wear pattern do not affect severe problem to undercarriage. But
the unusual (unexpected) wear may affect severe problems.
REMEDY: When wear is reached the repair limit, recommend replacement of link
otherwise hard facing build-up welding.
- 112 -
c) Wear of Tread Side Face
CAUSES: Wear is caused by contact of link tread side surface to
sprocket teeth side face, front idler flange side face and roller flanges,
and this wear is unavoidable to some degree.
If excessively fast progress of wear is noticed, the cause may be
assumed due to any of the following unusual operating condition:
1. Where machine is subject to frequent turns including many pivot turns.
2. Where turning of machine to a fixed direction is continued a long
time.
3. Where traveling across hillside or side cutting of a hill is continued
a longtime.
4. Where track is misaligned.
If any of these unusual conditions exists, link tread side face will be subjected to large part of machine
weight through the sprocket teeth side face, front idler side face and roller flanges, so that wear of tread
side face progresses quickly.
EFFECT: As width of tread is decreased, surface pressure exerted by track rollers, increases, therefore wear
of tread will be accelerated. Life of rollers is reduced. Excessively worn tread is difficult to repair by padding.
REMEDY: When any possible cause of wear is found out, advise customer to correct the cause. For example,
Adjusting tack alignment.
Replacing with narrower track shoe,
Replacing with sealed and lubricated track.
If wear has progressed until link tread is affected, recommend immediate build-up welding and removal of
the cause of wear of tread side face.
As complex contour of tread side face is impossible to repair by automatic welding, wear must be treated
early.
d) Wear of Pin Boss Top Face
CAUSES: Wear is caused by interference of pin boss top face with

roller flanges.
With progress of wear on link tread face, wear will occur also on rollers
which contact with link tread. Access of roller flange to pin boss top
face by the cumulative effect of wear of link and wear of roller will lead
to interference between them to cause wear of pin boss top face.
EFFECT: When wear progress excessively:

Repair of link becomes difficult.
Pin bore expands, making pin difficult to hold.
Roller flange will be damaged.
REMEDY: Repair links and rollers before interference

between pin boss and roller flange occurs.
(Interference between pin boss and roller flange can
be prevented by observing repair limit.)
If rail wear progress...
- 113 -
e) Wear of Pin Boss End Face
CAUSES: This wear accompanies the interference of track roller guard
inside surface with pin boss end face.
CAUSE 1: Long time travel of machine across hillside

Under this operating condition, thrust load caused by machine weight
will accelerate wear of link side face and roller flange side face. As the
result, link pin boss end will be brought in contact with track roller guard.
CAUSE 2: Wear due to interference caused by snaky track

Wear of link joint surfaces
Earth intruded between link joint surfaces will accelerate progress of wear of mating surfaces with
“bending” movement of track links, thus causing snaking movement of track.
Improper track tension

Loose track will cause excessively snaky track.
Broken track roller flange

Track roller with nicked flange will fail in its function to guide track links in proper alignment, thus
causing excessively snaky track.
When track becomes snaky due to any of above-mentioned causes, interference of pin boss with
roller guard will occur and wear of pin boss side face will result.
Snaking track
CAUSE 3: Deformation of track roller guard

Originally, pin boss side face is spaced from roller guard with a
clearance large enough to prevent interference between them even
if track is in lightly snaky condition. However, the clearance may be
decreased because of deformation of roller guard caused by hit with
rocks during machine operation on rocky ground.
When such reduction of clearance once arises, roller guard will
easily interfere with link pin boss even when snaky condition of track
is light causing wear of pin boss side face.
- 114 -
CAUSE 4: Worn roller flange side face or link side face
Long-time operation of bulldozer will cause worn roller flange side
face and worn link side face.
The whole wear of these surfaces help the track to becomes snaky.
With progress of wear, the amount of wear will exceed standard
clearance, thus causing wear of link pin boss side face due to
interference of it with roller guard.
EFFECT: When wear progresses excessively:

Track pins will become difficult to remove thus making repair of
link impossible, contrarily, pins will easily slip out due to reduction
of force-fit in link.
Track roller guard prevents track roller going off from track link
rail. Generally pin boss side face and the guard have some
rubbing and some wear in operation. But unusual “heavy” wear
may damage many parts.
REMEDY: When wear of pin boss side face is noticed, examine the following:
(1) Whether or not possible cause exists in job site conditions.
(2) Whether or not there is any possible cause which makes snaky track.
(3) Whether track roller guard is deformed or not.
(4) Whether progress of wear is found on roller flange side face and link side face or not.
When some cause is detected, advise customer to correct the cause.
For example,
Turning pins and bushings to prevent snaky track.
Applying build-up welding to track roller flanges.
Repair of roller guard.
f) Wear of Link Mating Face

CAUSES: Mating surfaces of inner and outer links are spaced with
proper clearance to assure smooth bending of track links. Earth intruded
in this clearance during machine operation will perform grinding action to
wear the mating surfaces.
Inner Outer
EFFECT:
Sand and/or soil
Track becomes snaky, thus causing shortened
life of rollers, sprocket wheel and front idler.
Progress of wear of link tread is accelerated.
Excessive wear makes link difficult to repair.
REMEDY:
Turn pins and bushings.
Replace with oil lubricated track.
- 115 -
g) Depth Wear of Counterbore Bottom Surface
CAUSE: The wear is caused by earth intruded in the clearance
between counterbore bottom surface and bushing end face.
EFFECT: Repair of link will become difficult.
REMEDY:
Turn or replace pins and bushings. Be sure to replace dust seal when
replacing pins and bushings.
Replace with sealed and lubricated track.
h) Wear of Counterbore Side Surface

CAUSE: The wear is caused by interference between bushing and
counterbore due to elongation of link pitch.
The wear will be progressed by excessively tightened track.

Wear of pins and bushing will be accelerated.
REMEDY:
Turn pins and bushings.
Keep proper track tension.
i) Expanded Shoe Bolt Holes

CAUSE: Shoe bolts are insufficiently torqued.
Improperly wide shoe is installed.
EFFECT: Bolts may be broken.

Shoes may get out of place.
REMEDY: Tighten shoe bolts to specified torque.

After 100-hour initial operation with new shoes, check bolts for
loosening. This is essential specially when operating on rocky ground.
Replace with narrower shoes.
j) Wear on Link Tread Center as dented

CAUSE: Wear is caused by changing contact width of link tread with
rollers
EFFECT: This is normal wear

As counter effect, center of roller tread wears with some remaining
protrusion
REMEDY: No problem Keep running
- 116 -
(2) Structural Problem
a) Crack on Link
CAUSES: During rocky-ground operation, running on and off large
rocks may cause twisted link and cracked link. The following is
assumable cause of cracking:
1) Where decreased thickness of shoe plate due to wear fails to
prevent shocks from directly affecting the link.
2) Where loose shoe bolts allow shocks to affect directly the link.
3) Where tilted shoe causes excessively twisted link.
4) Where failure of engagement between sprocket teeth and link
bushings due to elongated link pitch causes bushing to hit
sprocket tooth end and resulting shocks are transmitted to link.
EFFECT: When wear progresses excessively:

s 2EPAIROFLINKBECOMESDIFlCULT
s 4URNINGOFPINANDBUSHINGBECOMESDIFlCULT
REMEDY: Check for loosening of shoe bolts and check for adaptability
of track shoe to the ground condition of job site. Recommend
customer to replace track link assembly with new one.
b) Crack on Link (Press fitting area of track pin and bushing)

CAUSES: Even in the light operation, crack may be caused on link.
Only in case in which cracks are appeared on press fitting area of
track pin and bushing, the following is assumable cause of cracking.
1) Working in strong acidity soil condition.
2) Working in high-temperature and humidity.
REMEDY:
1) This crack have possibility to be occurred in most links in a track.
2) Links hardened lower is recommended for the lifetime extension.
But only in case in light operation.
Contact authorities and have consulting about the remedy.
c) Broken Link Tread

CAUSES: This is occurred by the high surface pressure due to the uneven
contact impact load with the roller and the roller flange riding-on load.
Impact load occurs on the hard ground or by the high speed travel.
The uneven contact load and the flange riding-on occur by the uneven
ground travel or the wider shoes.
Misalignment or incorrect shoe tension is assumable.
EFFECT: Because the surface of the broken link tread is worn, the
breakage occurs or disappears repeatedly. Therefore, it does not
matter.
The breakage more than 30% of the tread surface may lower the wear
service life.
REMEDY: When the larger breakage is found, the part is partially

replaced. Otherwise, the part is continued to be used as is.
And, the causes of breakage (refer to CAUSES) should be reduced.
- 117 -
d) Back Jamming of Track Link
Jamming
CAUSES: Pin and bushing go to rust. Specifically appears on storage

machine or low availability machine. (Excavators etc.)
REMEDY: Travel a machine about 20 minutes a month even in a

storage. Remove all sweat from a machine when stored.
e) Pin Came out

CAUSE: Strong force is applied on pin during working
Most possible cause is that wider shoe is used in rough terrain
EFFECT: In case of SALT, it leads to leak lub. Oil
REMEDY: Replace into narrower shoe after checking application
2) Bushing
(1) Wear Pattern
a) Wear of Bushing O.D.
As bushings are brought into engagement with sprocket teeth, wear of
bushing O.D. must be investigated in connection with wear of sprocket
teeth. The following is the definition of three important terms which must
be understood without confusion when wear of bushing O.D. is under
Forward discussion.
V
F R
- 118 -
(1) External wear on forward drive side ...F
This wear is caused by sliding motion which occurs between
rotatively contacting surfaces when a bushing leaves toothed face
of sprocket wheel while it is in forward-drive rotation.
(2) External wear of root ... V

This wear is caused by sliding motion of a bushing which moves
along the root of sprocket tooth to fill backlash when a shift of
forward-reverse travel is made.
(3) External wear on reverse drive side ... R

This wear is caused by sliding motion which occurs between
rotatively contacting surfaces when a bushing comes to mesh with
Direction of Direction of
toothed face of sprocket wheel while it is in reverse-drive rotation.
forward-drive rotation V reverse-drive rotation
R
F
EFFECT: Wall thickness of bushing is decreased, thus making bushing

liable to crack or break.
REMEDY: When bushing O.D. is close to its turnable limit, recommend customer to turn pins and bushings.
Assumable causes of abnormally quick progress of wear are intrusion of hard rock grits or quartz sand
between sprocket teeth and bushing outer diameter, and excessively tight track tension.
Perform soil survey in the job site and checking of track tension, and explain the result of investigation to
customer. Also, improper traveling speed of machine can affect largely wear of bushing O.D. If careless
operation of a machine is suspected as the cause of abnormal progress of wear of bushing O.D.,
observe actual operating condition of the machine at job site and advise the operator to operate the
machine at proper traveling speed under proper load.
b) Wear of Bushing I.D.

Forward drive rotation CAUSE:
This wear is caused by contact of bushing I.D. with pin. Wear will
progress only on the forward drive side with wear of pin O.D. and will
be accelerated by intrusion of earth inside the bushing.
EFFECT:
Link pitch will be increases.
Track will become snaky, thus causing wear of link side face
and counterbore.
REMEDY:
Turn or replace bushings and pins.
- 119 -
c) Wear of Bushing End O.D.
CAUSE: The wear is caused by contact of bushing to link counterbore
due to elongation of link pitch.
EFFECT: As wear progress on only one side of link counterbore, repair

of link will become difficult.
REMEDY:
Turn or replace bushings.
d) Wear of Bushing End Face

CAUSE: The wear is caused by friction of bushing with link counterbore
bottom and is found on the end surface of long bushing not provided
with dust seal.
EFFECT: Excessive progress of wear will make track more snaky.
REMEDY:
Replace bushings.
In the sealed type bushings, also replace seal assembly which may be
crushed instead of bushing end face being worn.
e) Wear on both side of Bushing O.D.

CAUSE: Wear is caused by contacting with inner flange of track roller
due to severe wear of link tread and/or T/Roller tread
EFFECT: Machine may vibrate during running
REMEDY: Replace worn parts (Link assy and/or T/Roller)
f) Off Center Wear

CAUSES: Misalignment of track and sprocket.
ACCELERATORS: (1) Alignment problems with track roller frame, track

roller, carrier roller and/or sprocket. (2) Worn rear guiding and/or final
drive guiding guards. (3) Side-hill operation.
EFFECT: Should not increase wear rate of bushing to wear limits.
REMEDIES: (1) Correct alignment. (2) Replace guiding and/or final

drive guiding guards.

a) Bushing Cracks (Through the wall)
CAUSES: Exceeding wear limit for respective degree of impact or
other criteria.
ACCELERATORS: Same as “Vertical Position” wear pattern.
EFFECT: (1) Loss of lubricant and resulting internal wear. (2) Makes
bushing non-reusable in wet joint and may not be reusable at all if a
piece is broken out of a dry joint.
REMEDIES: Re-evaluate decision to run past wear limit.
- 120 -
3) Pin
(1) Wear Pattern
a) One Side Wear on Pin O.D.
CAUSE: The wear will occur only on forward-drive side of track
on ground the wear is caused by contact of pin with bushing and
progress of wear will be excessively accelerated by intrusion of earth
and rock grits inside the bushing.
EFFECT: Link pitch will be elongated. As this wear causes snaky

track, wear of link side face and counterbore will result and wear of
roller flange, sprocket wheel and front idler will be accelerated.
REMEDY: Turn or replace pins to correct link pitch.
b) Wear of Pin End Face

CAUSE: This is an abrasion caused by roller guard in which it
appears as if upper half of pin end face is cut off.
EFFECT: Snaky track becomes out of control by roller guard.

Wear of roller flanges is accelerated.
REMEDY: Turn the worn pin to equalize wear of pin end face or
replace pin.

a) Pin Spalling
CAUSES: Flexing pin causes cracks to begin in oil reservoir hole and
spreads out to surface at a slow fatigue rate.
ACCELERATORS: Same as “Pin Galling.”
EFFECTS: Chip or flake of material may become loose from pin

surface. Pin should not be reused for wet or dry turn.
REMEDIES: Same as “Pin Galling.”
b) Pin Breakage
CAUSES: Crack starts on outer surface and spreads through entire
pin at a fast rate (not nearly as common as with Sealed Track Pins).
ACCELERATORS: Impact loads combined with other loads caused

by tight track, severe packing, too wide shoes and effects of worn
rear rollers.
EFFECT: Track separation with little or no warning.
REMEDIES: Eliminate or reduce controllable accelerator variables,

particularly too-wide shoes and entry of non-extrudable packing
materials (rocks, etc.) into the sprocket bushing contact area.
The following problem is externally visible and while the cause is the
same as with Sealed Track the effect is different and should be noted.
- 121 -
c) Pin Breakage (Impact Load)
CAUSES: High static or impact loads which cause crack to start at
outer surface (usually at pin wear step) and moves through entire pin
at a fast rate.
Pin cracking and breaking is less severe with Sealed and Lubricated
Track during absence of internal wear. However, it may be more
serious once lubricant is lost and internal wear is present due to faster
rate of internal wear and loss of pin strength due to reservoir hole.
ACCELERATORS: Horsepower, weight and speed of machine.

Impact and terrain conditions. Amount of internal wear that reduces
pin diameter. Tight track, too-wide shoe, worn rear rollers and severe
packing loads caused by rocks between bushing and sprocket are
main controllable variables.
EFFECT: Immediate track separation. Severe damage to other

components.
REMEDIES: Eliminate or reduce controllable accelerator variables,

particularly rocks which are getting into spaces between sprocket and
bushings.
4) Shoe
(1) Wear Pattern
a) Shoe Grouser Wear
CAUSE: Wear is caused by friction between grouser and earth which
occurs when grouser cuts into earth and kicks earth to produce
tractive force.
Abnormal progress of wear may be caused by erroneous
selection of shoe or by unsuitability for operation of machine.
(Frequent shoe slips due to excessive load or frequent sharp turning
of machine will accelerate wear.)
EFFECT:
Lacking of tractive force will lead to power losses.
Reduction of shoe strength may cause (bent cracked link).
REMEDY:
When grouser height is near to its repair limit, recommend repair by
lug-welding otherwise replacement of shoe with new one.
Adoption of lug-welding or shoe replacement should be determined by
also taking other faulty conditions after-mentioned into consideration.
Recommend to the customer to select the proper kind of shoe
depending on the soil of the individual job site.
b) Shoe Plate Wear

CAUSE: Wear is caused by friction between shoe plate and earth or
rock. This normal wear.
EFFECT: When wear progresses excessively. Reduction of shoe
strength will cause bent shoe. Track link may be cracked.
REMEDY:
Recommend to the customer to select the proper kind of shoe
- 122 -
c) Wear on Shoe Leading Edge
CAUSE: Wear is caused by contacting with rock guard. Track chain
may flex up between rollers as the machine travels over the ground
EFFECT: This type of wear does not affect the functionof the track
shoe and, therefore, is minor wear pattern. It does, however, reduce
the bending strength of the shoe
REMEDY: Keep running
d) Grouser Corner Wear

CAUSES Same as “Grouser Wear.”
ACCELERATORS: Same as “Grouser Wear” except terrain is probably
rougher. Wide shoes in high impact condition on rough terrain will
accelerate this effect particularly where much turning is evident.
EFFECT: Reduces effective shoe wear life and regrouserability.
REMEDIES: Reduce or eliminate controllable accelerators and use

the narrowest shoe that will give adequate flotation.

a) Shoe Bending
CAUSE: Bend of shoe may be caused by erroneous shoe selection,
worn grouser and plate, or running on large stones.
Standard shoe may be bent when operated on job sites of hard ground
or of stony ground.
Wide shoe are liable to bend, because wide shoes tends to be affected
by bending stress. This tendency will be specially appeared when
swamp shoe is used on stony ground.
EFFECT: When wear progresses excessively: Repair of shoe will
become difficult. Reduction of shoe strength will cause bent shoe.
REMEDY: Recommend customer to select the proper kind of shoe
b) Bolt Holes Wallowed Out

CAUSE: Insufficient strength of worn grouser and plate.
Too large width of shoe. Insufficient torquing of shoe bolts.
Loosened shoe bolts due to above-mentioned conditions will cause
expansion of shoe bolt holes.
EFFECT:
Retightening of bolts will be ineffective to keep bolts tightened long,
thus requiring replacement of shoe and link.
Loosen bolts will be broken and lost during operation.
Cracked shoe may result.
REMEDY: Advise customer to inspect for loosening of shoe bolts
before daily operation.
- 123 -
c) Hair Cracks
Hair cracks
Many hair cracks are seen at a surface of grouser top or plate.
CAUSE: Earth conditions are not abrasiveness. Heat due to frequent

shoe slipping.
REMEDY: Avoid shoe slipping.

Avoid overloading to a bucket that causes a machine body to drag.
(Excavators only)
d) Shoe Plate Mounting Bolt Loose or Drops off

CAUSE: Loosen and breakage of bolt
Wider shoe in rough terrain may cause this trouble
EFFECT: Causing secondary failure on shoe plate like bending or

breakage
REMEDY: Tighten the bolt, if loose or install new bolt

If wider shoe is installed, replace with narrower one
e) Shoe Plate Mounting Bolt Breakage even in "Light Operation"

CAUSE: If machine works on following condition, sometime shoe bolt
breaks even in light operation
1) Working in strong acidity soil condition
2) Working in high temperature and humidity condition
REMEDY: Cosult to Komatsu as special case
5) Idler
(1) Wear Pattern
a) Wear on Thread
CAUSE: Tread of idler, which contacts with link tread while it is rotating
on its shaft, is subject to wear caused by metal-to-metal contact and
by impact load which will occurs when track runs on a rock and be
transmitted to idler through link. Wear of idler tread will progress
uniformly under normal condition. Excessive progress of wear may
arise when very abrasive hard rock grits or quartz sand intrude between
the contacting surfaces.
EFFECT: No parts will be affected by wear of front idler tread.
REMEDY:
Effect of track tension to wear of rollers
- 124 -
When excessively quick progress of wear is claimed by customer, examination must
be made for improper track tension in addition to effect of soil, work conditions and
machine operating conditions.
When track tension is too tight, increased resistance between link tread and roller
tread will accelerate progress of wear. This will specially affect the front idler and
carrier rollers. Adjust track tension rather slack (approx. 5 mm larger in deflection
than standard deflection) on clay or muddy ground to prevent deposit of earth on the
sprocket tooth root, while adjusting track tension rather tight (approx. 5 mm small in
deflection than standard deflection) on rocky ground to prevent biting of rocks.
b) Uneven Flange Side Wear

CAUSE: Rollers are assembled on track frame so
that their alignment of sprocket wheel center is
maintained within tolerance.
As long as rollers are under this normal alignment,
they will not cause interference with track links.
EFFECT:
Wear of link tread side face will occur to shorten link
life.
Repair of roller will become difficult.
Oil floating seals will be subjected to excessive thrust load, thus causing
leakage of oil.
REMEDY: When tread O.D. and depth (at the severely worn part) are
Shim
close to repair limit, recommend repair by build-up welding. When wear
reaches service limit (beyond repair limit), recommend replacement of
Guide rollers.
plate
Clearance A Track frame
c) Flange Top Wear

(May be domed)
CAUSES: (1) Sliding contact with any abrasive material packed into
idler assembly area. (2) Impact contact and motion with track links
which have jumped out of tread area.
ACCELERATORS: Speed, packing, adhesion and abrasiveness of
packed material. Tool loose or too snaky track increased chances of
track link damage.
EFFECTS: Reduces wear measurement distance and resulting
accuracy. Reduces rebuildability in extreme cases.
REMEDIES: Rebuild if critical. Clean packed material away from area
behind the idler. Correct cause of links jumping out of tread and running
on center flange if this wear is present in absence of packing.
- 125 -
6) Track Roller
(1) Wear Pattern
a) Wear on Thread
CAUSE: Rollers are subject to wear as track rollers carry weight of
tractor while they are rolling on track links and carrier rollers carry
weight of track while they are rolling on track links. As center of roller
tread is in coincidence with center of link tread under normal condition,
wear of roller tread will progress unfirmly even when track is in slightly
snaky condition.
EFFECT:
(1) With contact of roller flange to link pin boss, wear of pin boss will
progress, thus making repair of link difficult.
REMEDY: When tread O.D. and tread depth are close to repair limit,
recommend repair of tread by build-up welding. When service limit is
reached beyond repair limit, recommend replacement of worn rollers.
Necessity of repair or replacement of rollers should be judged under

systematic examination of various conditions including the after
mentioned problems. Also, advise customer the optimum time of repair
or replacement, in connection with wear and remaining life of other
parts (track links, etc.).

When excessively quick progress of wear is claimed by customer,
examination must be made for improper track tension in addition to
effect of soil, work conditions and machine operating conditions.

CAUSE: The thrust load is supported by track roller flange side face and
link side face. Under this condition, normal contact between the center
of track roller tread and the center of link tread center is lost and, after
long-time operation, stepwise wear of track roller tread will result.
On the upper half of track, normal contact between the center of carrier
roller tread and the center of track link tread is lost and carrier rollers
are subjected to stepwise wear.
Therefore, uneven wear of track rollers and that of carrier rollers are
opposite to each other when wear is caused by traveling of machine
across hill side.
- 126 -
EFFECT:
Wear of link tread side face will occur to shorten link life.
Roller floating seals will be subjected to excessive thrust load, thus
causing leakage of oil.
REMEDY: When tread O.D. and depth (at the severely worn part) are
close to repair limit, recommend repair by build-up welding otherwise
replace roller with new one.
parts (track links, etc.)
Stepwise wear is difficult to repair flat by automatic build-up welding and,
therefore, it is necessary to repair rollers at early stage of progress of
wear. Such countermeasures include improvement of working steps to
prevent the machine from being subject to uneven load and the swapping
of right and left rollers to during their life cycle equalize wear of them.

a) Mounting Bolt Drop-off
CAUSE: Loosen and breakage of mounting bolts
EFFECT: T/Roller drops off and causing for critical damage on

undercarriage
REMEDY: Tighten the mounting bolt, if loose or install new mounting

bolts
b) Oil Leakage (Became wet)

CAUSE: Damage floating seal
EFFECT: Progressing to internal parts damage
REMEDY: Replace floating seal assy or T/Roller assy
- 127 -
7) Carrier Roller
(1) Wear Pattern
a) Wear on Thread
CAUSE: Rollers are subject to wear as track rollers carry weight of
tractor while they are rolling on track links and carrier rollers carry
weight of track while they are rolling on track links. As center of roller
tread is in coincidence with center of link tread under normal condition,
wear of roller tread will progress unfirmly even when track is in slightly
snaky condition.
EFFECT:
(1) With contact of roller flange to link pin boss, wear of pin boss will
progress, thus making repair of link difficult.
REMEDY: When tread O.D. and tread depth are close to repair limit,
recommend repair of tread by build-up welding. When service limit is
reached beyond repair limit, recommend replacement of worn rollers.

parts (track links, etc.).

When excessively quick progress of wear is claimed by customer,
examination must be made for improper track tension in addition to
effect of soil, work conditions and machine operating conditions.
CAUSE: The thrust load is supported by track roller flange side face
and link side face. Under this condition, normal contact between the
center of track roller tread and the center of link tread center is lost and,
after long-time operation, stepwise wear of track roller tread will result.
On the upper half of track, normal contact between the center of

carrier roller tread and the center of track link tread is lost and carrier
rollers are subjected to stepwise wear.
Therefore, uneven wear of track rollers and that of carrier rollers are
opposite to each other when wear is caused by traveling of machine
across hill side.
- 128 -
EFFECT:
Wear of link tread side face will occur to shorten link life.
Roller floating seals will be subjected to excessive thrust load, thus causing leakage of oil.
REMEDY: When tread O.D. and depth (at the severely worn part) are close to repair limit, recommend
repair by build-up welding otherwise replace roller with new one.
Necessity of repair or replacement of rollers should be judged under systematic examination of various
conditions including the after mentioned problems. Also, advise customer the optimum time of repair or
replacement, in connection with wear and remaining life of other parts (track links, etc.)
Stepwise wear is difficult to repair flat by automatic build-up welding and, therefore, it is necessary to
repair rollers at early stage of progress of wear. Such countermeasures include improvement of working
steps to prevent the machine from being subject to uneven load and the swapping of right and left rollers
to during their life cycle equalize wear of them.
Remarks: Similar wear pattern appears on following case as well

1) Mis-installation of C/Roller
2) Mis-allignment on Track Frame, Idler or Sprocket installation
So please check and correct it, if something wrong
c) Wear on Tread Center as protrusion

CAUSE: Wear is caused by contacting with link which worn as "Link
Tread Center as dented" (Please refer to Link wear)
EFFECT: This is normal wear and does not affect the function of C/Roller
REMEDY: No problem Keep running
d) Abnormal wear on tread

CAUSE: C/Roller is not rotating
Most probably mud and dirt which packed on T/Frame prevented
C/Roller from rotating
EFFECT: Shorten the life of C/Roller. May damege inner parts as well
Accelerate link tread wear also
REMEDY: Replace
- 129 -
8) Sprocket Teeth
Progress of wear of sprocket
The figure below defines several terms to prevent confusion in the following description.
Direction of forward-
drive rotation
Forward drive side

Root
Reverse drive side
(1) Wear Pattern

Typical wear of sprocket teeth is classified as shown above. In
actuality, wear will be more complex as described below and
subject to various operating conditions and ground conditions. Direction of forward-drive
rotation
3
1
5 2 4 6
1. Forward drive side wear

2. Reverse drive side wear
3. Wear of forward drive side tooth top
Direction of forward-drive 4. Wear of root
rotation 5. Wear of reverse drive side tooth top
6. Wear of side face
a) Forward Drive Side Wear

CAUSE:
The wear is caused by contact to bushings during forward-drive rotation
of sprocket.
Wear will be accelerated with the elongation of link pitch.
EFFECT: Wear of bushing O.D. will be accelerated.
REMEDY:
Replace sprocket rim or segment teeth.
Forward drive rotation Right and left sprockets may be alternated if their reverse drive side
wear is small.
- 130 -
b) Reverse Drive Side Wear
CAUSE:
The wear is caused by contact to bushings during reverse-drive rotation
of sprocket.
Wear will be accelerated with elongation of link pitch and by high-speed
reverse drive or loaded reverse drive.
EFFECT: Wear of bushing O.D. will be accelerated.
REMEDY:
Reverse drive rotation Replace sprocket rim or segment teeth.
Right and left sprockets may be alternated if their forward-drive side
wear is small.
c) Root Wear
CAUSE:
The wear is caused by sliding of bushing on root of sprocket teeth to
follow through backlash when a forward-reverse shift of drive rotation is
made.
EFFECT:
As pitch of sprocket wheel is decreased, wear of bushings will be
accelerated.
REMEDY: Replace sprocket rim or segment teeth.
Note: In the forward-reverse gearshifting, a bushing Forward drive

will slip along the sprocket tooth root by an
amount equal to backlash or the bushing will
make a sidewise slippage on the root, causing
wear between the bushing and sprocket.
Reverse drive
d) Tip Wear of Forward Drive Side

CAUSE: Wear is caused by elongation of link pitch.
EFFECT:
Pitting
This wear may occur in machine with new sprocket teeth, pins and
bushings. In this case, however, progress of wear will stop after new
parts have worn to match with others during the break-in running period.
REMEDY:
Forward drive rotation Turn pins and bushings.
Replace sprocket rim or segment teeth.
Right and left sprockets may be alternated if forward-drive side wear of
them is small.
- 131 -
e) Tip Wear of Reverse Drive Side
CAUSE:
Wear is caused by elongation of link pitch.
The wear is caused by forward drive rotation of sprocket wheel while
soil is deposited on sprocket root or around bushings. Deposit of soil
raises bushings near the reverse drive side tooth top of sprocket teeth,
thus causing wear of tooth top.
The same wear will also be caused by loosened track link tension
because mud may be deposited in sprocket root.
Reverse drive rotation EFFECT:
Pitting
This wear may occur in machine with new sprocket teeth, pins and
bushings. In this case, however, progress of wear will stop after new
parts have worn to match with others during the break-in running period.
REMEDY:
Remove mud after daily operation.
When this wear is caused by elongation of link pitch, replace pins and
bushings. Adjust track tension in the good condition.
f) Wear of Side Face

CAUSE:
This wear is caused by contact with link side face under the following
conditions:
Travel of machine across hillside.
REMEDY:
Maintain correct alignment of track.
Keep roller guard in properly maintained condition.
Keep proper track tension
g) Wear of Both Corner of Teeth Tip

CAUSE:
Wear is caused by contacting with inner flange of T/Roller (D/F type)
Mis-installation of T/Roller on last position
Last T/Roller must be S/F type

EFFECT: Shorten the life of Sprocket
REMEDY: Replace last T/Roller into S/F type from D/F type
- 132 -
3. Variables that Affect Undercarriage Parts
To extend the life of undercarriage system, not only select suitable track and track shoe, but to operate the
machine with more care. The variables that determine the life can be formed into three groups.
s Controllable variables include track tension adjustment, shoe width and alignment.
s Partially controllable variables is a condition may be influenced by uncontrollable variables but it is
compensable by the operator.
s Uncontrollable variables include ground condition and life determining factors given by the job.
3-1. Controllable Variables

So far we have explored causes of wear, factors that accelerate wear and the ways that wear affects
machine performance. To reduce wear and prolong undercarriage life, there are three ways to minimize
wear: maintenance, machine outfitting, alignment and method of operation.
These are three major controllable variable group and variables in it.
s -AINTENANCE4RACKADJUSTMENT
s -ACHINEOUTlT3PECIlCATION 3HOEWIDTH4RACKGUARDS
s !LIGNMENT2OLLERFRAME)DLERMOUNTING
1) Track Adjustment
)T IS EXTREMELY IMPORTANT TO MAINTAIN PROPER TRACK TENSION AT ALL TIMES OF OPERATION #HAIN TIGHTNESS IS
measured by the amount of track sag. Track sag has an inverse relationship with track tension, which means
that a large track sag indicates that the track is loose and a small track sag indicates that the track is tight.
Track Tension vs. Track Sag

4RACK4ENSIONLBS
4RACK3AG)NCHES
.OTICE FROM THE GRAPH THAT IF YOU DECREASE TRACK SAG JUST A LITTLE BIT EG FROM TO IT INCREASES
TENSIONTREMENDOUSLYABOUTLBS 4HISILLUSTRATESTHESENSITIVITYOFTRACKTENSIONANDTHEIMPORTANCE
of keeping it properly adjusted.
4RACK TENSION IS MAINTAINED BY A TRACK ADJUSTER THAT IS SITUATED BEHIND THE FRONT IDLER !DJUSTMENTS ARE
made by pumping or draining grease through a fitting on the track adjuster.
Effects of a Tight Track

s )NCREASEDWEARONALLUNDERCARRIAGECOMPONENTS
s )NCREASEDFRICTIONCAUSESMECHANICALLOSSANDREDUCEDDRAWBARPULL
s (OTTERTEMPERATURES
Effects of a Loose Track Track loosens (wave movement)
s 4RACKCHAINSIDETOSIDE
s 5PPERWAVINESSANDWHIPPING
s 0OPPING
s %XCESSIVENOISEANDSHAKING
- 133 -
2) Shoe
(1) Shoe Width/Shoe Type
Service life of the undercarriage depends on the selection of the right shoe. There are many different
types of shoes. The following chart shows the shoes that Komatsu crawlers are equipped with. Notice
that each shoe has advantages, disadvantages and is designed for specific applications.
Narrow shoe Standard shoe Wider shoe Swampy shoe
[Basic factor of shoe which affects performance and life]
&IRSTlNDMACHINEPRODUCTIVITYFACTORMOSTIMPORTANTTOTHEUSER
&INDWHATEFFECTTHEVARIOUSSHOESSELECTIONVARIABLESMAYHAVE
.EXTLOOKSTRAIGHTACROSSTOlNDWHATDEGREEOFWEARANDSTRUCTURALLIFEEFFECTSMAYBEEXPECTED
2EPEATTHESESTEPSUNTILALLPRODUCTIVITYANDLIFEFACTORSHAVEBEENCONSIDERED
- 134 -
(2) Factors Affecting Machine Production
a) Flotation
Ground materialISTHEBIGGESTFACTOR)TISVERYEASYTOSTAYAmOATWHENYOUAREWORKINGINHARDMATERIAL
like rock. But it is very difficult to keep the machine from sinking when you are working in a swamp.
Machine weight is also an important factor because the heavier the machine is, the harder it is to keep
it afloat.
Shoe width determines the contact area between the tracks and ground. Wider shoes provide more
contact area and allow the weight of the machine to be distributed over a larger area, thereby increasing
flotation. This concept is called ground pressure.
Ground pressure COMBINES THE EFFECTS OF MACHINE WEIGHT WITH SHOE WIDTH )T IS DETERMINED BY THE
following formulas:
Shoe
4RACKON'ROUND,ENGTH
Width
#ONTACT!REAX4RACKON'ROUND,ENGTHX3HOE7IDTH
'ROUND0RESSURE-ACHINE7EIGHT#ONTACT!REA
!SARULEOFTHUMBSHOEWIDTHMUSTBEWIDEENOUGHTOKEEPTHEMACHINEAmOATBUTNOTWIDER
b) Penetration
PenetrationISTHEPORTIONOFTHEGROUSERTHATDIGSINTOTHEGROUNDDURINGOPERATION'OODPENETRATION
MEANSTHATTHEWHOLEGROUSERGETSEMBEDDEDINTOTHEGROUND0OORPENETRATIONMEANSTHATVERYLITTLEOF
THEGROUSERGETSEMBEDDEDINTOTHEGROUND0ENETRATIONISDIRECTLYRELATEDTOTRACTIONWHICHMEANSTHAT
more penetration equals more traction. Traction is the machine’s ability to grip the ground and propel
ITSELFINAFORWARDORREVERSEDIRECTION)TISIMPORTANTTOUNDERSTANDTHATTRACTIONISAFUNCTIONOFGROUND
material, machine weight and shoe type, but it is NOT related to shoe width. Therefore, outfitting a
machine with wider shoes will not necessarily increase traction.
0OOR0ENETRATION
'OOD0ENETRATION
- 135 -
c) Maneuvering Ability
Maneuvering ability is a function of ground material, Stress increases
proportionately
machine weight, shoe type and shoe width. Wider shoes as shoe width
increases
make it more difficult to maneuver the machine because
they stick out further and offer more turning resistance. Bending driven by
distance from outer
edge of link
d) Robustness
Robustness is the ability to withstand wear and impact. Shoes
are subjected to a bending moment that increases proportionally
WITH SHOE WIDTH ! TRACK SHOE IS LIKE A LEVER THE LONGER THE
LEVERTHEEASIERITISTOBREAK&ORTHISREASONWIDERSHOESARE
more susceptible to wear and impact. They also increase the
effects of impact to all other undercarriage components. Some
common problems related to wide shoes are:
s )NCREASEDWEARONLINKSIDESROLLERSANDmANGES
s %XTERNALINTERNALBUSHINGWEAR
s 0INLOOSENING
s 0REMATURESEALFAILURE
s 7IDESHOESALSOCONTRIBUTETOPACKINGCONDITIONSBECAUSETHEYCANSCOOPDEEPERANDPROVIDEMORE
room for material accumulation.
(3) Undercarriage System Wear & Structural Life Factor

a) Shoe Wear Life
Wider shoes do not improve wear life. The extra wear material provided by wider grousers gives a little
extra life. The largest variable affecting shoe wear life is slippage.
b) Shoe Structural Life

Bending stress on the shoe increases proportionately to the distance from the outer edge of the link to
THEENDOFTHESHOE#RACKINGBENDINGANDHARDWARELOOSENINGINCREASESASSHOEWIDTHINCREASES
"ASIC2ULEOF4HUMB!LWAYSSPECIFYTHENARROWESTSHOEPOSSIBLETHATWILLPROVIDEADEQUATEmOTATION
and traction without excessive track slippage. See chart on following page.
c) Link Roller Idler Wear Life

Wear rates increase on link rail sides, rollers and idler flanges as shoe width increases because of
INCREASEDLOADINTERFERENCE)NCREASEDSHOEWIDTHCANALSOAGGRAVATELINKCRACKING
d) Pin and Bushing Wear Life

%XTERNAL BUSHING WEAR RATE ON 3EALED AND 3EALED AND ,UBRICATED 4RACK AND INTERNAL WEAR RATE ON
Sealed Track increases as shoe width increases in a given underfoot condition. This is due to the
increased loads, weight and twisting.
- 136 -
e) Pin and Bushing Structural Life
Too wide shoes in high impact or steep terrain can cause pins and bushings to loosen in the link bores.
4HISBECOMESMOREEVIDENTWITHHIGHSINGLEGROUSERSHOES,OSSOFPINANDBUSHINGRETENTIONPREVENTS
successful turn and replacement maintenance.
(4) Sealed and Lubricated Track Joint Life

4HEMOSTCOSTLYEFFECTOFTOOWIDESHOESINHIGHIMPACTCONDITIONSANDORSTEEPTERRAINISTHELOSSOFLUBRICANT
and seal life resulting in premature dry joints. The wider the shoe, plus the higher the impact, the greater the
chance of a pressed track joint “opening up,” allowing loss of lubricant. The loss of lubricant occurs when
the bushing slides back and forth along the pin. The clearance between the links created by this “opening
UPv IS CALLED END PLAY %ND PLAY IS PERMANENT AND CAN ONLY BE ELIMINATED BY PRESSING THE COMPONENTS
TIGHTASATINITIALASSEMBLYORWHENTRACKPRESSWORKISPERFORMED&ORMAXIMUMLUBRICANTANDSEALLIFETHE
machine should be equipped with the narrowest possible shoes which will provide adequate flotation.
)N ADDITION SHOES MAY HAVE GROUSER CORNERS CUT OFF TO REDUCE TURNING RESISTANCE AND BONDING FORCES
without loss of flotation and with little loss of overall wear life.
(5) Shoes for Special Conditions

Some shoes have a mud relief hole, which is drilled in the center
OFTHESHOEPLATE)TSPURPOSEISTOPREVENTPACKINGACCUMULATION Track Shoe
WITH-UD(OLE
BYHELPINGTHEMATERIALESCAPE%VERYTIMETHESPROCKETPUSHES
on a bushing it squeezes the material out.
0RIORTOIMPLEMENTINGAMUDRELIEFHOLEITISIMPORTANTTOCHECKTHAT
THE GROUND MATERIAL IS EXTRUDABLE %XTRUDABLE MATERIALS INCLUDE
clay, soil, snow and ice. Non-extrudable materials include rocks,
gravel, branches and brush.
3) Track Guards
The decision to install or not to install roller guards is considerable.
!LTHOUGH ROLLER GUARDS PROVIDE MANY BENElTS THERE ARE TIMES WHEN THEY
are best left off the machine.
2OLLER GUARDS SERVE TWO PURPOSES &IRST THEY PREVENT ROCKS FROM
impacting and clogging track rollers. Second, they provide additional
guidance for the track chain. The problem with roller guards is that they
often keep material in instead of keeping it out. This adverse effect often
OUTWEIGHSTHEBENElTS&ORTHISREASONROLLERGUARDSSHOULDNOTBEUSED
in high packing conditions.
4) Alignment
)N GENERAL A GOOD WAY TO IDENTIFY AN ALIGNMENT PROBLEM IS TO LOOK FOR UNBALANCED WEAR PATTERNS 4HIS
involves comparing left components with right components, front with rear and inner with outer. The four
MAINKINDSOFTRACKFRAMEMISALIGNMENTARETOE INTOE OUTBOWTILTANDTWIST
(1) Track Frame

s 4OE )N4OE /UT
s 4RACK"OW
s 4ILT
s 4WIST
- 137 -
a) Toe-In/Toe-Out
When viewed from the top, either or both of the roller frames is
not parallel to the center line of the tractor.
#!53% TEMPORARILY DURING LOAD ONLY OR PERMANENTLY BENT

diagonal brace or roller frame
%&&%#4 UNBALANCED WEAR WHEN COMPARING INBOARD VERSUS

outboard roller and idler flanges and rail sides — rollers worsen
from rear to front
2%-%$9STRAIGHTENDIAGONALBRACESANDREPAIRMOUNTINGBEARINGS
b) Track Bow
Similar to toe-in and toe-out, but roller frame is bent and curves
in or out with respect to tractor.
#!53%BENTROLLERFRAME
%&&%#4SIMILARTOTOE INANDTOE OUTEXCEPTREARROLLERSARENOT

affected
2%-%$9STRAIGHTENROLLERFRAME
c) Tilt
When viewed from front or rear the roller frame tilts toward or
away from tractor.
#!53%PERMANENTLYBENTDIAGONALBRACEBROKENMOUNTINGSOR
bearings
%&&%#4 UNBALANCED WEAR WHEN COMPARING INBOARD VERSUS

outboard roller, idler, link treads and flanges — unbalance from
front to rear on rollers
2%-%$9STRAIGHTENDIAGONALBRACEANDORREPAIRMOUNTINGS
d) Twist
When viewed from the front, the roller frame is twisted, with the
front end of the roller frame tilted out.
#!53% ROLLER FRAME TWISTED AROUND A HORIZONTAL AXIS PARALLEL TO

the tractor
%&&%#4SIMILARTOEFFECTOFTILTEXCEPTTHATREARROLLERSSHOULDNOT
be affected
2%-%$9STRAIGHTENROLLERFRAME
- 138 -
(2) Front Idler
4HEMAINKINDSOFIDLERMISALIGNMENTARETOE INTOE OUTSHIFTANDTWISTTILT
a) Toe-In/Toe-Out
#!53% Bent idler supports
Bent idler mounting yoke
%&&%#4 )NCREASED WEAR ON LINK SIDES IDLER mANGES AND FRONT
roller flanges.
2%-%$93TRAIGHTENBENTCOMPONENTS
b) Front Idler Shift

#!53% )MPROPERSHIMMING
%&&%#4 )NCREASED WEAR OF LINK SIDES IDLER mANGES AND ROLLER
flanges
2%-%$92EADJUST IDLER SUPPORT SHIMS #LEARANCE BETWEEN

TRACK FRAME AND GUIDE PLATES SHOULD BE BETWEEN
MMANDMM
c) Front Idler Twist/Tilt

#!53% Bent idler supports
Bent idler mounting yoke
5NEVENLYWORNIDLERWEARPLATES
%&&%#4 )NCREASED WEAR ON LINK SIDES IDLER mANGES AND FRONT
roller flanges
2%-%$93TRAIGHTENORREPLACEDAMAGEDCOMPONENTS
(3) Sprocket
4HEMAINKINDSOFSPROCKETMISALIGNMENTARETOE INTOE OUTSHIFTANDTWIST
a) Toe-In/Toe-Out
#!53% "ENTSPROCKETSHAFT
%&&%#4 )NCREASEDWEAROFLINKSIDESANDSPROCKETTOOTHSIDEWEAR
2%-%$92EPLACESHAFT
b) Sprocket Shift
#!53% 3PROCKETMOUNTEDINCORRECTLY
%&&%#4 )NCREASEDSPROCKETSIDEFACEWEARANDLINKSIDEWEAR
2%-%$92EPOSITIONSPROCKETMOUNTING
- 139 -
c) Sprocket Twist
#!53% "ENTSPROCKETSHAFT
%&&%#4 5NEVENSPROCKETWEARRAILWEARANDTRACKROLLERmANGES
2%-%$92EPLACESHAFT
5) Others
(1) Cleaning
0ACKING MATERIAL THAT ACCUMULATES ON UNDERCARRIAGE
components can become as hard as the components
THEMSELVES 2EGULAR CLEANING CAN GREATLY REDUCE THE
EFFECTS OF PACKING 5SE A SHOVEL TO CLEAR OUT THE AREA
between the track frame and the upper portion of the
chain. Then use water to wash away any remaining
material.
(2) Routine Inspection

When it comes to undercarriage life, early detection of wear, misalignment and damage is the key to
preventing a serious and costly condition. There are several items that should be checked regularly.
+EEP TRACK OF UNDERCARRIAGE WEAR 0AY SPECIAL ATTENTION TO BUSHING WEAR AND PREMATURE LINK PITCH
ELONGATION !LSO KEEP AN EYE OUT FOR ANY DIFFERENCES BETWEEN COMPONENT WEAR PATTERNS IE LEFT
VSRIGHTANDFRONTVSREAR 4HISCANOFTENREVEALOTHERHIDDENPROBLEMSLIKEMISALIGNMENTORPOOR
operator habits.
Watch out for component damage, such as cracks, bends, and breaks. These can lead to interference
ANDMALFUNCTION-OSTIMPORTANTLYCHECKROLLERSFOROILLEAKAGE,EAKAGEMEANSTHATOILISBEINGLOST
)FTHISCONDITIONISIGNOREDTHECOMPONENTWILLSEIZEANDCAUSEQUICKEXCESSIVEWEARANDDAMAGE
-ISALIGNMENTCAUSESUNNECESSARYWEARTOALLUNDERCARRIAGECOMPONENTS4HEMOSTCOMMONTYPEOF
misalignment is idler shift, which can usually be fixed by adjusting idler shims.
,OOSENUTSANDBOLTSCAUSEINTERFERENCEWITHMOVINGPARTSABNORMALWEARBOLTHOLEWALLOWINGBOLT

BREAKAGEACCELERATEDMISALIGNMENTANDCOMPONENTLOSS)TISVERYIMPORTANTTOAPPLYPROPERTORQUE
TOALLBOLTS)FBOLTSARENOTTIGHTENEDENOUGHTHENVIBRATIONWILLSLOWLYLOOSENTHEMUNTILTHEYAREFREE
On the other hand, if bolts are over-tightened their structural integrity will be weakened and they will
fail prematurely.
(3) Keeping Good Records

)TISIMPORTANTTOKEEPGOODRECORDSOFALLSERVICE RELATEDACTIVITYSUCHASWEARMEASUREMENTREPAIRAND
costs of repair. This information can be used to evaluate current wear and reduce future wear through
SCHEDULEDSERVICING!NEXCELLENTWAYTOACCOMPLISHTHISTASKISTOUSE#!2%SOFTWAREPROVIDEDTHROUGH
Komatsu.
- 140 -
3-2. Partially Controllable Variables
METHOD OF OPERATION
-ETHODOFOPERATIONISANOTHERFACTORTHATCANGREATLYINmUENCEWEAR4HEREARESEVERALRULESTHATSHOULDBE
observed to minimize wear:
1) Use Slowest Operating Speed

5SE SLOWEST OPERATING SPEED THAT WILL GET THE JOB DONE IN TIME 7EAR RATE IS PROPORTIONAL TO SPEED
Therefore, the faster you go, the more wear you will induce. When working in high impact conditions this
rule is even more critical and the lowest gears should always be used.
2) Minimize Reverse Travel

-INIMIZEREVERSETRAVELBECAUSEITCAUSESMUCHMOREWEARTOBUSHINGSANDSPROCKETSTHANFORWARDTRAVEL
4HISCONCEPTISTHOROUGHLYEXPLAINEDIN7EAR-ECHANISM#OMPLETELYAVOIDREVERSETRAVELINHIGHGEAR
or when climbing uphill.
3) Avoid Spinning the Tracks

)TISINEFFECTIVEANDSUBJECTSTHEUNDERCARRIAGETOUNNECESSARYWEAR)TAFFECTSGROUSERSTHEMOSTBECAUSE
they undergo a grinding
action.
4) Avoid Favoring One Side

!VOIDFAVORINGONESIDEBECAUSEITCAUSESUNEVENUNDERCARRIAGEWEAR/PERATORSSHOULDUSESYMMETRICAL
OPERATINGPATTERNSTOPRODUCEBALANCEDWEAR)FTHISISIMPOSSIBLEORHIGHLYUNPRODUCTIVETHENLEFTANDRIGHT
ROLLERS SHOULD BE SWAPPED PERIODICALLY (ERE ARE SOME
examples of preferred-side operations:
5) Frequent Turning in the Same Direction

&REQUENT TURNING IN THE SAME DIRECTION PRODUCES UNEVEN
wear on roller flanges and link side faces. Sometimes such
maneuvering is made necessary by worksite geometry and
job application.
But usually it is caused by poor operator habits
6) Alternatives
Operators should maneuver the machine so that the operating pattern has an even number of left and
RIGHTTURNS&OREXAMPLEINSTEADOFDOINGANOVALPATTERNWHICHREQUIRESONE SIDEDTURNINGOPERATORSCAN
DOASEMI OVALPATTERNWHICHINVOLVESSYMMETRICALTURNING!NOTHERALTERNATIVEISTODOAlGUREPATTERN
however this is not recommended because it is inefficient and redundant.
- 141 -
7) Traveling Across a Lateral Slope
4RAVELINGACROSSALATERALSLOPEPRODUCESHEAVYSIDE LOADINGONTHEDOWNHILLTRACK)TISBESTTOAVOIDTHIS
kind of operation altogether, but if the job requires it then the operator should change sides for each pass
to balance wear on both tracks.
8) Side-Hill Cutting
Side-hill cutting produces uneven wear because it involves
loading one track at a time. Where possible, the operator
should change sides for each pass.
9) Others
Avoid impact because it produces shock loads that are
transmitted to undercarriage components. This causes
CRACKINGBENDINGBREAKINGANDMISALIGNING)FTHEJOBINVOLVES
high impact conditions then operate using lowest gears.
Minimize counter-rotation )T PRODUCES HEAVY SIDE LOADING

because one track travels forward while the other travels in
REVERSE(OWEVERCOUNTER ROTATIONCANBEUSEDEFFECTIVELYTO
minimize preferred-side operations.
Avoid sharp turningESPECIALLYWHENTRAVELINGINHIGHGEARSBECAUSEITPRODUCESALOTOFSIDELOADING)T

is better to make wide, large radius turns.
Park machine properlyONAmATDRYSURFACE0ARKINGAMACHINEONASLOPEMAYCAUSEROLLERSEALSTO

become permanently deformed, especially in extremely hot or cold temperatures.
Minimize forward-reverse direction changes because it

causes root and radial wear.
- 142 -
3-3. Uncontrollable Variables
There are three groups of factors that affect undercarriage wear. These are earth conditions, terrain and job
application.
s 3OILANDUNDERFOOTCONDITION%ARTHCONDITIONS
s 4ERRAINCONDITION
s *OBAPPLICATION
1) Soil & Underfoot Condition

%ARTH CONDITIONS ARE ABRASIVENESS IMPACT PACKING MOISTURE TEMPERATURE AND CHEMICALS 4HESE
conditions cannot be changed, but their adverse effects can be partially controlled by good maintenance
(1) Abrasiveness
!BRASIVENESS IS A PROPERTY THAT DESCRIBES HARDNESS AND SHARPNESS OF ROCK PARTICLES IN THE GROUND
This property can greatly increase the rate of wear between moving components. Since abrasiveness
is difficult to measure quantitatively, it is usually rated qualitatively as being non-abrasive, moderately
abrasive or highly abrasive. This property can usually be determined by rubbing some moist material
between thumb and fingers.
Non-abrasive MATERIAL HAS A LOW PROPORTION OF HARD AND SHARP PARTICLES )T FEELS SLICK AND MOLDABLE
when moist. Example: clay.
Moderately abrasive MATERIAL HAS A MODERATE PROPORTION OF HARD AND SHARP PARTICLES )T HAS A GRITTY
texture when moist. Example: loam.
Highly abrasiveMATERIALHASAHIGHPROPORTIONOFHARDANDSHARPPARTICLES)TFEELSVERYCOARSEWHEN
moist. Example: corral rock, sand.
- 143 -
Relationship between analysis value of soil (contents of SiO2 and Al2O3)
and wear life of parts
The life of the undercarriage parts largely depends on how the machine is used and condition of the
SOIL AT THE JOB SITE !LL FACTORS RELATED TO SHORTENING THE LIFE OF UNDERCARRIAGE COMPONENT CAN NOT BE
EXPLAINEDWITHONLYTHEANALYSISVALUEOFTHESOIL(OWEVERWECANUSETHEANALYSISVALUEASTHElRST
step of the analysis of wear and utilize it for sales and service activities.

100
SiO2 +
!L/ Quartz
prophecy
Ba
(ARDSANDSTONE
'RANITE
Quartzite
Aa
Sand
Slate
50 !NDESITE
#ONGLOMERATEROCK
Shale
,IMESTONE
Basalt
Kanto loam
Tuff
-ICASLATE
0
BL 5 AL 10
Quantity of quartz in soil ,IFE)NDEX
!SPERPASTDATA
Remarks
4HESAMPLEOFTHESOILANDROCKMUSTBEABOUTTHESIZEOFTWOGOLFBALLS
)FPLURALTYPESOFSOILROCK AREMIXEDTOGETHERSAMPLESMUSTBETAKENFOREACHTYPE
4HEELEMENTOFSOILMUSTBEANALYZEDINMASSPERCENTAGE3EE*)3-+
- 144 -
Example of education
! CUSTOMER WHO MAINLY WORKS IN DISTRICT ! DECIDED TO UNDERTAKE A JOB IN DISTRICT " ! +OMATSU
SALESMAN HEARD THAT THIS CUSTOMER HAD SAID h4HE UNDERCARRIAGE PARTS BUSHINGS IN PARTICULAR OF
the machines used in district B seem to be worn quickly”. Then, the salesman analyzed the soils in
DISTRICTS ! AND " AND ESTIMATED THE LIFE OF THE UNDERCARRIAGE PARTS TO BE USED IN DISTRICT " ON THE
BASISOFTHELIFEOFTHEUNDERCARRIAGEPARTSOFTHECUSTOMERUSEDINDISTRICT!
%STIMATEDLIFEINDISTRICT"H %STIMATEDLIFEINDISTRICT!8",!,
X
H
!CTUALLIFEINDISTRICT!H
!A"A !NALYSISVALUESOFSOILINDISTRICTS!ANDB
!,", ,IVESESTIMATEDFROMANALYSISVALUESINDISTRICTS!AND")NDEX
The above salesman explained the above estimated life to the customer and succeeded in selling
THE SPARE PARTS &URTHERMORE SINCE HE NOTIlED THE SHORTENING OF THE WEAR LIFE OF THE PARTS BY THE
condition of each job site, the customer did not have any complaint on this matter.
(2) Impact
)MPACT IS DETERMINED BY THE PERCENTAGE OF TRACK SHOE AREA THAT MAKES CONTACT WITH THE GROUND
When the ground is soft and level, grousers fully penetrate the soil and the weight of the machine
IS EVENLY DISTRIBUTED OVER THE ENTIRE AREA OF TRACK (OWEVER WHEN BUMPY OR HARD GROUND CONDITIONS
obstruct penetration then the weight of the machine becomes unevenly distributed, producing stress
concentrations.
)MPACTCAUSESSTRUCTURALDAMAGESUCHASBENDINGBREAKINGCRACKINGCHIPPINGANDSPILLING&ORCRAWLER

dozers impact only contributes during travel, but for excavators it also contributes during stationary
OPERATION%ARTHCONDITIONSAREDESCRIBEDASLOWMODERATEORHIGHIMPACT
Low impact conditions provide good ground penetration and low exposure to bumps. Examples: sand,
soft soil.
Moderate impact conditions provide partial ground penetration and moderate exposure to bumps.
Examples: gravel, hard soil.
High Impact conditions provide poor and uneven ground penetration and constant exposure to tall
bumps. Examples: frozen ground, concrete, rock quarry, forestry.
(3) Packing
0ACKINGISGROUNDMATERIALTHATSTICKSTOTHEMOVINGPARTSOFANUNDERCARRIAGE)TAFFECTSUNDERCARRIAGE
components in six different ways.
A 3ERVES AS A COHESIVE AGENT THAT HELPS ABRASIVE PARTICLES STICK TO MOVING COMPONENTS EG SANDCLAY
MIXTURE 4HISGREATLYINCREASESWEAR
B -ATERIALACCUMULATESONBUSHINGSANDINSPROCKETTEETH4HISPRODUCESAMISMATCHBETWEENSPROCKET
PITCHANDLINKPITCHWHICHCAUSESINCREASEDWEARRATESDUETOIMPROPERENGAGEMENT2EVERSEDRIVE
SIDE TIP WEAR AND BUSHING /$ WEAR ARE TWO OF THE MOST SIGNIlCANT TYPES OF WEAR RESULTING FROM THIS
CONDITION 0ACKING CAN BECOME SO SEVERE THAT IT CAUSES hPOPPINGv WHICH IS A LOUD SLAPPING SOUND
PRODUCEDWHENASPROCKETTOOTHARRIVESTOOEARLYTOGRABTHENEXTBUSHINGINSTEADITRIDESONTOPOFTHE
bushing and slips when the next sprocket tooth makes contact.
C )NCREASESTRACKTENSIONWHICHCAUSESINCREASEDWEARONALLUNDERCARRIAGECOMPONENTS
- 145 -
D "INDS ROLLERS WHICH FORCES TRACK LINKS TO SLIDE ACROSS ROLLERS INSTEAD OF ROLLING ACROSS THEM 4HIS
PRODUCES mAT SPOTS ON ROLLERS AND ACCELERATED LINK TREAD WEAR )N FREEZING CONDITIONS THIS PROBLEM IS
compounded because frozen mud is very cohesive and difficult to remove.
E -AYHIDEACOMPONENTLEAKAGEPROBLEMTHATCOULDOTHERWISEBESEENANDCORRECTED
F 4AKESAWAYFROMAVAILABLEENGINEPOWERBYINTERFERINGWITHMOVINGCOMPONENTS4HISREDUCESMACHINE
performance and fuel economy.
(4) Moisture
-OISTURE CAUSES CONSIDERABLE DAMAGE TO UNDERCARRIAGE COMPONENTS 'ROUND MATERIAL CAN HAVE LOW
MODERATEORHIGHMOISTURECONTENT-OISTUREADVERSELYAFFECTSWEARINFOURWAYS
A #OMBINESWITHPACKINGMATERIALTOFORMACOHESIVECOMPOUNDTHATSTICKSTOCOMPONENTS-OISTMATERIAL
ISMOLDABLESOITCANEASILYlLLGAPS!FTERTHEPACKINGMATERIALDRIESNEWMATERIALSETTLESONTOPAND
FORMSANEWLAYER)NTHISWAYPACKINGMATERIALISABLETOACCUMULATE
B )NCREASESWEARBYMAKINGMATERIALMOREABRASIVE
C !LLOWSMATERIALTOTRAVELQUICKERBYmOWINGINTOMOVINGPARTS-OISTMATERIALCANALSOmOWPASTSEALS
and contaminate sealed components.
D #AUSESRUSTANDACCELERATESTHEEFFECTSOFCERTAINCHEMICALS
On the other hand, moisture also has these advantages:

Washes away packing material.
Softens material to make it more extrudable.
$ILUTESSOMECHEMICALS
(5) Temperature
Effects of hot temperature:
(EATTREATEDMETALSBECOMEWEAKERANDMORESUSCEPTIBLETOWEAR
Seals can melt or become weak and cause leakage.
#HEMICALCORROSIONISACCELERATED
Effects of cold temperature:

-ETALSBECOMEBRITTLEANDHAVELOWERRESISTANCETOIMPACT
Seals become rigid and lose resilience.
-OISTPACKINGMATERIALFREEZES
Oil becomes viscous and is unable to properly lubricate moving parts.
- 146 -
(6) Chemicals
Salts, acids and other chemicals contaminate lubricants and corrode metals and seals.
Surface-hardened metals are more susceptible to corrosion than plain metals.
2) Terrain Condition
#RAWLERSDOWORKONALMOSTANYKINDOFTERRAIN,ETSTAKEALOOKATSOMECOMMONTERRAINSANDHOWTHEY
affect undercarriage wear. Keep in mind that the terrain of a worksite, like earth conditions, cannot be
changed. But the adverse effects can be partially controlled by proper method of operation
(1) Uphill/Downhill
When working uphill machine weight is shifted to back rollers, causing them to wear faster. The same
HAPPENSTOFRONTROLLERSWHENWORKINGDOWNHILL!LSOWHENWORKINGUPHILLTHESPROCKETHASTOPUSHHARDER
AGAINSTTHEBUSHINGSTOPROPELTHEMACHINEFORWARD&ORTHISREASONFORWARDDRIVESIDEWEARISGREATER
4HEOPPOSITEISTRUEWHENTRAVELINGDOWNHILLTHESPROCKETDOESNTHAVETOPUSHASHARDSOFORWARDDRIVE
side wear is less.
(2) Lateral Slope

When working on a lateral slope machine weight is shifted to the
downhill side. This causes premature wear on roller flanges and link
side faces, especially on the downhill track.
(3) Crown/Depression
When working on a crown or depression the weight of the machine is not evenly distributed by the entire
TRACKSHOEAREA!CROWNPRODUCESHIGHGROUNDPRESSUREONTHEINNERSIDESANDADEPRESSIONPRODUCES
high ground pressure on the outer sides. This causes uneven wear, particularly between bushings and
sprocket.
Crown Depression
3) Job Application
*OB APPLICATION REFERS TO THE TYPE OF WORK THAT THE MACHINE IS DOING 4URNING DOZING GRADING RIPPING
PULLING SIDE HILL CUTTING EXCAVATING AND LOADING ARE SOME OF THE MOST COMMON JOB APPLICATIONS (ERE
WEWILLBRIEmYDISCUSSHOWTHEYAFFECTWEAR5SUALLYAJOBAPPLICATIONCANNOTBECHANGEDBUTITCANBE
partially controlled by choosing the correct machine outfit and employing a good method of operation.
- 147 -
(1) Turning
Turning wears flanges more than any other component. The above
diagram illustrates the wear pattern that occurs when the machine
TURNSLEFT.OTICETHATTHEIDLERANDFRONTROLLERS!" AREPUSHED
LEFTANDSCRAPEAGAINSTRIGHT SIDELINKFACES"UTREARROLLERS# ARE
pushed right and scrape against left-side link faces
(2) Dozing and Grading

Since these applications require pushing, more load is exerted on
the front of the machine. This produces greater wear on front rollers
and front idlers.
(3) Pulling, Ripping

Since these applications require pulling, more load is exerted on the
BACKOFTHEMACHINE)NRIPPINGOPERATIONSTHEFRONTOFTHEMACHINE
can even raise off the ground. This produces greater wear on back
rollers and sprockets.
(4) Side-Hill Cutting

)N SIDE HILL CUTTING OPERATIONS THE BLADE IS LOADED ON ONLY ONE SIDE
This produces increased wear on all undercarriage components on
the loaded side.
(5) Excavating
Weight of machine is repeatedly shifted from side to side and front
to rear. This causes link and bushing fatigue, which weakens their
structural integrity.
(6) Loading
Weight of machine is shifted from front to rear. This is because the
machine is constantly alternating between digging and carrying.
&RONT AND REAR ROLLERS ARE AFFECTED THE MOST BECAUSE THEY MUST
support the machine.
- 148 -
3-4. Reference
Critical variables that affect undercarriage component life.
Link Track Track Carrier

Group Variable Shoe Bushing Sprocket Idler
pitch link roller roller
Operation Machine speed
Shoe slipping
Long distance
drawing
Traveling on slope
Track tension
Maintenance
Packing materials
An element of soil
(SiO2)
Ground
Rocky ground
condition
(uneven terrain)
Soil ground
(Splashed soil)
Sticky soil ground
(Packing materials)
- 149 -
4. Maintenance and Adjustment
4-1. Proper Way of Track Installation on Machine
1. Conventional Track
4HEREISAWAYDIRECTION OFTRACKINSTALLATIONONMACHINE
0ROPERWAYOFTRACKINSTALLATIONISASSHOWNBELOW
0INMUSTBEFORWARDON
one link
View ! 1
View !
3
Shoe bolt position,

when you see
shoe plate from
rear of final drive
2
#HECKPOINTSFORPROPERTRACKINSTALLATION
7HENYOUSEEONELINKPORTIONONUPPERSIDEOFTRACKVIEW! PINSIDEMUSTBEFRONT
)N CASE OF SINGLE GROUSER SHOE GROUSER SHOULD BE FRONT NEAR PIN SIDE 3O ON FORWARD DRIVE TIP OF
grouser contact and penetrate into ground first.
◆ 9OUCANIMAGINETIPOFGROUSERASHEELOFYOURFOOT7HENYOUWALKINFORWARDYOURHEELCONTACTSONTO
ground first. So it’s same idea.
3HOEBOLTPOSITIONFORMSUPSIDEDOWNEDTRAPEZOIDALSHAPEWHENYOUSEETHEMFROMREARSIDEOFlNAL
drive.
Track can be installed in opposite way of the above. But it’s a wrong!
3OMETIMEWECANSEEITWRONGTRACKINSTALLATION ATJOB SITEASSHOWNINNEXTPAGE
- 150 -
Sample of wrong track installation
D85A D375A PC300
)FTRACKISINSTALLEDINOPPOSITEWAYFOLLOWINGPROBLEMSAREANTICIPATED
"OTH"USHING/$WEARAND3PROCKETWEARAREACCELERATED
)NCASEOF3INGLE'ROUSER3HOEONBULLDOZERTRACTIONFORCEISDECREASED
◆ 0LEASEREFERTOh2EFERENCE4ECHNICAL%XPLANATIONvFORDETAILS
)F CUSTOMER REPLACES TRACK BY HIMSELF WE SOMETIME SEE THE OPPOSITE TRACK INSTALLATION AS SHOWN IN THE
above photos.
So if you see it, please guide him on proper track installation by explaining the reasons.
- 151 -
2EFERENCE4ECHNICALEXPLANATION
7HYBOTHBUSHING/$ANDSPROCKETWEARAREACCELERATEDONWRONGTRACKINSTALLATION
"USHING/$ANDSPROCKETWEARISPROGRESSEDUNDERSLIDINGMOTIONAFTERCONTACTINGEACHOTHERWITHLOAD
◆ Bigger load makes more wear
)FTRACKISINSTALLEDPROPERLYTHESLIDINGMOTIONBETWEENBUSHINGANDSPROCKETHAPPENSINUPPERSIDEOFlNAL
drive then wear is progressed
◆ 0LEASEREFERTO5#43 FORDETAILS
"UTIFTRACKISINSTALLEDWRONGWAYPOSITIONOFTHESLIDINGMOTIONMOVESTOLOWERSIDEOFlNALDRIVENOMORE
SLIDINGMOTIONINUPPERSIDE THENWEARISPROGRESSEDTHERE
Proper track installation Wrong track installation
Condition of sliding motion at lower side of final drive
,OWERSIDEOFlNALDRIVEISFOLLOWINGSITUATION4HOSEAREDISADVANTAGESAGAINSTWEAR
"IGFORCEANDTORQUEISAPPLIEDBETWEENSPROCKETANDBUSHINGDURINGFORWARDDRIVE
◆ $OZINGANDRIPPINGWORKBYBULLDOZERISPERFORMEDUNDERFORWARDDRIVESOTHATBIGGESTFORCEISAPPLIED
during working.
◆ #F"IGFORCEISAPPLIEDONUPPERSIDEOFlNALDRIVEDURINGREVERSE"UTNOWORKISPERFORMEDNORMALLY
with reversing.
#LOSETOGROUNDSOTHATSANDANDDIRTPENETRATESEASILYONSLIDINGSURFACEBETWEENBUSHINGANDSPROCKET
)TWORKSASABRASIVEANDACCELERATESTHEWEAR
◆ #F5PPERSIDEOFlNALDRIVEISAWAYFROMDIRTANDSAND
4HEREFOREBOTH"USHING/$WEARAND3PROCKETWEARAREACCELERATEDIFTRACKISINSTALLEDOPPOSITEWAY
As a conclusion, proper way of track installation is ruled in order to minimize Bushing O.D. wear which
becomes criteria of track life in most cases
- 152 -
7HYTRACTIONFORCEISREDUCEDIFTRACKWITHSINGLEGROUSERSHOEISINSTALLEDWRONGWAY
$IRTANDSANDAREEASYTOSTICKANDBUILDUPONPLATEOFSINGLEGROUSERSHOE
'ROUSERUNDERDIRTBUILDUPCONDITIONONSHOEPLATECANNOTGETENOUGHPENETRATIONONGROUND
0OOR GROUSER PENETRATION IS OBVIOUS ESPECIALLY ON WRONG TRACK INSTALLATION AS SHOWN BELOW !S A RESULT
traction force is reduced.
Proper Track Installation
Built up dirt
Wrong Track Installation
2. Rotary Bushing Track (PLUS)

0,53 HAS A PARALLEL LINK 3O FOLLOWING ITEMS WHICH ARE CHECK POINTS TO CONFIRM PROPER WAY OF TRACK
INSTALLATIONFORCONVENTIONALTRACKOFF SETLINK CANTBEAPPLIED
7HENYOUSEEONELINKPORTIONONUPPERSIDEOFTRACKVIEW! PINMUSTBEFRONT

2. Shoe bolt position forms up side downed trapezoidal shape when you see them from rear side of final drive.
4HENINCASEOF0,53PLEASECONlRMPROPERWAYOFTRACKINSTALLATIONONMACHINEBYGROUSERPOSITIONONLY
- 153 -
Grouser Position PLUS Track
4HENINCASEOF0,53PLEASECONlRMPROPERWAYOFTRACKINSTALLATIONONMACHINEBYGROUSERPOSITIONONLY
7AYOF0,53TRACKINSTALLATIONISEXPLAINEDIN3HOP-ANUALSOPLEASEFOLLOWIT!NDFOLLOWINGSAREADDITIONAL
remarks for your reference.
7HEN0,53ISINSTALLEDONMACHINEASSEMBLINGMESHING OFMASTERLINKSHOULDBETHESAMECONDITION

as conventional track.
●-ASTERLINKWITHBOLT HOLESIDEHANGSOVERTOOTHERHALFFROMUPPERAT)DLERPOSITION
PLUS Track
Conventional Track
0LEASEBECAREFULONSHOEPLATEINSTALLATIONONTOLINKASSYASWELL)NCASEOFREPLACINGLINKASSYONLY
WITHRE USINGOLDSHOEPLATEETC
●)NCASEOF0,53SHOESHOEBOLTHOLEALIGNMENTISPARALLEL3OSHOEPLATECANBEINSTALLEDBOTHWAYS
CORRECTWAYANDWRONGWAY
●4HENPLEASECONlRMPOSITIONRELATION BETWEENSHOEGROUSERANDMASTERLINKASSHOWNBELOWPART
OF3HOP-ANUAL BEFOREINSTALLATION
Part of Shop Manual
2
2
1
1
- 154 -
4-2. Track Adjustment
The shoe tension remarkably affects the part wear and the strength. Therefore, it should be adjusted
PROPERLY&ORDETAILSREFERTOTHEITEMINh6ARIABLETHAT!FFECT0ARTSv
)NADDITIONFORTHEMEASUREMENTMETHODANDTHEPROPERVALUEREFERTOTHE3HOP-ANUALOFEACHMODEL
4-3. Idler Guide Adjustment

5NLESSTHEIDLERADJUSTMENTISPROPERTHEIDLERSTRENGTHISLOWEREDANDTHEUNEVENWEAROFTHESHOEANDTHE
roller occurs. Therefore, adjust it to the proper value.
s $ $ !DJUSTBYREPLACINGTHESHIMORTHEPLATE
s $ $ !DJUSTBYTHEBUILD UPWELDINGORTHEPARTREPLACEMENT
)NADDITIONFORTHESWAPPINGANDTHEPROPERVALUEREFERTOTHE3HOP-ANUALOFEACHMODEL
4-4. Track Roller Rotation

7EAR SPEED OF 42OLLER IS VARIED DEPEND ON ITS POSITION )F YOU REPLACE ALL 42OLLERS BASED ON MOST WORN
ONENORMALLYFRONTORREAR YOUMIGHTTHROWAWAYTHEONEWHICHSTILLREMAINSWEARALLOWANCECENTERSIDE
42OLLER TOGETHERATSAMETIME)TSWASTEOFMONEY
!DOPTINGOFh42OLLER3WAPPINGvHELPSYOUTOAVOIDSUCHSITUATIONANDIMPROVECUSTOMERSOPERATINGCOST(
CONSEQUENTLY0LEASEREFERTONEXTPAGEFORDETAILS
&OLLOWINGSARECONSIDERATIONPOINTSON42OLLERSWAPPINGWITHSOMECAUTION3OIFYOUHAVEADIFlCULTYTO
HANDLEONUNBALANCEDWEAROF42OLLERPLEASESTUDYTOAPPLYIT
#ONSIDERATION0OINTSON42OLLER3WAPPING)NCLCAUTIONS
)TSPREFERABLETOSWAPWHENWEARRATIOBETWEENMOSTWORNANDLEAST42OLLERATLEASTWITHINSAME
42OLLERTYPE3&$&
●)FTHEREISNOTMUCHDIFFERENCEOFWEARSWAPPINGISNOTEFFECTIVEWAY
)TSPREFERABLETOSWAPWHENAVERAGEWEARRATEOF42OLLERIS MID WEAR
●)FSWAPPINGISDONEAFTERMUCHWEAR42OLLERSLASTONLYFORSHORTPERIODTOWEARLIMITAFTERSWAPPING
)TSNOTEFFECTIVEWAY
3TICKTOSWAPAMONGSAMEmANGETYPE
●h3&⇔ 3&vANDh$&⇔$&v#AUTION,AST42OLLERMUSTBE3&ALWAYS
#ONSIDERTOSWAPBETWEEN,(42OLLERAND2(ASWELL
3WAPPING IS A BIG AND DANGEROUS JOB 3O ITS DIFlCULT TO DO IN lELD 4HEN ITS BETTER SCHEDULE IT WHEN
machine is brought to workshop for another repair.
Case study of T/Roller Swapping on D155A, AX-6
Current Condition (at Measured) Action

Original Position Wear Life % Flange Type (Swapping)
Front (1) 65% S Change to No. 5
2 50% D No change
3 50% S Change to Rear (7)
4 40% D No change
5 40% S Change to Front (1)
6 50% D No change
Rear (7) 65% S Change to No. 3
- 155 -
Reference:
1. T/Roller wear pattern
2. Reason why Swapping is effective to reduce UC cost ($/H)
7EARSPEEDOF42OLLERISVARIEDDEPENDONITSPOSITION
● ,OADISAPPLIEDATREARSIDEDURINGDOZINGANDRIPPINGSOREARSIDE42OLLERWEARSFASTER
● ,OADISAPPLIEDATFRONTSIDEDURINGTRAVELINGSOFRONTSIDE42OLLERWEARSFASTER
● 4HENNORMALLY42OLLERWEARISUNBALANCEDFRONTANDREARSIDE42OLLERWEARSFASTERTHANCENTERSIDE
one.
-AINTENANCEREPLACEMENT OF42OLLERUNDERUNBALANCEDWEARCONDITION
● )F42OLLERSAREREPLACEDALLWHENFRONTANDREAR42OLLERWHICHWEARSFASTER REACHEDWEARLIMITSOME
CENTERSIDEONESWHICHSTILLMIGHTHAVEWEARALLOWANCE AREREPLACEDTOGETHER)TSWASTEOFMONEY
●/NTHECONTRARYIF42OLLERSAREREPLACEDALLAFTERCENTERSIDE42OLLERWHICHNORMALLYWEARSSLOWER
REACHED WEAR LIMIT FRONT AND REAR 42OLLER WORN TOO MUCH ALREADY !ND IT MAY CAUSES FOR ANOTHER
TROUBLESUCHASBROKENINTERFEREWITHOTHER5#PARTSETC
"YRELOCATING42OLLERPOSITIONUNBALANCEDWEARCONDITIONCANBEIMPROVED
● 2ELOCATEFRONTANDREAR42OLLERWHICHWEARSFASTER TOCENTERSIDE
● 2ELOCATECENTERSIDE42OLLERWHICHWEARSSLOWER TOFRONTANDREAR
Swapping
4HEN TOTAL USAGE HOUR OF 42OLLER CAN BE EXTENDED BY SWAPPING !S A RESULT USER COST ( CAN BE
REDUCED)TALSOCONTRIBUTESTOAVOIDSECONDARYTROUBLEDUETOTOOMUCHWEAROF42OLLER
- 156 -
4-5. Field Action against Oil Leakage
#HECKTHESHOEOILLEAKAGEASFOLLOW
1) Hot Pin Checking

#HECKTHEPINSTEMPERATUREBYTHERMOMETERORHANDQUICKLYAFTERSTOPTHEMACHINEWHICHOPERATESOVER
MINUTES
(/4 0RETTYHOT)TCANTTOUCHCONTINUOUSLY -ORETHAN #

7!2- ,IKETEPIDWATERBUTITISHOTTERTHAN,INK !BOUT #
#/,$ !NORMALTEMPERATUREWHICHISSAMEAS,INK !BOUT #
2) Method for Dealing with Initial Oil Leakage
#HECk for heat
A #/,$ No action necessary

B W!2- #HECk oil
(/T
A /ILLEvel normal:#HECKAGAINAFTERHOURs
B /ILLEvel low:!DDOIL
C /ILDIRty: #HANGEOIL
D .OOIl -EASURELINKPITCH
A %LONGATIONLESS !DDOIL
THANMM
A .OOILLEAKAGE No action necessary
B /ILLEAKAGE#HARGEWITHGREASE
B %LONGATIONMORETHANMM2EPLACESET
E $Irty or -EASURELINKPITCH
sand in oil
A %LONGATIONLESSTHANMM&ILLWITHGREASE
B %LONGATIONMORETHANMM2EPLACESET
.OTE )FITISWARMORHOTFOR OFTHETIMESATTHEINITIALSTAGEREMOVEFROMTHECHASSISANDCONSIDER

carrying out an overall oil check and repair in the workshop.
- 157 -
3) Procedure
(1) Preparation
A 7HENTHETRACKASSEMBLYISATTACHEDTOTHEMACHINE
2AISE THE RIGHT SIDE TO SET THE MACHINE AT A
angle.
s #HANGEOILATTHESMALLPLUGSIDE
s 4HE SMALL PLUG IS INSTALLED TO THE RIGHT SIDE OF THE
chassis. Therefore, set with the right side of the
chassis raise. ^
s 4HEOPERATIONFROMSTEPISEASIERTOCARRYOUTAT
the following points.
s &OR THE RIGHT TRACK BETWEEN THE OUTSIDE CARRIER
rollers
s &ORTHELEFTTRACKATTHEWINDONPORTIONOFTHEIDLER
on the inside
B 7HEN THE TRACK ASSEMBLY IS REMOVED FROM THE

machine. Stand the track assembly as the small plug
upper side.
(2) Punch the small plug into pin oil hole with tool.
s 4HESMALLPLUGHOLEISDIA MM

s 5SEASUITABLEBARDIA -IN
s )TISCONVENIENTTOUSETHESPECIALTOOLTOPUNCHTHEPLUG
s $ONOTREMOVETHELARGEPLUGWITHADRILL φ MM
0ARTICLES OF RUBBER WILL BE REMAIN IN THE OIL HOLE AND OFTEN
Small plug
the plug is not completely installed in.
(3) Check oil quantity and contamination

s 4AKEAMEASUREOF# A
B
s #HECKACONTAMINATIONBYOILONTHEDIPSTICK
I /ILQUANTITY -AXφ
s #<MM⇒)NSTALLAPLUG A

s #MM⇒&ILLOIL B
II /ILCONTAMINATION
s #OLORISDARKBUTHAVEAmUIDITY⇒&ILLOIL
s (AVEANACRIDSMELLOFBURNING⇒&ILLINGOILUSINGVACUUM C
pump is recommended Oil
s %ARTH AND SAND CONTAMINATING ⇒ (AVE A PROBLEM ON
SEALING0RESSGREASEINTOTHEOILHOLEUNTILGREASESTICK
out from the joint of the track links.
- 158 -
(4) Filling oil using vacuum pump (when required)
<Vacuum up>
s 5SETHEVACUUMPUMP
.OTE ! HAND PUMP CAN BE USED IF THE VACUUM PUMP IS NOT
available, or the case of filling oil only.
! NOZZLE MUST BE INSERTED DEEPLY TO PREVENT AN
ACCUMULATIONOFAIR
Sealing rubber
<Filling up>
(ANDPUMP
Nozzle
Sealing rubber
(5) Install the small plug into the pin oil hole with tool.
s )TISCONVENIENTTOUSETHESPECIALTOOLTOINSTALLTHEPLUG
s )NSTALL THE PLUG UNTIL IT IS BEYOND THE CHAMFERED PORTION OF THE PIN )F IT IS PROTRUDING OUTSIDE THE
CHAMFEREDPORTIONOFTHEPINITISNOTINSTALLEDINPROPERLY4HISWILLCAUSETHEPLUGTOCOMEOUT
MM
Special tool
Small plug
No good Good
- 159 -
4-6. Requirement of the Shoe Bolts Tightening
5NLESS THE BOLT TIGHTENING IS PROPER THE BOLT LOOSENING DROP OR BREAKAGE MAY OCCUR 4HEREFORE TIGHTEN
properly.
!SFORTHESHOEBOLTTIGHTENINGFOLLOWTHEBELOWPRECAUTIONS
)NADDITIONASFORINSTALLINGANDREMOVINGTHESHOEBOLTFOLLOWTHEBELOWPRECAUTIONS
1. Master Bolt removal

s $ONOTREMOVETHEBOLTSONEBYONE!SFORFOURBOLTSLOOSENEACHONEBYONETOTWOTURNSANDMAKE
SURETHATFOURBOLTSTURNLIGHTLY!FTERTHATREMOVETHEM
s 7HENTHEBOLTSARETURNEDFORCIBLYINTHESTATETHATTHEBOLTSDONOTTURNLIGHTLYTHETHREADPORTIONOFTHE
bolt and the master link may be damaged.
2. Regular Bolt removal

s )FTHEBOLTCANNOTBELOOSENEDBYONETURN)FTHEROTATIONTORQUEDOESNOTBECOMEZERO DONOTTURNIT
forcibly and loosen the retaining bolts.
s )FTHEBOLTISTURNEDFORCIBLYINTHESTATETHATTHETORQUEISNOTZEROTHEREPAIRWORKISREQUIRED
3. Master bolt installation

s 5NTILTHEMATINGSURFACESOFTHEMASTERLINKCONTACTTIGHTLYALLOFFOURMASTERBOLTSSHOULDBEINSTALLED
manually.
s )NTHESTATETHATTHEMATINGSURFACESOFTHEMASTERLINKDONOTCONTACTTIGHTLYIFTHEBOLTSARETIGHTENED
forcibly, the thread portion of the bolt and the master link may be damaged.
When installing the shoe bolts

#OATTHETHREADOFBOLTSWITHAnti-friction compound (LM-P).
4IGHTENSHOEBOLTSINORDER -
)NITIALTIGHTENINGTORQUEANDTIGHTENINGANGLE
3EESHOEBOLTTORQUETABLE.EXTPAGE
$ONOTUSEANIMPACTWRENCHFORTHEMASTERLINKMOUNTINGBOLT
#OAT!NTI FRICTIONCOMPOUND,- 0 ONNECKOFMASTERBOLTAS
well.
$IRECTIONOF3HOE.UT-OUNTING
).34!,,).'3(/% .54$)2%#4)/.TO"%!3&//,/WS.
%$'%0/24)/.
20/24)/.
.543%!4).'3)$%
,).+3)$%/&-!4#().'
3(/%0,!4%
- 160 -
Shoe Bolt Tightening Torque Table
Bulldozer
Shoe Bolt Tightening Torque

Shoe bolt Master link bolt
Model Initial Torque Additional Initial Torque Additional
Tightening Tightening
kg䞉m ft-lbs kg䞉m ft-lbs
Angle Angle
7
A 6-8 44-57
8
6-8 44-57
D21 7A 90° ± 10° 6-8 44-57 180° ± 10°
With Swamp Shoe 9-11 65-80
P
6-8 44-57
8
With Swamp Shoe 9-11 65-80
21
EX
22
D31 19-23 138-167 90° ± 10° 11-19 80-137 180° ± 10°
21
PX
22
21
EX
22 19-23 138-167 90° ± 10° 11-19 80-137 180° ± 10°
EX & Exi 23
PLUS 10-14 73-101 120° ± 10° 18-22 131-159 180° ± 10°
D37
21
PX
22 19-23 138-167 90° ± 10° 11-19 80-137 180° ± 10°
PX & Pxi 23
PLUS 10-14 73-101 120° ± 10° 18-22 131-159 180° ± 10°
21 18-22 131-159
EX
22 120° ± 10° 18-22 131-159 180° ± 10°
14-18 102-130
EX & Exi 23 0°
PLUS 22-28 159-202 120° ± 10° 27-33 196-238 180°
-20°
D39
21 18-22 131-159
PX
22 120° ± 10° 18-22 131-159 180° ± 10°
14-18 102-130
PX & Pxi 23 0°
PLUS 22-28 159-202 120° ± 10° 27-33 196-238 180°
-20°
E 6
D41 18-22 131-159 120° ± 10° 18-22 131-159 180° ± 10°
P 6
18-22 131-159 18-22 131-159 ± 10°
EX & Exi 22 0°
PLUS 22-28 159-202 27-33 196-238
-20°
D51 120° ± 10° 180°
18-22 131-159 18-22 131-159 ± 10°
PX & Pxi 22 0°
PLUS 22-28 159-202 27-33 196-238
-20°
12
50-60 362-434
EX
15
PLUS 45-55 326-397
50-60 362-434
EX & Exi 23
PLUS 45-55 326-397 0°
D61 120° ± 10° 31-39 225-282 180°
12 -20°
50-60 362-434
PX
15
PLUS 45-55 326-397
50-60 362-434
PX & Pxi 23
PLUS 45-55 326-397
12 36-44 261-318
50-60 362-434
15
PLUS 31-39 225-282
EX 50-60 362-434
16
PLUS 31-39 225-282
50-60 362-434
17
PLUS 31-39 225-282
12 36-44 261-318
50-60 362-434
15
PLUS 31-39 225-282 0°
D65 120° ± 10° 31-39 225-282 180°
PX 50-60 362-434 -20°
16
PLUS 31-39 225-282
50-60 362-434
17
PLUS 31-39 225-282
50-60 362-434
15
PLUS 31-39 225-282
50-60 362-434
WX 16
PLUS 31-39 225-282
50-60 362-434
17
PLUS 31-39 225-282
- 161 -
Shoe Bolt Tightening Torque
Shoe bolt Master link bolt
Model Initial Torque Additional Initial Torque Additional
Tightening Tightening
kg䞉m ft-lbs kg䞉m ft-lbs
Angle Angle
0°
D68 ESS 12 36-44 261-318 120° ± 10° 31-39 225-282 180°
-20°
D70 LE 12 27-33 120° ± 10° 27-33 180° ± 10°
0°
A 21 36-44 261-318 120° ± 10° 31-39 225-282 180°
-20°
0°
E 21 36-44 261-318 120° ± 10° 31-39 225-282 180°
-20°
0°
ESS 2,2A 36-44 261-318 120° ± 10° 31-39 225-282 180°
-20°
15
0°
EX 15E0 31-39 225-282 120° ± 10° 31-39 225-282 180°
-20°
D85 15R
0°
P 21 36-44 261-318 120° ± 10° 31-39 225-282 180°
-20°
31-39 225-282
15
With Swamp Shoe 50-60
31-39 225-282 0°
PX 15E0 120° ± 10° 31-39 225-282 180°
With Swamp Shoe 50-60 -20°
31-39 225-282
15R
With Swamp Shoe 50-60
2
A 5
6
D155 54-66 391-477 120° ± 10° 54-66 391-477 180° ± 10°
5
AX 6
7
2
A
5
D275 72-88 521-636 120° ± 10° 45-55 326-397 180° ± 10°
5
AX
5E0
D355 A 5 72-88 521-636 120° ± 10° 45-55 326-397 180° ± 10°
3
5
5E0
D375 A 126-156 912-1128 120° ± 10° 63-77 456-557 180° ± 10°
5R
6
6R
3
D475 A 5 72-88 521-636 180° ± 10° 90-110 651-796 180° ± 10°
5E0
+20°
D575 A 3 190-230 1375-1663 120° ± 10° 180-220 1302-1591 180°
0°
- 162 -
Hydraulic Excavator
Shoe Bolt Tightening Torque Shoe Bolt Tightening Torque

Model Initial Torque Additional Model Initial Torque Additional
kg䞉m ft-lbs Tightening Angle kg䞉m ft-lbs Tightening Angle
PC60 7 10-14 73-101 90° ± 10° 6
6 7
US
8 7E0
PC78 10-14 73-101 90° ± 10° 8
6
UU
8 8R
PC88 MR 8 10-14 73-101 90° ± 10° 10
PC400 36-44 261-318 120° ± 10°
6 6
PC120 18-22 131-159 90° ± 10° 7
8
2 LC 7E0
US 8 8
PC128 10 18-22 131-159 90° ± 10° 8R
2 10
UU
8 6
2 7
8 7E0
US 8
8T
PC138 10 18-22 131-159 90° ± 10° 8R
2 10
PC450 36-44 261-318 120° ± 10°
USLC 8 6
10 7
6 LC 7E0
7 8
8 8R
8E0 Hybrid 10
10 10
PC200 45-55 326-397 120° ± 10° PC490 54-66 392-477 120° ± 10°
6 LC 10
7 6
LC 8 7
8E0 Hybrid 8
10 8E0
PC2䠍0i 10 45-55 326-397 120° ± 10° PC600 8R 72-88 521-636 120° ± 10°
PC210LCi 10 45-55 326-397 120° ± 10° 6
1 Hybrid 7
HB205 45-55 326-397 120° ± 10° 8
2 Hybrid LC
1 Hybrid 8E0
HB215 LC 45-55 326-397 120° ± 10°
2 Hybrid 8R
6 6
7 7
8 8
10 PC650 8E0 72-88 521-636 120° ± 10°
PC220 45-55 326-397 120° ± 10°
6 6
7 7
LC LC
8 8
10 8E0
3 PC700 LC 8E0 72-88 521-636 120° ± 10°
US 8 6
10 7
PC228 45-55 326-397 120° ± 10°
3 6
PC750 LC 72-88 521-636 120° ± 10°
USLC 8 7
10 6
SE
6 18-22 131-159 120° ± 10° 7
7 6
7E0 7
36-44 261-318 120° ± 10° 8
8
10 8E0
PC300
6 18-22 131-159 120° ± 10° 8R
7 PC800 8 72-88 521-636 120° ± 10°
LC 7E0 LC 8E0
36-44 261-318 120° ± 10°
8 8R
10 8
6 18-22 131-159 120° ± 10° SE 8E0
7 8R
7E0 8
36-44 261-318 120° ± 10°
8 8E0
10 PC850 8R 72-88 521-636 120° ± 10°
PC350 8
6 18-22 131-159 120° ± 10°
7 SE 8E0
LC 7E0 8R
36-44 261-318 120° ± 10°
8 6
10 PC1100 LC 6 126-154 912-1114 150° ± 10°
1 Hybrid SE 6
HB335 36-44 261-318 120° ± 10°
LC 1 Hybrid 7
1 Hybrid 8
HB365 36-44 261-318 120° ± 10°
LC 1 Hybrid 8R
PC1250 7 126-154 912-1114 150° ± 10°
LC
8
7
SE
8
PC1800 6 63-77 456-557 120° ± 10°
PC2000 8 63-77 456-557 120° ± 10°
- 163 -
5. Reference
5-1. Rebuilding
The replacing time of the undercarriage can be prolonged by the bushing turning or the lug welding of
shoe.
As for the method, refer to GUIDANCE FOR REUSABLE PARTS “Form No. SEBG4092”.
5-2. Necessary Dimension Table for Track Press Tool/Jig

When you disassemble/reassemble track for turning pin and bushing job etc, you need to install proper
tooling such as push tool, jaw etc onto track press. And those tooling must be met with track dimension for
each model.
Tooling for track press is designed and manufactured by each track press manufacturer. We, Komatsu, do
not produce those tooling by ourselves and just instruct that “Please contact with track press manufacturer
for pushing tools. Komatsu doesn’t prepare pushing tools as Special Service Tools” (Please refer to Guid-
ance for Reusable Parts “SEBG409202”)
Basic track dimensions are mentioned in Shop Manual of each model. But those are not sufficient enough
for manufacturing or selecting proper tooling for track press.
So we made necessary track dimension table for manufacturing or selecting below tool/jig for each model
as attached.
Tool/Jig Name
1 Push Tool
2 T/Press Jaw
3 Shoe Bolt Pitch Gauge
Please utilize the table. If you need any other dimension additionally which is not written in the table, please
contact us.
- 164 -
Necessary portion of dimension for selecting proper tool/jig
Necessary Dimension
Tool/Jig Name for selecting proper tool/jig
1 Push Tool A, B, D, H, I, J, R and Y
2 T/Press Jaw F, G, O and P
3 Shoe Bolt Pitch Gauge K, L, M and N
- 165 -
D65-12 D155-2
D31-22 D39-21 D61-12 D65-15
D31-21 D61-15 -15 -5 D375-5
D21-7,8 D37-22 D37-23 -22 D39-23 D41-6 D51-22 -15 -16 D85-15 D275-5 D475-5
D37-21 -23 -16 -6 -6
-23 -23 -23 -17
-17 -7
HD STD HD Dual Dual Dual
STD STD STD PLUS STD AR PLUS STD PLUS PLUS PLUS STD STD STD STD STD
HDAR AR HDAR Bushing Bushing Bushing
A Pin Total Length 141 170 170 160.1 184 184 180.8 199 220 240.1 226 211.8 253.7 240.3 257.8 291.6 289.6 290.2 321.1 321.1 367.7 367.7
B Pin O.D.(Press fit portion) 24 28 28 30 33.4 33.4 33.4 36 36 36 38 40 44.6 44.6 47 48.5 55.5 52 60 57.5 70 67
D Bushing O.D.(Press fit porion) 41 47 47 --- 56 56 --- 59 59 --- 59 --- 66.5 --- 74 77 90 90 98 98 113 113
F Bushing O.D.(Center) 41 50 54 54 56 56 56 50.5 63 63 65 65 73 73 79.5 81 90 98 98 108 116 126
G Link Inside Width 45 52.4 52.4 58 75.3 75.3 70.5 69.3 84.4 83.4 84.4 85.3 102 100.6 106 122.8 124.6 124.6 135 135 158 158
H Gap between Pin End and Bushing End 32.2 38.9 38.9 --- 35.7 35.7 --- 43.2 44.8 --- 46.8 --- 49.6 --- 49.9 51.9 46.5 46.5 54.5 54.5 61.8 61.8
I Protrusion of Bushing 1.1 2.8 2.8 --- 1.5 1.5 --- 1.5 2 --- 3.1 --- 3.1 --- 2 3.3 2 2 2 2 2 2
- 166 -
J Protrusion of Pin 3.1 4 4 4.8 3 3 4.8 3 3 4.7 4 4.7 3 4.7 4 4.5 4.3 4.3 4.3 4.3 4.7 4.7
Re:96 Re:96
K Shoe Bolt Pitch 43.4 57 57 43.4 57 57 50 57 57 50 62 54 72.2 57.2 70.6 76.2 76.2 76.2 82.5 82.5
Ma:84 Ma:84
Re:288 Re:288
L Shoe Bolt Gauge(Wide width) 99 112.4 112.4 102.4 144 144 120.8 144 158.4 143.4 160.4 132.9 178.4 168.4 182.8 219.8 235 235 253.4 253.4
Ma:276 Ma:276
Re:222 Re:222
M Shoe Bolt Gauge(Narrow width) 72 82.4 82.4 102.4 103.8 103.8 120.8 103.8 122.4 143.4 124.4 132.9 138.4 168.4 146 169 184.2 184.2 184 184
Ma:226 Ma:226
N Link Shoe Bolt Hole Dia. 12.3 14.3 14.3 16,3 16.3 16.3 18.3 16.3 16.3 18.3 20.3 20.3 20.3 22.3 22.3 24.3 27.8 27.8 30.8 30.8 33.8 33.8
O Distance from Pin Center to Link Tread Surface 40.5 47 50 59 55 63 65.5 61.5 61.5 66.5 72 74 78 83 80.5 84 96.7 96.7 105 105 110 110
P Link Pitch 135 154 154 154 171.5 171.5 171.5 171.5 175 175 190 190 203.2 203.2 216 228.6 260.4 260.4 280 280 317.5 317.5
R Flat Surface Dia. of Link Bushing Hole 66 64 64 --- 76 76 --- 80 80 --- 76 --- 80 --- 81 103 106 106 126 126 148 148
Y Flat Surface Dia. of Link Pin Boss 38 44 44 53 58 58 59 55 58 60 71 65 70 70 80 90 100 100 100 120 120 140
5-3. Lub. Oil Table (Oil type & Volume) for Idler, T/Roller and C/Roller
Please use the table when you need to refill lubrication oil on reassembled rollers after rebuilding etc (disas-
sembling E building up tread surface by welding E reassembling E refilling lubrication oil).
a) Bulldozer
IDLER C/ROLLER T/ROLLER
Model Type Annex S/N Oil Volume/PC Oil Volume/PC Oil Volume/PC
Lub. Oil Type Lub. Oil Type Lub. Oil Type
Starting Max〔cc〕 Min〔cc〕 Max〔cc〕 Min〔cc〕 Max〔cc〕 Min〔cc〕
D20,21A 7 75001
D20,21P 7 A 75001
D20,21PL 7 62001
D20PLL 7 62001
D20,21A 8 83001
D20,21P 8 83001
D21 D20,21PL 8 63001
TO30 130 110 TO30 90 80 TO30 80 ←
D20PLL 8 63001
D20,21A 8 E0 90001
D20,21P 8 E0 90001
D20,21PL 8 E0 70001
D20PLL 8 E0 70001
D31A 20 42001
D31AM 20 42001
D31E 20 42001
D31P 20 A 45001 250 230
D31P 20 45001
D31PL 20 45001
D31PLL 20 45001
D31EX 21 50001
D31/37 D31PX 21 50001
TO30 TO30 220 200 TO30 150 ←
D31PLL 21 1001
D31EX 22 60001
D31PX 22 60001 169 149
D37EX 21 5001
D37PX 21 5001
D37EX 22 60001
D37PX 22 60001
D39EX 21 1001
D39PX 21 1001
D39EX 22 3001
D39/41 D39PX 22 3001 TO30 210 200 GO85W140 200 180 GO85W140 275 255
D41P 6 B20001
D41P 6 K 50001
D41PF 6 K 29021
D51EX 22 B10001
D51 D51PX 22 B10001
TO30 210 200 GO85W140 200 180 GO85W140 215 205
D61E,EX 12 1001
D61P,PX 12 1001
D61EX 15 B40001
D61PX 15 B40001
D61 D61EX 15 E0 B45001
TO30 230 210 GO85W140 215 ← GO85W140 260 240
D61PX 15 E0 B45001
D61EX 23 30001
D61PX 23 30001
D63E 12 2001
D65E 12 60001
D65EX 12 60001
D65P 12 60001
D65PX 12 60001
D65EX 15 67001
D65PX 15 67001
D65WX 15 67001
D65EX 15 E0 69001
D65 D65PX 15 E0 69001 TO30 260 240 GO85W140 240 ← GO85W140 342 338
D65WX 15 E0 69001
D65EX 16 80001
D65PX 16 80001
D65WX 16 80001
D65EX 17 1001
D65PX 17 1001
D65WX 17 1001
D68ESS 12 1001
D85ESS 2 3001
D85A 21 35001
D85A 21 B 35001 320 280
D85C 21 36551
D85EX 15 10001
D85 D85PX 15 1001 GO85W140 GO85W140 530 470 GO85W140 290 260
D85EX 15 E0 11001
370 330
D85EX 15 R 20001
D85PX 15 E0 1201
D85PX 15 R 20001
- 167 -
D155C 1 15686
450 390
D155A 2 A 57001
D155A,AX 3 60001
450 390
D155A 5 65001 730 670
D155 D155AX 5 70001 GO85W140 GO85W140 680 570 GO85W140
D155A 6 85001 450 390
D155AX 6 80001 880 820
730 670
D155AX 7 90001 990 930
D275A 2 10001 1520 1280 730 620 1450 1300
D275A 5 25001
D275 D275AX 5 20001 GO85W140
900 800
GO85W140
700 600
GO85W140 1260(S) 1160(S)
D275AX 5 E0 30001 850(D) 750(D)
D275A 5 R 35001
D355C 3 4001
D355 D355A 5 12622
GO85W140 550 480 GO85W140 740 640 GO85W140 800 760
D375A 3 17001 1700 1450
D375A 5 18001
D375A 5 E0 50001
D375 D375A 5 R 55001
GO85W140
1050 950
GO85W140 800 700 GO85W140 1500 1400
D375A 6 60001
D375A 6 R 65001
D475A 3 10601 1500 1400
D475ASD 3 10601 2100 2000
D475A 5 20001
D475 D475ASD 5 20001
GO85W140 1500 1400 GO85W140 1355 1250 GO85W140 1500 1400
D475A 5 E0 30001 1600(S) 1500(S)
D475ASD 5 E0 30001 1500(D) 1400(D)
D575A 3 10105
D575 D575ASD 3 10101
GO85W140 3800 3500 GO85W140 1500 1400 Special Oil 2020 2000
- 168 -
b) Excavator
PC100 6 40001
PC100N 6 1004
85 75
PC120 6 45001 90 ←
PC120LC 6 45001
PC120 8 80001 155 145
PC128US 2 5001 105 90 85 75
PC128US 8 20001 90 ← 155 145
PC128UU 2 5001 105 90 85 75
PC100 TO30 TO30 76 68 TO30
PC128UU 8 23030 155 145
PC130 6 45001
85 75
PC130 7 70001
PC130 8 80001
90 ← 155 145
PC138US 2 4501
85 75
PC138USLC 2 1001
PC138US 8 20001
155 145
PC138USLC 8 20001
PC158US 2 10001 250 230
PC158USLC 2 10021
PC160LC 7 10001 255 245
PC160LC 7 E0 20001
PC160LC 8 25001
PC200 6 80001
PC200LC 6 80001 80 70
PC200SC 6 10001
PC200 7 200001
PC200LC 7 200001
PC200SC 7 20001
PC200 8 300001
PC200LC 8 300001 255 245
PC200 8 E0 1001
PC200LC 8 E0 1001
HB205 1 1001
HB215LC 1 1001
PC210 6 30001 80 70
PC210 7 40001
PC210LC 7 40001
PC200 PC210 8 60001
TO30 255 245 TO30
85 75
TO30 200 190
PC210LC 8 60001
PC220 6 50001
80 70
PC220LC 6 50001
PC220 7 60001
PC220LC 7 60001
PC220 8 70001
PC220LC 8 70001
PC228US 3 20001
255 245
PC228USLC 3 20001
PC228US 3 E0 40001
PC228USLC 3 E0 40001
PC228US 8 50001
PC228USLC 8 50001
PC230 6 10001 80 70
PC230 7 11001
PC230LC 7 11001
PC230 8 20001 255 245
PC230LC 8 20001
PC240LC 10 90001
PC270 7 10001
PC270 8 20001
155 145
PC270LC 8 30001
PC290LC 10 15001
PC300 6 30001
PC300LC 6 30001 500 450
PC300SC 6 10001
PC300 7 40001
PC300LC 7 40001
PC300 7 E0 50001
PC300LC 7 E0 50001
155 145
PC300 8 60001
PC300 PC300LC 8 60001
TO30 240 220 TO30 TO30 280 250
PC308USLC 3 20001
PC308USLC 3 E0 30001
PC350 6 10001
500 450
PC350LC 6 10001
PC350 7 20001
PC350LC 7 20001
PC350 7 E0 30001
155 145
PC350LC 7 E0 30001
PC350 8 60001
PC350LC 8 60001
PC360LC 10 70001 155 145
- 169 -
Starting Max 〔cc〕 Min 〔cc〕 Max〔cc〕 Min〔cc〕 Max〔cc〕 Min〔cc〕
PC400 6 30001
PC400LC 6 30001 500 450
PC400ST 6 10001
PC400 7 50001
PC400LC 7 50001
PC400 7 E0 60001
PC400LC 7 E0 60001
180 170
PC400 8 70001
PC400LC 8 70001
PC400 8 R 75001
PC400LC 8 R 75001 355 335 310 280
PC400 PC450 6 10001
TO30 TO30 TO30
500 450
PC450LC 6 10001
PC450 7 20001
PC450LC 7 20001
PC450 7 E0 30001
PC450LC 7 E0 30001
180 170
PC450 8 70001
PC450LC 8 70001
PC450 8 R 75001
PC450LC 8 R 75001
PC490LC 10 80001 385 365 200 190 330 300
PC550LC 8 70458
PC600 6 10001
PC600LC 6 10001
PC600 7 20001
PC600LC 7 20001
220 190
PC600 8 30001
PC600LC 8 30001
PC600 8 R 60001
PC600 PC600LC 8 R 60001
TO30 500 400 TO30 GO85W140 660 540
PC600LC 8 E0 65001
PC650 6 30001
PC650LC 6 30001 165 135
PC650 7 40001
PC650 8 50001
PC650 8 E0 65001 220 190
PC650LC 8 E0 65001
PC750 6 10001
PC750LC 6 10001
PC750 7 20001
PC750LC 7 20001
PC800 6 30001
PC800 7 40001
PC800 8 50001
PC800LC 8 50001
PC800SE 8 50001
PC800 PC800 8 R 60001
GO85W140 630 550 GO85W140 350 300 GO85W140 480 420
PC800LC 8 R 60001
PC800SE 8 R 60001
PC800LC 8 E0 65001
PC850 8 10001
PC850SE 8 10001
PC850 8 R 60001
PC850SE 8 R 60001
PC850 8 E0 65001
PC1250 7 20001
PC1250LC 7 20001
PC1250 8 30001
PC1250LC 8 30001
PC1250 PC1250SE 8 30001
GO85W140 830 750 GO85W140 500 450 GO85W140 850 800
PC1250SP 8 30001
PC1250 8 R 35001
PC1250SP 8 R 35001
PC1800 6 10001 1150 1050 1100 1000
PC2000 PC2000 8 20001
GO85W140
1450 1350
GO85W140 940 860 GO85W140
1450 1300
- 170 -
5-4. Wear Mechanism
1) Sprocket Teeth & Bushing O.D.
(1) Reverse and/or forward drive side wear
a) Sprocket wear during the engagement
CASE 1: On approach side in forward drive
(2) (1)
Y
C1'
Bushing Link Pin B'
C'
X
Track model
A C B C1
Where a bushing and sprocket tooth are in mesh with each other in a position B below the sprocket
center: if the sprocket center is moved from (1) to (2), the bushing B below the sprocket center will be
moved to B' in the sprocket tangential line from the state in mesh with sprocket tooth, causing a link (B)
to move to a position (C') by an X-angle.
The link (C1) will also be moved to a position (C1') simultaneously with the sprocket, which will not per-
mit a Y-angular change, since the link is already in mesh with the sprocket.
While the sprocket center is moving from (1) to (2), the link (C) will make a Y-angular change and the
bushing A integrated with this link will also make an a-angular change. At the time when the sprocket
center has moved to a position (2). The bushing A has already made an a-angular rotation and is going
to mesh with the subsequent sprocket tooth. Thus, there will occur no slippage between the bushing A
ands rocket tooth and the track rotation is made with contact between the bushing A inner face and pin.
- 171 -
CASE 2: On departure side in forward drive
A bushing and a sprocket tooth are in mesh with

each other at B in the sprocket C.L., and the bush-
ing is then moved from A to A1, A2 and A3. Where A3 C2 A1 C1 A1 C A
the sprocket center has been moved from (1) to (2),
the bushing A1 in the sprocket C.L. will be moved to
A2 in the tangential line of sprocket from the meshed
condition with a sprocket tooth causing the link (C) to X
move the position C1.
Where the link (C1) is in mesh with sprocket tooth,
B
the link (C1) is in the dotted line (C1') or in mesh with
C1'
sprocket by an X-angle. While the sprocket center is
moving from (1) to (2), the links (C) and (C1) will come
into the same line, indicating that the link to be moved
to a position C1' has been moved to a position C1 by
an X-angle. Consequently, the bushing (A1) integrated (2) (1)
with the link in (C1') will also be moved by an X-angle.

While the sprocket center is moving from (1) to (2), the bushing (A1) will slip by an X-angle in contact
with the sprocket.
CASE 3: On approach side in reverse drive
C A C1 A1 C2 A2
The reverse order of the movements among the

X
sprocket, link and bushing on the approach side in the
forward drive can be applied in this case.
Assume that a bushing and sprocket tooth are in mesh
C3
with each other in a position A1 in the sprocket C.L.
C4 When the sprocket center is moved from (1) to (2), the
bushing (A1) in the sprocket C.L. is moved to A2 in
the sprocket tangential line from the meshed condition
with sprocket tooth, causing the link (C1) to a position
Y C2 by an X-angle.
(1) (2)
The links (C3) and (C4) are moved in the meshed condition with each other and thus, no change in
the Y-angles at C3 and C4 will be made. The link (C) is moved from a position C1, giving no angular
change. The sprocket rotation for an X-angular change is made between the pins and bushings at A1
and A2. However, the pin at A and bushing at A1 are integrated with each other, and thus, when the link
(C1) is moved to C2, the bushing A1 is also moved to a position A2 simultaneously. Consequently, dur-
ing the movement from A1 to A2, the bushing and the sprocket tooth face will slip in the meshed condi-
tion with each other.
- 172 -
CASE 4: On departure side in reverse drive
(1) (2)
The reverse order of the movements among the

sprocket, link and bushing on the approach side
C2
in the forward drive can be applied in this case.
When the sprocket center is moved from (1) to (2),
C2' Y the bushing (A2) in mesh with the sprocket tooth
is moved to A2' and, the link (C1) is moved to (C1')
by an X-angle, since the pin in the bushing A2 is
by
X integrated with the link (C1).
The link (C2) is moved to (C2') in mesh with the
sprocket without a Y-angular change. Conse-
quently, when the link (C1) is moved to (C1'), the
A1 C1 C1' A2' A2 sprocket will be rotated between the bushing in-
ner face and pin at A2.
At this time, the bushing (A1) integrated with the link (C1) will also make a movement by an X-angle, but
no slippage will occur between the bushing and sprocket tooth face, because the meshing between the
sprocket tooth and bushing is separated as soon as the sprocket center is moved from (1) and (2).
In summarizing the above relationships between the sprocket and links:
(2) Short Notes

In the forward drive
(1) On the approach side (on the sprocket lower side), a bushing rotation is
already accomplished before the sprocket tooth comes into mesh with
the bushing, giving no sliding wear.
(2) On the departure side (on the sprocket upper side), the bushing is ro-
tated as the link makes an angular change in mesh with the sprocket
tooth, giving the sliding wear.
In the reverse drive
(3) On the approaching side (on the sprocket upper side), the link makes
an angular change after the sprocket tooth comes into mesh with the
bushing, giving the sliding wear between the sprocket tooth and bush-
ing O.D.
(4) On the departure side (on the sprocket lower side), the link makes an
angular change while the sprocket tooth face is being departed from
the bushing, causing the bushing to rotate. At this time, the bushing is
already departed from the sprocket tooth, giving no sliding wear.
In the note (2) and (3), the track on the departure side in (2) is rather loose in tension and the track on
the approaching side is rather tense. Thus, wear on the reverse side in liable to develop faster than that
on the forward drive side. Reverse traveling in high gear will accelerate wear on the sprocket teeth and
bushings.
- 173 -
(3) What happens if track is installed in the reverse manner ?
a) If track shoe assembly is installed in the opposite direction, track link tends to slip on a sprocket teeth
at the lower part of sprocket. (if it is installed properly, track link slips on a sprocket teeth at the upper
part of sprocket). Moreover sand is bitten between bushing and sprocket teeth more which accel-
erates wear of bushing and sprocket teeth.
b) Traction force reduces.

Track link starts to kink on the ground (called logging motion), by that extent traction force reduces.
Logging motion
Correct installation of track Reverse installation of track

shoe assembly shoe assembly
(4) Sprocket teeth tip wear on the forward drive side
If the link pitch is not matched to the sprocket pitch due to

extended link pitch, etc., the sprocket tooth tip will hit a bush-
ing when the sprocket is to come into mesh with the bushing,
causing wear to the tooth tip.
Link pitch elongation causes ...
(5) Sprocket teeth tip wear on the reverse drive side
CAUSE A: Where the link pitch is extended.
Improper engagement
due to elongation of link
If the link pitch is unmatched to the sprocket pitch
due to the extended link pitch, the sprocket tooth
tip will hit a bushing when the sprocket is to come
into mesh with the bushing in the reverse drive,
causing wear to the tooth tip.
- 174 -
CAUSE B: Where soil has stuck or packed to the sprocket tooth root.
Where a machine is operated in a terrain abundant in moisture

content or in clay easy to solidify, the mud is liable to stick to
the sprocket tooth lands. Continued operation of the machine
with the soil left unmoved from the sprocket teeth will allow the
soil to accumulate further on the previous soil, increasing the
dia. of the pitch circle of sprocket. In consequence, the larger
the pitch circle dia., the larger the sprocket pitch. As a result,
the sprocket pitch will be unmatched to the link pitch.
Packed soil
When the sprocket is to come into mesh with a bushing in the forward drive, the sprocket pitch will
be unmatched to the link pitch, causing the tooth tips of sprocket on the reverse drive side to hit the
bushing surface. Thus the wear occurs between the two.
The above wearing conditions are contrary to the case where the link pitch is extended, and occurs
also in a case where rocks are wedged between the sprocket teeth and bushing.
CAUSE C : When the trucks are too loose without tension adjustment
Back-jamming is a cause of reverse drive side

tooth tip wear. In reverse, the truck link on the
ground, around the idler and to the top side
of the sprocket is in tension. The slack is ac-
cumulated between the bottom of the sprocket
and the rear track roller. If there is too much
slack, "back jamming" of the track link between
the sprocket and the roller occurs. The bushings
slide up the reverse drive side to the tooth tip as
they are pushed from the sprocket.
When this occurs, adjust the tracks tension cor-
Slide up
rectly.
- 175 -
2) Chain Tightness
(1) Reverse Travel
Recall that in reverse drive cycle the majority of torque E D
transfer occurs at the top of the sprocket. This means that
the sprocket tooth at position D pulls on the bushing seated
in position D. Since the track chain is assembled as one
unit, bushing D pulls on the bushing beside it, which is
bushing E. Bushing E then pulls on the one beside it, and
so on. This chain reaction (pun intended) continues all the
way around the idler until it reaches the bushings at posi- F
tion F. These bushings cannot be pulled because they are
attached to shoes that are embedded into the ground, and
so the chain reaction tapers off. As a result, a large section
of chain (from D to F) remains very tight when traveling in
reverse.
(2) Forward Travel

The majority of torque transfer occurs at the bottom of the
sprocket. The sprocket tooth at position A pulls on the
bushing seated in position A. By the same chain reaction
principle, that bushing pulls on the one beside it, and so on.
But the reaction does not have far to go before it reaches
embedded shoes. In fact, the reaction only lasts a few link A
segments before tapering off. As a result, increased wear
only occurs in a small section of track during forward travel.
- 176 -
3) Pin/Bushing Internal Wear
(1) Pin/Bushing Rotation
As the track chain revolves around the sprocket and front
idler, the pins and bushings rotate independently of each oth-
er. This movement takes place four times per revolution; two
times as the chain bends around the sprocket and two times
as it bends around the front idler. This movement is the same
in both forward and reverse directions, but wear is much
greater in reverse. This is because of track chain tightness.
(2) Forward Travel

Recall that in forward travel only a small section of chain is tight and it is only long enough to include the
first internal turn (position on diagram). Therefore, this is the only internal turn that is critical because
the other three are not subjected to heavy loads

Front
Front
View from A
Wear occurs on this side
Driving force by sprocket
- 177 -
(3) Reverse Travel
However, in reverse travel the chain is tight all the way around the idler and extends far enough to include
three internal turns (positions 2, 3 and 4). Therefore, in reverse travel there are three internal turns that
are subjected to heavy load.
3 2

Front
View from A
Wear occurs on this side
Driving force by sprocket
(4) Conclusion
s "ECAUSEOFTRACKCHAINDYNAMICSINTERNALWEARALWAYSAFFECTSTHEONESIDEOFTHEPINSANDBUSHINGS
regardless of travel direction. This means that only one side of the pin OD and bushing ID is worn in-
ternally.
s 4RAVELING IN REVERSE CAUSES INCREASED WEAR ON THE FRONT IDLER AND ALL TRACK CHAIN COMPONENTS IN THAT
section.
s 4RAVELINGINREVERSECAUSESSOMUCHMOREWEARTHANFORWARDTRAVEL
Forward drive rotation
- 178 -
5-5. Operator’s Comfort & Vibration
1) As for the link tread surface, the uneven wear occurs under the structural conditions. (For details, refer
to 2-3. Wear & Problem 1) Link.)
Basic wear patterns are shown in the below figure. But, depending on the landform and the ground
condition of the jobsite, there is the pattern, which D and E do not appear clearly, or A does not appear
clearly.
Usually, the uneven wear does not matter, but on the peculiar ground conditions or at the peculiar speed,
it may affect the machine vibration.
The vibration can be reduced by replacing deteriorated isolation mounts where necessary, replacing any
broken or missing fasteners and by generally keeping the machine in good repair. A change in operating
speed or technique, or a change of counterweights or attachments may reduce the effect.
E
C
A
B
D
2) In the state that the machine is stopped on the level ground, the clearance is given at the idler lower por-
tion and the sprocket lower portion. But, when the roller wear is remarkably increased, this clearance
disappears and the machine may vibrate during traveling.
In this case, by inserting the plate into the bogie portion, the clearance can be obtained.
Clearance
- 179 -
5-6. Distinguishing from the Non-Genuine Parts
1) General View
There are many makers which produce the undercarriage parts. When the customer replaces the under-
carriage of his machine, sometime customer use non genuine parts. Accordingly, it is very important that
daily friendly relation with customers is maintained, the part replacement time is understood, the offer is
timely made, and the part order is obtained.
In addition, during the round, when the machine is found at the field, watch the undercarriage parts. If the
parts except the genuine ones are installed, check the following items, talk with the customers and ensure
the reason. After that, the countermeasures are examined to sell Komatsu genuine parts.
(1) What is the maker?

(2) What are specifications?
s 'REASESEALEDTRACKOR3!,4
s )STHETRACKTIGHTENINGMETHOD-ASTERLINKOR-ASTERPIN
s (IGHLINKOR,OWLINK
s )S3HOE(EAVYDUTYTYPEOR3TANDARDTYPE
s /THERS
(3) Customers purchasing reason
s 0RICE(OWMUCHISTHEDIFFERENCEFROM+OMATSUPARTPRICE
s $ELIVERY7HATISTHEDIFFERENCEFROM+OMATSU
s 1UALITY(AS+OMATSUPROBLEMS
s /THERS!RETHEREANYPROBLEMSFOR$"COUNTERMEASURE%TC
As for distinguishing methods from other makers, refer to the next items.
2) Way for Distinguishing from the Non-Genuine Part

As for the undercarriage parts, any maker’s parts are similar shapes. But the maker name can be distin-
guished by the stamp mark and the shape difference of the following parts.
(1) By Regular Link

s "ECAUSETHE,OGOMARKISSTAMPEDON,INKITISPOSSIBLETODISTINGUISH2EFERTOTHEATTACHEDlGURES
• Komatsu • Non-Genuine • Non-Genuine
s !S FOR +OMATSU ,INK ALWAYS +OMATSU MARK IS STAMPED ON IT )N ADDITION 0ART .O OR , 2 ETC ARE
stamped.
- 180 -
(2) By Master Link
Because the shape of Master Link engaging portion is different by makers, it is possible to distinguish
makers. Refer to the attached figures.
Komatsu original teeth Many teeth Flat teeth

• Komatsu • Non-Genuine • Non-Genuine
(3) Reference Points

s 3!,4AND'REASE3EALED4RACKAREDISTINGUISHEDBYTHEEXISTENCEOFTHEPLUGATTHEPINEND4HERE
is the plug on S.A.L.T.)
s !SFOR+OMATSU3!,4THEREARETHEPLUGATBOTHPINENDS"IGPLUGAND3MALLPLUG !SFORNON
Genuine, the plug exists at one end only. Accordingly, Komatsu track, it is necessary to ensure the ex-
istence of plug at both ends.
s !S FOR -ASTER ,INK IT IS BASICALLY 3!,4 TRACK "UT AS FOR NON 'ENUINE IT IS CAREFUL THAT 'REASE
Sealed Track may provide with Master Link.
Plug hole on both side Plug hole on one side

• Komatsu • Non-Genuine
- 181 -
II. Undercarriage Management
1. General
1) The purpose of UC Management is as follows. The wear status of UC parts is known, and corresponding
to it, the usage of UC parts is changed, and totally Cost/Hour of the customers is minimized.
For this, the considering points are as follows.
(1) Life of Pin and Bushing is matched to Link life. For the sake, whether Bushing is turned run to destruc-
tion are judged and treated.
(2) Life of T/Roller is matched to Link life. For the sake, whether Position Change of T/Roller is done or
not are judged and treated.
(3) Life of Shoe grouser is matched to Link life. For the sake, whether Shoe grouser is reused by lug-
welding Grouser or replaced with the new one are judged and treated.
(4) As for Idler, whether the building up by welding or the replacement are better are judged and treated.
(5) As for T/Roller, whether the building up by welding or Shell replacement or Ass’y replacement are bet-
ter is judged and treated.
(6) When judging whether UC parts are rebuilt, or abandoned, it is necessary to decide totally by consid-
ering the comparison of the local man-hour charge with the part price and the rebuilder’s level.
(7) The above-maintenance is done by Minimum Hour and it is necessary that Labor and Machine Down
are minimum.
2) Link is the key component on UC Management. For this reason, the treatment which the life of other UC
parts comes near Link life is the key point for reducing R & M cost.
3) Namely, at the same time when Link Ass’y maintenance is done, the maintenance of other UC parts
should be done. For this reason, Machine Down is less and the efficiency is the best.
4) Usually, as for Link Ass’y, Pin and Bushing are one time turn. And, after the turning, Link Ass’y is used un-
til destruction.
5) When it is used up without the turning, refer to 2-2. Wear Limit.
- 182 -
2. Countermeasure for R & M Cost Reduction
2-1. Precautions when Turning Pin & Bushing
Whether the parts can be reused or not after disassembly, refer to Reusable Guide.
1) Bushing O.D. wear

(1) When turning, Bushing O.D. wear should be within Wear Limit (100% Wear).
(2) If the wear exceeds 100%, the crack may already have occurred. Accordingly, if
Bushing is turned, oil may leak at the early stage.
(3) After the turning, when it is repaired due to the oil leakage, it is careful that it causes
the increased R & M Cost.
2) Link Tread Surface Wear

(1) When Bushing is turned, Link is reused as it is.
(2) Accordingly, at the time when Bushing is turned, it is desired that Link tread surface
wear is within 60% of Wear Limit (100% Wear). After the turning, Link is used until the Link tread sur-
face wear is more than 120%, and after that Link is run to destruction.
(3) When turning, if the tread surface wear already exceeds 70%, Life upto the destruction after the turn-
ing is decided by Link height wear rather than Bushing O.D.
(4) In that case, it is careful that the expected post-turning life cannot be obtained, and R & M Cost may
be increased.
3) Pin Wear
(1) When Bushing is turned, turn Pin to reuse it.
(2) After reusing by turning it, in order to maintain the strength, Pitch elongation should be within Wear
Limit.
(3) As for SALT, Pin wear is less, but in order to keep the contact surface same as the state before the
turning, similarly turn Pin when Bushing is turned. At that time, it is careful that Pin vertical hole faces
to Link tread surface. (When Vertical hole faces oppositely, Pin may be broken.)
(4) When Grease track is turned, the case may be that the one-side wear of Pin has already progressed.
(Shortly Pitch elongation has progressed.) But, by turning Pin, Pitch elongation comes near New one.
4) Reusing Seal
(1) Generally, when the service hour exceeds 4000H, Seal Deterioration progresses and the probability of
oil leakage from Seal becomes high.
(2) Accordingly, depend on the service hours until Bushing is turned, the judgement criteria for reusing
seal should be changed as follows.
(3) When the operating hour is within 2000H;
s "ASICALLY3EALISREUSED
s 7HETHER3EALISREUSEDORNOTCONlRMTOh2EUSABLE'UIDEv
(4) When the operating hour is 2000 to 4000H;
s 3EALISREPLACED
(5) When the operating hour is more than 4000H;
s 3EALISBASICALLYREPLACEDATTHEINTERVALOF(
- 183 -
5) Rollers Wear
Rollers are normally used continuously at bushing and pin turn as same as link so the wear life needs to
be longer than bushing and pin turn time.
However, it can be scheduled to be replaced even before bushing and pin turn when roller have shorter
wear life.
6) Sprocket Wear
(1) When the new Link Ass’y or Link Ass’y with turned Bushing is installed, the new Sprocket Teeth should
be installed.
(2) Even if the wear margin is remained on Teeth, Sprocket Teeth should be replaced. When new link is
installed. It is careful that if old Teeth are continued to use with new link assy, Bushing O.D. wear pro-
gresses due to uneven contact.

- 184 -
2-2. Contribution to R & M Cost Reduction for K-Bogie and Wedge Ring
1) Features of K-Bogie and Wedge Ring UC
(1) Because Shape of Link and Track Roller Guard is Wide link tread
changed, Pin end does not contact with Roller Guard.
(2) Because Pin adopts Wedge ring, Pin is surely retained.
Because of it, Pin press-fitting force to Link is reduced.
(Total Pin holding force is same as before.)
(3) As for K-Bogie, even when the vehicle is operated on
the slope and Link is loosened, T/Roller can be followed.
Therefore, the frequency of Link interference with Roller,
and Link riding to Roller becomes less. Shoe Link Pin
Wedge-Ring
2) Merit for R & M Cost Reduction
(1) Because Pin end wear does not occurs, especially no slant wear at pin end, when Pin is pressed out
for pin bushing turn, Press jig does not contact diagonally. Accordingly, pressing force is surely trans-
mitted, Pin is pressed out easily (Work man-hour is reduced.)
(2) Because Pin press-fitting force is half of the conventional one, Pin is pressed out easily. In addition,
because press-fitting force is small, when Pin is removed, Link inner surface scuffing is less. Accord-
ingly, when Link is reused, the cleaning up time of inner surface is less. (Work man-hour is reduced
and the part reusable ratio is increased.)
(3) The frequency of Link interference with Roller, and Link riding to Roller becomes less, the damage is
reduced. Accordingly, Life is increased. (Operation hours is prolonged.)
2-3. Contribution to R&M Cost Reduction on PLUS (Rotary bushing track)

1) Features of PLUS (Rotary bushing track)
Please refer to page 42, 43 for details.
2) Advantage for R & M Cost Reduction

(1) Improve Wear life.
Rotary bushing system improve wear life of bushing and sprocket.
High Link (Increase wear amount) improve the total track life (About 2-times than traditional track life).
(2) Eliminate pin and bushing turn.
PLUS eliminate pin and bushing turn, so no cost for it and no machine down.
(3) Benefit of R&M cost
In conbination of the above (1) and (2), PLUS can reduce R&M cost drastically
- 185 -
2-4. Case Study of Pin and Bushing Turning
Explanation of symbols
Bs : Bushing wear life potential to Service (Turning)
L<60% : Link less than 60% worn
Sh<100% : Shoe less than 100% worn
Sp(R) : Sprocket teeth wear life potential to replace
Ss : Seal wear life potential to replace
Sd : Seal wear life potential to destruction
Pattern 1. Bushing wear life: 4000 hours below
Track shoe assy

should be turned at
Bushing & Pin should be turned at
Shoe less than

100% worn
Bushing & Pin wear

Bs Bs
Ss Ss
Sh<100%
Wear limit
Link wear
Wear limit
Operating hours 4000H 8000H 12000H
Bushings and Pins should better be turned at 4000 hours when estimated bushing wear life is 4000 hours
and Link wear is estimated below 60%. At this time bushing seals and sprocket need to be changed at the
same time.
- 186 -
Pattern 2. Bushing wear life: 4000 to 6000 hours
Bushing wear life

potential to Service
(Turning)
Bushing & Pin wear
Ss Bs Ss
Wear limit Bs Seal wear life potential

SD to destruction
Link wear
Wear limit
Operating hours 4000H 6000H 8000H 12000H
Even if bushing wear life is estimated at 6000 hours, bushings and pins better be turned at 4000 hours
which is seal wear life potential to replace, at this time link wear better be 50% and below. After turned
bushings and pins with seal replacement, link assembly may be run to destruction at 10000 hours.
Pattern 3. Bushing wear life: 6000 hours and over
Seal wear life potential

to destruction
Bushing & Pin wear Ss SD Ss

Bs SD
Wear limit
Link wear
Wear limit
Operating hours 4000H 6000H 8000H 12000H
This is the cause of run to destruction of shoe assembly.

The link assembly life is determined from amount of link wear even bushing has longer wear life.
- 187 -
R & M comparison (just for reference purpose)
With referring to the sample pattern 1, 2, and 3 described, the R & M cost difference would be as follows.
It is not shown actual cost, it just for reference and understanding.
Work Items Pattern 1 Pattern 2 Pattern 3 Remarks
8,000 hours 10,000 hours 12,000 hours
Shoe assembly Parts cost 3,000 3,000 3,000 Sprocket teeth

removal & Parts cost 40,000 Link assembly
installation Labor 800 800 800
(1 time)
Bushing & Pin Parts cost 4,000 4,000 10% of Link assembly
turn Labor 1,600 1,600
(1 time)
Shoe removal & Parts cost

installation Labor 240 240 240
(1 time)
Transport Cost 200 200 200
Total amount 9,840 9,840 44,240
Cost per hour 1.23 0.98 3.69

(9,840/8,000) (9,840/10,000) (44,240/12,000)
- 188 -
III. Selection Guide
1. Track Selection
Track Selection
Grease
S.A.L.T.
Sealed
Model Conventional Track Rotary Bushing Track Track
Dual
STD AR HD HDAR Tar sand PLUS Bushing STD
Track
7 䕿䕿
A
D21
8 䕿䕿
7A 䕿䕿
P
8 䕿䕿
EX
21 䕿
22 䕿
D31
21 䕿
PX
22 䕿
21 䕿
EX
22 䕿
EX & Exi 23 䕿䕿
D37
21 䕿
PX
22 䕿
PX & Pxi 23 䕿䕿
21 䕿䕿
EX
22 䕿䕿
EX & Exi 23 䕿䕿䕿
D39
21 䕿䕿
PX
22 䕿䕿
PX & Pxi 23 䕿䕿䕿
E 6 䕿䕿䕿䕿
D41
P 6 䕿䕿䕿䕿
EX & Exi 22 䕿䕿䕿
D51
PX & Pxi 22 䕿䕿䕿
12 䕿䕿
EX
15 䕿䕿䕿
EX & Exi 23 䕿䕿
D61
12 䕿䕿
PX
15 䕿䕿䕿
PX & Pxi 23 䕿䕿
12 䕿䕿䕿䕿䕿
15 䕿䕿
EX
16 䕿䕿
17 䕿䕿
12 䕿䕿䕿䕿䕿
D65 15 䕿䕿
PX
16 䕿䕿
17 䕿䕿
15 䕿䕿
WX 16 䕿䕿
17 䕿䕿
D68 ESS 12 䕿
D70 LE 12 䕿
A 21 䕿䕿
E 21 䕿䕿
ESS 2,2A 䕿䕿
15 䕿
EX 15E 䕿
D85
15R 䕿
P 21 䕿䕿
15 䕿
PX 15E 䕿
15R 䕿
- 189 -
Track Selection
Grease
S.A.L.T.
Sealed
Model Conventional Track Rotary Bushing Track Track
Dual
STD AR HD HDAR Tar sand PLUS Bushing STD
Track
2 䕿䕿
A 5 䕿䕿
6 䕿䕿
D155
5 䕿䕿
AX 6 䕿䕿
7 䕿䕿
2 䕿
A
5 䕿䕿
D275
5 䕿
AX
5E0 䕿䕿
D355 A 5 䕿䕿
3 䕿
5 䕿䕿
5E0 䕿䕿
D375 A
5R 䕿䕿
6 䕿䕿
6R 䕿䕿
3 䕿䕿
D475 A 5 䕿䕿䕿
5E0 䕿䕿䕿
D575 A 3 䕿
Remarks :
As you noticed on the above chart, AR Bushing Track is not available for D61EX/PX-23 and D65EX/PX-16
and up anymore as First Fit installation.
So, in case of D61EX/PX-23 and D65EX/PX-16 and up, it’s recommended that you deliver the machine
with PLUS (Rotary Bushing Track) if job site application is abrasive and anticipating premature bushing and
sprocket wear.
- 190 -
2. Shoe Selection
Proper Shoe Selection

Shoe should be selected depending on the user's habits, jobsites condition or the model salesman's rec-
ommendation. Sometime, this decision does not reflect machine productivity and the total undercarriage
wear and/or life in hours or cost. Connecting machine productivity and undercarriage wear and life perfor-
mance, it is necessary to analyze the KUC.
For selection, any choice is possible. The proper example is the case based on the low ground pressure
(machines with wide shoes) which relatively increases productivity by working in the soft ground.
Critical variables that affect undercarriage component life.
Link Track Track Carrier

Group Variable Shoe Bushing Sprocket Idler
pitch link roller roller
Operation Machine speed
Shoe slipping
Long distance
drawing
Traveling on slope
Track tension
Maintenance
Packing materials
An element of soil
(SiO2)
Ground
Rocky ground
condition
(uneven terrain)
Soil ground
(Splashed soil)
Sticky soil ground
(Packing materials)
- 191 -
Optimum Shoe Selection Comes from Correct Recognition of Kind of Terrain
Correct shoe selection is not just restricted to the undercarriage. It is one of the most important factors that
contributes to high availability and long durability of the structural frames and the machine as a whole. Before
starting to operate a machine on a jobsite, check the kind of terrain. Use this information to select the optimum
shoes for use on that jobsite.
Rocky ground Rough ground Forest Swampy ground
Narrow shoe Standard shoe Wider shoe Swampy shoe
1. Narrow Shoes on Rough Ground

If a wider shoe than necessary is used, the track will more often ride over rocks and hit obstacles,
so the load on the shoe will be increased.
If the load on the shoe increases, the shoe durability is greatly reduced.
The load on the shoe is proportional to the distance from the link to the end of the shoe (L in the diagram
below), so the wider the shoe is, the greater the load becomes.
The shoe life is inversely proportional to the 4th power of the shoe load, so on rough ground where the load
is always applied to the shoe, if a wide shoe is used, the shoe life will become much shorter than that of
a narrow shoe. Load on the shoe can also cause the links to crack, pins to break or come out, and shoe
bolts to come loose.
Shoe life
ratio
SMR
Shoe life
ratio
SMR
- 192 -
2. Wide Shoes on Soft Ground
Before operating the machines on soft ground, check the ground pressure of the machine.
The ground pressure differs according to the shoe width and it can be calculated using the formula below.
The lower the ground pressure, the better the flotation.
A
B
Ground pressure (kg/cm2)

Machine weight (kg)
=
Length of track on ground (cm) x shoe width (cm) x 2
W
=
AxBx2
Compare the ground pressure of the machine and the hardness on soft ground to judge the ma-
chine trafficability on the jobsite.
The cone index is most widely used to express the hardness on soft ground. But, to estimate the ground
hardness, the ground pressure of a man is, used as a handy way of calculating. For example, if a man
stands on two feet and doesn’t sink, but when he stands on one foot and sinks slightly, it can be taken that
a machine with a ground pressure of less than approximately 0.4 kg/cm2 can travel on that ground. There-
fore, model A can travel there with 800 mm shoes or wider without sinking.
However, this is the case for the average ground pressure.
If the center of gravity changes, it may be difficult to guarantee the trafficability.
Ground pressure for each shoe width of model A
(kg/m2)
0.5
0.4 kg/cm 2
0.4
Ground pressure
0.3
600 700 800 900

Shoe width (mm)
- 193 -
1) Types of Shoe
Applications of different shoes in accordance with soil characteristics and working conditions.
Applicable soil
Type of shoe Advantage Disadvantages Remarks
and work
1 Single grouser shoe Because the shape of the Strength is somewhat Is available in
grouser is sharp, it easily reduced on rocky ground, various widths
bites into the ground and and bending and other to suit the soft-
General soil exclud- provides a large traction damage may occur. ness of the soil.
ing rocky ground force. The riding conform is a lit-
(for bulldozer) tle inferior to the triple and
double grouser shoes.
The road surface is liable
to be roughed.
The turning resistance is
large.
2 Heavy duty shoe Compared to a single

For rocky ground grouser shoe, the grouser
(for bulldozer) and plate portions of
this shoe are thicker and
stronger, providing high
bending resistance and
wear resistance.
3 Triple grouser shoe The three grousers have This shoe does not read-
Double the same height, hence ily bite into the ground, so
grouser shoe Hard ground Suit- turning ability is good. the traction force is low.
able for both soft Good riding comfort is ob-
and hard ground tained as compared with
(for hydraulic ex- a single grouser shoe.
cavator and dozer Rotating resistance is low.
shovel) Because three beams are
used, resistance to bend-
ing is high.
4 Swamp shoe Because the cross-sec- Unsuitable for ground oth- Various widths
tion of this shoe is an arc, er than swampy ground. are available to
the ground contact area When used off swampy suit the degree
Swamp areas is large, and buoyancy is ground, it is liable to bend of softness of
(for swamp dozer) easily obtained. due to its low strength. the swampy
This shoe is particularly ground.
suitable for use in swamp
areas and areas with low
ground pressure. The
ground surface is not
damaged when the ma-
chine travels over it, so
it is suitable for soil com-
paction and leveling work.
- 194 -
Applicable soil
Type of shoe Advantage Disadvantages Remarks
and work
5 Snow shoe For use on snow Wear and damage occur

To prevent transverse slip rapidly when this shoe is
1. Is provided with rib. used on general soil and
2. Grousers are stepped. rocky ground.
On snow For discharging ice and
snow
1. Holes are provided in
plate portion.
2. Tail of plate has been
eliminated.
6 Flat shoe Projections have been Because there are no

eliminated (heads of grousers, this shoe does
shoe bolts are recessed), not bite into the ground.
permitting work on paved
Paved roads roads without damaging
Indoor work road surface.
Turning resistance is very
low, and tracks are highly
wear resistant.
7 Roadliner (rubber) The surface of the shoe Use in the following plac-
in contact with the ground es will shorten the cutting
is made of rubber, so the life of the rubber.
machine can travel on (1) Rocky ground
Paved road paved roads without dam- (2) Cold areas
Indoor work aging the road surface. (below -25°C)
Prevents noise when ma- (3) Hot areas
chine is traveling. (above 65°C)
Because there are no
grouser, this shoe does
not bite into the ground.
8 Center hole shoe There is a hole in the Strength is somewhat

plate to remove any mud reduced on rocky ground,
or soil. and crack and other dam-
The sprocket removes age may occur.
Soil which clogs any mud or soil collected
between the track rails,
so clogging of the track is
reduced.
- 195 -
2) Applicable Shoe on Each Model
Bulldozer
Classification of the applications:
Classification Applicable terrain Limitations

A Rockly terrain, general These can be used over a wide range of general civil engineering work
terrain form crushed rock to preparation of residential land. There is no
particular limitation on their use.
B General or soft terrain These are used for general earthmoving work where the main work is
scraping operations and pushing operations when constructing golf
courses, and overburden stripping operations in coal mines. They
cannot be used on rocky ground. Be careful to avoid traveling over
rocks when carrying out operations on jobsites where there are
scattered rocks.
C Extremely soft terrain These are used on soft ground where B classification shoes would sink.
(swamps) These cannot be used on ground where there are scattered rocks.
Note: Select the proper shoe width for your customers, by taking the limiations described above into consider-
ation, (especially on wide shoes “B” and “C”).
Select the narrowest possible shoes, depending on the flotation and ground pressure of the machines.
If the shoe is too wide, the load on the track shoe increases and results in bends in the shoes, cracks in
the links, breakage and slipping out of the pins and lossening of the bolts.
- 196 -
Shoe application

Model (A) (B) (C)
Swamp
7 300 340
A
8 300 340
D21
7A 510 510
P
8 510 510
21 400
EX
22 400 460
D31
21 400 600 600
PX
22 600 600
21 400
EX
22 400 460
400 460
EX & Exi 23
PLUS 400 460
D37
21 600 600
PX
22 600 600
600 600
PX & Pxi 23
PLUS 600
21 460 510
EX
22 460 510
460 510
EX & Exi 23
PLUS 460 510
D39
21 635 700 700
PX
22 635 700 700
635 700 700
PX & Pxi 23
PLUS 635 700
E 6 510 560
D41
P 6 510 700 700
510 560
EX & Exi 22
PLUS 510 560
D51
710 720
PX & Pxi 22
PLUS 710
12 600
EX 600
15
PLUS 600
600
EX & Exi 23
PLUS 600
D61
12 600 860 860 1100
PX 860 860 1400
15
PLUS 860
860 860
PX & Pxi 23
PLUS 860
12 510 560 610 660
510 510 560 560 610 610 660 660
15
PLUS 510 560 610 660
EX 510 510 560 560 610 610 660 660
16
PLUS 510 560 610 660
510 510 560 560 610 610 660 660
17
PLUS 510 560 610 660
12 915 940
915 940
15
PLUS 915
D65
PX 915 760 940
16
PLUS 915 760
915 760 940
17
PLUS 915 760
810 660
15
PLUS 810 660
760
WX 16
PLUS 610 760 660
760
17
PLUS 610 760 660
D68 ESS 12 510 560 610
D70 LE 12 560 610
- 197 -
Shoe application

Model (A) (B) (C)
Swamp
A 21 560 560 610 610 660 660
E 21 560 560 610 610 660 660
ESS 2,2A 510 560 610
15 560 560 610 610 660 660
EX 15E0 560 560 610 610 660 660
D85
15R 560 560 610 610 660 660
P 21 910 910
15 910 910
PX 15E0 910 910
15R 910 910
2 560 560 610 610 660 660 710
A 5 560 560 610 610 660 660 710
6 560 560 610 610 660 660 710
D155
5 560 560 610 610 660 660 710
AX 6 560 560 610 610 660 660 710
7 560 560 610 610 660 660 710
2 610 710 760
A
5 610 710 760
D275
5 610 710 760
AX
5E0 610 710 760
D355 A 5 610 710 760
3 610 710 810
5 610 710 810
5E0 610 710 810
D375 A
5R 610 710 810
6 610 710 810
6R 610 710 810
3 710 810 910
D475 A 5 710 810 910
5E0 710 810 910
D575 A 3 860 860 910
- 198 -
Excavators/Front loaders
Classification of the applications:
Classification Applicable terrain Limitations

A Rocky terrain, river 1. Use low shift for traveling over harsh terrain with various obstacles
banks, & general such as rolling stones and fallen trees.
terrain
B General or soft terrain 1. Not applicable for traveling over harsh terrain with rolling stones and
fallen trees.
2. Travel in high shift only on flat ground; use half speed in low shift for
going over the obstacles, if they are unavoidable.
C Extremely soft terrain 1. Applicable only when “A” & “B” sink.
(swamps) 2. Not applicable for traveling over harsh terrain with rolling stones and
fallen trees.
3. Travel in high shift only on flat terrain; use half speed in low shift for
going over the obstacles if they are unavoidable.
D Paved road 1. Rubber pad shoes must be used mainly in machine operation on
paved road surfaces. If used on unpaved surfaces, shoe durability will
be badly deteriorated due to rubber cracks, cutouts, etc.
The following operations must be avoided.
(a) Work on broken concrete, gravel, etc.
(b) Work on sharp projections like reinforcing iron rods, glass, etc.
(c) Riding on concrete road shoulder, operation on bedrock and in
rivers with abundance of stones, pebbles, etc.
2. In operation on roads covered with water, ice, snow, gravel etc. be
careful to avoid the shoes slipping, especially in carrying or unloading
operation of a machine on or from a truck.
3. In operation at high temperature (65°C or higher) or at low temp.
(-25°C or lower), the rubber will be liable to damages because of the
changes in the physical properties.
Note: Select the narrowest possible shoes, depending on the flotation and ground pressure of the machines. If
the shoe is too wide, the load on the track shoe increases and results in bends in the shoes, cracks in the
links, breakage and slipping out of the pins and loosening of the bolts.
Shoe type
Double-grouser Swamp
Triple-grouser Rubber pad
- 199 -
Shoe application

Classification Classification Classification Classification
Model (A) (B) (C) (D)
Triple Double Single Triple Double Triple Double Rubber
Swamp
Grouser Grouser Grouse Grouser Grouser Grouser Grouser Pad
PC60 7 450 600 700 450
6 450 600 700 450
US
8 450 600 450
PC78
6 450 450
UU
8 450 600
PC88 MR 8 450 600 450
6 500 510 600 700 750 750 500
PC120
8 500 510 600 700 750 750 500
2 500 510 600 700 500
US 8 500 600 700 500
PC128 10 500 600 700 500
2 500 600 700 500
UU
8 500 600 700 500
2 500 510 600 700 750 750 500
8
US 500 510 600 700 750 750 500
8T
PC138 10 500 510 600 700 750 500
2 500 600
USLC 8 500 600 700 500
10 500 600 700 500
6 500 600 700 800 860 600
7 500 600 700 800 860 600
8 600 700 800 860 600
8E0 Hybrid 600 700 800
10 600 700 800
PC200
6 600 700 800 900
7 600 700 800 900 860 600
LC 8 600 700 800 900 860 600
8E0 Hybrid 600 700 800
10 600 700 800
PC2䠍0i 10 500 600 700 800
PC210LCi 10 600 700 800 900
1 Hybrid 600 700 800
HB205
2 Hybrid 600 700 800
1 Hybrid 600 700 800
HB215 LC
2 Hybrid 600 700 800 900
6 500 600 700 800 860
7 500 600 700 800
8 600 700 800
10 600 700 800
PC220
6 600 700 800
7 600 700 800
LC
8 600 700 800
10 600 700 800
3 600 700 800 860
US 8 600 700 800
10 600 700 800
PC228
3 600 700 800 860
USLC 8 600 700 800
10 600 700 800
6 600 700 800
7
600 700 800
7E0
8 600 700 800
10 600 700 800
PC300
6 600 700 800
7
600 700 800
LC 7E0
8 600 700 800
10 600 700 800
6 600 700
7
600 700
7E0
8 600 700
10 600 700
PC350
6 600 700
7
600 700
LC 7E0
8 600 700
10 600 700
1 Hybrid 600 700 800
HB335
LC 1 Hybrid 600 700 800
1 Hybrid 600 700
HB365
LC 1 Hybrid 600 700
6 600 700 800
7
600 700 800
7E0
8
600 700 800
8R
10 600 700 800
PC400
6 600 700 800
7
600 700 800 900
LC 7E0
8
600 700 800 900
8R
10 600 700 800 900
- 200 -
Classification Classification Classification Classification
Model (A) (B) (C) (D)
Triple Double Single Triple Double Triple Double Rubber
Swamp
Grouser Grouser Grouse Grouser Grouser Grouser Grouser Pad
6 600 700 800
7
600 700
7E0
8
600 700
8R
10 600 700
PC450
6 600 700 800
7
600 700 800
LC 7E0
8
600 700 800
8R
10 600 700 800
10 600 700 800
PC490
LC 10 600 700 800 900
6 600 700 750
7 600 600 700 750
8
8E0 600 600 700 750
PC600 8R
6 600 750 900
7 600 600 750 900
LC 8
8E0 600 600 750 900
8R
6 600 750
7 600
8
600
PC650 8E0
6 600
7 600
LC
8
600 600 750 900
8E0
PC700 LC 8E0 610 710 810
6 610 710 810 910
7 610 710 810 910
6 610 710 810 910 10101110
PC750 LC
7 610 710 810 910 10101110
6 610 710 810 910 1010
SE
7 610 710 810 910 1010
6 610 710
7 610 710
8
8E0 610 710 810 910
8R
PC800 8
LC 8E0 610 710 810 910
8R
8
SE 8E0 610 710 810 910 1010
8R
8
8E0 610 710
PC850 8R
8
SE 8E0 610 710 810 910 1010
8R
6 700 1000
PC1100 LC 6 1000 1200
SE 6 700
7 700 1000
8
700 1000
8R
PC1250 7 1000 1200
LC
8 1000 1200
7 700 1000
SE
8 700 1000
PC1800 6 810 810 1010
PC2000 8 810 810 1010
- 201 -
3) Practical Idea for Shoe Width Selection on D475A
Proper shoe selection to meet with job-site and application is very important to achieve best machine
performance and longer undercarriage life. We recommend that you refer to KUC Procedure Manual for
proper shoe (type & width) selection, as a general guideline. In addition to that, following is very useful
suggestion which we got from Bulldozer Specialist based on his long experience in field. So we introduce
it as a sample on D475A together with various photos of job-site and application.
1. STD shoe width for D475A is 710mm. Then 810 mm and 910 mm Shoe are optionally available. In
case of D475A Super Dozer, STD shoe width is 810 mm.
2. Consideration points on proper shoe width selection are as follows.

1) As a general rule, if there are rocks on working ground, STD 710 mm shoe is recommendable. In
this case, working with Semi-U Blade is normal combination.
2) If there is no rock, flat ground condition and long dozing application, 810 mm shoe is recommend-
able. In this case, working with Full-U Blade is better combination for effective operation.
3) As a general rule, if machine is equipped with Full U-Blade, working with 810 mm or 910 mm shoe
is normal combination. But if there are rocks on job-site, working with STD 710 mm shoe is recom-
mendable even machine is equipped with Full-U Blade.
4) For downhill or uphill dozing on normal (less rock) ground, gripping force on the ground by shoe is
required for effective operation. In such a case, 910 mm shoe is recommendable.
5) Wider shoe is for soft terrain. We also recommend that you use “shoe with hole” in order to prevent
mud or coal from packing.
3. Note for “shoe with hole”

1) Various shoes with hole are available from Komatsu. Please refer to UC Sales Guide “UCSG06-003”
for that. It shows P/N of available shoe with hole on each model.
2) Even your required size of shoe with hole is currently not available from Komatsu, we can prepare
those. So please contact with Komatsu.
3) Needless to say but we can install shoe with hole on new machine at our assembly line and deliver
to you. So please work together closely with your sales people at ordering of the machine.
s Example of jobsites (pictures)

s *OB3ITEh!v
s *OB3ITEh"v
s *OB3ITEh#v
s *OB3ITEh$v
s *OB3ITEh%v
s *OB3ITEh&v
s *OB3ITEh'v
s *OB3ITEh(v
- 202 -
Job Site “A”
D475A-5 Dual tilt
Full U Blade
Shoe width: 810 mm
s .O 2OCK
s &LAT
s ,ONG$OZING
Job Site “B”

D475A-5 Super dozer 1 unit
D475A-5 Dual tilt 1 unit
Full U Blade
Shoe width: 810 mm

s .O 2OCK
s ,ONG$OZING Full U Blade
- 203 -
Job Site “C”
Shoe width: 910 mm
20 degree
D475A-5 Dual tilt
Full U Blade
s.O 2OCK
s5PHILL,OADING
Job Site “D”

Full U Blade Shoe width: 810 or 910 mm
s5PHILL,OADING
15 degree
L/U: ON-OFF x
10 degree
- 204 -
Job Site “E”
s.O 2OCK
20 degree s$OWNHILL,OADING
12 degree
60 m
Shoe width: 910 mm with hole
Full U Blade
100 m
Job Site “F”
Full U blade: 34.4 m3 Super blade: 45.0 m3
6205 m 6465 m
Shoe width: 810 mm
- 205 -
Coal blade (Local sourcing)
Job Site “G”
7710 mm
Coal blade pile
Shoe width: 910 mm
Job Site “H”
s2OCKY!REA
Shoe width: 710 mm (STD)
Semi U blade: 27.2 m3
- 206 -
3. Track Roller Guard Selection
Bulldozer
Small-middle Class
Full roller guard Not full roller guard
Integral structure 3-part split type Center and end End section
full roller guard full roller guard section track guard track guard
Large Class
Full roller guard Not full roller guard
Bogie full Split type full Bogie roller Add-on full Center end section
roller guard roller guard guard roller guard track guard
Hydraulic Excavator
1. When using hydraulic excavator, it is necessary to make most appropriate choices of the track roller
guards fitting to respective working environments. Given below are the criterion for the choices.
2. Although track roller choices have so far been made according to the natural environmental conditions un-
der the SAR (special specifications for specific environmental condition), this chart provides clearer crite-
rion for the choices in consideration of respective functions of different types of track roller guards.
Without roller Center roller Center and final

guard guard roller guard Full roller guard
- 207 -
4. Hints for Field Action
1) Wear Criteria on the Soft Ground
Only on the sandy terrain where the impact load is scarcely applied, in order to prolong the wear life, the
wear criteria of the bushing and the sprocket are changed into special value.
In addition, in order to minimize the sand entry to the sprocket engaging portion, sometime sand entry pre-
vention cover is effective.
Portion Contents
Bushing Increased criteria (Part dimensions are not changed.)

Sprocket Increased criteria (Part dimensions are not changed.)
Note) If the peculiar wear occurs on the undercarriage, in order to consider the improvement counter-
measure, please send the wear dimension information.
2) Soil Packing
Phenomena
If the soil is sticky, the wear of each portion of the undercarriage is accelerated. The soil accumulated on
the track frame accelerates the wear on the tread surfaces of the carrier roller and the link. In addition,
because the soil drops into the idler portion, the wear of the tread surface on the idler and the link is ac-
celerated. And, because the soil drops into the sprocket, the wear of the sprocket teeth profile and the
bushing are accelerated. The soil wound into the track frame accelerates the wear of the tread surface
on the track roller and the link.
The remarkable soil clogging into the link portion causes for the shoe jumping.
Action
Remove the soil daily.
As for the prevention of the soil entry, the installation of the covers is recommended. (In case of the vi-
cious soil, this may cause the bad effect.)
In order to reduce the soil clogging into the link portion, it is recommended that the hole at the shoe cen-
ter for releasing the soil is produced.
3) Skid Guard
Phenomena
Wide shoes may be installed on the hydraulic excavator used by the forestry. When the ends of shoes
ride on the stubble or the boulders, the life of each portion of the undercarriage is shortened.
(Shoe bend, shoe bolt breakage, track pin breakage, removal of track pin or bushing, etc)
As the shoe width is wider, the life reduction is larger.
Action
As the method for lessening the life reduction, it is recommended that the skid guard is installed.
Because the load is supported by the whole shoes, the load concentration to the one piece of shoe can
be avoided.
- 208 -
Skid guard
4) Tri Link Track for Oil Field Application

Phenomena
Wider shoe are used on bulldozer which works in oil field in many cases. In such a case, if shoe edge rides
on the stubble or the boulders, big bending moment is applied on shoe mounting potion at link and causes
for many troubles on undercarriage such as shoe bending, shoe bolt breakage, track pin came off etc.
Thus undercarriage life is shortened.
Action
It is recommended to install additional link assy at near end of shoe edge.
Additional link assy increases regidity of shoe assy and help shoe from bending
Remarks: Installation of additional link assy should be done by locally
Additional Link Assy
- 209 -
5) Shoe Jumping
Phenomena
During traveling, track bushing jumps to next teeth suddenly with big banging noise.
If shoe jump happens, abnormal load applies on each undercarriage parts and it causes for another trouble
such as bushing crack.
Considerable cause
Following conditions on undercarriage would be causing for shoe jumping sometime due to improper
meshing of Track Bushing with Sprocket Teeth.
(1) Sand/mud (sometime snow) packing on bottom of Sprocket Teeth.
(2) Loose track due to Link Pitch Extension or Improper Track Adjustment
(3) Too much wear on Bushing O.D. and Tip of Sprocket Teeth.
Packed soil/mud at bottom of sprocket teeth prevents Track Bushing from

proper meshing with Sprocket Teeth
Bushing meshes with Tip side of Sprocket Teeth
Finally Bushing jumps to next Teeth
Recommended action for improvement

(1) Remove packed soil/mud daily.
(2) Install “Shoe plate with hole”, if machine works at sticky soil condition.
- 210 -
6) Brittle Fracture of Shoe Bolt
Phenomena
Shoe bolt is broken suddenly without loosening under following occasion.
(1) Machine works at rusty ground condition with high contents of sulfur or salt.
(2) After machine parked for long period.
Breakage
Breakage
Sample of brittle fracture (1) Sample of brittle fracture (2)
Cause
It’s a Brittle Fracture
High-Tensile Strength Bolt is used for shoe bolt.
It has enough strength to hold high axial load so we can tighten it with very high torque.
But as a trade-off, high internal stress is generated on bolt itself.
So, in very rare case, shoe bolt is broken due to its internal stress under above-mentioned occasion.
Action
When you’ve experienced this kind of trouble, please contact to Komatsu.
7) Precaution for long traveling

Avoid long traveling the machine at high speed.
If you do so, lubrication oil temperature of track rollers rises rapidly and overheats.
Such condition leads oil leakage due to deterioration of O-ring of floating seal.
If you need to travel the machine at high speed for long distance, “please stop the machine every one hour
for 30 minutes at least and let the track rollers cool down before travelling again” as instructed by Operation
& Maintenance Manual.
Oil leakage
- 211 -

008-003-KUC-Guia para Medicion de Carrileria

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5) Caution at C/Roller installation

II. Undercarriage Management......................................................................................................................... 182

III. Selection Guide ............................................................................................................................................ 189

1) KUC Measurement Kit

Inspection & Measurement Tool List

Depth reference plane 1st vernier

O.D. measuring Stopper

Track roller measuring adaptor

2. How to read the multi-scale.

(2) 1st and 2nd verniers

link and ﬁx the 1st vernier with a stopper.

Lock the 1st vernier

2 Then, set an adaptor on the bolt used for

3. Precautions for use of the multi-scale.

Remarks: Multi scale is not supplied anymore due to supplier problem

Purpose: To check abrasion on the face

Sprocket wear gauge

The above type gauges have been developed for

(See a sample sketch below)

Align here on the center of bolt

(1) Part Number

3) The tool enables you to easily measure the tread

(3) Cautions in Measuring with The Ultrasonic Measurement Tool

3) Inputting data of the machine to be measured

4.2 Measuring each Component (see note). Follow

Note: Refer to “Ultrasonic Measuring Point Table”

Additional couplant is available: Part Number 799-A50-1130 4 oz. bottle.

Subject: KOMATSU ULTRASONIC UNDERCARRIAGE TOOL

The ultrasonic tool measures and records

Measuring and evaluating undercarriage wear

• Decreases the amount of time required to

(1) Part Number

3) The depth gauges enable you to measure link

(4) How to Use

4.3 Outer Shape of Bushing

4.4 Measurement of Grouser Height

4.5 Measurement of Carrier Roller Tread

4.7 Measurement of Link Pitch

4) Simple Wear Check Gauge

1. Features and usage of gauges

Track Gauge Roller Gauge

2. Available model for gauges (Gauge drawings are ready)

1. Want to check undercarriage wear condition in short and limited time.

3. Want to show and explain UC wear condition to customer visually.

(if it’s over wear limit)

Gauge touches link tread surface

Bushing O.D. wear check

It’s better see from upper side to

Shoe grouser wear check

Gauge touches to tip of

Gauge touches to Idler tread (both)

Gauge not reaches to top of Idler

This means Idler

C/Roller wear check

Gauge touches to C/R tread (both)

Gauge not reaches to top of flange

This means C/Roller

T/Roller wear check

Gauge touches to T/R tread (both)

Gauge not reaches to top of flange

This means T/Roller