KUC Procedure Manual Edition 12

SELA 1208-06
PROCEDURE MANUAL
EDITION 12
November 2006
FOREWORD
We updated KUC Procedure Manual by adding undercarriage related data of following machines
which were model changed and introduced in the market recently to meet with Tier 3 (emission
control) regulation.
Added Model S/N

D85EX-15EO 11001 up
D85PX-15EO 1201 up
D155AX-6 80001 up
D275AX-5EO 30001 up
D375A-5EO 50001 up
D475A-5EO 30001 up
PC200/200LC-8 300001 up
PC210/210LC-8 60001 up
PC220/220LC-8 70001 up
PC230/230LC-8 20001 up
PC300/300LC-7EO 50001 up
PC350/350LC-7EO 30001 up
PC400/400LC-7EO 60001 up
PC450/450LC-7EO 30001 up
PC600/600LC-8 30001 up
PC650/650LC-8 50001 up
PC800/800LC-8 50001 up
PC850-8 10001 up
PC1250/1250LC-8 30001 up
PC2000-8
Hoping the revised KUC Procedure Manual will support 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
3) Measurement Kit by KSA ............................................................................................................ 16
1-2. Measuring Technique ....................................................................................................................... 20
1) Link Height ................................................................................................................................... 20
2) Bushing O.D. ............................................................................................................................... 20
3) Link Pitch ..................................................................................................................................... 21
4) Shoe Grouser .............................................................................................................................. 22
5) Idler .............................................................................................................................................. 23
6) Track Roller ................................................................................................................................. 23
7) Carrier Roller ............................................................................................................................... 24
8) Sprocket Teeth ............................................................................................................................ 24
9) Other Check Point ....................................................................................................................... 25
10) Ultrasonic Measuring Point Table ................................................................................................ 26
1-3. Calculation of Hour Left .................................................................................................................... 28
1) Basic Idea .................................................................................................................................... 28
2) 3-Ways for Calculating of Hours Left ........................................................................................... 30
1-4. Study on Point of Sales .................................................................................................................... 36
2. Undercarriage Component ....................................................................................................................... 37
2-1. Structure & Function ......................................................................................................................... 37
1) Overview ...................................................................................................................................... 37
2) Shoe Assy ................................................................................................................................... 38
(1) General .................................................................................................................................. 38
a) Grease Sealed vs S.A.L.T. (Sealed and Lubricated Track) ............................................. 38
b) Master Pin vs Master Link ................................................................................................ 38
c) HD Link & AR Link ............................................................................................................ 39
d) Wedge Ring Type UC ...................................................................................................... 41
(2) Link ........................................................................................................................................ 42
(3) Bushing .................................................................................................................................. 42
(4) Pin ......................................................................................................................................... 42
(5) Seal ....................................................................................................................................... 43
(6) Shoe ...................................................................................................................................... 45
3) Rollers ......................................................................................................................................... 45
(1) Idler ........................................................................................................................................ 45
a) Track Adjuster & Recoil Spring ........................................................................................ 45
(2) Track Roller ........................................................................................................................... 46
a) X-Bogie vs K-Bogie .......................................................................................................... 48
b) T/Roller Sequence ............................................................................................................ 50
(3) Carrier Roller ......................................................................................................................... 53
4) Sprocket ...................................................................................................................................... 54
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2-2. Wear Limit ......................................................................................................................................... 55
1) General View ............................................................................................................................... 55
(1) Rebuilt vs Run to Destruction ................................................................................................ 55
(2) Normal Limit vs Impact Limit ................................................................................................. 55
2) Concept on Wear Limit for each UC Parts .................................................................................. 56
2-3. Wear & Problem ............................................................................................................................... 58
1) Link .............................................................................................................................................. 58
2) Bushing ........................................................................................................................................ 64
3) Pin ............................................................................................................................................... 66
4) Shoe ............................................................................................................................................ 67
5) Idler .............................................................................................................................................. 69
6) Track Roller ................................................................................................................................. 71
7) Carrier Roller ............................................................................................................................... 72
8) Sprocket Teeth ............................................................................................................................ 74
3. Variables that Affect Undercarriage Parts ................................................................................................ 77
3-1. Controllable Variables ....................................................................................................................... 77
1) Track Adjustment ......................................................................................................................... 77
2) Shoe ............................................................................................................................................ 78
(1) Shoe Width/Shoe Type .......................................................................................................... 78
(2) Factors Affecting Machine Production ................................................................................... 79
(3) Undercarriage System Wear & Structural Life Factor ........................................................... 80
(4) Sealed and Lubricated Track Joint Life ................................................................................. 81
(5) Shoes for Special Conditions ................................................................................................ 81
3) Track Guards ............................................................................................................................... 81
4) Alignment ..................................................................................................................................... 81
(1) Track Frame .......................................................................................................................... 81
(2) Front Idler .............................................................................................................................. 83
(3) Sprocket ................................................................................................................................ 83
5) Others .......................................................................................................................................... 84
(1) Cleaning ................................................................................................................................ 84
(2) Routine Inspection ................................................................................................................. 84
(3) Keeping Good Records ......................................................................................................... 84
3-2. Partially Controllable Variables ......................................................................................................... 85
1) Use Slowest Operating Speed .................................................................................................... 85
2) Minimize Reverse Travel ............................................................................................................. 85
3) Avoid Spinning the Tracks ........................................................................................................... 85
4) Avoid Favoring One Side ............................................................................................................. 85
5) Frequent Turning in the Same Direction ...................................................................................... 85
6) Alternatives .................................................................................................................................. 85
7) Traveling Across a Lateral Slope ................................................................................................. 86
8) Side-Hill Cutting ........................................................................................................................... 86
9) Others .......................................................................................................................................... 86
3-3. Uncontrollable Variables ................................................................................................................... 87
1) Soil & Underfoot Condition .......................................................................................................... 87
2) Terrain Condition ......................................................................................................................... 91
3) Job Application ............................................................................................................................ 91
3-4. Reference ......................................................................................................................................... 93
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4. Maintenance and Adjustment ................................................................................................................... 94
4-1. Track Adjustment .............................................................................................................................. 94
4-2. Idler Guide Adjustment ..................................................................................................................... 94
4-3. Track Roller Rotation ........................................................................................................................ 94
4-4. Field Action against Oil Leakage ...................................................................................................... 94
4-5. Requirement of the Shoe Bolts Tightening ....................................................................................... 97
5. Reference ............................................................................................................................................... 100
5-1. Rebuilding ....................................................................................................................................... 100
5-2. Wear Mechanism ............................................................................................................................ 100
1) Sprocket Teeth & Bushing O.D. ................................................................................................ 100
2) Chain Tightness ......................................................................................................................... 105
3) Pin/Bushing Internal Wear ......................................................................................................... 106
5-3. Operator’s Comfort & Vibration ....................................................................................................... 108
5-4. Distinguishing from the Non-Genuine Parts ................................................................................... 109
1) General View ............................................................................................................................. 109
2) Way for Distinguishing from the Non-Genuine Part ................................................................... 109
II. Undercarriage Management ........................................................................................................................ 111

1. General ................................................................................................................................................... 111
2. Countermeasure for R & M Cost Reduction ........................................................................................... 112
2-1. Precautions when Turning Pin & Bushing ...................................................................................... 112
1) Bushing O.D. wear .................................................................................................................... 112
2) Link Tread Surface Wear ........................................................................................................... 112
3) Pin Wear .................................................................................................................................... 112
4) Reusing Seal ............................................................................................................................. 112
5) Rollers Wear .............................................................................................................................. 113
6) Sprocket Wear ........................................................................................................................... 113
2-2. Contribution to R & M Cost Reduction for K-Bogie and Wedge Ring ............................................. 114
1) Features of K-Bogie and Wedge Ring UC ................................................................................. 114
2) Merit for R & M Cost Reduction ................................................................................................. 114
2-3. Case Study of Pin and Bushing Turning ......................................................................................... 115
III. Selection Guide ............................................................................................................................................ 118

1. Track Selection ....................................................................................................................................... 118
2. Shoe Selection ........................................................................................................................................ 119
1) Types of Shoe ........................................................................................................................... 122
2) Applicable Shoe on Each Model ................................................................................................ 124
3) Practical Idea for Shoe Width Selection on D475A ................................................................... 131
3. Track Roller Guard Selection .................................................................................................................. 136
4. Hints for Field Action ............................................................................................................................... 146
1) Wear Criteria on the Soft Ground .............................................................................................. 146
2) Soil Packing ............................................................................................................................... 146
3) Skid Guard ................................................................................................................................. 147
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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 following
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 regular
scale.
2 The scale of the 1st vernier coincides with the 6.5-division of the regular scale. That is, the regular
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 attach-
Shoe
ing the depth contacting face to the 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
Adaptor
tip of the 2nd vernier with the 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 wher-
ever 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 bending. 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 mea-
surement 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.
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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) before
Wear before turn of track bushing
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.
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(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
• Turn on the power of the tool, press the FILE
button, and select CREATE.
• Select KOMATSU template and input model
name, serial number, service meter,
measurement date, and track type.
• Using the Up and Down arrows to scroll through
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.
- 14 -
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.
- 15 -
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 Shape for easy measurement

and caliper with screw
1) Three kinds of calipers are available suitably for parts
to be measured.
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 Depth gauge
and grouser heights accurately.
(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.
- 18 -
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.
- 19 -
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.
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
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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.
- 21 -
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
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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. The
By the multiscale
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 center
By the ultrasonic measurement tool
of the part from the center of the tread width.
(Common with single flange and double flange types)
- 23 -
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 value with
Type C Type G
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.
See Measuring point table.
Type D Type E Type F
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.

- 24 -
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)
• Warm and hot pin indicates loss of lubrication oil.
(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.)
- 25 -
10) Ultrasonic Measuring Point Table
Bulldozer
measurement type measurement type

Model C. Roller Idler Sprocket Model C. Roller Idler Sprocket
D21-6 A A A D475-1 C B B
D21-7 A A A D475-2 C B B
D31-18 A A A D475-3 C B B
D31-20 A A A D475-5, 5EO C B B
D31-21 A A B D575-2 C B B
D37-2 A A A D575-3 C B B
D37-5 A A A
D37-21 A A B
D39-21 B A B
D41-5 C B A
D41-6 B A A
D53-17/-18 C B B
D58-1 C B B
D61-12 C A B
D61-15 C A B
D63-1 C B B
D65-8/-11 C B B
D65-12 C B B
D65-15 C B B
D68-1 C B B
D75S-5 C B B
D81-1 C B B
D85A, E-18 C B B
D85-15, 15EO C B B
D85P-18 C B B
D85A, E-21 C B B
D85P-21 C B B
D135A-1 C B B
D135A-2 C B B
D155A-2 C B B
D155A-3 C B B
D155A-6 C B B
D155AX-6 C B B
D275-2 C B B
D275-5, 5EO C B B
D355-3 C B B
D355-5 C B B
D375-1 C B B
D375-2 C B B
D375-3 C B B
D375-5, 5EO C B B
- 26 -
Hydraulic excavator
measurement type measurement type

Model C. Roller Idler Sprocket Model C. Roller Idler Sprocket
PC60-6 E A C PC600/LC-7 C B B
PC60L-6 E A C PC600/LC-8 C B B
PC70-7 E A C PC650SE-5 C B B
PC78US-6 E A C PC710-5 C B B
PC78UU-6 E A C PC750-6 C B B
PC80-3 E A C PC750-7 C B B
PC90-1 E A C PC800-6/7 G B B
PC100-5 E A C PC800-8 G B B
PC100L-5 C B C PC1000/LC-1 C B B
PC100-6 E A C PC1100/LC-6 G B B
PC100L-6 C B C PC1250-7 G B B
PC120-5 E A C PC1250-8 G B B
PC120-6 E A C PC1600-1 C B B
PC128UU-1 E A C PC1800-6 C B B
PC130-5 E A C
PC130-6 E A C
PC150-5 C A C
PC158US-2 C A C
PC200-5 C A B
PC210-5 C A B
PC220-5 C A B
PC200/LC-6 C A B
PC200/LC-7 C B B
PC200/LC-8 C B B
PC220/LC-6 C A B
PC220/LC-7 C B B
PC220/LC-8 C B B
PC228-3 C A B
PC230/LC-6 C A B
PC300-5 C B B
PC300/LC-6 C B B
PC300/LC-7, 7EO C B B
PC310/LC-5 C B B
PC350/LC-6 C B B
PC400/LC-5 C B B
PC400/LC-6 C B B
PC400/LC-7, 7EO C B B
PC450/LC-6 C B B
PC600/LC-6 C B B
- 27 -
1-3. Calculation of Hour Left
1) Basic Idea
(1) The purpose of UC wear measurement is as follows.
1 To calculate the remaining service life (hours) based on the dimension.
2 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.
1 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.
2 But when the wear progresses to the deeper portion, the hardness is lowered. Therefore, the wear
progresses faster.
3 A 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 B)
→ A wear does not go on in the relation with hours in propotion.
- 28 -
(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.
*1 The method that “Percent Worn Chart” and “Hours Left Chart” are used.
*2 The method that “Wear Life %” is calculated by using “KUC Program (Software)”, and based on this,
“Total Potential Hour” is calculated.
*3 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 1, but currently, Percent Worn Chart is not prepared.
Accordingly, use 2 or 3. Basically, use 2 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 3 Wear Life % Table is convenient. For each detail, refer to the following item.
- 29 -
2) 3-Ways for Calculating of Hours Left
(1) Percent Worn Chart & Hours Left Chart
• This is the way that while checking the table, the calculation
is done manually. D375A-2 #16001 - #16999
IDLER Tread Step Tread Radius Thickness
• The way is as follows. 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, convert 27.5
28.8
1.08
1.13
40
50
452.5
451.3
17.81
17.77
25.0
23.8
0.98
0.94
30.0 1.18 60 450.0 17.72 22.5 0.89
the wear value of the idler step to a percentage. 30.6 1.21 65 449.4 17.69 21.9 0.86
31.3 1.23 70 448.8 17.67 21.3 0.84
* Wear rate = 70% Measure 31.9
32.5
1.25
1.28
75
80
448.1
447.5
17.64
17.62
20.6
20.0
0.81
0.79
Wear value 33.1 1.30 85 446.9 17.59 19.4 0.76
Step 2. Using the HOURS LEFT CHART below, draw a line up 33.8 1.33 90 446.3 17.57 18.8 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
38.8
1.48
1.53
120
130
442.5
441.3
17.42
17.37
15.0
13.8
0.59
0.54
40.0 1.57 140 440.0 17.32 12.5 0.49
Step 3. Draw a curve parallel to the nearest curve to point A up 41.3 1.62 150 438.8 17.27 11.3 0.44
to the right and find point B where it intersects the

Note: 1. Always use the PERCENT WORN
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 intersect and Serial No.
the horizontal axis (operating hours) at point C. This 2. Obtain the wear rate from the measured
point C (2100 hours) indicates the service limit for repair wear value using the PERCENT WORN
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)
• However, since the KUC Program has been introduced, “Percent Worn Chart” is not maintained. Therefore,
as for the new models, both “Percent Worn Chart” and “Hours Left Chart” are not prepared.
- 30 -
(2) KUC Program Software is Used.
• This method is alternative for the method that Total Potential Hour is obtained by using the both “Percent
Worn Chart” and “Hours Left Chart”.
• After setting the operation and the usage conditions of the undercarriage in Program, 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.
• After that, based on the calculated “Wear Life %”, “Total Potential Hour” and “Remaining Life (Total
Potential Hour - Current SMR) are manually calculated.
• “Total Potential Hour” is the hour that the UC part reaches from “New” to “100% Wear Limit”, and is
calculated by the following formula.
Total Potential Hour = Current SMR / Wear Life %
FEATURE OF THE PROGRAM

The program
- Can be processed by only clicking its menu bar,
- Has all standard value and wear criteria,
- Automatically calculate wear life percent with formula “y=aXk”,
- Automatically calculate second wear life after bushing turn basing on the first measurement.
- Create colored report rapidly,
- Create wear percent graphs automatically
for not only standard measurement but also ultrasonic measurement.
- 31 -
SUMMARY OF THE PROGRAM
Program Main Menu

There are four (4) functions which are
1. Create New Inspection Report
2. Edit Library
3. View of Library, Standard value &
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.
Once the base information are registered, only
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
colors, which are
Black (under 80%),
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
be searched by clicking only menu button, and it
is required to input correct data and save.
- 32 -
View function
All saved inspection report, standard value at 0%
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
Inspection report, Summary report for fleet
customer and Summary report for models are
able to print by clicking menu button only as
same as graph creation.
- 33 -
• Precautions when using KUC Program
•1 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.
•2 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”.
•3 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.
- 34 -
(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.
• Because the read value is “Wear Life %”, same as KUC Program, “Total Potential Hour” can be calculated
by the following formula.
Total Potential Hour = Current SMR/Wear Life %
• “Wear Life % Table” was respectively delivered by UC Sales Promotion Material “UCFN04-014 (Bulldozer)”
and “UCFN05-001 (Excavator)”.
• When their tables are printed out, they can be conveniently used at the field. Therefore, use them.
- 35 -
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.
- 36 -
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, front idlers (1), carrier rollers (2) and track rollers (3) are mounted. The track looped around each
track frame is driven by the sprocket wheel 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, this 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 maintain smooth rolling of
the track.
- 37 -
(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
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
- 38 -
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
Regular bushing limit as the regular bushing but is slightly shorter. This
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
B65-12 m/c machine: S/N 65001 and up
NOTE: On D39-21 and D61-12, the idea of HD track link has been applied on STD track link since the
beginning
- 39 -
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 wear 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
“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, long Worn
wear life could be achieved. value
AR track link has 1.5 times wear life to STD track Busing
link. 1.5 times
Hours
- 40 -
d) Wedge Ring Type UC
1) Wedge ring was installed at the end of pin. It partially

take charge of holding pin so that pin press fitting
Link
force can be reduced.
2) Shape of link side face and guard has been changed Wedge ring
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 a pin end. Pin
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
- 41 -
(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.
(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
A
The essential qualities of a pin are endurance to constant
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
A
fatigue.
- 42 -
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
(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)
- 43 -
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 water, Entry of soil
but in addition to this, the bending and sliding motion creates a
Entry of soil
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 portion in the Load ring
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 spacer is set inside Sealing
the seal to protect it from overload and keep the deflection of the part
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
- 44 -
(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.
- 45 -
Track shoe Assy
Rubber cushion Grease chamber

Spring
Idler
A 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
Flange a rubber cushion.
As the tread and flange are prone to

wear, these portions are hardened
to extend the life.
(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 of single
Single flange type track roller
or double flange rollers are decided depends upon machine size.
Double flange type track roller

S D S D S D S
A crawler type vehicle works on a rough ground. Therefore,

Example for D155A model
single and double flange rollers are positioned to release a
S: Single flange type track roller lateral trust while the vehicle is working.
D: Double flange type track roller
- 46 -
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 chamber
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
- 47 -
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 rigid Ensures almost the same traction force

undercarriage. as a conventional rigid undercarriage.
- 48 -
On uneven ground
Seesaw movement is performed Compared with a rigid type, the actual ground
corresponding to ground surface. 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 travel Rough terrain 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.
2) K-bogie
Komatsu improved the ability of track roller to track link, and improved riding comfort for operator in
addition to reduction in load on undercarriage.
• Greater K-bogie stroke maintains consistent track tension and alignment.
• The design eliminates link pin-boss, providing greater clearance between track link and roller flange.
- 49 -
On flat ground
Bogie center
Bogie center
Bogie stroke
On uneven ground
Bogie center
Improved Operator Ride & Comfort
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
- 50 -
S: Single flange
D: Double flange
Model No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 Remarks
D20, 21-6 S S S S S S P, PL S PL
D20, 21-7, 8 S S S S S S PL S PLL
D31-16 S S S S S S PL S PLL S PLL
D31-17, 18, 20 S S S S S S P, PL S PLL S PLL
D31EX-21 S S S S S
D31EX-21 S D S D S OPTION
D31P-21 S S S S S S
D31P-21 S D S S D S OPTION
D37-1, 2, 5 S S S S S SP
D37-21 S S S S S S
D37-21 S D S S D S OPTION
D39-21 S S S S S S
D39-21 S D S S D S OPTION
D40, 41A, E-1 S D S D S
D40, 41P-1 S D S S D S
D41A-6 S S S S S
D41A-6 (HD) S D S D S OPTION
D41E, P-6 S S S S S SP
D41E-6 (HD) S D S S D S OPTION
D41P-6 (HD) S D S D S D S OPTION
D50, 53-17, 18 S D S D S DP SP
D58E-1 S D S S D S
D58P-1 S D S D S S D S
D61E-12, 15 S D S S D S
D61P-12, 15 S S D S S D S S
D63-1 S D S D S D S
D60, 65A-6, 7 S D S S D S
D60, 65E, P-6, 7 S D S D S D S
D60, 65A-8, 11 S D S S D S
D60, 65E-8, 11 S D S D S D S E type only
D65E-12, 15 S S D S D S S
D65P-12, 15 S S D S S D S S
D66-1 S D S S D S
D68-1 S D S D S D S
D75S-3 S D S D S D S
D75S-5 S D S D S D S
D83E-1 S D S D S D S
D80, 85A-18 S D S S D S
D80, 85P-18 D S D S S S D S
(to be continued)
- 51 -
S : Single flange
D: Double flange
Model No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 Remarks
D85A, E-21 S D S S S D S
D85P-21 D S D S S S D S
D85EX-15, 15EO S D S S S D S
D85PX-15, 15EO S S D S S S D S
D85E-SS-2 S S D S S D S S
D95-2 S D S D S D S
D135-1, 2 D S D S S D S
D150, 155-2 D D D S D D S
D155A, AX-3, 5 D S S D D S
D155AX-6 S D S D S D S
D275-2 S D D S S D D S
D275-5, EO S D D D D D S
D355-3, 5 D D D S D D S
D375-3 S D D S D S
D375-3, 5, 5EO S D S D S D S
D375-5EO S D D D D D D S 8 roller type
D455-1 D D S D S D S
D475-3SD S D S D S D S
D475-3, 5 S D D D D D S
D475-5EO S D D D D D D S 8 roller type
D575-2 D S D S D S
D575-2SD D S D S D S D S
D575-3 D S D S D S D S
- 52 -
(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.
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.
- 53 -
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 pitch

(Sprocket 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.
- 54 -
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
• When rebuilding by turning Bushing, build up by welding Roller 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”

• When the UC parts are used to the very end and abandoned without turning Bushing, etc, it is usual 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
• This is Wear Limit at the time when the machine is operated at the sandy land without rocks, etc, and at
the jobsite where the shock is not given to each portion of the undercarriage.
Impact Limit
• This is Wear Limit at the time when the machine is operated at the rocky land, and at the jobsite where
the shock is given to each portion of the undercarriage.
Komatsu’s Concept when the criteria of Impact and Normal are specified. (Remarks)
• Only Bulldozer has both criteria of Normal and Impact. As for H/E, it is basically not operated at the rocky
land, and its travel is less. Therefore, the criteria is one.
• In addition, Bushing O.D. and the Pitch elongation have both criteria of Normal and Impact, and except
them, other UC parts have one criteria.
• As for Grease Sealed Track of Bulldozer, both Bushing O.D. and Pitch elongation have the criteria of
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.
- 55 -
• As for SALT of Bulldozer, Bushing O.D. has the criteria of Normal and Impact. As for SALT, because
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)
• Wear Limit is specified by considering the rebuilding. Therefore, when the wear is within Wear Limit, after
rebuilding by weld-overlaying the tread surface, the strength can be maintained.
• Wear Limit is specified by considering the interference with other parts. Therefore, 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
• From the view point of Life, generally on the wear balance with other parts due to the soil, the following
items are considered.
• Two times life of Bushing O.D. (Bushing is turnable.)
(2) Bushing (O.D. Wear)

• This is specified by considering the turning use. Therefore, when the wear is within Wear Limit, even 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)

• This is specified by considering the turning use. Therefore, when the wear is within Wear Limit, even 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.
• This is specified by considering Track Sag adjustment. Therefore, when the Pitch elongation occurs, if
the wear is within Wear Limit, Track Sag can be absorbed within the range of Idler forward adjustment
amount.
(4) Idler (Tread Surface Wear)

• Wear Limit 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.
• Wear Limit 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.
- 56 -
(5) Track Roller
• Wear Limit 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.
• Wear Limit is specified by considering the 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

• Wear Limit 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.
• Wear Limit 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.
(7) Shoe (Grouser Height Wear)

• Wear Limit is specified by considering the rebuilding. Therefore, when the wear is within Wear Limit, the
enough strength is maintained, and the bend does not occur. Accordingly, the rebuilding is possible by
the lug-weld.
• From the view point of performance, when the grouser wear is within Wear Limit, the performance is
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.
- 57 -
2-3. Wear & Problem
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.
- 58 -
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...
- 59 -
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.
- 60 -
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.
- 61 -
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:
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.
- 62 -
(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:

• Repair of link becomes difficult.
• Turning of pin and bushing becomes difficult.
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) 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.
c) 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.
- 63 -
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
(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 toothed
face of sprocket wheel while it is in reverse-drive rotation.
Direction of Direction of
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.
- 64 -
b) Wear of Bushing I.D.
CAUSE:
Forward drive rotation
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.
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.
- 65 -
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.
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.”
- 66 -
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.
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).
- 67 -
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 depending
on the soil of the individual job site.

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
depending on the soil of the individual job site.
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.
- 68 -
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)
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
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.
- 69 -
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.
- 70 -
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.
- 71 -
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.
(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.
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.

(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.
- 72 -
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.
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.
- 73 -
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.
- 74 -
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:
Replace sprocket rim or segment teeth.
Right and left sprockets may be alternated if forward-drive side wear of
them is small.
- 75 -
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
- 76 -
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.
• Controllable variables include track tension adjustment, shoe width and alignment.
• Partially controllable variables is a condition may be influenced by uncontrollable variables but it is
compensable by the operator.
• 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.
• Maintenance: Track adjustment

• Machine outfit (Specification): Shoe width, Track guards
• Alignment: Roller frame, Idler mounting
1) Track Adjustment
It is extremely important to maintain proper track tension at all times of operation. Chain 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
Track Tension (lbs)
Track Sag (Inches)
Notice from the graph that if you decrease track sag just a little bit (e.g. from 1.0" to 0.5") it increases tension
tremendously (about 3000 lbs). This illustrates the sensitivity of track tension and the importance of keeping
it properly adjusted.
Track tension is maintained by a track adjuster that is situated behind the front idler. Adjustments are made
by pumping or draining grease through a fitting on the track adjuster.
Effects of a Tight Track

• Increased wear on all undercarriage components
• Increased friction causes mechanical loss and reduced drawbar pull
• Hotter temperatures
Effects of a Loose Track Track loosens (wave movement)

• Track chain side to side
• Upper waviness and whipping
• Popping
• Excessive noise and shaking
- 77 -
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]
1. First find machine productivity factor most important to the user.

2. Find what effect the various shoes selection variables may have.
3. Next, look straight across to find what degree of wear and structural life effects may be expected.
4. Repeat these steps until all productivity and life factors have been considered.
- 78 -
(2) Factors Affecting Machine Production
a) Flotation
Ground material is the biggest factor. It is very easy to stay afloat when you are working in hard material,
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. It is determined by the following
formulas:
Shoe
Track on Ground Length
Width
Contact Area = 2 x (Track on Ground Length x Shoe Width )

Ground Pressure = Machine Weight / Contact Area
As a rule of thumb, shoe width must be wide enough to keep the machine afloat, but not wider.
b) Penetration
Penetration is the portion of the grouser that digs into the ground during operation. Good penetration
means that the whole grouser gets embedded into the ground. Poor penetration means that very little of
the grouser gets embedded into the ground. Penetration is directly related to traction, which means that
more penetration equals more traction. Traction is the machine’s ability to grip the ground and propel itself
in a forward or reverse direction. It is important to understand that traction is a function of ground 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.
Good Penetration
Poor Penetration
- 79 -
c) Maneuvering Ability
Stress increases
Maneuvering ability is a function of ground material, proportionately as
machine weight, shoe type and shoe width. Wider shoe width
increases
shoes make it more difficult to maneuver the machine
because they stick out further and offer more turning Bending driven by
resistance. 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. A track shoe is like a lever; the longer the lever,
the easier it is to break. For this reason, wider shoes are 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:
• Increased wear on link sides, rollers and flanges

• External/internal bushing wear
• Pin loosening
• Premature seal failure
• Wide shoes also contribute to packing conditions because they can scoop deeper and provide more
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 the
end of the shoe. Cracking, bending and hardware loosening increases as shoe width increases.
Basic Rule of Thumb: Always specify the narrowest shoe possible that will provide adequate flotation 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 increased
load interference. Increased shoe width can also aggravate link cracking.
d) Pin and Bushing Wear Life

External bushing wear rate on Sealed and Sealed and Lubricated Track 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.
- 80 -
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.
This becomes more evident with high single grouser shoes. Loss of pin and bushing retention prevents
successful turn and replacement maintenance.
(4) Sealed and Lubricated Track Joint Life

The most costly effect of too wide shoes in high impact conditions and/or steep terrain is the loss of lubricant
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 up” is called end play. End play is permanent and can only be eliminated by pressing the
components tight as at initial assembly or when track press work is performed. For maximum lubricant and
seal life the machine should be equipped with the narrowest possible shoes which will provide adequate
flotation.
In 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 of Track Shoe
with Mud Hole
the shoe plate. Its purpose is to prevent packing accumulation by
helping the material escape. Every time the sprocket pushes on a
bushing it squeezes the material out.
Prior to implementing a mud relief hole it is important to check that
the ground material is extrudable. Extrudable 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. Although
roller guards provide many benefits there are times when they are best left
off the machine.
Roller guards serve two purposes. First, 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 outweighs the benefits.
For this reason, roller guards should not be used in high packing conditions.
4) Alignment
In general, a good way to identify an alignment problem is to look for unbalanced wear patterns. This
involves comparing left components with right components, front with rear and inner with outer. The four
main kinds of track frame misalignment are toe-in/toe-out, bow, tilt and twist
(1) Track Frame

• Toe-In/Toe-Out
• Track Bow
• Tilt
• Twist
- 81 -
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.
CAUSE: temporarily (during load only) or permanently bent diagonal

brace or roller frame
EFFECT: unbalanced wear when comparing inboard versus

outboard roller and idler flanges and rail sides — rollers worsen
from rear to front
REMEDY: straighten diagonal braces and repair mounting bearings
b) Track Bow
Similar to toe-in and toe-out, but roller frame is bent and curves in
or out with respect to tractor.
CAUSE: bent roller frame
EFFECT: similar to toe-in and toe-out except rear rollers are not
affected
REMEDY: straighten roller frame
c) Tilt
When viewed from front or rear the roller frame tilts toward or away
from tractor.
CAUSE: permanently bent diagonal brace, broken mountings or

bearings
EFFECT: unbalanced wear when comparing inboard versus

outboard roller, idler, link treads and flanges — unbalance from
front to rear on rollers
REMEDY: straighten diagonal brace and/or repair mountings
d) Twist
When viewed from the front, the roller frame is twisted, with the
front end of the roller frame tilted out.
CAUSE: roller frame twisted around a horizontal axis parallel to

the tractor
EFFECT: similar to effect of tilt except that rear rollers should not
be affected
REMEDY: straighten roller frame
- 82 -
(2) Front Idler
The main kinds of idler misalignment are toe-in/toe-out, shift and twist/tilt
a) Toe-In/Toe-Out
CAUSE: 1 Bent idler supports
2 Bent idler mounting yoke
EFFECT: Increased wear on link sides, idler flanges and front roller
flanges.
REMEDY: Straighten bent components
b) Front Idler Shift

CAUSE: Improper shimming
EFFECT: Increased wear of link sides, idler flanges and roller

flanges
REMEDY: Readjust idler support shims. Clearance between track

frame and guide plates should be between 0.5 mm and
1.0 mm.
c) Front Idler Twist/Tilt

CAUSE: 1 Bent idler supports
2 Bent idler mounting yoke
3 Unevenly worn idler wear plates.
EFFECT: Increased wear on link sides, idler flanges and front roller
flanges
REMEDY: Straighten or replace damaged components
(3) Sprocket
The main kinds of sprocket misalignment are toe-in/toe-out, shift and twist
a) Toe-In/Toe-Out
CAUSE: Bent sprocket shaft
EFFECT: Increased wear of link sides and sprocket tooth side wear.
REMEDY: Replace shaft
b) Sprocket Shift
CAUSE: Sprocket mounted incorrectly
EFFECT: Increased sprocket side face wear and link side wear.
REMEDY: Reposition sprocket mounting
- 83 -
c) Sprocket Twist
CAUSE: Bent sprocket shaft
EFFECT: Uneven sprocket wear, rail wear and track roller flanges
REMEDY: Replace shaft
5) Others
(1) Cleaning
Packing material that accumulates on undercarriage
components can become as hard as the components
themselves. Regular cleaning can greatly reduce the
effects of packing. Use 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.
1 Keep track of undercarriage wear. Pay special attention to bushing wear and premature link pitch
elongation. Also, keep an eye out for any differences between component wear patterns (i.e. left vs.
right and front vs. rear). This can often reveal other hidden problems, like misalignment or poor operator
habits.
2 Watch out for component damage, such as cracks, bends, and breaks. These can lead to interference
and malfunction. Most importantly, check rollers for oil leakage. Leakage means that oil is being lost. If
this condition is ignored the component will seize and cause quick, excessive wear and damage.
3 Misalignment causes unnecessary wear to all undercarriage components. The most common type of
misalignment is idler shift, which can usually be fixed by adjusting idler shims.
4 Loose nuts and bolts cause interference with moving parts, abnormal wear, bolt hole wallowing, bolt
breakage, accelerated misalignment and component loss. It is very important to apply proper torque to
all bolts. If bolts are not tightened enough then vibration will slowly loosen them until they are free. On
the other hand, if bolts are over-tightened their structural integrity will be weakened and they will fail
prematurely.
(3) Keeping Good Records

It is important to keep good records of all service-related activity, such as wear measurement, repair and
costs of repair. This information can be used to evaluate current wear and reduce future wear through
scheduled servicing. An excellent way to accomplish this task is to use CARE software, provided through
Komatsu.
- 84 -
3-2. Partially Controllable Variables
METHOD OF OPERATION
Method of operation is another factor that can greatly influence wear. There are several rules that should be
observed to minimize wear:
1) Use Slowest Operating Speed

Use slowest operating speed that will get the job done in time. Wear 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

Minimize reverse travel because it causes much more wear to bushings and sprockets than forward travel.
This concept is thoroughly explained in Chapter 4 - Basic Wear. Completely avoid reverse travel in high gear
or when climbing uphill.
3) Avoid Spinning the Tracks

It is ineffective and subjects the undercarriage to unnecessary wear. It affects grousers the most because
they undergo a grinding
action.
4) Avoid Favoring One Side

Avoid favoring one side because it causes uneven undercarriage wear. Operators should use symmetrical
operating patterns to produce balanced wear. If this is impossible or highly unproductive then left and right
rollers should be swapped periodically. Here are some
examples of preferred-side operations:
5) Frequent Turning in the Same Direction

Frequent 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 right
turns. For example, instead of doing an oval pattern, which requires one-sided turning, operators can do a
semi-oval pattern, which involves symmetrical turning. Another alternative is to do a figure 8 pattern, however
this is not recommended because it is inefficient and redundant.
- 85 -
7) Traveling Across a Lateral Slope
Traveling across a lateral slope produces heavy side-loading on the downhill track. It is best to avoid this
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 cracking,
bending, breaking and misaligning. If the job involves high impact
conditions then operate using lowest gears.
Minimize counter-rotation. It produces heavy side-loading

because one track travels forward while the other travels in
reverse. However, counter-rotation can be used effectively to
minimize preferred-side operations.
Avoid sharp turning, especially when traveling in high gears because it produces a lot of side loading. It is
better to make wide, large radius turns.
Park machine properly on a flat, dry surface. Parking a machine on a slope may cause roller seals to
become permanently deformed, especially in extremely hot or cold temperatures.
Minimize forward-reverse direction changes because it

causes root and radial wear.
- 86 -
3-3. Uncontrollable Variables
There are three groups of factors that affect undercarriage wear. These are earth conditions, terrain and job
application.
• Soil and underfoot condition (Earth conditions)

• Terrain condition
• Job application
1) Soil & Underfoot Condition

Earth conditions are abrasiveness, impact, packing, moisture, temperature and chemicals. These conditions
cannot be changed, but their adverse effects can be partially controlled by good maintenance
(1) Abrasiveness
Abrasiveness 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. It feels slick and moldable when
moist. Example: clay.
Moderately abrasive material has a moderate proportion of hard and sharp particles. It has a gritty texture
when moist. Example: loam.
Highly abrasive material has a high proportion of hard and sharp particles. It feels very coarse when
moist. Example: corral rock, sand.
- 87 -
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. All factors related to shortening the life of undercarriage component can not be explained
with only the analysis value of the soil. However , we can use the analysis value , as the first step of the
analysis of wear and utilize it for sales and service activities.
(%)
100
SiO2 +
Al2O3 Quartz
prophecy
Ba
Hard sandstone
Granite
Quartzite
Aa
Sand
Slate
50 Andesite
Conglomerate rock
Shale
Limestone
Basalt
Kanto loam
Tuff
Mica slate
0
Quantity of quartz in soil BL 5 AL 10
Life (Index)
(As per past data)
Remarks
1. The sample of the soil and rock must be about the size of two golf balls.
If plural types of soil (rock) are mixed together, samples must be taken for each type .
2. The element of soil must be analyzed in mass percentage (See JIS M8214, K0121).
- 88 -
Example of education
A customer who mainly works in district A decided to undertake a job in district B. A Komatsu salesman
heard that this customer had said "The 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 A and B,
and estimated the life of the undercarriage parts to be used in district B, on the basis of the life of the
under carriage parts of the customer used in district A.
Estimated life in district B (h) = Estimated life in district A X BL/AL

= 4000 x 3/5.7
= 2100 (h)
Actual life in district A : 4000 h

Aa, Ba : Analysis values of soil in districts A and b
AL, BL : Lives estimated from analysis values in districts A and B (Index)
The above salesman explained the above estimated life to the customer and succeeded in selling the
spare parts. Furthermore, since he notified 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
Impact 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. However, when bumpy or hard ground conditions obstruct penetration then
the weight of the machine becomes unevenly distributed, producing stress concentrations.
Impact causes structural damage such as bending, breaking, cracking, chipping and spilling. For crawler
dozers impact only contributes during travel, but for excavators it also contributes during stationary operation.
Earth conditions are described as low, moderate or high impact.
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
Packing is ground material that sticks to the moving parts of an undercarriage. It affects undercarriage
components in six different ways.
a) Serves as a cohesive agent that helps abrasive particles stick to moving components (eg. sand/clay
mixture). This greatly increases wear.
b) Material accumulates on bushings and in sprocket teeth. This produces a mismatch between sprocket
pitch and link pitch, which causes increased wear rates due to improper engagement. Reverse drive side
tip wear and bushing OD wear are two of the most significant types of wear resulting from this condition.
Packing can become so severe that it causes “popping”, which is a loud slapping sound produced when a
sprocket tooth arrives too early to grab the next bushing; instead it rides on top of the bushing and slips
when the next sprocket tooth makes contact.
- 89 -
c) Increases track tension which causes increased wear on all undercarriage components.
d) Binds rollers, which forces track links to slide across rollers instead of rolling across them. This produces
flat spots on rollers and accelerated link tread wear. In freezing conditions this problem is compounded
because frozen mud is very cohesive and difficult to remove.
e) May hide a component leakage problem that could otherwise be seen and corrected.
f) Takes away from available engine power by interfering with moving components. This reduces machine
performance and fuel economy.
(4) Moisture
Moisture causes considerable damage to undercarriage components. Ground material can have low,
moderate or high moisture content. Moisture adversely affects wear in four ways:
a) Combines with packing material to form a cohesive compound that sticks to components. Moist material
is moldable so it can easily fill gaps. After the packing material dries new material settles on top and forms
a new layer. In this way packing material is able to accumulate.
b) Increases wear by making material more abrasive.
c) Allows material to travel quicker by flowing into moving parts. Moist material can also flow past seals and
contaminate sealed components.
d) Causes rust and accelerates the effects of certain chemicals.
On the other hand, moisture also has these advantages:

1 Washes away packing material.
2 Softens material to make it more extrudable.
3 Dilutes some chemicals.
(5) Temperature
Effects of hot temperature:
1 Heat treated metals become weaker and more susceptible to wear
2 Seals can melt or become weak and cause leakage.
3 Chemical corrosion is accelerated.
Effects of cold temperature:

1 Metals become brittle and have lower resistance to impact.
2 Seals become rigid and lose resilience.
3 Moist packing material freezes.
4 Oil becomes viscous and is unable to properly lubricate moving parts.
- 90 -
(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
Crawlers do work on almost any kind of terrain. Let’s take a look at some common terrains and how they
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
happens to front rollers when working downhill. Also when working uphill the sprocket has to push harder
against the bushings to propel the machine forward. For this reason forward drive side wear is greater.
The opposite is true when traveling downhill; the sprocket doesn’t have to push as hard so forward drive
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
track shoe area. A crown produces high ground pressure on the inner sides and a depression produces
high ground pressure on the outer sides. This causes uneven wear, particularly between bushings and
sprocket.
Crown Depression
3) Job Application
Job application refers to the type of work that the machine is doing. Turning, dozing, grading, ripping, pulling,
side-hill cutting, excavating and loading are some of the most common job applications. Here we will briefly
discuss how they affect wear. Usually a job application cannot be changed, but it can be partially controlled
by choosing the correct machine outfit and employing a good method of operation.
- 91 -
(1) Turning
Turning wears flanges more than any other component. The above
diagram illustrates the wear pattern that occurs when the machine turns
left. Notice that the idler and front rollers (A & B) are pushed left and
scrape against right-side link faces. But rear rollers (C) 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
back of the machine. In ripping operations the front of the machine
can even raise off the ground. This produces greater wear on back
rollers and sprockets.
(4) Side-Hill Cutting

In 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. Front
and rear rollers are affected the most because they must support the
machine.
- 92 -
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)
- 93 -
4. Maintenance and Adjustment
4-1. Track Adjustment
The shoe tension remarkably affects the part wear and the strength. Therefore, it should be adjusted properly.
For details, refer to the item in “3. Variable that Affect Parts”.
In addition, for the measurement method and the proper value, refer to the Shop Manual of each model.
4-2. Idler Guide Adjustment

Unless the idler adjustment is proper, the idler strength is lowered and the uneven wear of the shoe and the
roller occurs. Therefore, adjust it to the proper value.
• D21-D85: Adjust by replacing the shim or the plate.
• D155-D575: Adjust by the build-up welding or the part replacement.
In addition, for the adjustment and the proper value, refer to the Shop Manual of each model.
4-3. Track Roller Rotation

Usually, as for the track roller wear, the end or the front portion wears fast and the center portion wears slowly.
Accordingly, in order to prolong the replacing life of whole track rollers, the track roller rotation is carried out.
As for the arrangement of the track roller, there are the single-flange and the double-flange. For these
information, refer to the arrangement in “2-1. Undercarriage Component, Structure & Function 3) Roller”.
In addition, in order to increase the efficiency of this work, the following are recommended.
1) The replacement work should be done at the time when the bushing is reversed or when the shoe is
replaced.
2) The average wear of the track rollers is less than 50%.
3) As the rough standard, the ratio of the maximum and the minimum wear is more than 1.3.
4-4. Field Action against Oil Leakage

Check the shoe oil leakage as follow.
1) Hot Pin Checking

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)
- 94 -
2) Method for Dealing with Initial Oil Leakage
Check for heat
(a) COLD: No action necessary

(b) WARM, Check oil
HOT
(a) Oil level normal: Check again after 500 hours
(b) Oil level low: Add oil
(c) Oil dirty: Change oil
(d) No oil Measure link pitch
(a) Elongation less Add oil

than 3 mm
(a) No oil leakage: No action necessary
(b) Oil leakage: Charge with grease
(b) Elongation more than 3 mm: Replace 1 set
(e) Dirty or Measure link pitch

sand in oil
(a) Elongation less than 3 mm: Fill with grease
(b) Elongation more than 3 mm: Replace 1 set
Note: If it is warm or hot for 5 - 10% of the times at the initial stage, remove from the chassis and consider
carrying out an overall oil check and repair in the workshop.
3) Procedure
(1) Preparation
a) When the track assembly is attached to the machine.
Raise the right side to set the machine at a 5-10 angle.
• Change oil at the small plug side.

• The small plug is installed to the right side of the
chassis. Therefore, set with the right side of the
chassis raise.
• The operation from step 2 is easier to carry out at the 5~10°
following points.
• For the right track: between the outside carrier rollers
• For the left track: at the windon portion of the idler on
the inside
b) When the track assembly is removed from the machine.

Stand the track assembly as the small plug upper side.
- 95 -
(2) Punch the small plug into pin oil hole with tool.
• The small plug hole is dia. 6. 30 mm
Min.
• Use a suitable bar (dia. 3-5).
• It is convenient to use the special tool to punch the plug.
• Do not remove the large plug with a drill. φ3-5 mm
Particles of rubber will be remain in the oil hole and often the Small plug
plug is not completely installed in.
(3) Check oil quantity and contamination

A
• Take a measure of C. B
• Check a contamination by oil on the dipstick.
i) Oil quantity Max. φ5
• C< > 50 mm ⇒ Install a plug

= A
• C > 50 mm ⇒ Fill oil B
ii) Oil contamination

• Color is dark, but have a fluidity ⇒ Fill oil
C
• Have an acrid smell of burning ⇒ Filling oil using vacuum
Oil
pump is recommended
• Earth and sand contaminating ⇒ Have a problem on sealing.
Press grease into the oil hole until grease stick out from the
<Vacuum up>
joint of the track links.
(4) Filling oil using vacuum pump (when required)

• Use the vacuum pump
Note: A hand pump can be used if the vacuum pump is not
Sealing rubber
available, or the case of filling oil only.
(A nozzle must be inserted deeply to prevent an <Filling up>
accumulation of air.)
Hand pump Sealing rubber

Nozzle
(5) Install the small plug into the pin oil hole with tool.
• It is convenient to use the special tool to install the plug.
• Install the plug until it is beyond the chamfered portion of the pin. If it is protruding outside the chamfered
portion of the pin, it is not installed in properly. (This will cause the plug to come out.)
0-3 mm
Special tool
Small plug
No good Good
- 96 -
4-5. Requirement of the Shoe Bolts Tightening
Unless the bolt tightening is proper, the bolt loosening, drop or breakage may occur. Therefore, tighten
properly.
As for the shoe bolt tightening, follow the below precautions.
In addition, as for installing and removing the shoe bolt, follow the below precautions.
1. Master Bolt removal

• Do not remove the bolts one by one. As for four bolts, loosen each one by one to two turns and make
sure that four bolts turn lightly. After that, remove them.
• When the bolts are turned forcibly in the state that the bolts do not turn lightly, the thread portion of the
bolt and the master link may be damaged.
2. Regular Bolt removal

• If the bolt can not be loosened by one turn (If the rotation torque does not become zero), do not turn it
forcibly and loosen the retaining bolts.
• If the bolt is turned forcibly in the state that the torque is not zero, the repair work is required.
3. Master bolt installation

• Until the mating surfaces of the master link contact tightly, all of four master bolts should be installed
manually.
• In the state that the mating surfaces of the master link do not contact tightly, if the bolts are tightened
forcibly, the thread portion of the bolt and the master link may be damaged.
When installing the shoe bolts

(1) Coat the thread of bolts with Anti-friction compound (LM-P).
(2) Tighten shoe bolts in order 1 - 4
(3) Initial tightening torque and tightening angle:
See shoe bolt torque table. (Next page)
(4) Do not use an impact wrench for the master link mounting bolt.
- 97 -
Shoe Bolt Tightening Torque Table
Bulldozer and Dozer Shovels

kg·m
Model Item kg.m ft-lbs Additional tightening angle

Shoe bolt 90° ± 10°
D20, 21-7/-8 6-8 44 - 57
Master link bolt 180° ± 10°
D31, 20
D31-21
13 - 17 95 - 122
D37, 5
D37-21
D39-21
18 - 22 130 - 159
D41A, E, P-6
D53-17, 18 18 - 22 131 - 159
Shoe bolt 50 - 60 362 - 434 120° ± 10°
D61E, P-12/-15
Master link bolt 31 - 39 225 - 282 180° ± 10°
Shoe bolt 50 - 60 261 - 318 120° ± 10°
D65-12/-15
Master link bolt 31 - 39 225 - 282 180° ± 10°
Shoe bolt 36 - 44 261 - 318 120° ± 10°
D85-21 –010°
Master link bolt 31 - 39 225 - 282 180° ±
–20°
31 - 39 (Single shoe) 225 - 282
D85-15, 15EO Shoe bolt 45 - 55 (Swamp shoe) 326 - 397 120° ± 10°
Master link bolt 31 - 39 225 - 282 –010°

180° ±
–20°
D155-2 40 - 50 290 - 361 +20°
Master link bolt 120° ±
+010°
D155A, AX-3 Shoe bolt 120° ± 10°
54 - 66 391 - 477
AX-5, AX-6 Master link bolt 180° ± 10°
Shoe bolt 72 - 88 456 - 556 120° ± 10°
D275-2, -5, 5EO
Master link bolt 45 - 55 326 - 397 180° ± 10°
Shoe bolt 140 - 170 1013 - 1229 -
D355-3, 5 +20°
Master link bolt 45 - 55 326 - 397 120° ±
+010°
Shoe bolt 126 - 156 911 - 1128 120° ± 10°
D375A-3, -5, 5EO
Master link bolt 63 - 77 456 - 567 180° ± 10°
Shoe bolt 72 - 88 521 - 636
D475A-3/-5, 5EO 180° ± 10°
Master link bolt 90 - 110 651 - 796
Shoe bolt 190 - 230 1375 - 1663 120° ± 10°
D575A-2, 3 +20°
Master link bolt 180 - 220 1302 - 1591 120° ±
+010°
Note: 1 kgm = 9.807 Nm

1 kgm = 7.233 ft-lbs
- 98 -
Hydraulic Excavator
kg·m
Model kg.m ft-lbs Additional tightening angle

PC60-6, 7
PC78US-6 10 - 14 73 - 101 90° ± 10°
PC78UU-6
PC100-6
PC120-6 18 - 22 131 - 159 90° ± 10°
PC138US-2
PC200-6, 7, 8
PC220-6, 7, 8 45 - 55 325 - 398 120° ± 10°
PC228US-3
PC300-6/-7, 7EO 36 - 44 131 - 159 120° ± 10°
PC400-6/-7, 7EO 36 - 44 261 - 319 120° ± 10°
PC600-6/-7, 8 72 - 88 521 - 636 120° ± 10°
PC750-6/-7, PC800/850-8 72 - 88 521 - 636 120° ± 10°
PC1100-6, PC1250-7/-8 126 - 154 911 - 1114 150° ± 10°
PC1600-1 63 - 77 456 - 556 120° ± 10°
PC1800-6, PC2000-8 63 - 77 456 - 556 120° ± 10°
Note: 1 kgm = 9.807 Nm

1 kgm = 7.233 ft-lbs
- 99 -
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. 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 permit
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.
- 100 -
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 bushing is then
moved from A to A1, A2 and A3. Where the sprocket A3 C2 A1 C1 A1 C A
center has been moved from (1) to (2), the bushing A1
in the sprocket C.L. will be moved to A2 in the tangen-
tial line of sprocket from the meshed condition with a
sprocket tooth causing the link (C) to move the posi- X
tion C1.
Where the link (C1) is in mesh with sprocket tooth, the
B
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
(2) (1)
an X-angle. Consequently, the bushing (A1) integrated
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
X The reverse order of the movements among the

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 C2 by
Y 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, during the
movement from A1 to A2, the bushing and the sprocket tooth face will slip in the meshed condition with
each other.
- 101 -
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 in
C2
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
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 inner
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 bush-
ing, giving the sliding wear between the sprocket tooth and bushing 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 al-
ready 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.
- 102 -
(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 accelerates 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.
- 103 -
CAUSE B: Where soil has stuck or packed to the sprocket tooth root.
Where a machine is operated in a terrain abundant in mois-

ture content or in clay easy to solidify, the mud is liable to stick
to the sprocket tooth lands. Continued operation of the ma-
chine with the soil left unmoved from the sprocket teeth will
allow the soil to accumulate further on the previous soil, in-
creasing 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 accumulated
between the bottom of the sprocket and the rear
track roller. If there is too much slack, "back jam-
ming" of the track link between the sprocket and
the roller occurs. The bushings slide up the re-
verse drive side to the tooth tip as they are pushed
from the sprocket.
When this occurs, adjust the tracks tension cor- Slide up
rectly.
- 104 -
2) Chain Tightness
(1) Reverse Travel
Recall that in reverse drive cycle the majority of torque trans- E D
fer 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 position F. These F
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 bush-
ing seated in position A. By the same chain reaction prin-
ciple, that bushing pulls on the one beside it, and so on. But
the reaction does not have far to go before it reaches embed-
ded shoes. In fact, the reaction only lasts a few link seg-
ments before tapering off. As a result, increased wear only A
occurs in a small section of track during forward travel.
- 105 -
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 other. 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 for-
ward and reverse directions, but wear is much greater in re-
verse. 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 1 on diagram). Therefore, this is the only internal turn that is critical because the
other three are not subjected to heavy loads
A
1
Front
Front
View from A
Wear occurs on this side
Driving force by sprocket
- 106 -
(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
A
Front
View from A
Wear occurs on this side
Driving force by sprocket
(4) Conclusion
• Because of track chain dynamics, internal wear always affects the one side of the pins and bushings,
regardless of travel direction. This means that only one side of the pin OD and bushing ID is worn
internally.
• Traveling in reverse causes increased wear on the front idler and all track chain components in that
section.
• Traveling in reverse causes so much more wear than forward travel.
- 107 -
5-3. 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 portion
and the sprocket lower portion. But, when the roller wear is remarkably increased, this clearance disap-
pears and the machine may vibrate during traveling.
In this case, by inserting the plate into the bogie portion, the clearance can be obtained.
Clearance
- 108 -
5-4. Distinguishing from the Non-Genuine Parts
1) General View
There are many makers which produce the undercarriage parts. When the customer replaces the undercar-
riage 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?
• Grease sealed track or S.A.L.T.?
• Is the track tightening method Master link or Master pin?
• High link or Low link?
• Is Shoe Heavy duty type or Standard type?
• Others
(3) Customers purchasing reason
• Price? (How much is the difference from Komatsu part price?)
• Delivery? (What is the difference from Komatsu?)
• Quality? (Has Komatsu problems?)
• Others (Are there any problems for DB countermeasure? Etc?)
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

• Because the Logo mark is stamped on Link, it is possible to distinguish. Refer to the attached figures.
• Komatsu • Non-Genuine • Non-Genuine
• As for Komatsu Link, always Komatsu mark is stamped on it. In addition, Part No. or L, R, etc are
stamped.
- 109 -
(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.A.L.T. and Grease Sealed Track are distinguished by the existence of the plug at the pin end. (There
is the plug on S.A.L.T.)
• As for Komatsu S.A.L.T., there are the plug at both pin ends. (Big plug and Small plug.) As for non-
Genuine, the plug exists at one end only. Accordingly, Komatsu track, it is necessary to ensure the
existence of plug at both ends.
• As for Master Link, it is basically S.A.L.T. track. But, as for non-Genuine, it is careful that Grease Sealed
Track may provide with Master Link.
Plug hole on both side Plug hole on one side

• Komatsu • Non-Genuine
- 110 -
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 better
is judged and treated.
(6) When judging whether UC parts are rebuilt, or abandoned, it is necessary to decide totally by consider-
ing 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 until
destruction.
5) When it is used up without the turning, refer to 2-2. Wear Limit.
- 111 -
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 Bush-
ing 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 surface
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 turning
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;
• Basically Seal is reused.
• Whether Seal is reused or not, confirm to “Reusable Guide”.
(4) When the operating hour is 2000 to 4000H;
• Seal is replaced.
(5) When the operating hour is more than 4000H;
• Seal is basically replaced at the interval of 4000H.
- 112 -
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
progresses due to uneven contact.
- 113 -
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 changed, Wide link tread
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 transmitted,
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.)
- 114 -
2-3. 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.
- 115 -
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

to destruction
Link wear SD
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.
- 116 -
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)
- 117 -
III. Selection Guide
1. Track Selection
Sealed and Lubricated Track Grease Sealed Track

Model
STD AR HD HDAR Tar sand STD
D21-7
D21-8
D31-20
D31-21
D37-5
D37-21
D39-21
D41-6
D53-17
D53-18
D61-12
D61-15
D65-12
D65-15
D85-21
D85-15, 15EO
D155-2
D155-3
D155-5, 6
D275-2
D275-5, 5EO
D355-3
D355-5
D375-3
D375-5, 5EO
D475-3
D475-5, 5EO
- 118 -
2. Shoe Selection
Proper Shoe Selection

Shoe should be selected depending on the user's habits, jobsites condition or the model salesman's recom-
mendation. 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 performance, 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)
- 119 -
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 Shoe life

ratio ratio
SMR SMR
- 120 -
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 machine
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. Therefore, 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)
- 121 -
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
General soil provides a large traction damage may occur. softness of the
excluding rocky force. The riding conform is a soil.
ground little inferior to the triple
(for bulldozer) 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

grouser shoe, the grouser
For rocky ground and plate portions of this
(for bulldozer) shoe are thicker and
stronger, providing high
bending resistance and
wear resistance.
3 Triple grouser shoe The three grousers have This shoe does not
Double grouser the same height, hence readily bite into the
shoe turning ability is good. ground, so the traction
Hard ground Good riding comfort is force is low.
Suitable for both obtained as compared
soft and hard with a single grouser
ground shoe.
(for hydraulic Rotating resistance is
excavator and low.
dozer shovel) Because three beams are
used, resistance to
bending is high.
4 Swamp shoe Because the cross- Unsuitable for ground Various widths
section of this shoe is an other than swampy are available to
arc, the ground contact ground. When used off suit the degree
area is large, and swampy ground, it is of softness of
buoyancy is easily liable to bend due to its the swampy
Swamp areas obtained. low strength. ground.
(for swamp dozer) This shoe is particularly
suitable for use in swamp
areas and areas with low
ground pressure. The
ground surface is not
damaged when the
machine travels over it,
so it is suitable for soil
compaction and leveling
work.
- 122 -
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 shoe grousers, this shoe does
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

in contact with the ground places will shorten the
is made of rubber, so the cutting life of the rubber.
machine can travel on (1) Rocky ground
Paved road paved roads without (2) Cold areas
Indoor work damaging the road (below -25°C)
surface. (3) Hot areas
Prevents noise when (above 65°C)
machine is traveling. 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
The sprocket removes damage may occur.
Soil which clogs any mud or soil collected
between the track rails,
so clogging of the track is
reduced.
- 123 -
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.
- 124 -
Shoe application
Small Model Middle Model

Shoe width Classifi- Shoe width Classifi-
Model Shoe type Model Shoe type
mm (in.) cation mm (in.) cation
D21A-7, 8 Single-grouser 300 (11.8) A D41A-6 Single-grouser 406 (16.0) A
340 (13.8) B 460 (18.1) A
D21P-7, 8 Swamp 510 (20.1) C D41E-6 Single-grouser 510 (20.1) A
Single-grouser 510 (20.1) C 560 (22.0) B
D21PL-7, 8 Swamp 700 (27.6) C D41P-6 Single-grouser 510 (20.1) B
D31A, E-20 Single-grouser 330 (13.0) A 700 (27.6) C
400 (15.7) B Swamp 700 (27.6) C
D31P-20 Single-grouser 400 (15.7) B D53A-17, 18 Single-grouser 460 (18.1) A
600 (23.6) C 510 (20.1) B
Swamp 600 (23.6) C D53P-17, 18 Single-grouser 860 (33.9) C
D31EX-21 Single-grouser 400 (15.7) A Swamp 860 (33.9) C
D31PX-21 Single-grouser 400 (15.7) A D61EX-12, 15 Single-grouser 600 (23.6) A
600 (23.6) C D61PX-12 Single-grouser 600 (23.6) A
Swamp 600 (23.6) C 860 (33.9) C
D37E-5 Single-grouser 330 (13.0) A Swamp 860 (33.9) C
400 (15.7) B 1100 (43.3) C
D37P-5 Single-grouser 400 (15.7) B D61PX-15 Single-grouser 860 (33.9) C
Swamp 600 (23.6) C Swamp 860 (33.9) C
D37EX-21 Single-grouser 400 (15.7) A 1400 (55.1) C
D37PX-21 Single-grouser 600 (23.6) B D65EX-12, 15 Single-grouser 510 (20.1) A
Swamp 600 (23.6) C 560 (22.0) B
D39EX-21 Single-grouser 460 (18.0) A 610 (24.0) B
510 (20.1) C 660 (26.0) C
D39PX-21 Single-grouser 635 (25.0) B D65PX-12, 15 Single-grouser 915 (36.0) C
700 (27.6) C Swamp 950 (37.4) C
Swamp 700 (27.6) C
- 125 -
Shoe application
Large Model Large Model

D85EX-15, Single-grouser 560 (22.0) A D275A-2 Heavy duty 610 (24.0) A
15EO 610 (24.0) B 710 (28.0) B
660 (26.0) C 760 (29.9) C
Heavy duty 560 (22.0) A D275A, Heavy duty 610 (24.0) A
610 (24.0) B AX-5, 5EO 710 (28.0) B
660 (26.0) C 760 (29.9) C
D85PX-15, Single-grouser 910 (35.8) C D355A-3, 5 Heavy duty 610 (24.0) A
15EO Swamp 910 (35.8) C 710 (28.0) B
D85A-21 Single-grouser 560 (22.0) A 760 (29.9) A
610 (24.0) B D375A-3 Heavy duty 610 (24.0) A, B
660 (26.0) C 710 (28.0) B
Heavy duty 560 (22.0) A 810 (31.9) C
610 (24.0) B D375A -5, Heavy duty 610 (24.0) A, B
660 (26.0) C 5EO 710 (28.0) B
D85E-21 Single-grouser 560 (22.0) A 810 (31.9) C
610 (24.0) B D475A-3 Heavy duty 710 (28.0) A
660 (26.0) C D475A-5, 810 (31.9) B
5EO
Heavy duty 560 (22.0) A 910 (35.8) C
610 (24.0) B D475A-3, 5 Heavy duty 810 (31.9) A, B
660 (26.0) C SUPER DOZER 910 (35.8) D
D85P-21 Single-grouser 910 (35.8) C D575A-2 Heavy duty 760 (29.9) A
Swamp 910 (35.8) C 810 (31.9) B
D155A-2 Single-grouser 560 (22.0) A 860 (33.9) B
610 (24.0) B 910 (35.8) C
660 (26.0) B D575A-2 Heavy duty 860 (33.9) B
710 (28.0) C SUPER DOZER 910 (35.8) C
Heavy duty 560 (22.0) A D575A-3 Heavy duty 860 (33.9) A, B
610 (24.0) B SUPER DOZER 910 (35.8) B
660 (26.0) B
D155A, AX-3 Single-grouser 560 (22.0) A
610 (24.0) B
660 (26.0) B
710 (28.0) C
Heavy duty 560 (22.0) A
610 (24.0) B
660 (26.0) B
D155A, Single-grouser 560 (22.0) A
AX-5, 6 610 (24.0) B
660 (26.0) B
710 (28.0) C
Heavy duty 560 (22.0) A
610 (24.0) B
660 (26.0) B
- 126 -
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
- 127 -
Shoe application
Small Model Middle Model

PC60-7 Triple-grouser 450 (17.7") A PC200-6 Triple-grouser 500 (19.7") A
600 (23.6") B PC200-7 600 (23.6") A
PC200-8
Swamp 700 (27.6") C 700 (27.6") B
PC78US-6 Triple-grouser 450 (17.7”) A 800 (31.5") C
600 (23.6”) B Swamp 860 (33.9") C
PC100-6 Triple-grouser 500 (19.7") A Rubber pad 600 (23.6") D
600 (23.6") B PC210-6 Triple-grouser 500 (19.7") A
700 (27.6") C 600 (23.6") A
Swamp 750 (29.5") C PC210-7/8 Triple-grouser 600 (23.6") A
Rubber pad 500 (19.7") D PC200-6 Triple-grouser 600 (23.6") A
PC120-6 Triple-grouser 500 (19.7") A 700 (27.6") B
600 (23.6") B 800 (31.5") C
700 (27.6") C PC200LC-6 Triple-grouser 600 (23.6") A
750 (29.5") C PC200LC-7 700 (27.6") B
PC200LC-8
Swamp 750 (29.5") C 800 (31.5") C
Rubber pad 500 (19.7") D 900 (35.4") C
PC130-6 Triple-grouser 500 (19.7") A Swamp 860 (33.9") C
Rubber pad 500 (19.7") D Rubber pad 600 (23.6”) D
PC150-5 Triple-grouser 500 (19.7") A PC200LC-6 Triple-grouser 600 (23.6") A
600 (23.6") B 700 (27.6") B
700 (27.6") C 800 (31.5") C
PC150HD-5 Triple-grouser 600 (23.6") A 900 (35.4") C
700 (27.6") B PC210LC-6 Triple-grouser 600 (23.6") A
800 (31.5") C PC210LC-7/8
900 (35.4") C PC220-6 Triple-grouser 500 (19.7") A
PC220-7 *600 (23.6") A
PC150NHD-5 Triple-grouser 600 (23.6") A
PC220-8
700 (27.6") B 700 (27.6") B
PC150SE-5 Triple-grouser 500 (19.7") A 800 (31.5") C
700 (27.6") B PC228US Triple-grouser 600 (23.6”) A
PC228USLC-3 700 (27.6”) B
720 (28.4") C
Swamp 800 (31.5") C 800 (31.5”) C
PC158US-2 Triple-grouser 550 (21.6”) A Swamp 860 (33.9”) C
700 (27.6”) B PC220LC-6 Triple-grouser 600 (23.6") A
PC220LC-7 700 (27.6") B
PC180LC-5 Triple-grouser 800 (31.5") C
PC220LC-8
600 (23.6") A 800 (31.5") C
700 (27.6") B PC230-6 Triple-grouser 600 (23.6") A
PC230LC-6
800 (31.5") C
PC250LC-6 Triple-grouser 600 (23.6") A
900 (35.4") C
700 (27.6") B
PC180LLC-5 Triple-grouser 600 (23.6") A
800 (31.5") C
700 (27.6") B
PC300-5 Triple-grouser 500 (19.7") A
800 (31.5") C
600 (23.6") A
900 (35.4") C
700 (27.6") B
PC180NLC-5 Triple-grouser 600 (23.6") A
750 (29.5") B
700 (27.6") B
800 (31.5") C
800 (31.5") C
850 (33.5") C
Standard shoe
For North America
- 128 -
Middle Model Large Model
PC300-6 Triple-grouser 600 (23.6") A PC600-6 Triple-grouser 600 (23.6") A
PC300LC-6 700 (27.6") B 750 (29.5") B
800 (31.5") C PC600LC-6 Triple-grouser 600 (23.6") A
PC300LC-7, 700 (27.6") B PC600-8 Triple-grouser 600 (23.6") A
7EO
800 (31.5") C 750 (29.5") B
PC350-6 Triple-grouser 600 (23.6") A PC600LC-8 Triple-grouser 600 (23.6") A
PC350LC-6 700 (27.6") B 750 (29.5") B
PC350-7 Triple-grouser 600 (23.6") A PC750-6, 7 Double-grouser 610 (24.0") A
PC350LC-7, 700 (27.6") B 710 (28.0") A
7EO
810 (31.9") B
700 (27.6") B PC800-8 Double-grouser 610 (24.0") A
800 (31.5") C 710 (28.0") A
PC400LC-6 Triple-grouser 600 (23.6") A 810 (31.9") B
700 (27.6") B 910 (35.8") B
800 (31.5") C PC750SE-6 Double-grouser 610 (24.0") A
900 (35.4") C 710 (28.0") A
PC400-7, Triple-grouser 600 (23.6") A 810 (31.9") B
7EO 700 (27.6") B 910 (35.8") B
800 (31.5") C 1010 (39.8") C
PC400LC-7, Triple-grouser 600 (23.6") A PC750LC-6, 7 Double-grouser 610 (24.0") A
7EO 700 (27.6") B 710 (28.0") A
800 (31.5") C 810 (31.9") B
900 (35.4") C 910 (35.8") B
PC450-6 Triple-grouser 600 (23.6") A 1010 (39.8") C
700 (27.6") B 1100 (43.7") C
800 (31.5") C PC800LC-8 Double-grouser 810 (31.9") B
PC450LC-6 Triple-grouser 600 (23.6") A 1010 (39.8") C
700 (27.6") B 1100 (43.7") C
PC450-7, Triple-grouser 600 (23.6") A PC800-6, 7 Double-grouser 610 (24.0") A
7EO 700 (27.6") B 710 (28.0") A
PC450LC-7, Triple-grouser 600 (23.6") A PC850-8 Double-grouser 610 (24.0") A
7EO 700 (27.6") B 710 (28.0") A
PC800SE-6 Double-grouser 610 (24.0") A
Standard shoe 710 (28.0") A
PC1000-1 Double-grouser 710 (28.0") A
910 (35.8") B
1010 (39.8") C
PC1000LC-1 Double-grouser 1010 (39.8") C
1210 (47.6") C
PC1000SE-1 Double-grouser 710 (28.0") A
PC1100-6 Double-grouser 700 (27.6") A
1000 (39.4") B
PC1100SP-6 Double-grouser 700 (27.6") A
PC1100LC-6 Double-grouser 1000 (39.4") B
1200 (47.2") C
- 129 -
Large Model
Shoe width Classifi-
Model Shoe type
mm (in.) cation
PC1250-7, 8 Double-grouser 700 (27.6") A
1000 (39.4") B
PC1250LC-7,8 Double-grouser 1000 (39.4") B
1200 (47.2") C
PC1600SE-1 Double-grouser 810 (31.8”) A, B
PC1800-6 1010 (39.8") C
PC2000-8
Standard shoe
- 130 -
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 perfor-
mance 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 recommendable.
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 recommend-
able 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.
• Example of jobsites (pictures)

• Job Site “A”
• Job Site “B”
• Job Site “C”
• Job Site “D”
• Job Site “E”
• Job Site “F”
• Job Site “G”
• Job Site “H”
- 131 -
Job Site “A”
D475A-5 Dual tilt
Full U Blade
Shoe width: 810 mm
• No-Rock
• Flat
• Long Dozing
Job Site “B”

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

• No-Rock
• Long Dozing Full U Blade
- 132 -
Job Site “C”
Shoe width: 910 mm
20 degree
D475A-5 Dual tilt

Full U Blade
• No-Rock
• Uphill Loading
Job Site “D”

Full U Blade Shoe width: 810 or 910 mm
• Uphill Loading
15 degree
L/U: ON-OFF x
10 degree
- 133 -
Job Site “E”
• No-Rock
20 degree • Downhill Loading
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
- 134 -
Coal blade (Local sourcing)
Job Site “G”
7710 mm
Coal blade pile
Shoe width: 910 mm
Job Site “H”
• Rocky Area
Shoe width: 710 mm (STD)
Semi U blade: 27.2 m3
- 135 -
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 under
the SAR (special specifications for specific environmental condition), this chart provides clearer criterion 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
- 136 -
Bulldozer
Small-middle Class
1. When using bulldozers, 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.
The part is presently available and applicable for use.
( STD : Standard spec.)
Types Full roller guard
Integral structure 3-part split type
full roller guard full roller guard
Local
add-on type
Applicable models A E P PL PLL A E P PL PLL
D20-7
D21-7
D31-20
D37-5
D39-21
D41-5, 3
D41-6
D50-18
D53-18, 17 STD
D58-1 STD
D60-12
D61-12
E P
D65-12 EX PX
Determination criterion for

different working environments
Rocks and soil containing The part is effective for prevention of catching pebbles.
boulders and gravel (A and E)
Sand and sandy soil The part is effective for prevention of pitch squeaking.
(A, E and P)
Claycy soil (P and PL) Be careful when using this part since the soil sets when dried. (Note 1)
Swamp (PL and PLL) The part is effective for prevention of snaking of the track.
(Prevents side sliding of the track shoes.) (Note 1)
The part is effective for prevention of disengagement of the track shoes.
Slopes The part is effective for prevention of disengagement of the track shoes.
(Prevents side-sliding of the track shoes.)
(Note 1) Although soil and sand tend to enter less, once they enter, they may not be easily discharged depending on the type
of soil, so make the choice in consideration of past experience with machines having been used in the subject area
and of the working environments of the machine.
- 137 -
Small-middle Class
Types Center and end End section track

section track guard
guard
Short length guard for

installation at the center section
Applicable models A E P PL PLL A E P PL PLL

D20-7 STD STD STD STD
D21-7 STD STD STD
D31-20 STD STD STD STD STD
D37-5 STD STD STD
D39-21 STD STD
D41-5, 3 STD STD STD
D41-6 STD STD STD
D50-18 STD
D53-18, 17 STD
D58-1 STD
D60-12 STD
D61-12 STD PPX STD
E P
D65-12 EX STD PX STD EEX
Rocks and soil containing The part is not suitable The part is not suitable
boulders and gravel
(A and E)
Sand and sandy soil No noticeable difference from use of
(A, E and P) the end-section only track guard
Although sand and soil tend to enter
Claycy soil (P and PL) The part is effective for prevention of
more, they can be easily discharged
disengagement or side-sliding of the
and this part is being employed.
track shoes
Swamp (PL and PLL)
Slopes The part is not suitable The part is not suitable
- 138 -
Large Class
Types Full roller guard

Bogie full roller Split type full
guard roller guard
Applicable models A E P A E P
D85-21 STD STD
D85-21B
D155-2 STD
D155-3
D155-5
D275-2 STD
D375-3
D475-3
D575-2
D575-2 Super
Rocks and soil containing The part is effective for prevention of catching pebbles.
boulders and gravel
(A and E)
Sand and sandy soil The part is effective for prevention of pitch squeaking.
(A, E and P)
Clayey soil (A, E and P) Be careful when using this part since the soil sets when dried. (Note 1)
Slopes The part is effective for prevention of disengagement of the track shoes.
(Prevents side-sliding of the track shoes.)
(Note 1) Although soil and sand tend to enter less, once they enter, they may not be easily discharged depending on the
type of soil, so make the choice in consideration of past experience with machines having been used in the
subject area and of the working environments of the machine.
- 139 -
Large Class
Types Bogie roller guard Add-on full roller

guard
Applicable models A E P A E P
D85-21
D85-21B
D155-2
D155-3 STD
D155-5 STD OPTION
D275-5 STD OPTION
D375-3, -5 STD OPTION
D475-3 STD
D575-2 STD
D575-2 Super STD
Rocks and soil containing Although sand and soil tend to enter The part prevents stones from
boulders and gravel more, they can be easily discharged entering between rollers on the rocky
(A and E) and this part is being employed. soil
Sand and sandy soil The part is effective for prevention of
(A, E and P) disengagement or side-sliding of the
track shoes.
Clayey soil (A, E and P)
Slopes The part is not suitable
- 140 -
Large Class
Type Center end section

track guard
Applicable models A E P
D85-21
D85-21B STD
D155-2
D155-3
D155-5
D275-2
D375-3
D475-3
D575-2
D575-2 Super
Soil containing boulders The part is not suitable
and gravel (A andm E)
Sand and sandy soil Although sand and soil tend to enter
(A, E andm P) more, they can be easily discharged
and this part is being employed.
The part is effective for prevention of
Clayey soil (A, E and P)
disengagement or side-sliding of the
track shoes.
Slopes The part is not suitable
- 141 -
Hydraulic Excavator
( STD : Standard spec. OPT : Optional spec.)
Types Without roller guard Center roller guard
Appicable models Std. Z Std, Z

PC60-7 STD OPT
PC70-7 STD OPT
PC75UU-3 STD
PC78US-5 STD
PC78US-6 STD OPT
PC78UU-6 STD
PC100-6 STD OPT
PC100L-6 STD
PC120-6 STD STD OPT OPT
PC128US-2 STD OPT
PC128UU-2 STD OPT
PC130-6 STD OPT
PC138US-2 STD OPT
PC150-5 STD
PC200-6 STD STD
PC200LC-6 STD STD
PC210-6 STD
PC210LC-6 STD
PC220-6 STD STD
PC220LC-6 STD STD
PC230-6 STD
PC230LC-6 STD
PC300-6 STD STD
PC300LC-6 STD STD
PC350-6 STD
PC350LC-6 STD
PC400-6 STD STD
PC400LC-6 STD STD
PC450-6 STD
PC450LC-6 STD
PC600-6 STD
PC600LC-6 STD
PC650-5 STD
PC650LC-5 STD
PC650SE-5
Soil containing The part is not suitable. Although sand and soil tend to enter more,
boulders and gravel they can be easily discharged and this part is
being employed.
Sand and sandy soil Although sand and soil tend to enter more,
they can be easily discharged and this part is
Clayey soil being employed.
Slopes The part is not suitable. The part is effective for prevention of disen-
gagement or side-sliding of the track shoes.
Z: Excel
(to be continued)
- 142 -
Hydraulic Excavator
Types Without roller guard Center roller guard
Appicable models Std. Z Std, Z

PC710-5
PC710SE-5
PC750-6 STD
PC750LC-6 STD
PC800-6
PC1000-1
PC1000LC-1
PC1000SE-1
PC1000SP-1
PC1100-6 STD
PC1100LC-6 STD
PC1600-1
PC1800-6 STD
Soil containing The part is not suitable. Although sand and soil tend to enter more,
boulders and gravel they can be easily discharged and this part is
being employed.
Sand and sandy soil Although sand and soil tend to enter more,
they can be easily discharged and this part is
Clayey soil being employed.
Slopes The part is not suitable. The part is effective for prevention of disen-
gagement or side-sliding of the track shoes.
Z: Excel
- 143 -
Types Center and final Full roller guard

roller guard
Appicable models Std. Z Std. Z

PC100-6
PC100L-6
PC120-6
PC130-6
PC150-5
PC200-6 OPT OPT
PC200LC-6 OPT OPT
PC210-6 OPT
PC210LC-6 OPT
PC220-6 OPT OPT
PC220LC-6 OPT OPT
PC230-6 OPT OPT
PC230LC-6 OPT OPT
PC300-6 OPT OPT
PC300LC-6 OPT OPT
PC350-6 STD
PC350LC-6 STD
PC400-6 OPT OPT
PC400LC-6 OPT OPT
PC450-6 STD
PC450LC-6 STD
PC600-6
PC600LC-6
PC650-5
PC650LC-5
PC650SE-5
PC710-5 STD
PC710SE-5 STD
PC750-6 OPT OPT
PC750LC-6 OPT OPT
PC800-6 STD
Soil containing The part is effective for prevention of snaking The part is effective for prevention of catching
boulders and gravel of the track. (Prevents side-sliding of the pebbles.
Sand and sandy soil track shoes.) (Note 1) The part is effective for prevention of pitch
The part is effective for prevention of disen- squeaking.
Clayey soil gagement of the track shoes. Be careful when using this part since the soil
sets when dried. (Note 1)
Slopes The part is effective for prevention of disen- The part is effective for prevention of disen-
gagement or side-sliding of the track shoes. gagement of the track shoes. (Prevents side-
sliding of the track shoes.)
Z: Excel
(Note 1) Although soil and sand tend to enter less, once they enter, they may not be easily discharged depending on the type of soil,
so make the choice in consideration of past experience with machines having been used in the subject area and of the
working environments of the machine.
(to be continued)
- 144 -
Types Center and final Full roller guard

roller guard
Appicable models Std. Z Std. Z

PC1000-1
PC1000LC-1
PC1000SE-1
PC1000SP-1
PC1100-6 OPT OPT
PC1100LC-6 OPT
PC1600-1 STD
PC1800-6 STD OPT
Soil containing The part is effective for prevention of snaking The part is effective for prevention of catching
boulders and gravel of the track. (Prevents side-sliding of the pebbles.
Sand and sandy soil track shoes.) (Note 1) The part is effective for prevention of pitch
The part is effective for prevention of disen- squeaking.
Clayey soil gagement of the track shoes. Be careful when using this part since the soil
sets when dried. (Note 1)
Slopes The part is effective for prevention of disen- The part is effective for prevention of disen-
gagement or side-sliding of the track shoes. gagement of the track shoes. (Prevents side-
sliding of the track shoes.)
Z: Excel
(Note 1) Although soil and sand tend to enter less, once they enter, they may not be easily discharged depending on the type of soil,
so make the choice in consideration of past experience with machines having been used in the subject area and of the
working environments of the machine.
- 145 -
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
prevention 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 countermea-
sure, 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
accelerated. 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 vicious
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 center
for releasing the soil is produced.
- 146 -
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.
Skid guard
- 147 -

KUC Procedure Manual Edition 12

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KUC Procedure Manual Edition 12

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SELA 1208-06

Added Model S/N

I. General Information ......................................................................................................................................... 6

II. Undercarriage Management ........................................................................................................................ 111

III. Selection Guide ............................................................................................................................................ 118

Inspection & Measurement Tool List

1. Names of parts of a multi-scale and adaptor.

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

Lock the 1st vernier

2 Then, set an adaptor on the bolt used for

3. Precautions for use of the multi-scale.

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 of

(3) Cautions in Measuring with The Ultrasonic Measurement Tool

4.2 Measuring each Component (see note). Follow

Note: Refer to “Ultrasonic Measuring Point Table” on

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

(1) Part Number

No. PART NUMBER DESCRIPTION Q'ty SIZE

Note: You can order components individually.

(3) Feature Shape for easy measurement

(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

(1) By Manual Tool

Obtain an average value by measuring more than 3 places on both right

Sealed and Lubricated Track

(1) Grouser height by the multi-scale

Grouser type shoe Swamp shoe

(2) Grouser height by the ultrasonic measurement tool

Grouser type shoe Swamp shoe

Type A Type B Type C

See Measuring point table.

• Warm and hot pin indicates loss of lubrication oil.

(2) Gap of Link Face

Gap of linked faces may be measured by the thickness gauge.

(3) Roller Flange Wear

Tread width by the multi-scale

(4) Shoe Bolt Loose

measurement type measurement type

measurement type measurement type

More than 50% B

Depth of worn out

A 50% point of a allowance

Conditions: Multi-scale Idler wear gauge Ultrasonic

to the right and find point B where it intersects the

FEATURE OF THE PROGRAM

Program Main Menu

Create New Report-1