service repair manual

1. SERVICE MANUAL
EXCAVATOR
JS140, JS200, JS205, JS215
EN - 9813/0400 - ISSUE 7 - 02/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2018 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

2. 15 - Engine
00 - Engine
00 - General
15 - 3 9813/0400-7 15 - 3
00 - General
Introduction ...................................................... 15-3
Health and Safety ........................................... 15-4
Technical Data ................................................. 15-5
Component Identification ................................. 15-6
Fault-Finding .................................................... 15-8
Drain and Fill ................................................. 15-20
Clean ............................................................. 15-20
Introduction
Basic Description
The Cummins mechanical fuel injected engine has
fuel ignited by compression ignition (C.I.). The engine
operates on a four stroke cycle.
The engine cylinders are arranged in-line. The
cylinder head assembly has one inlet valve and one
exhaust valve for each cylinder. Each valve has a
single valve spring.
The crankshaft gear turns the camshaft gear and fuel
injection pump gear. The gears are contained in a
casing at the front of the engine.
The camshaft operates the valves by means of cam
followers and push rods. The cam followers can be
accessed by means of a removable cover on the side
of the engine block.
Access for valve clearance maintenance is by means
of a removable cover for each individual cylinder.
The oil pump is also driven by the crankshaft gear.
A pulley mounted on the front of the crankshaft
incorporates a vibration damper. The pulley drives
a FEAD (Front End Accessory Drive) belt which in
turn drives fan, coolant pump and alternator pulleys.
The belt tension is set by an automatic tensioner
mechanism.
Engine efficiency, efficiency of emission controls, and
engine performance depend on adherence to correct
operation and maintenance recommendations.
Engine performance and efficiency also depend on
the use of recommended fuels, lubrication oils, and
coolants. Refer to: PIL 78-24.

3. 15 - Engine
00 - Engine
00 - General
15 - 4 9813/0400-7 15 - 4
Health and Safety
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
cool before servicing the unit.
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
Notice: The engine and other components could
be damaged by high pressure washing systems.
Special precautions must be taken if the machine is
to be washed using a high pressure system.Make
sure that the alternator, starter motor and any other
electrical components are shielded and not directly
cleaned by the high pressure cleaning system. Do
not aim the water jet directly at bearings, oil seals or
the engine air induction system.
WARNING! To bleed the injectors you must turn the
engine. When the engine is turning, there are parts
rotating in the engine compartment.Before starting
this job make sure that you have no loose clothing
(cuffs, ties etc) which could get caught in rotating
parts.When the engine is turning, keep clear of
rotating parts.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
Notice: Do not exceed the correct level of engine oil
in the sump. If the maximum is exceeded, the excess
must be drained to the correct level. An excess of
engine oil could cause the engine speed to increase
rapidly without control.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
WARNING! Hot oil and engine components can burn
you. Make sure the engine is cool before doing
this job.Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin cancer.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
WARNING! Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants.Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
accordance with local regulations. Use authorised
waste disposal sites.

4. 15 - Engine
00 - Engine
00 - General
15 - 5 9813/0400-7 15 - 5
Technical Data
For: Cummins 4BT 3.9C Tier 3
..................................................... Page 15-5
For: Cummins 6BT 5.9 Tier 3
..................................................... Page 15-5
(For: Cummins 4BT 3.9C Tier 3)
Table 28.
Description Data
Engine type Cummins 4BT 3.9
Emission compliance Tier 3
Number of cylinders 4
Nominal bore size 102mm
Stroke 120mm
Cylinder arrangement Vertical In-line
Combustion Cycle 4-stroke
Firing order 1-3-4-2
Compression ratio 17.5:1
Swept volume 3.92L
Valve clearance (cold) Inlet 0.25mm, Exhaust
0.51mm
Rotation (viewed from
front)
Clockwise
Weight (approximate) 350kg
Oil pressure At idle speed 0.7bar
(10.1psi). At rated speed
2.07bar (30.0psi)
(For: Cummins 6BT 5.9 Tier 3)
Table 29.
Description Data
Engine type Cummins 6BT 5.9
Emission compliance Tier 3
Number of cylinders 6
Nominal bore size 102mm
Stroke 120mm
Cylinder arrangement Vertical In-line
Combustion Cycle 4-stroke
Firing order 1-5-3-6-2-4
Compression ratio 17.5:1
Swept volume 5.88L
Valve clearance (cold) Inlet 0.25mm, Exhaust
0.51mm
Rotation (viewed from
front)
Clockwise
Weight (approximate) 440kg
Oil pressure At idle speed 0.7bar
(10.1psi). At rated speed
2.07bar (30.0psi)

5. 15 - Engine
00 - Engine
00 - General
15 - 6 9813/0400-7 15 - 6
Component Identification
The illustrations show a 6 cylinder variant. 4 cylinder
variants have the same main components and
component locations.
Figure 92.
B
A
C
E
F
D
G
H
J
GN
K
L
M
A Fuel filter / water separator B Connection - fuel inlet
C Fuel lift pump D Dipstick
E Connection - oil pressure switch F Engine mounting
G Fuel bleed pump H In-line fuel injection pump
J Engine fan K High pressure fuel lines
L Oil filler cap M Turbo air inlet
N Turbo exhaust outlet

6. 15 - Engine
00 - Engine
00 - General
15 - 7 9813/0400-7 15 - 7
Figure 93.
A
B
C
D
E
F
G
H
J
K
LM
W
X
V
U
T
S
R
P
Q
N
A Turbo air outlet B Engine air inlet
C Front lift bracket D Coolant outlet
E Automatic belt tensioner F Fuel pump drive cover
G Front gear cover H Fan pulley
J FEAD (Front End Accessory Drive) K Vibration damper
L Coolant pump M Coolant inlet
N Coolant heater return P Oil cooler
Q Oil drain plug R Alternator
S Oil filter T Starter motor and solenoid
U Flywheel housing V Fuel injection nozzles
W Rear lift bracket X Connection - fuel return

7. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 26 9813/0400-7 15 - 26
03 - Main Bearing
Introduction
In a piston engine, the main bearings are the
bearings on which the crankshaft rotates.
The bearings hold the crankshaft in place and
prevent the forces created by the piston and
transmitted to the crankshaft by the connecting rods
from dislodging the crankshaft, instead forcing the
crank to convert the reciprocating movement into
rotation.
Figure 94.
A
B
A Main bearing
B Crankshaft

8. 15 - Engine
15 - Camshaft
00 - General
15 - 29 9813/0400-7 15 - 29
00 - General
Introduction .................................................... 15-29
Check (Condition) .......................................... 15-30
Introduction
The relationship between the rotation of the camshaft
and the rotation of the crankshaft is of critical
importance.
Since the valves control the flow of the air/fuel
mixture intake and exhaust gases, they must be
opened and closed at the appropriate time during the
stroke of the piston.
For this reason, the camshaft is connected to the
crankshaft through a gear mechanism.
When the engine runs the crankshaft drives the
camshaft through the gears. The camshaft opens
and closes the inlet and exhaust valves through the
push rods in time with the four stroke cycle.

9. 15 - Engine
15 - Camshaft
00 - General
15 - 30 9813/0400-7 15 - 30
Check (Condition)
1. Inspect the camshaft gear teeth for signs of
damage or excessive wear.
2. Inspect the cam lobes for signs of excessive
wear, scoring or pitting.
3. Inspect the cam bearing surfaces for signs
of excessive wear, or scoring. Check that the
dimensions are within service limits.
4. Inspect the cam bearing surfaces inside the
crankcase for signs of excessive wear, or
scoring. Check that the dimensions are within
service limits.
5. Inspect the bearing surfaces of the tappets for
signs of excessive wear or damage. Check that
the dimensions are within service limits.
6. Inspect the tappet bores inside the crankcase for
signs of excessive wear or damage. Check that
the dimensions are within service limits.
7. If any of the camshaft bearings or lobes are worn
or damaged then the relative oil feed galleries
in the crankcase and camshaft may be blocked.
Make sure all oil ways are clear and free from
debris.

10. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 35 9813/0400-7 15 - 35
03 - Drive Belt
Health and Safety .......................................... 15-35
Check (Condition) .......................................... 15-36
Remove and Install ....................................... 15-36
Health and Safety
Notice: A drive belt that is loose can cause
damage to itself and/or other engine parts.

11. 15 - Engine
18 - Engine Belt
03 - Drive Belt
15 - 36 9813/0400-7 15 - 36
Check (Condition)
At the recommended service interval, visually inspect
the drive belt for damage.
1. Make the machine safe.
Refer to: PIL 01-03.
2. Stop the engine and let it cool down.
3. Renew the drive belt if it has cracks or if it is
frayed or has pieces of material missing.
Figure 95.
A
B
C
A Crack in belt
B Missing piece of belt
C Frayed belt
Remove and Install
Remove
1. Make the machine safe.
Refer to: PIL 01-03.
2. Remove the compressor belt (if installed).
Refer to: PIL 15-18-04.
3. Using a suitable ratchet inserted into the square
drive on the spring loaded tensioner, carefully
rotate the tensioner to release the tension on the
belt.
4. Lift the FEAD (Front End Accessory Drive) belt
from the engine and then release the tensioner.
5. Make sure that the fan pulley and idlers rotate
smoothly and that there is no excessive bearing
play. Replace defective pulleys and idlers.
Figure 96.
D
F
C
H
A
B
G
E
A Spring loaded tensioner
B Compressor belt
C Fan pulley
D Ratchet
E Idler 1
F FEAD belt
G Idler 2
H Square drive
Install
1. The installation procedure is the opposite of the
removal procedure.

12. 15 - Engine
18 - Engine Belt
04 - Compressor Belt
15 - 37 9813/0400-7 15 - 37
04 - Compressor Belt
Adjust ............................................................ 15-37
Remove and Install ....................................... 15-38
Adjust
1. Make the machine safe.
Refer to: PIL 01-03.
2. Use a suitable gauge to measure the belt tension.
Position the gauge at the position shown. The
tension should be as specified.
Weight/Force: 60 ± 2.5kg
3. If the tension is not correct, adjust the belt.
Figure 97.
E
D
C
A
B
A Screws 1 (x 2)
B Compressor
C Screws 2 (x 2)
D Measuring position - tension
E Belt
3.1. Loosen the two screws 1.
3.2. Loosen the two screws 2.
3.3. Rotate the compressor on the screws 1 to
increase or decrease the belt tension as
applicable.
3.4. Tighten the screws 1 and screws 2.
3.5. Start the engine and let it run at low idle for
the specified time period.
Duration: 15min
3.6. Stop the engine and remeasure the belt
tension.

13. 15 - Engine
18 - Engine Belt
04 - Compressor Belt
15 - 38 9813/0400-7 15 - 38
Remove and Install
Remove
1. Make the machine safe.
Refer to: PIL 01-03.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Remove the cooling fan.
4. Loosen the two screws 1.
5. Loosen the two screws 2.
6. Rotate the compressor on the two screws 1 so
that the tension on the belt is released.
7. When the tension is slack remove the belt from
the pulleys.
8. Inspect the belt for cracks, fraying or missing
pieces. If the belt is defective replace it with a
new one.
Figure 98.
E
F
D
C
A
B
A Screws 1 (x 2)
B Compressor
C Screws 2 (x 2)
D Drive pulley
E Belt
F Compressor clutch pulley
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. Tension the belt correctly.
Refer to: PIL 15-18-04.

14. 15 - Engine
21 - Oil Filter
00 - General
15 - 41 9813/0400-7 15 - 41
00 - General
Health and Safety .......................................... 15-41
Check (Level) ................................................ 15-42
Remove and Install ....................................... 15-42
Health and Safety
Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves
to prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants.Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
accordance with local regulations. Use authorised
waste disposal sites.
CAUTION! Oil will gush from the hole when the drain
plug is removed. Keep to one side when you remove
the plug.
CAUTION! The oil filter canister will contain some oil
which could spill out when you remove the canister.

15. 15 - Engine
21 - Oil Filter
00 - General
15 - 42 9813/0400-7 15 - 42
Check (Level)
Engine oil and oil filter replacement must be
completed in accordance with the service schedules.
Failure to replace the oil and filter at the
recommended interval could cause serious engine
failure.
We recommend that you check the oil level before
starting a cold engine. Park the machine on level
ground at the end of the working day, then check the
oil level the next day.
1. Make the machine safe. If the engine has been
running, let it cool before you check the oil level.
Refer to: PIL 01-03.
2. Get access to the engine.
3. Check that the oil level is between the two level
marks on the dipstick.
3.1. A false level will be shown on the dipstick if
the oil is hot.
4. If necessary, add the recommended oil through
the oil filler point.
Refer to: PIL 01-09-15.
Figure 99.
A
C
B
A Dipstick
B Level marks
C Oil filler point
Remove and Install
Drain the oil when the engine is warm as
contaminants held in suspension will then be drained
with the oil.
1. Remove the belly plate and get access to the
drain point for the engine oil from below the
machine.
2. Place a container of suitable size beneath the
drain point.
3. Remove the self sealing drain plug outer cover.
4. Fit the self sealing drain kit threaded union (with
attached pipe). Drain the engine oil into a suitable
container.
5. Remove the self seal drain kit, clean and refit the
outer cover. Do not over tighten the cover.
Figure 100. OIl drain - self sealing drain plug
A
B
A Drain plug outer cover
B Drain kit threaded cover (with attached pipe)
6. Unscrew the oil filter canister.
7. Clean the seal face of the filter head.
8. Smear the seal on the new filter canister with
clean engine oil.
9. Screw in the new filter canister (hand tight only).
10. Through the filler point, fill the engine with the
recommended oil to the MAX mark on the
dipstick. Wipe off any spilt oil, install the filler cap
and make sure it is secure.
11. Operate the engine at idle, make sure that the
oil pressure low warning light is extinguished
immediately after the engine starts. If it does not

16. 15 - Engine
21 - Oil Filter
00 - General
15 - 43 9813/0400-7 15 - 43
extinguish, stop the engine and investigate the
cause.
12. Check for oil leakage. When the oil has cooled,
check the oil level again, and if necessary top up
with clean engine oil.
Figure 101. Oil filter installation
A
A Oil filter canister

17. 15 - Engine
30 - Valve
00 - General
15 - 51 9813/0400-7 15 - 51
00 - General
Introduction .................................................... 15-51
Adjust ............................................................ 15-52
Introduction
The valve train system opens and closes the
valves with correct timing in relation to the piston
movements. The valve train system controls the flow
of air into the cylinders and out of the cylinders during
engine operation. The cylinder head assembly has
two valves for each cylinder. Each valve has one
valve spring. The ports for the inlet valve and the
exhaust valve are on the left side of the cylinder
head.
Each push rod has one end in a valve tappet and the
other end under a rocker arm.
The valves extend through the cylinder head. The
valves are made from a special metal to provide a
long service life. Damaged or worn valves cannot be
lapped or reground and must be replaced with new
ones. Each valve stem has an oil seal.
The Valve seat inserts are pressed into the cylinder
head. The seat inserts are also made from a special
metal to provide for a long service life. Damaged or
worn valve seat inserts can be removed and replaced
with new ones.
The valve moves along a steel valve guide. These
valve guides are installed in the cylinder head and
can be replaced.

18. 15 - Engine
30 - Valve
00 - General
15 - 52 9813/0400-7 15 - 52
Adjust
Figure 104.
A
G
H
J
E
F
D
E
C
B
A Valve clearance B Adjusting screw
C Locknut D Rocker arm
E Valve F Valve spring

19. 15 - Engine
30 - Valve
00 - General
15 - 53 9813/0400-7 15 - 53
G Camshaft H Cam follower
J Push rod
Checking Valve Clearance
The valve clearance is the gap between the rocker
arm toe and the top of the valve stem. Engine
performance and power output depend on this
setting being correct.
Refer to the applicable technical data for the correct
valve clearances. Refer to: PIL 15-00-00.
1. Make sure that the engine is cold - do not check
clearance when engine is hot.
2. Remove the rocker cover.
3. Turn the crankshaft until the valves of the cylinder
to be checked are "overlapping" - exhaust valve
about to close and inlet valve about to open.
4. Turn the crankshaft another revolution.
Angle: 360°
5. Both valves should be fully closed.
6. Insert a feeler gauge into the valve clearance
gap between the rocker arm toe and the top of
the valve stem. The correct setting is when the
correct thickness feeler gauge can be inserted
and removed from the gap but a slight drag
resistance is felt.
7. If the clearance is incorrect adjust the clearance.
8. Repeat step 6 for the other valve in the pair.
9. Repeat the steps 3 to 8 for each pair of valves.
Adjusting the Valve Clearance
1. Turn the crankshaft until the valves of the cylinder
to be adjusted are "overlapping" - exhaust valve
about to close and inlet valve about to open.
2. Turn the crankshaft another revolution.
Angle: 360°
3. Both valves should be fully closed.
4. Slacken the adjusting screw locknut.
5. Turn the adjusting screw to increase or decrease
the clearance gap.
6. Insert a feeler gauge into the valve clearance
gap between the rocker arm toe and the top of
the valve stem. The correct setting is when the
correct thickness feeler gauge can be inserted
and removed from the gap but a slight drag
resistance is felt. Tighten the locknut.
7. Check the clearance again with a feeler gauge
as in step 6
8. Repeat the above steps for each pair of valves
which require adjustment.

20. 27 - Driveline
36 - Track
00 - General
27 - 5 9813/0400-7 27 - 5
00 - General
Introduction ...................................................... 27-5
Component Identification ................................. 27-6
Check (Condition) ............................................ 27-7
Introduction
The left and right track assemblies are installed on
the machine undercarriage.
Each track consists of a chain and a series of bolt on
shoe plates.
The gearbox sprocket is engaged with the chain and
transmits the drive from the track motor gearbox to
the chain.
The chain runs on several bottom rollers mounted
on the undercarriage. The rollers carry the weight
of the machine. Top rollers keep the chain clear of
the undercarriage. The number of top and bottom
rollers is dependent on the machine variant. A track
guide prevents the chain being forced sideways off
the bottom rollers.
The chain runs on an idler wheel at the opposite end
of the carriage. The idler wheel bracket mounting can
slide forwards and backwards in the undercarriage.
This allows the chain to be tensioned using a grease
cylinder. A spring loaded recoil unit acts as a shock
absorber. This allows the idler wheel to move in the
carriage if the track is subjected to shock loads, when
travelling over rough ground for example.
Figure 131. Typical track installation
E
D
B
A
C
F
G
A Top roller
B Shoe plate
C Idler wheel
D Undercarriage
E Bottom roller
F Gearbox sprocket
G Track motor gearbox

21. 27 - Driveline
36 - Track
00 - General
27 - 6 9813/0400-7 27 - 6
Component Identification
Figure 132. Typical track installation
F M E
D
G
K J H
C
A B
L
A Top roller B Shoe plate
C Idler wheel D Undercarriage
E Bottom roller F Gearbox sprocket
G Track motor gearbox H Idler wheel bracket mounting
J Recoil unit K Grease cylinder
L Track guide (if installed) M Chain

22. 27 - Driveline
36 - Track
00 - General
27 - 7 9813/0400-7 27 - 7
Check (Condition)
The track assembly is subjected to high forces and
operates in a harsh environment. To enable the
maximum service life, check the condition of the
assembly at regular intervals as follows.
1. Clean off mud and debris from the track and
undercarriage.
2. Check that the track tension is correct.
Refer to: PIL 27-36-03.
3. Check the gearbox sprocket teeth for excessive
wear.
3.1. Make sure the fixing bolts are installed and
tightened to the correct torque.
4. Check the steel track chain for defective pins,
bushes and links.
4.1. Measure the wear status.
Refer to: PIL 27-36-03.
5. Check that the shoe plates are not excessively
worn or distorted.
5.1. Make sure the fixing bolts are installed and
tightened to the correct torque.
6. Check the condition of the top and bottom rollers.
6.1. Check that the wearing diameters are within
the wear limits.
6.2. Check that the fixing bolts are installed and
tightened to the correct torque.
6.3. Check that there are no oil leaks.
6.4. Check that the rollers rotate with the chain.
7. Check the condition of the track guide (if
installed).
7.1. Check that it is free from distortion and
excessive wear.
7.2. Check that the fixing bolts are installed and
tightened to the correct torque.
8. Check the condition of the idler wheel.
8.1. Make sure that the idler wheel rotates with
the chain.
8.2. Check the wearing diameter for excessive
wear.
8.3. Check that there no oil leaks.
8.4. Check that the axle mounting bracket fixing
bolts are installed and tightened to the
correct torque.
9. Check the condition of the tensioner / recoil unit.
9.1. Make sure the recoil spring is free from
packed material such as soil, clay and sand.
9.2. Make sure the recoil spring is not broken.
9.3. Check that the grease cylinder seals and
check valve maintain the pressure in the
grease cylinder.
If the track components show signs of premature
wear or failure, investigate the operating conditions.
1. Make sure the machine is being operated as
intended, especially with the track motors at the
rear when travelling or excavating.
2. Make sure that the applicable maintenance
schedule is being followed.
Refer to: PIL 78-24.
3. Make sure that the correct shoe plates are
installed for the operating environment.
4. Make sure that packed material is being removed
from the undercarriage when necessary.
Excessive packing of materials such as soil, clay
and sand causes premature wear of the track
and undercarriage components.
5. If the machine is stored in a harsh environment,
such as wet freezing conditions, make sure the
operator follows the correct procedures.
Refer to: PIL 27-36-03.

23. 27 - Driveline
36 - Track
03 - Steel Track
27 - 8 9813/0400-7 27 - 8
03 - Steel Track
Introduction ...................................................... 27-8
Component Identification ................................. 27-9
Check (Condition) .......................................... 27-10
Adjust ............................................................ 27-17
Remove and Install ....................................... 27-18
Store and Recommission .............................. 27-20
Introduction
The steel track consists of track links which are
connected using pins and bushes to form a chain.
The ends of the chain are connected by means
of a removable master pin. This enables removal
and installation of the track. The master pin has a
tapered recess in the centre of its diameter to enable
identification.
The steel track is a wear item. When it is at the
end of its service life it must be replaced. It is
possible to extend the service life of the pins and
bushes by dismantling the chain and assembling with
the pins and bushes rotated to present new wear
surfaces, this is known as 'turning'. The time involved
may make this uneconomical, it may be more cost
effective to replace the chain assembly with a new
one.
Figure 133.
A
A Steel track chain

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25. 27 - Driveline
36 - Track
03 - Steel Track
27 - 9 9813/0400-7 27 - 9
Component Identification
The illustration shows a chain link with a normal pin,
bush and sealing washers. The single master pin,
master bush and spacer assembly is also shown.
Figure 134. Typical track link assembly
G
F
D C J
AB
E
H
H
E
D
C
A
B
A
E
G
F
F
E
A Spacers (master bush) B Master bush
C Master pin D Pin
E Links (right) F Seal washers
G Bush H Links (left)
J Tapered recess

26. 27 - Driveline
36 - Track
03 - Steel Track
27 - 10 9813/0400-7 27 - 10
Check (Condition)
Measuring the Normal Wear Status
To check the normal wear status of the steel track
chain proceed as follows.
1. Make the machine safe.
Refer to: PIL 01-03.
2. Clean the tracks and undercarriage. It will not be
possible to get accurate wear measurements if
there is an accumulation of dirt and debris on the
components.
Refer to: PIL 01-33.
Link Rail Surface Wear Status
As the link rail surface wears the distance between
the rail and the underside of the shoe plate reduces.
Figure 135.
A
A Link rail surface wear area
Measure the distance as follows.
1. Use a suitable depth gauge to make the
measurements as shown.
Figure 136.
D
A B
C
A Shoe plate underside
B Track pin
C Track link - rail wear face
D Depth gauge
1.1. Position the gauge on the outside of the
links in-line with the ends of the track pins.
1.2. Make sure the gauge is flat against the rail
surface and perpendicular to the underside
of the shoe plate
1.3. Take measurements to the specified degree
of accuracy.
Length/Dimension/Distance: 0.25mm
2. Compare the measurements with the track
link wear guide given in Technical Data (PIL
27-36-03).
2.1. Use the data to obtain the wear percentage
value.
Track Pitch (Internal Wear Status)
As the internal mating faces of the track pins and
bushes wear, the pitch distance of the track chain
links increases. Measure the distance as follows.
1. Use an old track pin or suitable bar to stretch the
chain as shown.
1.1. Place the pin on the gearbox sprocket and
slowly operate the track motor so that the
chain is tensioned. Do not operate the track
motor past the position shown. Get the help
of an assistant.
2. Use a suitable tape measure calibrated in the
increments specified and measure the distance
over four chain links.
Length/Dimension/Distance: 0.5mm