JLG | Compact Crawler Booms X15JP - X430AJ - Rubber Track Maintenance/Replacement

Stop the machine on a flat and solid ground. Raise the machine off the ground safely and, if needed, support it by applying stable blocks or jack stands under the undercarriage frame. In correspondence with the undercarriage central roller, measure distance “A” of the bottom of the roller to the hard internal part of the rubber belt. Track tension is normal if measure “A” is between 10 and 15 mm. If the tension is not within the above measure, or too tight, please follow the procedure illustrated in the fol

As an alternative to the above-mentioned procedure, you can follow the procedure below. In this case, the check is less accurate and precise. However, effective for evaluating if the rubber track is too slack.

Stop the machine on a flat and solid ground. In correspondence of the upper skid of the carriage, measure distance of the bottom of the skid to the hard internal part of the rubber belt, lifting the belt manually. The track tension is normal if measure “A” is between 10 and 15 mm. If the tension is not within the above measure, or too tight, please follow the procedure illustrated in the following paragraph.

DANGER: THE GREASE CONTAINED IN THE HYDRAULIC TRACKS IS UNDER PRESSURE. IF THE VALVE TRACK TENSION IS TOO LOOSE, IT COULD BE EXPELLED UNDER THE EFFECT OF THE PRESSURE OF GREASE, SERIOUSLY ENDANGERING THE SAFETY OF THE OPERATOR. WHEN GRAVEL OR MUD IS STUCK BETWEEN THE SPROCKET TEETH AND TRACK LINKS, REMOVE IT BEFORE TIGHTENING THE TRACKS.

Stop the machine on a flat and solid ground. Raise the machine off the ground safely and, if needed, support it by applying stable blocks or jack stands under the undercarriage frame.

• To loosen the track, slowly unscrew grease release valve (1) counterclockwise for no more than a turn. If the grease does not start drain, slowly rotate the track. If also in this case the grease not emerges repeat the rotation of a lap of the valve and then slowly rotate the track. Repeat these steps until the grease begins to drain by unscrewing the valve of not more than one turn at a time.

DANGER: THE GREASE CONTAINED IN THE HYDRAULIC TRACKS IS UNDER PRESSURE. IF THE VALVE TRACK TENSION IS TOO LOOSE, IT COULD BE EXPELLED UNDER THE EFFECT OF THE PRESSURE OF GREASE, SERIOUSLY ENDANGERING THE SAFETY OF THE OPERATOR.

DANGER: BEFORE INSTALLING THE RUBBER TRACKS, MAKE SURE THAT YOU ARE ALWAYS IN SAFE CONDITIONS WITH THE MACHINE SUSPENDED FROM THE GROUND.

Machine Positioning

• Stabilize the machine on level ground

• Fully extend the undercarriage

• Remove the tracks

• Remove the key ignition, and a tag with warning do no start the machine.

Replacement Roller Lower Wheel and Tracks Adjuster

Disassembly

• Remove the nuts 2 on the lower roller.

• Remove the lower roller 3.

• Remove the front idler 5.

• Remove the tracks adjuster 4.

Assembly

• Fit the tracks adjuster 4.

• Install the front idler 5.

• Install the lower roller 3.

• Apply loctite 243 and torque the nuts 2 on the lower roller at 125 Nm (92 ft. lbs.)

Sprocket Removal

• Fully extend the undercarriage

• Remove the tracks

• Remove the key ignition, and a tag with warning do not start the machine.

• Remove screws 6.

• Remove the sprocket 7.

Gear Motor Removal

• Remove cover 9.

• Disconnect and tag the hydraulic hoses from the gear motor.

• Remove the valve 10 to access all the screws 11 (on single speed versions only).

• Remove the screws 11.

• Remove the gear motor 12

Gear Motor Installation

• Fix the screws 11.

• Install the valve 10

• Connect the Hydraulic hoses.

• Install the cover 9.

Sprocket Installation

• Instal the sprocket.

• Instal the screws 6.

TRACKS EXTENSION REMOVAL

• Stabilize the machine on level surface.

• Fully extend the undercarriage.

• Turn OFF the machine.

• Remove the key ignition, and a tag with warning do not start the machine.

• Open the hydraulic cap, and operate the function undercarriage extend/retract to discharge any residual pressure in the system.

NOTE: Before to install the undercarriage frame inspect the slide guides 9.

Inspecting The Mounting Bolts

NOTICE: TO COMPENSATE FOR SETTLING, THE BOLTS MUST BE RETIGHTENED WITH THE PRESCRIBED TIGHTENING TORQUE. RETIGHTENING MUST BE EXECUTED WITHOUT EXERTING ADDITIONAL EXTERNAL STRESS ON THE BOLTED UNION

Execution only by a specialist.

Special tools required

• Torque wrench

• Hydraulic clamping fixture

NOTICE: REGULARLY LUBRICATE THE SLEW DRIVES TO PROLONG THEIR SERVICE LIFE AND ENSURE SAFE OPERATION.

NOTICE: ALWAYS USE THE LUBRICANTS SPECIFIED IN THE ORDER DRAWING. IF USING OTHER LUBRICANTS PAY ATTENTION TO THE RELATIVE MIX ABILITY OF THE SUBSTANCES. THE STANDARD LUBRICANTS USED ARE “R.TECC NORPLEX LKP2” FROM RHENUS, OR THE GREASE "OPTIMOL LONGTIME PD0" FROM CASTROL. IF IN DOUBT, OR IF THERE IS NO SPECIFICATION ON THE DRAWING, CONSULT WITH OUR CUSTOMER SERVICE. USING THE WRONG LUBRICANT MAY CAUSE DAMAGE TO THE SLEW DRIVES AND REDUCE THE SERVICE LIFE. IN THIS CASE, ANY WARRANTY SHALL BE EXCLUDED. COMPLY

• If possible, use a central lubrication system to lubricate the raceway system. In this regard ensure that the hoses are filled with grease at commissioning and that the storage tanks are regularly topped up with grease

• An automatic re-lubricating system significantly facilitates re-lubrication for the raceway system and the toothing. Functional safety as well as wear behavior are is improved.

• Comply with the instructions in the operating manual provided by the respective manufacturer for lubrication of optional intermediate gear units, brakes, and motors.

• If it is evident that moisture has penetrated into the slew drive, or has been absorbed by the grease, you must re-lubricate more intensively.

Lubricating The Slew Drive

• Fresh lubricant.

• Lubricating nipple, bearing ring.

• Lubricating ring housing.

• In succession, press grease into all lubricatingnipples while simultaneously turning the slew drive all the way through, until a continuous collar of grease forms under at least one seal.

• Ensure that old lubricant can escape without obstruction.