Komatsu has long been a prominent name in the construction equipment industry, offering durable machinery with advanced technologies. The Komatsu 85E, a powerful machine used primarily in heavy-duty tasks like excavating and grading, has earned a reputation for its efficiency. However, as with any complex equipment, the transmission system can face issues, particularly when it comes to the oil. This article delves into the transmission oil problems that Komatsu 85E owners often encounter, offering insight into potential causes and solutions.
Overview of the Komatsu 85E
The Komatsu 85E is part of Komatsu's well-regarded lineup of excavators, designed for high-performance tasks in tough working environments. Known for its robust hydraulic systems and efficient fuel usage, it has become a staple in the construction and mining industries. With a focus on long-term reliability, the 85E is built to handle heavy workloads, but like all machinery, it is subject to wear and tear.
The transmission system in the Komatsu 85E plays a crucial role in the machine's ability to move and operate its various components effectively. The oil within this system is essential for lubrication, cooling, and smooth operation. Problems with the transmission oil can affect the machine's performance, causing both immediate and long-term issues if not properly addressed.
Common Transmission Oil Problems

1. Low Transmission Oil Level
   • Symptoms: Erratic shifting, hesitation when the machine is put into gear, or difficulty in maintaining a consistent speed.
     
   • Cause: Over time, the transmission fluid can slowly leak due to wear and tear on seals or hoses. External damage or poor maintenance practices, such as not properly checking oil levels, can also result in low fluid.
     
   • Solution: Always regularly check the oil level to ensure it's within the manufacturer's recommended range. If the oil is low, top it up with the appropriate transmission fluid. Be sure to inspect for any leaks in the transmission system, paying close attention to seals, hoses, and connections. If any leaks are found, replace the damaged parts promptly to prevent further fluid loss.
     
2. Contaminated Transmission Oil
   • Symptoms: Poor shifting, slipping gears, or overheating. The oil may appear dark or have a burnt smell.
     
   • Cause: Contaminants such as dirt, metal shavings, or water can get into the transmission oil, either due to a poor seal or improper maintenance. The oil itself may also degrade over time due to extreme temperatures and heavy use.
     
   • Solution: Drain the old transmission oil and replace it with fresh oil that meets the specifications for the Komatsu 85E. Additionally, replace the oil filter to ensure that no contaminants remain in the system. In severe cases, a full transmission flush may be necessary. Regularly changing the oil and performing routine maintenance can help prevent contamination buildup.
     
3. Overheating of Transmission Oil
   • Symptoms: The machine may exhibit sluggish performance, slipping gears, or overheating alarms.
     
   • Cause: Insufficient oil flow due to clogged lines or filters can cause the oil to overheat. Heavy-duty use in high temperatures, especially in demanding environments, can also strain the transmission, raising the oil temperature.
     
   • Solution: Ensure that the cooling system for the transmission is functioning properly. Clean or replace any clogged filters and check the oil cooler for blockages. Make sure the oil is of the right viscosity and that it is regularly replaced to maintain cooling efficiency. If necessary, install an additional cooler to reduce transmission temperatures during extended operation.
     
4. Incorrect Oil Type
   • Symptoms: Irregular shifting, difficulty engaging gears, or overheating.
     
   • Cause: Using the wrong type of transmission fluid can result in improper lubrication and cooling, which can affect the overall performance of the transmission system.
     
   • Solution: Always use the oil type recommended by the manufacturer. The Komatsu 85E requires a specific transmission fluid designed for its hydraulic and transmission system. Refer to the user manual for the correct fluid specifications, and avoid mixing different types of oils.
     
5. Worn or Damaged Seals
   • Symptoms: Leaking transmission fluid, inconsistent shifting, and poor machine performance.
     
   • Cause: Over time, seals in the transmission system can wear down or get damaged, allowing fluid to escape.
     
   • Solution: Inspect the seals around the transmission area regularly. If there is noticeable fluid leakage or performance issues, check the seals for cracks, tears, or other damage. Replace any damaged seals immediately to prevent further fluid loss and potential transmission failure.
     

• Regular Oil Checks: Check the transmission oil level regularly, especially before and after heavy use. This simple step can help identify leaks early and prevent serious damage.
  
• Oil Changes: Follow the manufacturer’s recommendation for oil change intervals. Regular oil changes prevent contamination buildup and ensure that the transmission remains properly lubricated.
  
• Monitor Temperature: Keep an eye on the transmission temperature, especially when working in hot climates or under heavy loads. High temperatures can lead to oil breakdown and transmission damage.
  
• Inspect Seals and Hoses: Regularly check all seals and hoses in the transmission system for wear and tear. Damaged parts should be replaced promptly to avoid fluid leaks and potential system failures.
  
• Use Recommended Fluids: Always use the type and grade of transmission fluid specified by Komatsu for the 85E model. This ensures that the fluid is compatible with the machine’s hydraulic and transmission systems.
  

Berkeley Pump History and the 8x6 Model
Berkeley Pumps, a division of Pentair, has been manufacturing centrifugal pumps since the 1930s. Known for their rugged construction and high-volume water handling, Berkeley pumps are widely used in agriculture, dredging, mining, and industrial dewatering. The 8x6 SAE-mounted centrifugal pump is a popular configuration, referring to an 8-inch discharge and 6-inch suction diameter. These pumps are often paired with diesel engines via SAE bell housings and flywheel couplings, making them ideal for mobile and remote applications.
The 8x6 model is typically used in dredging barges, flood control, and high-capacity irrigation. With impeller sizes ranging from 12 to 14 inches and flow rates exceeding 3,000 gallons per minute, the pump is engineered for continuous-duty operation. Berkeley’s modular design allows for field repairs and component swaps, but spline failures remain one of the more challenging issues.
Understanding Spline Coupling and Shear Failure
The spline shaft is the mechanical interface between the pump and the engine flywheel. It transmits torque from the engine to the impeller, allowing water to be accelerated through the volute. A typical spline shaft has multiple teeth (or splines) that engage with a female coupling on the flywheel.
Terminology Note: “Spline” refers to a series of ridges or teeth on a shaft that fit into grooves on a mating part, allowing torque transmission. “Shear failure” occurs when the material is overloaded and breaks along a plane perpendicular to the applied force.
In the case of the Berkeley 8x6, the spline shaft sheared off halfway—losing 2 inches of its 4-inch engagement length. This type of failure is often caused by:

• Misalignment between engine and pump
  
• Excessive vibration due to worn bearings
  
• Overloading during startup or cavitation
  
• Corrosion weakening the spline interface
  

• Removing the impeller
  
• Pressing out the shaft
  
• Replacing bearings and seals
  
• Rebalancing the assembly
  

• Spacer Fabrication
  Installing a precision-machined spacer behind the flywheel to push the female spline outward, engaging the remaining good portion of the male spline. This requires concentric alignment and dynamic balancing to avoid vibration.
  
• Spline Extension Adapter
  Through-bolting a female spline extension onto the flywheel, allowing deeper engagement with the shaft. This method must ensure torque transmission without introducing eccentric loads.
  
• Flywheel Replacement
  Sourcing a longer flywheel or custom Hayes coupling that extends further into the pump shaft. Hayes Manufacturing offers SAE flywheel couplings with various depths and spline configurations.
  
• Welding Repair
  Attempting to weld new spline teeth onto the shaft. This is generally discouraged due to heat distortion, metallurgical incompatibility, and risk to adjacent components—especially if the flywheel includes vulcanized rubber dampers.
  

• Measuring shaft runout with a dial indicator
  
• Inspecting bearing races for pitting or discoloration
  
• Checking impeller clearance against the volute
  
• Verifying concentricity between engine and pump mounts
  

• New shaft and bearing kit: $1,000–$1,500
  
• Used pump with low hours: $2,000–$3,000
  
• New pump: $9,000–$10,000
  
• Custom spacer or adapter: $300–$600 (plus labor)
  

• Availability of parts
  
• Urgency of operation
  
• Access to machining tools
  
• Long-term reliability needs
  

Motor graders are essential heavy machinery in the construction, road maintenance, and mining industries. Among the various brands of motor graders, Galion has long been recognized for its reliability and performance, particularly in the production of older, mechanically-driven models. However, like any piece of heavy equipment, they are not without their issues. One of the most common challenges with older Galion motor graders is engine performance problems. This article aims to provide a comprehensive understanding of the typical engine problems, their causes, and troubleshooting solutions.
Understanding the Galion Motor Grader
Galion, a historic manufacturer of motor graders, has been producing these machines for many years, primarily focusing on the construction and roadwork markets. The company’s legacy dates back to the early 1900s, and it is widely regarded for its sturdy, dependable graders. Despite being out of production for several decades, Galion graders are still in use today, particularly in smaller fleets or for specialized tasks, due to their reliability and simplicity compared to modern models.
The Galion motor grader, like other graders, is designed for precise grading and leveling of surfaces, whether it's for roads, airstrips, or construction sites. The machines typically feature a six-wheeled configuration, with a large adjustable blade mounted in the middle, which can be manipulated to the desired angle for grading purposes.
Common Engine Issues with Galion Motor Graders
Engine problems are among the most frequent complaints from Galion motor grader owners, especially as these machines age. The most common issues include:

1. Engine Crank No Start
   • A "no-start" condition can be caused by various factors, including a dead battery, faulty fuel supply, or electrical issues such as bad ignition connections.
     
   • Cause: Corroded terminals, dead battery, malfunctioning starter motor, or fuel system issues.
     
   • Solution: Ensure the battery is charged and the terminals are free of corrosion. Inspect the starter motor, fuel lines, and filters for damage or blockages. In some cases, it may be necessary to check the ignition switch and wiring for loose or broken connections.
     
2. Overheating Engine
   • An overheating engine can be disastrous if left unchecked, leading to severe engine damage.
     
   • Cause: Insufficient coolant levels, clogged radiators, or malfunctioning thermostats.
     
   • Solution: Regularly check coolant levels and ensure the radiator is free of debris. If overheating persists, inspect the thermostat for proper function. Flushing the cooling system and replacing worn components may be necessary to restore normal operation.
     
3. Low Power Output
   • If the grader engine struggles to maintain power, it can hinder productivity and even damage other components.
     
   • Cause: Clogged air filters, fuel delivery issues, or improper fuel quality.
     
   • Solution: Replace air filters regularly to maintain optimal air intake. Inspect the fuel system for issues such as clogged filters or fuel injectors. If the fuel supply is contaminated or low-grade, this can also reduce engine performance.
     
4. Excessive Smoke or Emissions
   • Black or white smoke from the exhaust is a sign that the engine is not operating efficiently.
     
   • Cause: Unburned fuel, oil leaks, or faulty injectors.
     
   • Solution: Clean or replace fuel injectors if they are clogged or malfunctioning. Ensure proper oil levels and use the correct oil grade for the engine. A clogged air filter can also cause improper combustion, leading to smoke. If the problem persists, perform a full diagnostic check on the engine’s fuel system.
     
5. Engine Misfires or Rough Running
   • Misfiring or a rough idle can indicate problems with the engine’s ignition system or fuel delivery.
     
   • Cause: Faulty spark plugs, dirty fuel injectors, or fuel contamination.
     
   • Solution: Check and replace spark plugs if necessary. Inspect fuel injectors and clean or replace them if they are clogged. Additionally, verify that the fuel being used is clean and free of impurities that could affect combustion.
     

• Daily Inspections: Before starting your motor grader, perform a daily check of key components. Look for any visible leaks, worn-out belts, and inspect fluid levels (oil, coolant, hydraulic fluid).
  
• Air Filter Maintenance: Regularly check and replace air filters to avoid dirt and debris entering the engine, which can cause excessive wear and reduced performance.
  
• Fuel System Care: Replace fuel filters at regular intervals and ensure the fuel supply is clean and uncontaminated. Water in the fuel can lead to poor combustion and engine misfires.
  
• Cooling System: Keep the radiator and cooling system free of debris, and flush the system periodically. Check the thermostat for proper function, as a faulty thermostat can lead to overheating.
  
• Lubrication: Ensure that the engine’s moving parts are properly lubricated with high-quality engine oil. Regular oil changes are essential to prevent excessive wear.
  

The Importance of Degreasing in Heavy Equipment Maintenance
Heavy equipment such as excavators, bulldozers, graders, and loaders operate in environments where grease, oil, hydraulic fluid, and grime accumulate rapidly. Degreasing is not just about aesthetics—it’s a critical maintenance task that affects cooling efficiency, component inspection, and long-term reliability. A clean machine allows technicians to spot leaks, cracks, and wear early, preventing costly failures.
In industries like mining, construction, and forestry, degreasing is often performed weekly or monthly depending on usage intensity. A 2023 survey of fleet managers in North America revealed that 78% of unscheduled downtime events were linked to overlooked leaks or contamination—issues that could have been caught with regular cleaning.
Types of Degreasers and Their Applications
Degreasers fall into several categories, each suited to specific tasks and materials:

• Butyl-Based Degreasers
  Effective against petroleum-based grime such as motor oil and hydraulic fluid. These water-soluble cleaners break down hydrocarbons and are commonly used in automotive and industrial settings.
  
• Non-Butyl Degreasers
  Designed for organic residues like animal fats and soap scum. Less common in heavy equipment but useful in food-grade environments or mixed-use facilities.
  
• Solvent-Based Degreasers
  Powerful cleaners that dissolve grease instantly. Often flammable and toxic, requiring ventilation and protective gear. Best for engine bays and metal components.
  
• Biodegradable Degreasers
  Eco-friendly options that balance cleaning power with environmental safety. Ideal for outdoor use near water sources or in regulated zones.
  
• Heavy-Duty Industrial Degreasers
  Formulated for thick, baked-on grime. These are typically concentrated liquids or gels and require dilution. Examples include Zep Industrial Purple Cleaner and 3D Grand Blast.
  

• Simple Green Pro HD
  Non-corrosive, biodegradable, and safe on painted surfaces. Effective for general cleaning and degreasing of undercarriages, hydraulic arms, and cabs.
  
• Zep Industrial Purple Cleaner
  Highly concentrated and aggressive. Best for engine compartments and track assemblies. Requires gloves and eye protection.
  
• Spray Nine Heavy Duty Cleaner
  Combines degreasing with disinfecting. Useful for shared equipment and high-touch surfaces. Fast-acting with a 10-second sanitization window.
  
• Oil Eater Cleaner Degreaser
  Water-based and biodegradable. Suitable for daily maintenance and light-duty cleaning. Can be used in pressure washers.
  
• 3D Grand Blast Engine Degreaser
  Designed for engine blocks and transmission housings. Powerful yet safe on aluminum and steel. May require thorough rinsing to avoid residue.
  

• Pre-Rinse
  Remove loose dirt with water to prevent dilution of the degreaser.
  
• Apply Degreaser
  Use a pump sprayer or foam cannon for even coverage. Let it dwell for 5–15 minutes depending on product strength.
  
• Agitate
  Scrub with brushes or pads on stubborn areas. Avoid wire brushes on painted surfaces.
  
• Rinse Thoroughly
  Use high-pressure water to remove all residue. Incomplete rinsing can lead to corrosion or slippery surfaces.
  
• Dry and Inspect
  Allow components to air dry or use compressed air. Inspect for leaks, cracks, or wear.
  

• Nitrile gloves
  
• Safety goggles
  
• Respirator mask (for solvent-based products)
  
• Waterproof boots
  

• Use biodegradable products when possible
  
• Capture runoff with containment mats or berms
  
• Dispose of waste through certified hazardous material channels
  
• Avoid degreasing near storm drains or natural water sources
  

• Daily: For equipment in food processing or medical waste handling
  
• Weekly: For machines in muddy or oily environments
  
• Monthly: For general construction and landscaping use
  
• Quarterly: For seasonal or low-use equipment
  

In the world of heavy trucks and machinery, transmissions are vital components that influence both the performance and efficiency of a vehicle. Among the various types of transmissions, auxiliary transmissions and 13-speed gearboxes have a significant place, especially in older models. These systems are essential for drivers who need both precision and power when handling large, heavy loads over long distances.
Understanding Auxiliary Transmissions
An auxiliary transmission, often referred to as a "splitter" or "range" transmission, is a secondary gearbox mounted on the main transmission. It allows the driver to multiply the number of available gears, providing more control over the engine’s power and torque. The auxiliary transmission is particularly useful in trucks that need to haul heavy loads or travel through challenging terrains.
How Does It Work?

• Positioning: Typically installed between the main gearbox and the driveshaft, the auxiliary transmission engages either through a lever or an airshift system.
  
• Gear Multiplication: The primary function is to multiply the effective number of gears by providing additional gear ratios.
  
• Efficiency: This system provides better fuel efficiency and smoother power delivery, especially in situations that require frequent gear shifting, such as hauling heavy loads on steep inclines.
  

• Enhanced Gear Ratios: The 13-speed gearbox allows drivers to fine-tune the engine’s output by using more gears. It makes driving on highways, handling hills, and starting from a standstill significantly easier.
  
• Fuel Efficiency: By allowing the engine to stay within its optimal RPM range, a 13-speed gearbox ensures better fuel economy, especially during long hauls.
  
• Smooth Shifting: The additional gears help avoid large jumps in RPMs between shifts, leading to a smoother driving experience.
  

• Main and Auxiliary Gearboxes: A typical 13-speed gearbox uses a 9-speed main transmission combined with a 4-speed auxiliary unit, giving the driver more control over engine power.
  
• Shifting Mechanism: The system is usually split into a high/low range, with each range offering different gears. In practice, the driver shifts through the main transmission for regular driving, then uses the auxiliary system when additional gears are needed.
  

• Don’t Rush: The transition from one range to another requires the driver to give the vehicle’s RPMs time to settle. Rushing through shifts can cause undue strain on the transmission and reduce the lifespan of the components.
  
• Understanding Gear Ratios: Knowing when to use which gear, whether in the high or low range, is vital to maximizing both efficiency and power. In heavy loads, drivers tend to shift through lower gears in the auxiliary system to maintain better control.
  

• Fluid Changes: Just like any other part of the vehicle, regular fluid changes for the gearbox and auxiliary transmission can extend the life of the system.
  
• Lubrication: Proper lubrication of the gears is essential to prevent wear and ensure smooth shifting.
  
• Check for Leaks: Transmission fluid leaks can lead to significant damage if left unchecked. Routine inspections help identify these issues before they become critical.
  

• Clutch Slipping: This is often a sign of worn-out clutch plates. If the clutch doesn’t fully engage, it can cause slipping, resulting in loss of power and potential damage to the gearbox.
  
• Shifting Difficulties: If the transmission is hard to shift, the issue could be due to low or dirty transmission fluid, or worn synchronizers that need replacement.
  
• Transmission Overheating: This could be due to clogged or dirty cooling systems, especially if the truck operates in harsh conditions for extended periods.
  

The Mystery of Unfamiliar Components
In the world of heavy equipment, encountering unknown parts is not uncommon—especially when dealing with older machines, aftermarket modifications, or obscure OEM designs. Whether it's a bracket with no obvious purpose, a hydraulic fitting that seems out of place, or a set of pins that don’t match any known diagram, operators and mechanics often find themselves asking: “What are these for?”
This question isn’t just about curiosity—it’s about safety, performance, and maintenance. Misidentifying a component can lead to improper repairs, missed inspections, or even equipment failure. Understanding the function of ambiguous parts requires a blend of experience, documentation, and sometimes a bit of detective work.
Common Categories of Unidentified Parts
Unfamiliar components typically fall into a few categories:

• Mounting Hardware: Brackets, clamps, and flanges used to secure accessories or optional equipment.
  
• Hydraulic Adaptors: Fittings or ports for auxiliary attachments, often capped if unused.
  
• Electrical Connectors: Plugs or terminals for sensors, diagnostics, or lighting systems.
  
• Wear Indicators: Tabs or protrusions designed to show wear limits on bushings or pins.
  
• Transport Locks: Pins or plates used to immobilize moving parts during shipping.
  

• Consult the Manual: OEM service manuals often include exploded diagrams and part numbers.
  
• Trace the Connection: Follow hoses, wires, or brackets to their origin or destination.
  
• Compare with Similar Models: Cross-reference with machines of the same series or generation.
  
• Ask the Manufacturer: Dealers and technical support teams can often identify parts from photos.
  
• Use Online Databases: Platforms like EPCs (Electronic Parts Catalogs) allow part number lookups.
  

• Check for signs of wear or stress
  
• Ensure it’s not part of a safety system
  
• Verify it’s not required for future attachments
  
• Document its removal for future reference
  

• Japanese excavators may include ports for hydraulic breakers, even if not installed.
  
• European wheel loaders often have wiring for beacon lights, regardless of local regulations.
  
• U.S. graders may include brackets for snow wing attachments, unused in southern states.
  

• Report unfamiliar parts during inspections
  
• Avoid improvising with unknown components
  
• Use proper terminology when describing parts
  
• Photograph and document findings for expert review
  

The Komatsu PW140-7 is a popular model in the Komatsu series of wheeled excavators. Known for its versatility and powerful hydraulic system, the PW140-7 is used across various industries, including construction, demolition, and material handling. However, like any heavy equipment, it can face operational challenges. One of the most common issues reported by operators is hydraulic load-related problems, which can significantly affect performance if not addressed promptly.
Komatsu PW140-7 Overview
The Komatsu PW140-7 is a wheeled excavator designed for maximum efficiency and operational versatility. It is equipped with an advanced hydraulic system that provides smooth and powerful lifting, digging, and moving capabilities. The machine is typically used for urban construction projects, landscaping, and materials handling where mobility and precision are essential.
Key Features:

• Hydraulic System: The PW140-7 is powered by a state-of-the-art hydraulic system that drives its digging and lifting operations, allowing for smooth and efficient movement of loads.
  
• Engine Power: Powered by a Komatsu SAA6D107E-1 engine, the PW140-7 offers impressive power while maintaining fuel efficiency, making it ideal for long hours of operation.
  
• Versatility: The excavator is equipped with various attachments, including a standard bucket, a grapple, or even a hammer, making it versatile for a range of construction and excavation tasks.
  

• Low Hydraulic Fluid Levels: One of the most frequent causes of slow hydraulic response is insufficient hydraulic fluid. This can occur if there is a leak in the system or if fluid has not been properly topped up.
  
• Contaminated Hydraulic Fluid: If the hydraulic fluid becomes contaminated with dirt, water, or debris, it can cause the system to work inefficiently, leading to slower movement and higher chances of failure.
  
• Worn Hydraulic Pump or Valves: Over time, the hydraulic pump or control valves can wear down, causing reduced flow and pressure, ultimately affecting performance under load.
  

• Regularly check and maintain hydraulic fluid levels. Ensure that the fluid is free from contamination by replacing it as per the manufacturer’s guidelines.
  
• Inspect the hydraulic pump and valves for wear. If these components are worn out, they should be replaced immediately to restore the system’s performance.
  
• Clean the hydraulic filters and replace them if necessary.
  

• Worn Seals or O-Rings: The seals and O-rings in the hydraulic system can wear out over time, leading to leaks. These components are crucial for maintaining pressure in the system.
  
• Loose Hoses and Connections: Over time, the hoses may become loose or deteriorate, resulting in fluid leaks.
  
• Cracked Hydraulic Lines: Hydraulic lines can crack under stress or due to impact, leading to leaks that can severely affect the machine's ability to function.
  

• Regularly inspect all hydraulic hoses, connections, and seals for signs of wear. Tighten any loose fittings, and replace any damaged or worn hoses and seals.
  
• When replacing seals, use the correct parts specified by Komatsu to maintain system integrity and avoid further leaks.
  
• Perform regular pressure tests to check for leaks in the hydraulic lines.
  

• Low Hydraulic Fluid Levels: Low fluid levels can result in poor cooling of the hydraulic system, causing it to overheat.
  
• Blocked Coolers or Filters: If the hydraulic cooler or filter becomes blocked with dirt and debris, it can restrict the flow of cool fluid, leading to overheating.
  
• Excessive Load: Continually running the machine under heavy load without sufficient rest or cooling periods can cause the hydraulic system to overheat.
  

• Ensure that the hydraulic fluid is topped up and maintained at the proper levels.
  
• Clean the hydraulic cooler and filters regularly to ensure they are not blocked or clogged.
  
• Monitor the machine’s operational load and ensure that it is within the recommended limits for the specific tasks at hand.
  

• Faulty Control Valve: The control valve, which regulates the flow of hydraulic fluid to various parts of the machine, can malfunction, causing erratic movement.
  
• Air in the Hydraulic Lines: If air enters the hydraulic system, it can cause inconsistent movement, particularly under load. This air can be introduced during improper servicing or due to leaks.
  
• Low Pressure in the Hydraulic System: If the hydraulic pump is not generating enough pressure, it will cause the system to function erratically.
  

• Inspect and repair or replace any faulty control valves.
  
• Bleed the hydraulic lines to remove any trapped air.
  
• Check and replace the hydraulic pump if it is not generating the required pressure.
  

• Adhere to Regular Maintenance Schedules: Follow the manufacturer’s maintenance schedule for hydraulic fluid changes, filter replacements, and system inspections.
  
• Use High-Quality Hydraulic Fluids: Always use the recommended hydraulic fluids and lubricants to ensure optimal system performance.
  
• Inspect the System Regularly: Frequently check for leaks, low fluid levels, and signs of wear on seals, hoses, and filters.
  
• Ensure Proper Load Handling: Avoid overloading the machine and make sure to operate it within its specified load limits. Excessive load can stress the hydraulic system and lead to faster wear.
  

The Rise of Hitachi’s Compact Excavators
Hitachi Construction Machinery, established in 1970 as a division of Hitachi Ltd., quickly became a global leader in hydraulic excavator technology. The EX series, launched in the late 1980s, marked a turning point in compact excavator design. The EX60, introduced in the early 1990s, was engineered for urban construction, utility work, and precision excavation. With an operating weight of approximately 13,000 pounds and a bucket breakout force exceeding 9,000 pounds, the EX60 offered a powerful yet nimble solution for contractors.
By the end of the 1990s, Hitachi had sold tens of thousands of EX60 units worldwide. Its popularity stemmed from its hydraulic precision, durable undercarriage, and compatibility with tight job sites. The EX60 was often seen in municipal fleets, landscaping operations, and infrastructure projects across Asia, Europe, and North America.
Core Specifications and Travel System Design
The EX60 is powered by a four-cylinder Isuzu 4JB1 diesel engine, producing around 55 horsepower. Its travel system consists of two hydraulic motors mounted on each track, fed by a variable displacement pump. The machine uses a center rotary joint to distribute hydraulic flow between upper and lower structures, allowing 360-degree rotation while maintaining travel power.
Terminology Note: A “rotary joint” (also called a swivel joint) is a hydraulic component that enables fluid transfer between rotating and stationary parts. “Variable displacement pump” adjusts flow rate based on demand, improving efficiency.
The travel motors are equipped with planetary gear reduction and spring-applied, hydraulically released brakes. This configuration ensures smooth movement and automatic braking when hydraulic pressure drops.
Symptoms of Travel Issues
Operators have reported several travel-related problems in aging EX60 units:

• Machine struggles to climb inclines
  
• Travel speed is inconsistent or sluggish
  
• Turning with one track is difficult or impossible
  
• Sudden jerks or resistance during movement
  
• Audible banging or catching sensation from tracks
  

• Track tension and alignment
  
• Wear on track rollers and idlers
  
• Clearance between track shoes and frame
  

• Excessive smoke during movement
  
• Engine bogging when tracks engage
  
• Poor response when switching directions
  

• Fuel filter condition
  
• Air intake restrictions
  
• Engine compression and injector performance
  

• Case drain flow test on each travel motor
  
• Pressure test at the pump outlet and motor inlet
  
• Visual inspection of rotary joint seals
  
• Track movement test on level and inclined surfaces
  

• Replace hydraulic filters every 500 hours
  
• Use high-quality ISO VG 46 hydraulic oil
  
• Grease track rollers and idlers weekly
  
• Inspect rotary joint seals annually
  
• Maintain engine performance with regular servicing
  

The Kato HD820III is a versatile and reliable crawler crane used in various industries, particularly in construction and heavy lifting operations. Known for its durability and high lifting capacity, the HD820III is widely used in infrastructure development, mining, and other heavy-duty applications. However, like any piece of heavy equipment, it is not immune to issues, especially when subjected to demanding environments or heavy usage.
Kato HD820III Overview
The Kato HD820III is part of Kato Works' extensive range of cranes and construction machinery. This series of crawler cranes is designed for performance and stability, offering powerful lifting capabilities and excellent maneuverability. It is built to handle large-scale construction projects that require precise lifting and hoisting in difficult terrain.
Key Features:

• Lifting Capacity: The HD820III is capable of lifting substantial loads, making it ideal for construction projects that involve heavy materials or complex structures.
  
• Hydraulic System: Equipped with a high-performance hydraulic system, the crane is capable of executing precise and efficient movements, ensuring smooth operation even under heavy loads.
  
• Crawler Undercarriage: The crawler design allows the crane to operate on soft or uneven ground, making it a suitable choice for various job sites.
  
• Advanced Control System: The crane comes with an advanced control system that ensures safe operation and allows for better load handling and movement precision.
  

• Low Hydraulic Fluid: Insufficient fluid can lead to decreased performance or complete failure of the lifting mechanism.
  
• Damaged Hydraulic Hoses: Leaks or tears in hydraulic hoses can result in a loss of pressure, leading to failure in lifting operations.
  
• Contaminated Hydraulic Fluid: Dirt and debris can contaminate hydraulic fluid, causing blockages or damage to the system's components.
  

• Regularly check and maintain hydraulic fluid levels. Replace fluids and filters as recommended in the manufacturer's maintenance schedule.
  
• Inspect hoses for wear and tear, replacing damaged or worn hoses promptly.
  
• Clean hydraulic components and replace any contaminated fluid to ensure smooth operation.
  

• Fuel System Problems: Clogged fuel filters, water in the fuel, or an inefficient fuel pump can all cause engine performance issues.
  
• Air Filter Blockage: A clogged air filter restricts airflow to the engine, affecting its efficiency.
  
• Worn Engine Components: Over time, components like pistons, valves, or the turbocharger may wear out, leading to reduced engine power or failure.
  

• Regularly inspect the fuel system for contamination and replace filters as needed.
  
• Clean or replace the air filter regularly to prevent clogs.
  
• Follow the recommended maintenance schedule for engine components and replace worn-out parts.
  

• Loose or Corroded Connections: Loose or corroded battery terminals and wiring connections can lead to intermittent power loss or failure to start.
  
• Faulty Sensors: The crane relies on various sensors for safety and performance monitoring. A faulty sensor can disrupt operations.
  
• Blown Fuses: A blown fuse can stop critical electrical systems from functioning, causing the crane to stop operating.
  

• Inspect all electrical connections regularly for signs of corrosion or looseness.
  
• Replace faulty sensors and wiring as needed.
  
• Check and replace fuses to ensure all electrical systems are working properly.
  

• Track Tension Issues: Over time, the tension in the tracks may loosen or become too tight, leading to uneven wear.
  
• Track Pad Wear: The pads on the tracks wear down due to continuous movement, especially in abrasive or rocky environments.
  
• Damaged Rollers and Idlers: The rollers and idlers that support the tracks can wear out, causing difficulty in movement or uneven track wear.
  

• Regularly inspect track tension and adjust it according to the manufacturer's specifications.
  
• Replace worn-out track pads and ensure that the tracks are properly aligned.
  
• Inspect and replace damaged rollers and idlers as part of a comprehensive undercarriage maintenance plan.
  

• Faulty Control Valves: The control valves manage hydraulic flow and pressure. If these become faulty, it can affect the crane's lifting and operating abilities.
  
• Malfunctioning Joystick or Levers: A worn or malfunctioning joystick or lever can prevent operators from accurately controlling the crane.
  

• Regularly inspect control valves and replace any that are malfunctioning.
  
• Clean or replace control levers and joysticks as needed to ensure smooth operation.
  

• Follow Manufacturer’s Maintenance Schedule: Always adhere to the maintenance guidelines provided by Kato for inspections, lubrication, and fluid changes.
  
• Inspect Regularly: Routine inspections of all major systems—hydraulics, electrical, engine, and undercarriage—are crucial in catching problems early.
  
• Use Quality Parts: When replacing parts, always opt for genuine Kato replacement parts to ensure the crane's optimal performance and longevity.
  
• Keep the Crane Clean: A clean machine is less prone to damage. Regularly clean the crane, especially the engine compartment, hydraulic lines, and undercarriage.
  

The Terex Legacy and TA27 Development
Terex Corporation, founded in 1933, evolved from a division of General Motors into a global manufacturer of heavy equipment. By the 1990s, Terex had expanded its product line to include articulated dump trucks (ADTs), targeting mining, quarrying, and large-scale earthmoving operations. The TA27, introduced in the late 1990s, was part of the TA series that included models ranging from TA25 to TA40. These trucks were designed for high payload capacity, rugged terrain performance, and ease of maintenance.
The TA27 features a payload capacity of approximately 27 metric tons and is powered by a Detroit Diesel Series 60 engine producing around 350 horsepower. Its six-wheel drive configuration and articulated steering allow it to navigate rough terrain with agility. By the early 2000s, Terex had sold thousands of TA27 units globally, with strong adoption in North America, Europe, and Australia.
Brake System Architecture
The TA27 uses a dual braking system consisting of:

• Service brakes: hydraulically actuated wet disc brakes on all axles
  
• Parking brake: spring-applied, hydraulically released disc brake on the driveline
  
• Emergency brake: integrated with the parking brake system
  

• Brake warning light activation during operation
  
• Soft or spongy pedal feel
  
• Delayed brake response
  
• Inability to release parking brake
  

• Low hydraulic fluid levels
  
• Air ingress into the hydraulic lines
  
• Worn brake pads or discs
  
• Faulty treadle valve or pressure sensors
  

• Check hydraulic fluid levels daily
  
• Use ISO VG 46 hydraulic oil with anti-wear additives
  
• Replace brake fluid filters every 500 hours
  
• Bleed the system after any hose or component replacement
  

• Brake not releasing due to low hydraulic pressure
  
• Brake dragging during motion
  
• Warning light remaining on despite release
  

• Inspecting the hydraulic release solenoid
  
• Testing the pressure switch and wiring
  
• Replacing worn brake pads and checking caliper alignment
  

• Increased stopping distance
  
• Metallic grinding noise
  
• Uneven pad thickness
  

• Inspect brake discs every 1,000 hours
  
• Replace pads when thickness drops below 5 mm
  
• Use OEM or high-quality aftermarket components
  

• Air drier to remove moisture
  
• Relay emergency valve to control air flow
  
• Pressure protection valve to isolate circuits
  

• Brake lockup
  
• Inconsistent pedal feel
  
• Air leaks and compressor overload
  

• Draining air tanks daily
  
• Replacing air drier cartridges every 1,000 hours
  
• Testing valve function with a pressure gauge