Troubleshooting Track Issues on the Kobelco 120 Excavator

[MikePhua]

The Kobelco 120 is a popular tracked excavator used in various construction and excavation tasks. However, like all heavy machinery, it can sometimes experience track-related problems. One common issue reported by operators is the track coming off the rollers or becoming misaligned. This can cause a loss of mobility and even lead to costly damage if not addressed promptly. This article will guide you through troubleshooting and fixing track issues on the Kobelco 120 excavator.
Common Symptoms of Track Problems

1. Track Off the Rollers
   • One of the most common problems is when the track comes off the rollers, leaving the machine unable to move properly. This could occur while the machine is operating or even when the machine is idle.
     
2. Track Slipping or Jumping
   • Sometimes, the track may slip or jump, causing uneven motion or even causing the machine to stop entirely. This may happen due to the tension not being properly adjusted or an issue with the track itself.
     
3. Excessive Wear on Track Components
   • Over time, track components like the sprockets, rollers, and idlers may wear out, leading to misalignment and track slippage. This could result in the track coming off entirely.
     

Causes of Track Issues on the Kobelco 120

1. Improper Track Tension
   • Description: Track tension is crucial for keeping the track on the rollers. If the tension is too loose or too tight, the track can slip off the rollers or cause damage to other track components.
     
   • Solution: Regularly check the track tension using the manufacturer’s recommended procedures. Adjust the tension by turning the tension bolt or hydraulic tensioner as needed.
     
2. Damaged or Worn Track Components
   • Description: Worn or damaged components like sprockets, rollers, and idlers can cause the track to misalign or come off the rollers. This is particularly common on machines that have seen heavy use or are operating in tough conditions.
     
   • Solution: Inspect the track components for excessive wear, cracks, or damage. If any components are found to be worn or damaged, replace them immediately to prevent further damage to the track.
     
3. Track Misalignment
   • Description: Track misalignment occurs when the track is not positioned correctly on the rollers or sprockets. This can be caused by uneven wear, improper installation, or damage to the frame or rollers.
     
   • Solution: Check for any misalignment in the track. If the track is out of line, adjust the position of the rollers or sprockets to realign the track. In some cases, the frame or other components may need to be repaired or replaced.
     
4. Hydraulic Tensioner Malfunction
   • Description: The Kobelco 120 uses a hydraulic tensioner to maintain track tension. If the tensioner malfunctions, it may not apply the correct amount of pressure to the track, leading to misalignment or the track coming off.
     
   • Solution: Inspect the hydraulic tensioner for leaks or malfunctions. If necessary, repair or replace the tensioner.
     

Steps to Troubleshoot and Fix Track Issues

1. Inspect the Track and Components
   • Action: Begin by inspecting the track and its components, including the rollers, sprockets, and idlers. Look for signs of excessive wear, cracks, or damage.
     
   • Why: Identifying worn or damaged components early can prevent further issues and keep your excavator running smoothly.
     
2. Check the Track Tension
   • Action: Check the tension of the track to ensure it is neither too tight nor too loose. The correct tension will keep the track in place while also preventing excessive wear on the rollers and sprockets.
     
   • Why: Proper track tension is essential for preventing track issues, including the track coming off the rollers.
     
3. Adjust Track Tension
   • Action: If the track tension is incorrect, adjust it using the appropriate tools and methods as specified in the service manual. If the excavator has a hydraulic tensioner, you may need to adjust the hydraulic pressure.
     
   • Why: Correct tension will help maintain the proper alignment of the track and prevent it from coming off during operation.
     
4. Realign the Track
   • Action: If the track is misaligned, adjust the rollers and sprockets to ensure the track sits correctly. In some cases, you may need to replace the track if it is severely misaligned or damaged.
     
   • Why: Proper alignment ensures the track moves smoothly and evenly, preventing it from slipping off the rollers.
     
5. Replace Worn or Damaged Components
   • Action: If you find any worn or damaged components, such as sprockets, rollers, or idlers, replace them immediately. Inspect the entire track system to ensure there is no additional wear on the frame or other components.
     
   • Why: Worn components can cause further damage to the track and other machinery parts, leading to costly repairs and downtime.
     

Preventive Maintenance for Track Systems

1. Regular Track Inspections
   • Action: Perform regular inspections of the track, rollers, sprockets, and other components to identify any signs of wear or damage.
     
   • Why: Regular inspections help detect issues early before they lead to major problems.
     
2. Track Lubrication
   • Action: Keep the track system lubricated according to the manufacturer’s guidelines to reduce wear and friction on the track components.
     
   • Why: Proper lubrication helps reduce the risk of track issues and extends the life of the track components.
     
3. Proper Operation Techniques
   • Action: Operate the excavator according to the manufacturer’s recommended guidelines, avoiding excessive speed or sudden movements that could damage the track.
     
   • Why: Operating the machine properly reduces stress on the track system and helps prevent issues such as misalignment or excessive wear.
     
4. Regular Track Tension Checks
   • Action: Check the track tension regularly, especially if the machine is operating in rough conditions.
     
   • Why: Keeping the track at the correct tension helps maintain optimal performance and prevents the track from slipping or coming off.
     

Conclusion
Track issues on the Kobelco 120 excavator, such as the track coming off the rollers, can be caused by a variety of factors, including improper track tension, worn components, or misalignment. By conducting regular inspections, adjusting the tension, and replacing damaged parts as necessary, operators can prevent track problems and ensure their machine operates at peak efficiency. Implementing a strong preventive maintenance routine will help extend the lifespan of the track system and avoid costly repairs down the road.