Addressing Track Bolt Wear: Maintaining OTT Tracks for Longevity and Performance

[MikePhua]

Track systems in heavy machinery, especially in the case of over-the-tire (OTT) tracks, play a critical role in the machine's overall performance. As machines are subjected to tough working conditions, the wear and tear on various components—especially the bolts connecting the tracks—become a significant concern. OTT tracks are often used on wheeled machines to convert them into tracked vehicles, enhancing their mobility in muddy, sandy, or uneven terrains. However, like any mechanical system, they are prone to wear, especially when subjected to harsh working environments. One of the most common issues with OTT tracks is bolt wear, which can lead to malfunctioning and, in some cases, costly repairs.
Understanding OTT Tracks and Their Purpose
OTT tracks are designed to provide additional traction to wheeled equipment such as skid steers, loaders, and backhoes. These tracks fit over the machine's existing tires and are ideal for improving performance in soft ground conditions or where traditional wheels would struggle. They enhance the machine’s stability and distribution of weight, thus preventing tire damage and enhancing productivity in areas where the terrain would otherwise hinder the vehicle’s movement.
While OTT tracks bring numerous benefits, such as better flotation in soft soils, they also come with some challenges. Regular maintenance and attention to detail are required to ensure that the machine performs at its best over the long term. One of the most significant issues that operators face is the wear of the bolts used to secure the tracks to the wheels.
What Is Track Bolt Wear?
Track bolt wear occurs when the bolts connecting the OTT tracks to the machine’s tires begin to degrade, usually due to repeated stress, friction, and exposure to harsh environments. Over time, bolts can become loose, stripped, or corroded, leading to potential track slippage, instability, or even complete detachment of the tracks. This type of wear can occur more quickly when machines are used on challenging terrains, such as rough, rocky ground or where dirt and debris can infiltrate the system.
This wear can cause several problems, including:

• Track Slippage: As bolts wear down, the tracks may begin to slip or shift on the wheels, leading to a loss of traction.
  
• Increased Maintenance Costs: Worn bolts often need to be replaced more frequently, leading to increased downtime and maintenance expenses.
  
• Reduced Performance: The effectiveness of OTT tracks diminishes as the bolts wear out, ultimately affecting the machine’s overall performance and efficiency.
  
• Safety Risks: Loose or worn-out bolts can lead to equipment failure, posing potential safety risks for operators and other workers on-site.
  

Factors Contributing to Bolt Wear in OTT Tracks
Several factors contribute to the rapid wear of bolts in OTT tracks. These include:

1. Terrain: Machines operating on rocky, uneven, or abrasive surfaces experience increased wear on bolts and other components. Sharp rocks or debris can cause friction that accelerates bolt degradation.
   
2. Load and Stress: Overloading the machine or operating it under stress for prolonged periods can cause excessive wear on the bolts. Machines operating in high-impact scenarios or working with heavy loads are particularly prone to this kind of wear.
   
3. Lack of Maintenance: Without proper lubrication, cleaning, and periodic tightening, bolts are more likely to wear prematurely. Dirt and debris can accumulate on the tracks, leading to abrasive contact that accelerates wear.
   
4. Environmental Exposure: Exposure to extreme temperatures, humidity, or chemical environments can cause bolts to corrode or weaken. Rust, in particular, is a common issue for bolts that are not properly maintained.
   

Preventing and Managing Track Bolt Wear
Proper care and maintenance are key to preventing excessive wear of the track bolts. Here are several practices that operators can implement to manage and reduce bolt wear:
1. Regular Inspection and Tightening
Inspect the bolts regularly to ensure that they are securely fastened. Tightening bolts as needed can prevent them from becoming loose over time, reducing the risk of slippage or detachment. Additionally, checking for signs of wear or corrosion should be part of routine maintenance.
2. Lubrication
Proper lubrication of the track system can help minimize friction, reducing the stress placed on the bolts. Regularly lubricating the track and bolt connections will help maintain smooth operation and prevent premature wear.
3. Cleaning and Debris Removal
Keeping the track system clean of dirt, debris, and gravel is essential for reducing friction and preventing abrasive wear. Implementing a cleaning schedule where the tracks are washed after working in particularly dirty or rocky areas can go a long way in prolonging the life of the bolts.
4. Choosing the Right Tracks for the Job
It’s important to choose the correct type of OTT tracks based on the working conditions. Tracks designed for specific environments, such as rocky or wet terrains, are often reinforced with tougher materials to better withstand wear. Selecting the right track design for the job will ensure greater longevity and reduce the risk of wear on the bolts.
5. Monitor Machine Loads
Excessive loads can place significant stress on the entire track system. Operators should ensure they are adhering to the manufacturer’s recommended load limits to prevent overloading, which can contribute to wear and tear.
When to Replace Worn Bolts
Even with the best maintenance practices, bolts will eventually wear out. It’s crucial to recognize when they need to be replaced to avoid more serious problems. Look out for the following signs:

• Loose or Wobbly Bolts: If the bolts can be moved or are not staying in place, it’s a clear sign that they need replacing.
  
• Corrosion: Rusted or corroded bolts weaken over time and need to be replaced promptly.
  
• Visible Wear: If the bolts are visibly worn, cracked, or damaged, they need to be replaced before further use.
  

Cost of Ignoring Bolt Wear
Neglecting bolt wear in OTT tracks can lead to a host of problems, including track failure, reduced operational efficiency, and even safety hazards. The cost of replacing worn bolts is minimal compared to the cost of more serious damage, such as damaged track systems, premature wear on other parts, or expensive repairs to the overall machine. Additionally, not addressing bolt wear in a timely manner can lead to significant downtime, reducing overall productivity and costing the company money in lost opportunities.
Conclusion: Ensuring the Longevity of OTT Tracks
OTT tracks are a great addition to wheeled equipment, providing improved traction, stability, and performance in challenging environments. However, as with all mechanical systems, regular maintenance is essential to ensure their longevity. By understanding the factors that contribute to track bolt wear and implementing a proactive maintenance strategy, operators can extend the life of their equipment, reduce downtime, and ultimately save on repair costs.
Regular inspection, lubrication, and cleaning, combined with using the right tracks for the job, are key strategies in maintaining track performance. As with all aspects of heavy equipment maintenance, an ounce of prevention is worth a pound of cure. With proper care, OTT tracks can continue to perform efficiently for many years, providing operators with a reliable solution to tough working conditions.