OTC Undercarriage Press in Heavy Equipment Track Service

[MikePhua]

The Role of Undercarriage Presses in Track Maintenance
Undercarriage presses are essential tools in the maintenance and rebuilding of track-type equipment, particularly in the mining, forestry, and construction sectors. These hydraulic presses are designed to remove and install track pins, bushings, and links in steel track chains used on dozers, excavators, and other crawler machines. The OTC undercarriage press, manufactured by OTC Tools (a division of Bosch Automotive Service Solutions), has become a staple in many service shops due to its rugged design and high-pressure capabilities.
OTC, originally founded in 1925 in Owatonna, Minnesota, built its reputation on hydraulic tools and specialty service equipment. Their undercarriage press systems are engineered to handle the extreme forces required to disassemble and reassemble track chains, which are often tensioned to thousands of pounds and subjected to abrasive environments.
Terminology Clarification

• Track chain: A continuous loop of steel links and bushings that forms the undercarriage of tracked machines.
  
• Pin and bushing: Cylindrical components that connect track links and allow rotation during travel.
  
• Press frame: The structural body of the hydraulic press that holds the track chain in place.
  
• Hydraulic ram: A piston-driven actuator that applies force to remove or install components.
  

OTC Press Design and Capabilities
The OTC undercarriage press is typically configured as a horizontal frame with a hydraulic cylinder capable of exerting 100–200 tons of force. It includes adjustable supports, safety guards, and interchangeable tooling for different track sizes.
Key specifications:

• Rated force: 100–200 tons depending on model
  
• Ram stroke: 6–12 inches
  
• Power source: Electric or air-over-hydraulic pump
  
• Tooling: Pin drivers, bushing pushers, link supports
  
• Safety: Pressure relief valve, lockout controls, shielded work zone
  

A technician in Alberta used an OTC press to rebuild the track chains on a D6R dozer. The job involved pressing out 38 pins and bushings, replacing them with hardened aftermarket components, and reassembling the chain—all completed in under six hours with minimal manual effort.
Setup and Operation Workflow
To operate the press safely and efficiently:

• Position the track chain horizontally on the press bed
  
• Align the pin or bushing with the press tooling
  
• Secure the chain using adjustable clamps or supports
  
• Activate the hydraulic pump and apply pressure gradually
  
• Monitor alignment and adjust tooling as needed
  
• Release pressure and inspect component fit before moving to next link
  

Recommended accessories:

• Pin driver sets for various diameters
  
• Bushing push plates with hardened surfaces
  
• Chain support blocks to prevent sagging
  
• Hydraulic pressure gauge for monitoring force
  
• PPE: face shield, gloves, steel-toe boots
  

A contractor in Georgia added LED lighting and a foot-operated control valve to his OTC press, improving visibility and reducing operator fatigue during long rebuild sessions.
Common Challenges and Solutions
Issues that may arise during pressing operations include:

• Misalignment causing bent pins or cracked bushings
  
• Insufficient pressure due to pump wear or fluid contamination
  
• Tooling slippage from worn driver surfaces
  
• Chain distortion from uneven support or over-pressing
  
• Hydraulic leaks at cylinder seals or hose fittings
  

Solutions:

• Use alignment jigs and verify centerline before pressing
  
• Replace hydraulic fluid annually and inspect pump filters
  
• Resurface or replace worn tooling components
  
• Support chain evenly with cribbing or custom blocks
  
• Inspect seals and torque fittings to spec before each use
  

A fleet manager in British Columbia implemented a pre-use checklist for his press operators, reducing tooling damage and improving rebuild consistency across multiple machine types.
Preventive Maintenance and Long-Term Reliability
To extend the life of the OTC press:

• Lubricate moving parts monthly
  
• Inspect hydraulic hoses and fittings quarterly
  
• Replace seals and ram packing every 1,000 hours
  
• Clean press bed and tooling after each use
  
• Store tooling in labeled bins to prevent mix-ups
  

Component lifespan estimates:

• Hydraulic cylinder: 5,000–7,000 hours
  
• Tooling sets: 2,000–3,000 cycles depending on material
  
• Pump unit: 4,000–6,000 hours with regular service
  
• Frame structure: 10+ years with proper care
  

A crew in Texas added a digital cycle counter to their press, allowing them to track usage and schedule preventive maintenance based on actual workload rather than calendar intervals.
Conclusion
The OTC undercarriage press is a cornerstone of efficient track chain service in heavy equipment maintenance. With its high-force capability, modular tooling, and durable construction, it enables technicians to perform rebuilds with speed, safety, and precision. When paired with disciplined setup, regular maintenance, and skilled operation, the press becomes more than a tool—it becomes a productivity multiplier. In the world of steel tracks, force is essential—but control is what makes it effective.