Tips for Getting the Track Back onto the Front Idler: A Comprehensive Guide

[MikePhua]

When working with tracked machinery, such as excavators, bulldozers, or skid steers, dealing with a derailed track can be a frustrating and time-consuming task. A track that has come off the front idler can render your machine immobile, delaying work and potentially causing damage if not fixed promptly. In this guide, we’ll explore the steps for re-installing the track onto the front idler, provide tips for preventing this issue in the future, and share some expert advice on how to handle track derailments effectively.
Why Tracks Come Off the Front Idler
Tracks can come off the front idler for several reasons, all of which usually involve issues with tension, alignment, or wear. Common causes include:

1. Track Tension Issues: If the track tension is too loose, it can slip off the front idler, especially during sharp turns or when the machine is under load.
   
2. Misalignment of the Track: Over time, the track and idler wheels may become misaligned, causing the track to derail.
   
3. Excessive Wear: Worn-out track components, such as the rollers, idler, or sprockets, can cause uneven track wear, which leads to the track slipping off.
   
4. Operational Factors: If the machine is operated improperly, such as using excessive speed while turning or working on uneven ground, it can lead to track derailment.
   

By understanding these causes, operators can take steps to prevent track issues from arising and keep their machines running smoothly.
Step-by-Step Guide: How to Get the Track Back onto the Front Idler
Getting the track back onto the front idler is a process that requires patience, the right tools, and some mechanical know-how. Here’s a general step-by-step guide to help you get the job done:

1. Safety First: Before starting any work, ensure that the machine is turned off and secure. Place the machine on stable ground, and if necessary, use blocks or wedges to stabilize the machine further. Always wear proper safety gear, including gloves, steel-toed boots, and safety glasses.
   
2. Release the Tension: Begin by relieving the track tension. Most machines have a hydraulic track tensioning system that can be adjusted from the operator’s cabin or a designated area on the machine. If your machine has a manual tensioning system, you may need to use a wrench to loosen the tension.
   
3. Lift the Track: With the track tension relieved, use a jack or hydraulic lifting tool to lift the track slightly off the ground. This will help provide enough slack to reposition the track over the front idler.
   
4. Align the Track: Once there’s enough slack, carefully align the track with the front idler and track roller assembly. It’s essential that the track is centered to prevent future derailment. Align the track in a straight line to avoid putting excessive stress on the rollers or sprockets.
   
5. Reposition the Track on the Idler: Slowly and carefully maneuver the track so that it fits over the front idler wheel. Depending on your machine, this may require slight adjustments to the track or idler position. Some operators use a pry bar or lever to gently guide the track back onto the idler.
   
6. Adjust the Track Tension: Once the track is properly positioned on the front idler, it’s time to re-tension the track. Follow the manufacturer’s instructions for the correct tension. Over-tightening the track can lead to excessive wear, while too little tension can cause the track to slip off again.
   
7. Check for Alignment: Once the track is back in place, check the alignment of the track and the idler. Ensure that the track is properly seated and that the machine is sitting evenly on the ground. If there’s any misalignment, it can cause the track to come off again.
   
8. Test the Machine: Before resuming work, slowly drive the machine forward or backward to ensure the track is operating properly. Listen for any unusual noises, and watch for any signs of the track slipping or coming loose again. If everything appears to be in good working order, you’re ready to get back to work.
   

Common Tools Used for Track Reinstallation

1. Hydraulic Jack: A hydraulic jack is crucial for lifting the machine and creating enough slack to work with the track.
   
2. Pry Bars: A pry bar or crowbar can help shift the track into position if necessary.
   
3. Wrenches or Impact Tools: For adjusting the track tension, wrenches and other tools are required.
   
4. Track Tool Kit: Some equipment comes with a track tool kit designed specifically for re-installing tracks, making the process much easier.
   

Preventing Track Derailment in the Future
While track derailments are common, they can often be prevented with regular maintenance and careful operation. Here are some preventive tips:

1. Regularly Check Track Tension: One of the most important steps in maintaining track stability is to regularly check and adjust track tension. Track tension should be checked before each use and adjusted according to the manufacturer’s specifications.
   
2. Inspect Track Components for Wear: Regularly inspect the track, rollers, idlers, and sprockets for any signs of wear or damage. Worn-out components should be replaced immediately to prevent further damage and derailments.
   
3. Lubricate Components: Lubrication is key to maintaining smooth movement of the track system. Regularly lubricate the rollers, idlers, and other moving parts to reduce friction and wear.
   
4. Operate the Machine Correctly: Avoid making sharp turns at high speeds, especially on uneven terrain. If possible, try to drive the machine in a straight line when operating in areas with rough ground to reduce stress on the tracks.
   
5. Monitor Operating Conditions: Avoid operating the machine on very steep slopes or rough, uneven terrain unless absolutely necessary. If operating on such terrain is unavoidable, proceed with caution and adjust your driving technique accordingly.
   

Real-World Example: A Skidder’s Track Incident
A logging company was working in the rugged forested terrain of the Pacific Northwest when one of their skidder’s tracks came off the front idler. The crew immediately followed the reinstallation procedure, using a jack to lift the machine and relieve track tension. Despite the setback, they were able to get the track back in place and continue working that same day. After this incident, the crew committed to more frequent track inspections and invested in better equipment for track maintenance, significantly reducing future derailments. This is a great example of how proactive maintenance and proper reinstallation can keep a machine running smoothly.
Conclusion: Mastering Track Maintenance for Smooth Operations
Track derailments are a common challenge for heavy equipment operators, but with the right tools, knowledge, and maintenance practices, you can prevent these issues from disrupting your work. Whether you’re working with excavators, bulldozers, or skid steers, understanding how to re-install a track onto the front idler, and taking steps to avoid derailment, will keep your equipment running efficiently and safely. Regular maintenance, careful operation, and quick responses to any issues will help extend the life of your machine and minimize downtime.