Fixing a Broken Track on Heavy Equipment: A Complete Guide

[MikePhua]

Heavy equipment, especially tracked machines like excavators and bulldozers, are invaluable assets in the construction, mining, and agricultural industries. Tracks are essential to the performance of these machines, providing stability, traction, and the ability to navigate rough terrains. However, tracks are also subject to wear and tear, and in some cases, they can break, causing significant downtime and operational challenges. This article will walk you through the causes of a broken track, how to diagnose the issue, and steps for fixing it, using real-world examples and practical advice.
Understanding a Broken Track: Causes and Implications
When a track breaks, it typically leads to an immediate halt in the machine’s operation. A broken track is a critical issue, as it can prevent a machine from moving, compromising productivity and potentially leading to costly delays. Understanding the reasons behind a track failure is key to preventing it and ensuring that your equipment continues to perform efficiently.

1. Worn Out or Damaged Tracks
   One of the most common causes of a broken track is excessive wear. Tracks, like any other component, experience gradual degradation over time. As the rubber or steel links wear down, they become more prone to snapping, especially under heavy loads or rough conditions.
   Additionally, damage to individual links can occur from striking rocks, debris, or other obstacles. Repeated contact with hard surfaces can weaken the integrity of the track, leading to failure.
   
2. Improper Track Tension
   Proper track tension is crucial for the longevity and performance of the track. If the track is too tight, it can cause excessive wear on both the track and the undercarriage components. On the other hand, if the track is too loose, it can slip off the sprockets or lead to uneven wear, which might eventually result in the track breaking.
   
3. Track Misalignment
   If the machine’s tracks are misaligned, they can wear unevenly, causing one side to become weaker than the other. Misalignment can occur due to improper installation, damaged components like rollers or sprockets, or even improper maintenance practices.
   
4. Excessive Load
   Running a machine with an excessive load can put extra strain on the tracks, causing them to stretch or break. Whether it’s lifting heavy materials or overloading the machine, excessive strain on the track can cause catastrophic failure.
   

Diagnosing the Broken Track
Diagnosing a broken track often involves visually inspecting the machine to identify any visible signs of failure. Here are the steps for diagnosing a broken track:

1. Visual Inspection
   Start by performing a thorough visual inspection of the track. Look for visible cracks, tears, or missing links. Check if the track has come off the sprocket or if there are any loose or damaged rollers or idlers.
   
2. Check the Track Tension
   Use the manufacturer’s recommended procedure for checking track tension. This typically involves measuring the deflection of the track at certain points. If the track is too loose or too tight, adjust the tension to the proper level.
   
3. Examine the Undercarriage
   If the track is not visibly broken, check the undercarriage components such as the sprockets, rollers, and tensioners. Worn or damaged components can contribute to improper track movement and lead to failure. A thorough inspection can help identify any underlying issues that might have contributed to the track breaking.
   

Steps to Fix a Broken Track

1. Prepare the Equipment and Work Area
   Before you start, ensure that the machine is securely parked on flat ground. Engage the parking brake and make sure that the area is safe to work in. Have the proper tools ready, such as track jacks, a wrench set, and a hoist if necessary.
   
2. Lift the Machine
   Use a track jack or an appropriate lifting device to raise the machine off the ground. This will relieve the tension on the tracks and allow you to remove or replace them. Make sure that the machine is stable and supported properly before proceeding.
   
3. Remove the Damaged Track
   Depending on the severity of the damage, you may need to remove the track entirely. Start by loosening the track tension. Once the tension is released, remove any bolts or pins securing the track to the undercarriage. You may need to use a hoist to lift the track off the machine.
   
4. Inspect and Replace Damaged Components
   Once the track is removed, inspect the undercarriage components such as the sprockets, rollers, and idlers for damage. If any components are damaged or excessively worn, they should be replaced before installing a new track.
   
5. Install the New Track
   Carefully install the new or repaired track. Ensure that the track is aligned properly with the sprockets and undercarriage components. Once the track is in place, tighten any bolts or pins that hold it in position.
   
6. Adjust Track Tension
   After the new track is installed, adjust the tension according to the manufacturer’s specifications. Proper tension is essential for the track to function properly and for the longevity of the components.
   
7. Test the Machine
   Once everything is reassembled and the track is in place, test the machine by moving it slowly in a controlled manner. Monitor the track to ensure it runs smoothly and the machine operates correctly.
   

Preventing Future Track Failures
To prevent future track failures and increase the lifespan of your equipment, consider the following preventative measures:

1. Regular Inspections
   Regularly inspect your tracks and undercarriage components for signs of wear and damage. Early detection of issues can help prevent more serious problems, including broken tracks. Pay close attention to the condition of the rollers, sprockets, and tensioners.
   
2. Proper Track Tension
   Maintaining the proper track tension is crucial for the health of the track. Regularly check and adjust the tension as needed to prevent over-tightening or excessive slack. Refer to the manufacturer’s manual for the correct tensioning procedure.
   
3. Avoid Overloading
   Always ensure that the machine is not overloaded. Operating within the recommended load limits helps reduce the strain on the tracks and prevents premature wear.
   
4. Track Maintenance
   Keep the tracks clean and free from debris. Dirt, mud, and other materials can accumulate in the tracks and cause premature wear. Regular cleaning, especially after working in harsh conditions, can help prolong the life of the tracks.
   
5. Invest in High-Quality Tracks
   Not all tracks are created equal. Invest in high-quality tracks that are designed for your machine and operating conditions. While they may come at a higher initial cost, quality tracks can save you money in the long run by reducing maintenance and replacement costs.
   

Real-World Example: Dealing with Track Failures in the Field
A construction company in Arizona was working on a site with rocky terrain when one of their excavators experienced a broken track. The track had been showing signs of wear for some time, but the company had been postponing repairs due to the high cost of replacing the track. When the track finally broke, the machine was rendered inoperable, causing significant delays on the job site.
After replacing the broken track and performing a thorough inspection of the undercarriage, the company learned the importance of regular track maintenance. They began scheduling regular inspections and adjusted the track tension more frequently, which helped prevent further breakdowns. This proactive approach reduced their equipment downtime and saved the company time and money in the long term.
Conclusion: Keeping Your Tracks in Top Shape
A broken track is a serious issue that can cause significant downtime and damage to your heavy equipment. However, with the right knowledge and tools, you can effectively diagnose and repair broken tracks. By following proper maintenance practices and addressing issues early, you can prolong the life of your tracks and ensure that your equipment runs smoothly. Regular inspections, proper tensioning, and attention to load limits are key to preventing track failures and maintaining optimal performance.